Operating Instructions
Contents
1. M Series 2 3 Stages Oil Quantities Type M1 M2 M3 M4 M002 003 0 4 0 35 0 6 0 55 0 57 05 0 6 0 55 M102 103 0 65 0 6 0 95 0 8 0 7 0 7 0 95 0 8 M172 173 0 7 0 65 095709 0 8 0 8 0 992 09 M202 203 1 211 1 2 1 2 2419 2 1 2 M272 273 1 1 1 ZU LES ES 2 17 M282 283 1 7 1 6 3 2 85 2 8 I 2 5 3 2 85 M372 I 373 27169 3 4 3 3 3 13 3 4 3 3 M472 473 4 5 4 8 7 6 Lord 817 6 M502 503 s 128 Vlei 1157105 128 17 M572 573 716 12 8 11 7 11 5 10 5 12 87 11 7 M602 603 M672 673 22 57 20 22 5 20 20 18 225 20 22 5 20 M702 703 35 32 35 32 M772 773 35 32 35 32 M872 873 53 45 53 45 M972 973 90 87 90 87 Vent Plug 26 Op YILMAZRED KT RN4 na Oil filling FH Oil level Symbols Nr Drai2. M Series 5 6 Stages Oil Quantities Symbols M2 A B M3 A B M4 A B 1 7 0 6 T5706 17706 2 85 0 95 33 095 2 0 0 7 3 0 7 2 85 0 95 33 0195 26 07 7 6 2 1 7 01 2 1 7 6 2 1 5 1 4 117027 1057 2 NR 7 5 1 4 11 7321 10 5 2 11 7121 7 5 1 4 20 3 4 18731 20 3 4 10 9 7283 20 3 4 18 3 1 20 3 4 10 5 2 8 32 3 4 28731 32 3 4 20 2 8 32 3 4 28 3 1 32 3 4 20 2 8 45 3 4 1 7 10 55 SES 1 5 0 5 45 3 4 1 7 10 55 28 2 8 1 2 0 4 2 85 0 8 25 07 2 85 0 8 2 4 0 65 3 3 0 8 3 0 7 3 3 0 8 2 6 0 65 1 612 WE 1 672 5 13 11 772 10 5 1 9 11 7 2 15113 NR 105 219 11 702 or leo 20 3 3 18 3 20 3 3 10 5 2 6 20933 18 3 20733 105726 na Oil filling 374 YILMAZ RED KT R Nr Drain plug v i Oil level Vent Plug 29
3. LAT 1 Shaft 2 Bearing 7 3 Coupling Hub 7 2 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 ae ane 1 Hub 574 YILMAZ RED KT R pi 21 Operating Instructions M N Series Installing 7 3 Fitting Couplings 7 3 1 By fitting couplings be sure that there is some clearance between the two elements R T 7 3 2 By fitting couplings be sure that there is no eccentricity between the two shafts 7 3 3 By fitting couplings be sure that the two shafts are not angular miss aligned 22 YILMAZ RED KT R 4 Operating Instructions M N Series Maintanence and Inspections 8 Maintenance and Inspections Under normal ambient and working conditions the gear unit should be checked according the following intervals For definition of normal working conditions refer to the product catalogue Selecting Gearbox section
4. Every 3 000 working hours Every 4 000 working Every 10 000 working Every 25 000 item to check replace or every 6 months hours hours or every 3 years working hours Check for oil leakage 7 Check for oil level Check oil leakage from seal Check Rubber buffer x Change if necessary Check Bearings Noise x Change if necessary Change Mineral Oil x See Below for details x See Below for Change Synthetic PAO 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 reference For M series Mineral oil is used unless it is differently ordered For oil type and quantities refer to the following tables il For normal ambient conditions 70 degrees Celsius oil bath temp Should be taken as 574 YILMAZ RED KT R pi 23 Operating Instructions M N Series Lubrication 9 Lubrication 9 1 Oil Types Ambient Temperature DIN C 51517 3 Lubricant Forced Mm Lubrication Beyond Castrol Kluber Sew Lubrication ISO gi vet Energol GR XP 680 LUBRICATION Kluberoil GEM 1 680 N Mobilgear XMP 680 Energol GR XP 460 Kl beroil GEM 1 460 N
5. 25 025 2 85 0 25 2 4 0 25 2 4 0 25 1 9 0 25 3 3 0 25 3 0 25 3 3 0 25 2 6 0 25 2 6 0 25 4 0 4 7 6 0 4 7 0 4 7 6 0 4 5 0 4 5 0 4 6 0 50 11 7 0 50 10 5 0 50 11 7 0 50 7 51050 7 5 0 50 6 0 50 il 10 50 10 5 0 50 11 7 70 50 1 510 50 we ov 050 8 5 0 90 20 0 90 18 0 90 20 0 90 11 0 90 10 5 0 90 85 090 20 0 90 18 0 90 20 0 90 110 90 10 5 0 90 18 1 32 1 28 1 32 1 20 1 20 1 18 1 32 1 28 1 32 1 20 1 20 1 20 2 15 45 2 15 39 2 15 45 2 15 28 2 15 28 2 15 Symbols 50 7 87 7 na Oil filling Nd Drain plug 80 7 8717 6577 FH Oil level 69 7 Vent Plug YILMAZ RED KT R 4 Operating Instructions M N Series Lubrication Oil Levels Plugs and Quantities
6. 35 32 30 28 35 32 N772 773 39 32 30 28 39 32 N872 873 N972 973 Symbols na Oil filling 374 YILMAZ RED KT R 53 45 45 39 Nr Drain plug 53 45 v i Oil level Vent Plug 2 Operating Instructions M N Series Lubrication Oil Levels Plugs and Quantities 28 M1 A B M2 A B M Series 4 Stages Oil Quantities M3 A B M4 A B M5 A B M6 A B 1 6 0 25 22854 0 25
