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1.                    L1 L2 L3 L1 L2 L3   230V   230V   400V   400V    230V   400V      1 12 1 13 T   r 12  13 1                                       an   2          LI L2    A Y    28 YILMAZ RED  KT  R   4    Operating Instructions  E Series  Mounting    Standard type brakes basic wiring diagram          The electric connection must be done by experienced electric technician   AN The gearbox and the motor must be grounded to prevent potential differences of earth    and gearbox motor     Delayed Braking                                                                                         220 V   RST  OOO en  Fren Bobini  M  3     Delayed Running Brake   24V   RSTN Fren Bobini  27 LZ                 P  r                               Sudden Braking                                                                                                        220 V   RSTN    gt   Ooo  o   Fren Bobini  M  3      Sudden Brake   24 V    RSTN Fren Bobini                                                                         374 YILMAZ RED  KT  R                                                                29    Operating Instruction  E Series  Mounting    30       6 5  Check the mounting position    The mounting position must be in accordance with the mounting position mentioned on the  name plate  If different please contact YILMAZ REDUKTOR for possibilities of using in a  different mounting position  Refer to the mounting positions and oil guantities on this manual  and adjust the oil
2.            7 7 3  By fitting couplings be sure that the tvvo shafts are not angular miss aligned                                      374 YILMAZ RED  KT  R 39    Operating Instruction         E Series A    Maintenance and Inspections 9    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      Every 3 000  working hours  or every 6 months    Every 10 000  working hours or  every 3 years    Item to check   Replace Every 4 000 working    hours    Every 25 000  working hours       Check for oil leakage x       Check for oil level       Check oil leakage from seal x       Check Rubber buffer x  Change if necessary        x  Change    Check Bearings Noise if necessary        x  See Below for    Change Mineral Oil details        x  See Below for    Change Synthetic PAO Oil details        Change Sealing       Change Bearing Grease       Change Bearings       Check for noise Changes                      45000  40000 L  35000 N  30000    25000  20000  15000  10000  5000                  Mineral      Synthetic PAO       SyntheticPG                Oil change interval  Hours                 70 80 90 100 110 120 130 140 150 160  Oil bath temperature  Celcius        14  For normal ambient conditions 70  C oil bath temperature should be taken as reference    Synthetic oil are using in E 030
3.     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       PPP PP PER BPE       374 YILMAZ RED  KT  R 23    Operating Instruction  E Series    Safety    A  A    24    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   Tightining    M16 190  M20 370      540       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 ext
4.    L       35    374 YILMAZ RED  KT  R    Operating Instruction         E Series   2    Mounting 2    7 4 2  Assemble the parts      shown bellow                            1  Bolt 4  Moment Kolu  5  Makina Ba  lant   Kolu       36 YILMAZ RED  KT  R x   4    Operating Instruction    E Series  Mounting    7 4 3  For the fixing bold position refer to the following dimensions                                                                                  374 YILMAZ RED  KT  R    ap    37    Operating Instruction       E Series  Mounting 2    7 5  Fitting outputshaft elements  Use the following illustration to assemble output shaft units    1 2    1  Gear shaft end  2  Thrust bearing  3  Coupling hub       s    7 6  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            T                                                                         1  Hub                                                                                           38 YILMAZ RED  KT  R   74    Operating Instruction ac     E Series  Mounting 2    7 7  Fitting Couplings  7 7 1  By fitting couplings be sure that there is some clearance between the two elements    7                                                 7 7 2  By fitting couplings be sure that there is no eccentric between the two shafts                                                      