7. Mobilgear XMP 460 Energol GR XP 320 Kluberoil GEM 1 320 N Mobilgear XMP 320 Mineral Oils Energol GR XP 220 Kluberoil GEM 1 220 N Mobilgear XMP 220 Energol GR XP 150 Kluberoil GEM1 150 N Mobilgear XMP150 Energol GR XP 100 Energsyn SG XP 680 Kluberoil GEM 1 100 N Klubersynth GH 6 680 Mobil Glygoyle 680 Energsyn SG XP460 Aphasyn PG460 Klubersynth GH 6 460 Mobil Glygoyle 460 Energsyn SG XP320 Aphasyn PG320 Klubersynth GH 6 320 Mobil Glygoyle 320 Energsyn SG XP 220 Aphasyn PG 220 Klubersynth GH 6 220 Energsyn SG XP 150 Aphasyn PG 150 Klubersynth GH 6 150 Klubersynth GH 6 100 Klubersynth GEM4 680 N Mobilgear SHCXMP680 Synthetic Enersyn EP XF 460 Alphasyn T 460 Klubersynth GEM4 460 N Mobilgear SHC XMP460 Oils Enersyn EP XF 320 Alphasyn T 320 Klubersynth GEM4 320 N Mobilgear SHC XMP 320 Enersyn EP XF 220 Alphasyn T 220 Klubersynth GEM4 220 N Mobilgear SHC XMP 220 Enersyn EP XF 150 Alphasyn T 150 Klubersynth GEM4 150 N Mobilgear SHC XMP 150 CLP NSF H1 Food Grade Oil CLPE Bio degra dable Oil Mineral Greases 120 Working Temperatures C 20 Energrease LS 3 Synthetic Greases 30 100 Working Temperatures C 24 Energrease SY 2202 Optileb GT 320 Tribol BioTop 1418
8. 1039 26 20 3 3 18 3 20 3 3 10 5 2 6 BY 383 28 3 Se 20 2 6 32 3 3 28 3 3213 3 45 3 3 28 2 6 20 2 6 Symbols na Oil filling 374 YILMAZ RED KT R Nr Drain plug 87 7 6 v i Oil level 65 5 Vent Plug 31 Y C O par O Bn fe Y E O Ke Sum O Y Q Y O n A LD o E ew UI e gt 3 O ss 9 4 Mounting Positions M Series N Series Indicated mounting positions are determined as reference directional position of the gearbox Mounting surfaces are not binding 32 YILMAZ RED KT R 4 Operating Instructions M N 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 anything if you are not sure what you are doing and contact YILMAZ REDUKTOR Any change or operation done without the informa tion of YILMAZ REDUKTOR is in your own risk and responsibility and YILMAZ REDUKTOR does not take any responsibility Gearbox Does Not Start Up Gearbox Does Not Start Up Gearbox Does Not Start Up Gear
9. 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 celsius 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 celsius ambient conditions the gear unit surface temp could be so high causing burns when touched YILMAZ RED KT R 4 Operating Instructions M N Series Safety N 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 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 mechanical installation part ae 4 5 Case of Fire The gear reducer itself is not combustible However it usually contains a synthetic or mineral 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 IN foam
10. Cikis Mili Flan Merkezleme Toleranslar Merkezleme Faturas DIN748 Faturas Toleranslar 50mm ye kadar k6 ap 50mm zeri m6 N tipi EE A TE men e e REG KE EE NR 6 3 Check the ambient temperature The ambient temperature must be between 5 celsius to 40 celsius 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 60Hz up to 3kW includ ing 3kW and 400 690 V 50 60 Hz over 3kW and is indicated on the motors name plate unless it is differently ordered In case of only gear unit is supplied from YILMAZ please observe the name plate of the electric motor and the instructions of the supplier Check the basic electric connection diagrams below Use experienced electric technician Using wrong connection or voltage can damage the electric motor or environment YILMAZ RED KT R 4 Operating Instructions M N Series Electricity The following wiring diagram is for standard 230 400 V 50Hz AC electric motors For different voltages please contact YILMAZ REDUKTOR For gear units supplied without motor refer to the motor manufacturers user manuel 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 Power at 400V 50Hz Pole Number 2
11. 320 Spheerol AP3 Klubersynth GEM4 100 N Kluberoil 4 UH1 320 N Klubersynth GEM 2 320 Centoplex 2 EP Petamo GHY 133 N Mobil SHC Cibus 320 Mobilux EP 3 Mobiltemp SHC100 Cassida Fluid GL 320 Alvania RL3 Cassida RLS 2 YILMAZ RED KT R 4 Operating Instructions M N Series Lubrication as as 9 2 Changing the Oil Refer to the nameplate to find out the correct oil type filled inside the gearbox Do not mix synthetic oils with mineral oils which will cause serious damage to the ear unit The oil change must be done by using the filling draining and level plugs according the mounting position illustrated at oil plugs tables Extended intensive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin immediately Hot oil can cause scalding When changing oil protect yourself against contacting hot oil use protective gloves 374 YILMAZ RED KT R gt gt 0 25 Operating Instructions M N Series Lubrication 9 3 Oil Levels Plugs and Quantities
12. 4 Operating Instructions M N Series Lubrication Oil Levels Plugs and Quantities N Series 5 6 Stages Oil Quantities M2 A B M3 A B M4 A B 1 7 0 6 1 5 0 5 1 7 0 6 285 095 25 07 285 095 3 3 0 95 3 07 3 3 0 95 7 6 2 1 11 7 12 1 7 01 2 1 16 21 11 7721 7 5 1 4 1172072 117 022 7 5 1 4 20 3 4 20 3 4 10 5 2 8 20 3 4 20 3 4 10 5728 32 3 4 32 3 4 20 2 8 32 3 4 32 3 4 20 28 45 3 4 45 3 4 28 2 8 87 8 1 7 10 55 2 85 0 8 25 07 87 8 1 71 0 55 2 85 0 8 1 2 0 4 1 2 0 4 65 33 2 4 0 65 3 3 0 8 3 0 7 3 3 0 8 2 6 0 65 7 6 2 S 7 6 2 Sl 7 6 2 7118 7 6 2 5 13 11772 1025 1 9 UR TOS 11 7 2 105718 11 732 TOT Tc 20 33 18 3 20 33
13. EE 14 Og ON et 15 6 Insfalling the Gear Unit ueber 15 SEH eee 121 8 oun de e ga A YY eee ener een 15 6 2 Checking E a de Maut RS soccer tec cet oe ered ee 16 6 3 Checking ambient temperatures aaa i laa lal asla yalin a anal 16 6 4 Checking voltage Sup ON asel nee lay yali gl kl neee sl reis 16 YILMAZ RED KT R KA Operating Instructions M N Series Contents 6 5 Checking mounting OO SON ME 19 6 6 HOW t0 se Dreaiher BUG eege 19 AER Checking oll Tevel EEN 19 6 8 Checking shaft ends and mounting faces ssssssssssneeenenn enke nenne nnnennnenenenennn 19 6 9 Protection from corrosive envitropment anne nano nnne anne nnnnnnnn 19 6 10 Checking accessibility to oil DINGS aa 20 Mechanicalinstallatlon aaa aaa nan ana 20 7 1 Installing output shaft elemente sets 21 7 2 Correct position of output shaft elements nennen nenn nenn nenne 21 P SOU CONNECCION een 22 8 Maintenance amp Inspection asiri minnie Grain amana d yada ge alba LENE E NERE ERR Ee 23 KE e gz fg A e en 24 e f RR YE MA MM AE 24 e e pe A E 25 I IE e gt ge d E 26 J4 kd pe FO SUNS aan ee ee ee 32 10 TroubleshootingGuide eee aaa aaa asan ennnen 33 FED POS EE 36 TED sb e A A YY PN A 36 T2 Re e e NR ee ee 36 11 3 Disposal of metal PATE ee ayal ila anla ayal amli Sage lanma alla 36 12 AppendiX EE 37 12 1 Warranty COMGINOING MN 38 12 2 Wa
14. N Series Safety Heel pi EH 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 maximum permitted values are indicated on the nameplate of the product But the all 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 require ments of the directive 2006 42 EC The gearbox must be started up maintained and oper ated 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 data provided on nameplate catalogue 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
15. YE Telephone 90 0 212 886 90 01 6 lines Fax 90 0 212 886 54 57 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 Factory Tel 90 0 212 886 90 01 8 line 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
16. 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 celsius and no abrasive media must attack the paint and seals If different working conditions this must be informed to YILMAZ REDUKTOR 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 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 374 YILMAZ RED KT R 1 Operating Instr
17. starting up condensator and running condensator as well If nothing helps go to ID 100 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 supply to the motor according the motors nameplate Still does not work go to ID 100 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 manufacturers manuel If brake is supplied from YILMAZ observe this manuel for correct brake wiring diagram If still not work supply the brake with voltage according its nameplate directly For example 198 V 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 clicking 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 chosen motor Go to ID 003 33 Operating Instructions M N Series Troubleshooting Guide Q K Gearbox Does Not Work in Low speeds Frequencies Gearbox Does Not Start Mornings or Afte