5.    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  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 if the 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 m
6.   E 040  E 050  E 063 E 075  E 080 types and Mineral oil  are using for E 100 and E 125 types     40 YILMAZ RED  KT  R   74    Operating Instruction  E Series  Lubrication    9 Lubrication  9 1 Oil Types      evre S  cakl          C   Ambient Temperature    C   Umgebungstemperatur    C   Yag Cinsi DIN    Beyond  Petroleum    Kl  ber  Lubrication          Lubricant 51517 3    2 Bas  ngl    Art des Schmiers    Yaglama  Forced  Lubrication  Druckschmier     Dald  rma  Yaglama  Dip Lubrication  Tauchschmier        bp    KLOBEI  LUBRICATION    Mobil           50    Energol  GR XP 680    Kl  beroil  GEM 1 680 N    Mobilgear  XMP 680          45    Energol  GR XP 460    Kl  beroil  GEM 1 460 N    Mobilgear  XMP 460          40  Mineral Yaglar    Energol  GR XP 320    Kl  beroil  GEM 1 320 N    Mobilgear  XMP 320       Mineral Oil  Mineral  l 22  30    Energol  GR XP 220    Kl  beroil  GEM 1 220 N    Mobilgear  XMP 220           20    Energol  GR XP 150    Kl  beroil  GEM 1 150 N    Mobilgear  XMP 150       Energol  GR XP 100    Energsyn  SG XP 680    Kl  beroil  GEM 1 100 N    Kl  bersynth  GH 6  680    Mobil  Glygoyle 680    Tivela  S 680       Energsyn  SG XP 460    Aphasyn  PG 460    Kl  bersynth  GH 6  460    Mobil  Giygoyle 460    Tivela  S 460       Energsyn  SG XP 320    Aphasyn  PG 320    Kl  bersynth  GH 6  320    Mobil  Glygoyle 320    Tivela  5 320       Energsyn  SG XP 220    Aphasyn  PG 220    Kl  bersyn  GH 6  221    Tivela  S 220       Energsyn  SG XP 150    Aphasyn  
7.   Shaft Tolerance Shaft  Diameter  H8  Diameter                                              6 3  Check the ambient temperature   The ambient temperature must be between  5   C to  40   C for standard type gear units  If  different contact YILMAZ REDUKTOR for special solutions     6 4  Check the voltage supply    The standard geared motors are supplied with 230 400 V 50 60 Hz up to 3 kW including 3  kW and 400 690 V 50 60 Hz over 3 kW and is indicated on the motors name plate unless it  is differently ordered     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 connection  diagrams below  Use experienced electric technician        STOP Using wrong connection or voltage can damage the electric motor or environment     374 YILMAZ RED  KT  R 27    Operating Instruction    E Series  Mounting    The following wiring diagram is for standard 230 400 V 50 Hz AC electric motors  For dif   ferent voltages please contact YILMAZ REDUKTOR  For gear units supplied without motor   refer to the motor manufacturers user manual     The electric connection must be done by experienced electric technician   The gearbox  the motor and the brake must be grounded to prevent potential differences of  earth and gearbox motor        Nominal Powers at 400V  50Hz    230V D  400V Y  400V  D     Pole Number    Starting Principle Direct or Y D    Basic motor connection wiring diagram
8.  Ring       5  Flange 11  Worm Wheel  17  Circlips 23  Input Flange       6  O Ring 12  Bearing 18  Seal 24  Bolt                   374 YILMAZ RED  KT  R 13    Operating Instructions    E Series    Part Designation    3 7  E    08 Types          Standard       08    1    e basic        diagram  Parts may differ for special a    lications        Standard Part List    1  Bolt    7  Bearing    13  Bearing    19  Input Flange       2  Output Flange    8  Worm Wheel    14  Seal    20  Bolt       3  Seal    9  Bearing    15  Oil Plug    21  Seal       10  Housing    16  Worm Gear       5  Side Cover    11  Closing Cap    17  Bearing       6  O Ring    12  Circlips          18  O Ring          YILMAZ RED  KT  R 74    Operating Instructions  E Series  Part Designation    3 8  ET   00 Types          Standard ET   00    type basic part diagram  Parts may differ for special applications   Standard Part List    5  Bearing 11  Bearing 17  O Ring       6  Worm Wheel 12  Seal 18  Flange       7  Bearing 13  Oil Plug 19  Bolt       8  Housing 14  Worm Gear 20  Seal       9  Closing Cap  15  Key                   10  Circlips 16  Bearing    374 YILMAZ RED  KT  R 15    Operating Instructions  E Series  Part Designation       3 9  ET   01    Types          Standard ET  01    type basic part diagram  Parts may differ for special applications   Standard Part List    1  Key 7  Bearing 13  Bearing 19  Bearing       2  Solid Output Shaft  8  Worm Wheel  14  Circlips 20  O Ring       3  Seal 9  Beari