18. 30V A 400 V Y 400V 2 gt Basic motor connection wiring diagram LI L2 L3 LI L2 L3 230V 230V 400V 400V 230V 400V I1 J EN I3 J 1 EN I3 J w2 We wm uz v2 e Ce Ce Ll 12 Ce A Y 374 YILMAZ RED KT R Operating Instructions M N Series Electricity Standard type brakes basic wiring diagram The gearbox and the motor must be grounded to prevent potential differences of earth and gearbox motor The electric connection must be done by experienced electric technician Delayed Running Brake 380 V Sudden Brake 380 V L1 L2 L3 N L1 L2 L3 N A o e Brake Coil Brake Coil M M IT Delayed Running Brake 24 V Sudden Brake 24 V L1 L2 L3 N Brake Coil L1 L2 L3 N Brake Coil i f gt 4 In Ke In SS te YILMAZ RED KT R KA Operating Instructions M N Series Installing 6 5 Check the mounting p
19. Operating Instructions M N Series Lubrication Oil Levels Plugs and Quantities 30 N Series 4 Stages Oil Quantities M1 A B M2 A B M3 A B M4 A B M5 A B M6 A B 1 620 25 2 83 10 25 257 025 2 85 0 25 2 4 0 25 2 4 0 25 1 9 0 25 3 3 0 25 3 0 25 3 3 0 25 2 6 0 25 2 6 0 25 4 10 4 7 6 0 4 710 4 7 6 0 4 5 0 4 5 0 4 6 0 50 11 7 0 50 10 5 0 50 11 7 0 50 7 5 0 50 7 5 0 50 8 5 0 90 20 0 90 18 0 90 20 0 90 11 0 90 10 57090 18 1 32 1 28 1 32 1 20 1 20 1 Symbols 20 215 na Oil filling 45 2 15 325 Drain plug V 45 2 15 FH Oil level 28 2 15 281215 Vent Plug YILMAZ RED KT R
20. P K 34522 Esenyurt stanbul TURK YE Telephone 90 0 212 886 90 01 8 line Fax 90 0 212 886 54 57 gt 4 YILMAZ REDUKTOR Warranty Decleration and Instruction Manual Receipt Form YILMAZ REDUKTOR products are warranted for 2 Two years covering all parts and materi als 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 Address ATATURK Mah Lozan Cad No 17 P K 34522 Esenyurt Istanbul TURKIYE Telephone 90 0 212 886 90 01 8 line 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 instruction 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 ATAT RK Mah Lozan Cad No 17 P K 34522 Esenyurt stanbul TURK
21. YILMAZ REDUKTOR ISO 9001 YILMAZ REDUKTOR ISO 9001 v YILMAZ RED KT R M N Series Gear Units OIMCE 0106 1112 Operating Instructions Operating Instructions M N Series Contents gym eee 02 1 HowtoUselhisManual aaa asama nun anne 04 2 Unit Designati ON e a lr un nnmnnn nne 05 2 1 Detailed Unit Designall n nennen 05 2 2 Nameplate UnitDesignatlon erener 06 3 Standard Type Gearbox Part List nun an 07 SIM VPE 3 SLAG LE 07 32 N YPE 3 E e TC 08 3 3 M N Additional Stage for 4 Stage Types sssssssssssssccsssssssscssscccceecees 09 3 4 M N Motor FlangeforDirectCouplediypes 10 3 5 M N Types B5 B14 Motor Flange 000000000000000oooooooooonnnnnenssssnnnnnnnee 10 3 6 M N Types Input Bearing Housing with Solid Input Shaft 10 AL E 11 A 1 IN EHE T ee a ee ee 11 4 2 MPLODEL USO en ner een 11 4 32 Dare INS UCONN EY ee ee 12 4 3 1 General Safety Instructions nenn nenn nnnn nano anne nenn nennen 12 4 3 1 1 Working on the Gear Un 12 4 3 1 2 e Le E 12 4 3 1 3 IAN er 12 4 3 E E e gt EE 12 4 3 1 5 Ambient Conditions KE ee 12 4 4 eier aile Melen 13 ASS Ol EE 13 4 5 1 Suitable Extinguishing AgENIS u anne 13 4 5 2 Unsuitable Extinguishing Adennen 13 es LIAS e CREEK riage see ee E E need 14 Un SOON All OWN
22. ain may have caused the damage Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigid You are using chain drive or enough Check if you are using the correct diameter of pinion gear chain drive and you are not exceeding max allowed ra dial load Check the position of your output element and re calculate your radial load and check if this fit to the maximum allowed radial load Go to ID 100 Output Shaft is Defect Please check the wiring diagram of the brake There are two different kind of brake wiring diagram The standard gearbox delivered from our factory is set to delayed brak ing For sudden braking check the wiring diagram Gearbox is stopping too late 027 You are using braked motor For fast opening of big brakes over 100 Nm you may Gearbox is starting too late You are using braked motor need shock transformers which is supplied by YILMAZ Go to ID 100 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 REDUK Service Required No self solution found TOR or with information of YILMAZ REDUKTOR Any change without informing YILMAZ REDUKTOR will can cel the warranty manufacturer declaration and YILMAZ REDUKTOR will take no responsibility 11 Disposal lf your product is no longer of use and you wish to dispose it refer to the instructions here If you have any questions regarding ecol
23. box Does Not Start Up Gearbox Does Not Start Up You hear no noise and shaft is not turning You are not using any driver or frequency inverter You hear no noise and shaft is not turning You are using frequency inverter or driver You hear some noise but both motor shaft and gearbox shaft is not turn ing You are not using any driver frequency inverter or braked motor You hear some noise but both motor shaft and gear box shaft is not turning You are using driver or frequen cy inverter You hear some noise but both motor shaft and gear box shaft is not turning You are using braked motor 374 YILMAZ RED KT R Please Check the voltage supply and freguency 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 Please observe the frequency inverter driver manual Check the motor by supplying direct voltage to see if the problem is on your driver frequency inverter Still does not work go to ID 001 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 chosen motor Loosen the gearbox from the load torque If it works than the starting torque is insufficient and higher motor power is needed For mono phase motors check the
24. ear 17 Key 25 Cover 33 Oil plug 10 Bearing 18 Seal 26 Circlips 34 Bolt 11 Circlips 19 Circlips 2 Bearing 35 Eye bolt 12 Cover 20 Bearing 28 Gear 36 Oil plug 13 Output Flange 21 Spacer 29 Key 37 Top side cover 14 Bolt 22 Gear 30 Gear 38 Screw Pin 15 Key 23 Bearing 31 Bearing 16 Output Shaft 24 Circlips 32 Circlips YILMAZ RED KT R 4 lications Operating Instructions M N Series Parts Designation 3 3 M N Additional Stage for 4 Stage Types MN additional stage for 4 stage types part diagram Standard Parts List Circlips 9 Gear Bearing 10 Circlips Gear 11 Key Oil plug 12 Key Bearing 13 Bolt Circlips 14 Additional Housing Shaft 15 Screw Pin Seal 374 YILMAZ RED KT R 9 Operating Instructions M N Series Parts Designation 3 4 M N Motor Flange for Direct Coupled Types Parts List 6 Key Gear 8 Circlips 9 Nut 10 Key 3 5 M N Types B5 B14 Motor Flange Parts List 1 Shaft 6 Seal 2 Circlips 7 Gear 3 Bearing 8 Circlips 4 Circlips 9 Nut 5 B5 B14 Flange 10 Key Parts List 7 Circlips 8 Gear 9 Circlips 10 Key 11 Key 100 YILMAZ RED KT R KA Operating Instructions M
25. emble 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 damage Goto ID 100 YILMAZ RED KT R KA Operating Instructions M N Series Troubleshooting Guide Check Your moving parts for noise Disassemble the gearbox Gearbox is noisy Regular knocking noise and run without load If you still hear the noise one of the gears inside is defect Go to ID 100 Check the output shaft connection elements for run out Take Regular up and down out the output shaft element and run without load If you still Gearbox is noisy noise hear the noise one of the gears has run out problem Go to ID 100 Gearbox is with braked motor and noise is coming from the brake side ran domly Low randomly clicking noise may come from the brake disk which is normal If noise level is disturbing the brake may be defect or brake clearance is not adjusted Go to ID 100 Gearbox is noisy You are using frequency The frequency inverter parameters are not optimise for the inverter and the noise frequency range or motor you are using Observe the frequency level is changing inverters manual If still same problem change the ratio of gear according your speed box Go to ID 100 If ambient Temp is over 40 Celsius or none stop work over 16 Se i hours please change the top plug with a breather plug Observe O
26. fog easy accessible around the gear unit High temperatures produce irritating steam Use a protective breathing appreciates 4 5 2 Unsuitable extinguishing agents Do not spray with water 374 YILMAZ RED KT R 00000 a B Operating Instructions M N Series AN Checking 14 5 Things to Check Before the Gear Unit or Geared Motor is Installed If gear 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 Thinks 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 im mediately 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 upper foot connection holes for lifting up the gear unit by using eyebolts The eyebolts should be capable to carry the weight of gearboxes Do not hang additional loads on the gear box by lifting Use suitab