9.  basic part diagram  Parts may differ for special a    lications        Standard Part List    1  Oil Seal    7  Bearing    13  Oil Plug    19  Seal       2  Bolt    8  Housing    14  Worm Gear       3  Side Cover    9  Closing Cap    15  Bearing       4  O ring    10  Circlips    16  O Ring       5  Bearing    11  Bearing    17  Input Flange       6  Worm Wheel       12  Seal       18  Bolt          YILMAZ RED  KT  R 74    Operating Instructions  E Series    Part Designation    3 2 E    01    Types          Standard E   01    type basic part diagram  Parts may differ for special applications   Standard Part List    1  Key 7  Bearing 13  Bearing 19  O ring       2  Solid Output Shaft  8  Worm Wheel  14  Circlips 20  Input Flange       3  Seal 9  Bearing 15  Seal 21  Bolt       4  Bolt 10  Housing 16  Oil Plug 22  Seal       5  Side Cover 11  Closing Cap  17  Worm Gear                   6  O ring 12  Circlips 18  Bearing    374 YILMAZ RED  KT  R 9    Operating Instructions  E Series    Part Designation       3 3  E    02 Types          Standard E   02    type basic part diagram  Parts may differ for special applications   Standard Part List    1  Key 7  Side Cover 13  Closing Cap   19  Worm Gear       2  Solid Output Shaft   8  O Ring 14  Circlips 20  Bearing       3  Bolt 9  Bearing 15  Bearing 21  O Ring       4  Flange 10  Worm Wheel   16  Circlips 22  Motor Flange       5  Seal 11  Bearing 17  Seal 23  Bolt                   6  Bolt 12  Housing 18  Oil Plug 24  Seal    10 Y
10.  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   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 conforming  gear 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     YILMAZ RED  KT  R      4    Operating Instructions    E Series  Control    6 2  Check the shaft dimensions to fit     Output Shaft Flange Centering   Tolerance  DIN748    Centering Sho    Shoulder   Up to 50mm k6 ulder Tolerance  Over 50mm m6 Diameter  g6     Hollow  Hollow Shaft  Output
11.  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 see if oil comes out from that plug  If oil comes out tighten the plug again   If no oil comes out take out the filling plug and add oil until oil comes out from the level plug  and tighten both plugs after finish  Be sure you are using the correct oil mentioned on the  oil tables on this manual     Do not mix synthetic oils with mineral which can cause serious damage on the gear unit     6 8  Check shaft ends and mounting faces    Before you start to installing be sure that all the connection 
12.  s  s   ss seene neee 40  HRS 41  IL RR RE Kr PA SM ee ee 42  9 2 Changing the ON RR nent Een 42  9 3  Mounting FF SUDO 1        A een 42  2218 1817  are ae Ba aaa                  9 43  10 Troubleshooting GU esinin menem dana amaa S  ral AA amman ennn 44  n He      e ai HT 47  11 1 Disposal TH nen anne een 47  11 2 Disposal of sealing 2 en ee ee 47  11 3  Disposal of Me  nee MV e en EYY 47  12 Appendix    une ne ee een 48  122 Warranty  e M   D  N se e e ln a Dias 49  12 3 teni a ab A E          GA betes 49  12 4 Service Contact POUMS aaa ee 51    a YILMAZ RED  KT  R   74    Operating Instructions  E Series  General Informations    1  How To Use This Manual    Take attention to the following safety and warning signs for proper understanding and guick 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     Important Information     H8 Dre    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 
13. 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     
14. 02          Petamo  GHY 133 N       Mobiltemp  SHC 100       Cassida  RLS2          Multis  Complex  SHD 220    41    Operating Instruction  E Series  Lubrication       9 2  Changing the oil  Refer to the nameplate to find out the correct oil filled inside the gearbox      Do not mix synthetic oils with mineral oils which will cause serious damage to the gear unit  The  oil change must be done by using the filling  draining and level plugs according the mounting    position illustrated in section 9 4     as    Extended  intensive contact with oils can lead to skin irritations   Avoid extended contact with oil  and clean oil off skin thorough          Hot oil can cause scalding   When changing oil  protect yourself against contacting hot oil     9 3 Mounting Positions                                                 Figured mounting positions of M1 to M6 are determined as reference of directional position of the gearbox  Mounting surfaces are not binding     a YILMAZ REDUKTOR ya    Operating Instruction  E Series  Lubrication    9 4 Oil Quantities  liter                                                                                                                                                                                                                                                                                                  Oil Quantities  liter                                                  374 YILMAZ RED  KT  R          43    Operating Instruction    E Series 