27. il 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 Celsius degrees 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 during this time is recommended If stored in open areas protect against insect damage 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 the temperature class and are different from standard type geared units Therefore Standard units can not be installed on Potentially explosive atmospheres 374 YILMAZ RED KT R 0 B Operating Instructions M N Series Installing 16 6 2 Check Shaft Dimensions and Tolerances
28. il is Leaking Oil Leakage from Seal i i _ this manual for using breather plug If this is not your case the seal could be damaged Go to 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 posi Oil is Leaking Oil Leakage from Plug tion The plug may be not tight enough There are some parti cles under the plug rubber surface Clean and tighten the plug If still same problem go to ID 100 Gearbox is noisy Observe exactly where the oil is coming out It could be seal or plug point where it comes out and leaks over the housing If Oil is Leaking Oil Leakage from Housing this is your case go to ID 018 019 If you are sure oil comes out from housing than housing has some micro split crack Go to ID 100 The sealing liquid under cover is split defect Disassemble Oil is Leaking Oil Leakage from Cover the cover and put new sealing liquid Assemble the cover and tighten the bolts If still same problem go to ID 100 Gearbox is mov The movement of gear box is because of the run out of the ing regularly on its You are using Torque Arm shaft which you assemble the gearbox This has no bad af mounting point fect or harm to the gearbox and is normal unless you are using torque arm The movement of gear box is because of the run out and clear ance of the shaft which you assemble the gearbox Check the clearance of the assembling shaft and the clearances on y
29. le hoisting equipment which is capable to hold the gear units weight Refer to the catalogue for various types weights If the earbox is delivered with steel carrying construction use the construction holes for lift ing the gear unit See drawing bellow for hoisting point Do not stay beneath under the lifting hoisting eguipment which may cause serious injuries by falling 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 weigh of our gear unit Ensure that the load is slowly and carefully handled and placed YILMAZ RED KT R 4 Operating Instructions M N Series AN Checking 5 2 Storage If the geared unit or geared motor will be stored up to 3 years refer to the following instructions With Packing Use corrosion protection oil for the output shaft and connection surfaces like flange surface 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 Relative 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 Celsius degrees Without Packing Use protection o
30. me 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 warranty 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 Istanbul TURKEY Phone 90 0 212 567 93 82 83 Fax 90 0 212 567 99 75 Factory YILMAZ REDUKTOR Sanayi ve Ticaret A S ATATURK Mah Lozan Cad No 17
31. n plug Operating Instructions M N Series Lubrication Oil Levels Plugs and Quantities Type N Series 2 3 Stages Oil Quantities M1 M2 M4 N002 003 N102 103 0 4 0 35 0 65 0 6 0670155 0 95 0 8 0 7 0 7 0 6 0 55 0 95 0 8 N172 173 077065 0 95 09 0 8 0 8 095709 N202 203 1271 2 1 2 2 1 9 2 1 2 N272 273 de zl A Mail ES Pad ied N282 283 1 7 11 6 3 2089 2 8 2 5 3 2 85 N372 373 Zn 3 4 3 3 3 3 3 4 3 3 N472 473 4 5 4 8 7 6 7 5 7 8 7 6 N502 503 716 12 8711 7 11597105 12 8 11 7 N572 573 716 12 8 11 7 11 97 10 5 12 8 11 7 N602 603 225120 20 18 225 20 N672 673 22 5 20 20 18 22 5 20 N702 703
32. o work under max 120 Celsius If higher than 120 Celsius and using ATEX conforming gear box immediately stop the system and contact YILMAZ REDUKTOR Go to ID 100 If not ATEX confirming check the oil type and oil guantity level according your mounting position and check the nameplate mounting position If nameplate mounting position does not fit the actual position go to ID 100 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 conform ing gearboxes are designed to work under max 120 Celsius If higher than 120 Celsius and using ATEX conforming gear box immediately stop the system and contact YILMAZ REDUKTOR If not ATEX gearbox the gearbox is designed to work under max 80 Celsius If higher than 80 Celsius check the oil type and oil quantity level according your mounting position and check the nameplate mounting position If nameplate mounting position does not fit the actual position go to ID 100 Standard Gearboxes are designed to work under 40 Celsius ambient temperature If ambient temp is higher than 40 Celsius special solutions gearboxes are required Please contact YILMAZ Check Your moving parts for noise Disassemble the gearbox and run without load If you still hear the noise motor bearings or gearbox bearings are defect Change bearings Go to ID 100 Check Your moving parts for noise Disass
33. ogical disposal methods please consult our service points given on the backside of this manual 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 guidelines 11 2 Disposal of Sealing Remove the sealing rings from the gear reducer and clean them of oil and grease residues Dispose of the sealing as composite material metal plastic 11 3 Disposal of Metal Divide up the remainder of the gear reducer into iron aluminium non ferrous heavy metal if pos sible Dispose of it according to the valid national guidelines 36 YILMAZ RED KT R 4 gt 4 YILMAZ REDUKTOR Warranty Conditions 1 The geared motors and gear units are warranted for two year except the electric mo tor 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 document and last for two years If the start up time is more then three months after the billing ti
34. or 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 YILMAZ RED KT R 4 Operating Instructions M N Series Type Designations 2 Unit Designation 2 1 Detailed Unit Designation M R 47 3 90S 4 L02 Brake L 220V With Fan P 24V With Fan S 220 V Without Fan Z 24 V Without Fan 01 10 Nm 10 100 Nm 02 25 Nm 20 200 Nm 04 40 Nm 30 300 Nm 05 50 Nm 40 400 Nm Motor Size For MV NV Types For MN NN types 90S 4 A06 63 B5 A09 90 B5 B06 63 B14 B09 90 B14 Pole Number A07 71 B5 A10 100 B5 Fame Lengt B07 71B14 B10 100 B14 N A08 80B5 A11 112 B5 B08 80B14 B11 112 B14 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 Without Motor RF With Motor and Output Flange Foot Mounted M Type RB With Motor Agitator Neck at Output N Type TF Without Motor and Output Flange Foot Mounted M Type TB Without Motor Agitator Neck at Output N Type Gearbox Type M Series N Series 374 YILMAZ RED KT R A13 132B5 A25 250B5 B13 132 B14 A28 280 B5 A16 160 B5 A31 315 BS A18 180 B5 A20 200 B5 A22 225 BS Operating Instructions M N Series Type Designations 2 2 Nameplate uni
35. osition 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 dif ferent 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 manual 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 M Series under normal ambient and working conditions Up to 30 degree Celsius 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 MT 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 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
36. our machine This has no bad affect or harm to the gearbox unless you are using torque arm Gearbox is mov ing randomly on its You are using Torque Arm mounting point Motor is running over its Moto i Nang UP mina current The motor power is not enough or some overload to the motor is possible The motor may be defect Go to ID 100 Check the motor Fan Hub and rips They must be free of dust If you are using forced external fan check if it is working f you are using frequency inverter in low speeds and you do not have forced external fan you may need forced external fan Go to ID 100 Motor is heating up Ambient is dusty 374 YILMAZ RED KT R 25 Operating Instructions M N Series Troubleshooting Guide lee eme Ramey ooo Motor is running but Gear box shaft does not turn Some part key gear may be defect inside gearbox Scratching noise comes out Go to ID 10 The radial load or polygon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigid You are using chain drive or enough Check if you are using the correct diameter of pinion gear chain drive and you are not exceeding max allowed ra dial load Check the position of your output element and re calculate your radial load and check if this fit to the maximum allowed radial load Go to ID 100 Gearbox Housing is Defect The radial load or polygon effect of the ch