15. 3  Bearing    19  Key       2  Solid Output Shaft    8  Worm Wheel    14  Circlips    20  Bearing       9  Bearing    15  Washer    21  O Ring       10  Housing    16  Seal    22  Input Flange       5  Side Cover    11  Closing Cap    17  Oil Plug    23  Bolt       6  O Ring    374 YILMAZ RED  KT  R       12  Circlips       18  Worm Gear          24  Seal    19    Operating Instructions  E Series  Part Designation       3 13  ET   05 Types             Standard ET   05    type basic part diagram  Parts may differ for special applications   Standard Part List    1  Key 7  Bolt 13  Housing 19  Oil Plug 25  Bolt       2  Solid Output Shaft   8  Side Cover 14  Closing Cap  20  Worm Gear  26  Seal       3  Circlips 9  O Ring 15  Circlips 21  Key       4  Bolt 10  Bearing 16  Bearing 22  Bearing       5  Output Flange 11  Worm Wheel   17  Circlips 23  O Ring       6  Seal 12  Bearing 18  Seal 24  Input Flange                   20 YILMAZ RED  KT  R   4    Operating Instruction  E Series  Part Designation    3 14  ET    08 Types       Standard ET   08    1    e basic part diagram  Parts may differ for special a    lications        Standard Part List    1  Bolt    7  Bearing    13  Bearing    19  O Ring       2  Output Flange    8  Worm Wheel    14  Seal    20  Input Flange       3  Seal    9  Bearing    15  Oil Plug    21  Bolt       4  Bolt    10  Housing    16  Worm Gear    22  Seal       5  Side Cover    11  Closing Cap    17  Key       6  O Ring    374 YILMAZ RED  KT  R       12  
16. 32    a    Operating Instruction    E Series    Mounting          2  2        o       o   o  F   D                    F                               Bolt             Use the following table for shaft tightening torques     7 2  Shaft tightening torques    Type                            33      74 YILMAZ RED  KT  R    Operating Instruction         E Series 2      Mounting    7 3 Advised Shaft Dimensions and Accessiories  Advised shaft dimensions are indicated below and YILMAZ REDUKTOR provides this di     mensions as standart                                                                                                                                                                                                                                                                                                                                                  Bt Gt    _ G1 B _  I     MT _B2_  g       P 7     p 1 b1           1   L   T   P  iliq                      z S ET I      M      B          Nee       11 2              05  _B3 G1 BM   B2    82   R 21 Ao  e       4                   ap   wE                 6  1  M     M  H     A 00          L L3 al  Ex xxx 02                                                                                        34 YILMAZ RED  KT  R 74    a    7 4 1  Use the torque arm connection according the following drawing     7 4 Torque Arm Connection    Operating Instruction    E Series  Mounting          He                          N          2    2 
17. Circlips          18  Bearing       21    Operating Instruction  E Series    Safety       El H    E    N  N    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 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 hav
18. ILMAZ RED  KT  R 74    Operating Instructions  E Series    Part Designation    3 4  E    03    Types       Standard E   03   t    e basic part diagram  Parts may differ for special a    lications        Standard Part List    1  Bolt    7  Bearing    13  Bearing    19  Motor Flange       2  Flange    8  Worm Wheel    14  Seal    20  Bolt       3  Seal    9  Bearing    15  Oil Plug    21  Seal       4  Bolt    10  Housing    16  Worm Gear       5  Side Cover    11  Closing Cap    17  Bearing       6  O Ring    374 YILMAZ RED  KT  R       12  Circlips          18  O Ring       11    Operating Instructions  E Series  Part Designation       3 5  E   04 Types          Standard E   04    tyoe basic part diagram  Parts may differ for soecial