37. r Long Time Stop Gearbox is Heating Up too Much Gearbox is Heating Up too Much Gearbox is Heating Up too Much Gearbox is noisy Gearbox is noisy You are using frequency inverter Ambient Temperature is below 5 Celsius You are using Worm Gear Box and ambient temperature is lower than 40 Celsius You are using Helical Gear Box Ambient temp is lower than 40 Cel S US Ambient Temp is over 40 Celsius Noise is regular continuous Noise is random For very low speeds the frequency inverters frequency is lower ing down For very low frequencies the inverter parameter and motor parameter must be optimise Also for low speeds the efficiency of the gearbox may vary too much Specially for worm gearboxes The recommended frequency 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 recommended range The oil is not in accordance with your working conditions Change to lower viscosity oils Observe this manual 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 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 conform ing gearboxes and standard worm gearboxes are designed t
38. rrantiypaper eee 39 Ze e EE 40 574 YILMAZ RED KT R pi 3 Operating Instructions M N Series General Informations 1 How To Use This Manual Take attention to the following safety and warning signs for proper understanding and quick reference m gt Electric Hazard Can cause severe or fatal injuries Mechanical Hazard Can cause severe or fatal injuries Likely to be Hazardous Can cause minor injuries Damage Risk Can damage the drive or environment Important Information EC Machinery Directive Within terms of the EC machinery directive 2006 42 EC the gear reducer is not considered an 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 regulations 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 M and N Series gear units and is applicable only for M and M 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 f
39. 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 by loosening or braking the gear unit Even the gear unit is installed totally correctly according this Manuel 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 Turn ing parts can cause severe or fatal injuries For different kind of basic installations refer to the following illustrations YILMAZ RED KT R 4 Operating Instructions M N Series Installing 7 1 Fitting output shaft elements Use the following illustration to assemble output shaft units 1 2
40. t designation Nameplate unit designation is a short abbreviation from the detailed designation A sample name plate for M Series a YILMAZ REDUKTOR YILMA www yr com tr C RED KT R MADE IN TURKEY Type MR473 90S 4 Serial N 100658986 Power 1 1 kW Ratio 219 Speed 6 4 rpm M Pos M1 Oil ISO VG 320 Mineral Oil Qty 4 Abbreviations Serial N Serial Number M Pos Mounting Position MR473 90L 4 Type Motor Size Serial Number 100658986 YILMAZ RED KT R 4 Operating Instructions M N Series Part Designation 3 Standard Type Gearbox Part List 3 1 M Type 3 Stages Standard M type 3 stages basic part diagram Parts may differ for special applications Parts List 9 Gear 17 Circlips 25 Bearing 33 Eye Bolt 10 Bearing 18 Bearing 26 Gear 34 Oil plug 11 Circlips 19 Spacer 2 Key 35 Top Side Cover 12 Cover 20 Gear 28 Gear 36 Screw Pin 13 Output shaft 21 Bearing 29 Bearing 14 Key 22 Circlips 30 Circlip 15 Key 23 Cover 31 Oil plug 16 Seal 374 YILMAZ RED KT R 24 Circlips 32 Bolt Operating Instructions M N Series Parts Designation 3 2 N Type 3 Stages Standard N type 3 stages basic part diagram Parts may differ for special a Parts List 9 G
41. 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 374 YILMAZ RED KT R gt 18 Operating Instructions M N Series Installing 20 6 10 Check accessibility to filling breather and drain plugs The filling breather and drain plugs must be freely accessible for further checking and
42. uctions M N Series Safety 12 gt PP PE DPD 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 technician 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 suit able 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 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
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