applications     Standard Part List    7  Bearing 13  Bearing 19  Bearing       8  Worm Wheel 14  Circlips 20  O Ring       9  Bearing 15  Washer 21  Input Flange       10  Housing 16  Seal 22  Bolt       5  Side Cover 11  Closing Cap 17  Oil Plug 23  Seal                6  O Ring 12  Circlips 18  Worm Gear       12 YILMAZ RED  KT  R 74    Operating Instructions  E Series  Part Designation    3 6 E    05    Types          Standard E   05    type basic part diagram  Parts may differ for special applications   Standard Part List    1  Key 7  Bolt 13  Housing 19  Oil Plug 25  Seal       2  Solid Output Shaft   8  Side Cover 14  Closing Cap  20  Worm Gear       3  Circlips 9  O Ring 15  Circlips 21  Bearing       4  Bolt 10  Bearing 16  Bearing 22  O
19. 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 liguit  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 You are using Torque Arm which you assemle the gearbox  This has no bad affect or harm to  on its mountin  Int g 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      of the shaft which you assemle the gearbox  Check the clearance of  022 moving randomly          i    You are using Torgue Arm the assemling shaft and the clearances on your machine  This has  on its mountin  ini S no bad affect or harm to the gearbox unless you are using torgue  oin  9 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 m
20. PG 150    Kl  bersynth  GH 6  150    Tivela  5 150       Sentetik Ya  lar  Synthetic Oil    Kl  bersynth  GH 6  100       Synthetisches   l    Kl  bersynth  GEM 4 680 N    Mobilgear  SHC XMP  680       Degol  PAS 460    Enersyn  EP XF 460    Kl  bersynth  GEM 4 460 N    Mobilgear  SHC XMP  460       Degol  PAS 320    Enersyn  EP XF 320    Kl  bersynth  GEM 4 320 N    Mobilgear  SHC XMP  320       Degol  PAS 220    Enersyn  EP XF 220    Kl  bersynth  GEM 4 220 N    Mobilgear  SHC XMP  220       Degol  PAS 150    Enersyn  EP XF 150       Kl  bersynth  GEM 4 150 N    Mobilgear  SHC XMP  150                Kl  bersynth  GEM 4 100 N       G  da Uyumlu Ya    Food Grade Oil  Schmierung f  r  Lebensmittel  l    Optileb  GT320    Kl  beroil  4 UH1 320 N    Mobil  SHC  Cibus 320    Cassida  Fluid  GL 320    Nevastane  SL 320         evre Dostu Ya    Biodegradable Oil  Biologisch  abbaubar   l          Mineral Gresler    20       120   al    ma S  cakl         C   Mineral Grease    20       120 Working Temperature   C   Mineral Fett    20       120 Betriebstemperatur   C        Aralub  HL3    Energrease  LS 3    Tribol  BioTop  1418 320    Spheerol  AP3    Kl  bersynth  GEM 2 320    Centoplex  2EP    Mobilux  EP3    Alvania  RL3    Multis  Complex  EP2       Sentetik Gresler    30       100   al    ma S  cakl         C   Synthetic Grease    30      100 Working Temperature   C   Synthetisches Fett    30       100 Betriebstemperatur   C     374 YILMAZ RED  KT  R          Energrease  SY 22
21. YILMAZ RED  KT  R ISO 9001 YILMAZ RED  KT  R ISO 9001    v    RED  KT  R       E Series Gear Units    OIECE0201 1012    Operating Instructions    Operating Instructions    E Series  Contents  Kontenis A A A MN 02  1 How To Use This Manual ea ea ara        ge        05  2  Type   e MR AE a 06  2 1 Detailed unit designations sees 06  2 2 Nameplate unit design  li  n     ce 07  3 Part List of Standard Type Gear Units         uunneunnnnssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnen 08  SUITES TE RB    BU ee Re 08  20  LL A ee adadan 09  303  E02 DES oda ala ee lala 10  50  R 03                          i   11  3 05  B   04 TYPOS en ee ee 12  3 06  E05 D   YR a a a e 13  307  E  08 UY ia ce AY ne KE VA MERE Ve               14  SA m TYPES nn an ae e ME enge 15  3 09  EL  O e MEM RR A ee bo   16           ID ee a ee KE egal 17  3 11  ET cR TYPES e   e B  d  n 18                            19  e e T05 TYPES        ME                20  TE eS                                21  4 R   lm i   a  a ak al man      22  4 1 intented  AG   NE anin ii e amala ilmekle 22  4 2 Impr    er USS anne a r  n AA      ib l   e a 22  4 3 Safety Insir  clions               23  4 3 1 General Safety Instruclions    un 23  4 3 1 1 Working on gear                                      5 2                                            23       D  N  N   el le kl lem 23  4 3 1 3 WVU NE ae ag   l kd gd kak 23  A SAA   ey eg an en 23  4 3 1 5 Ambient Conditions    sse eee eee eee 22  4 4 5  Ses 00    24  4 5 Ca
22. ay need forced external fan  Goto ID 100    YILMAZ RED  KT  R KY    Operating Instruction  E Series  Hata Tespit Rehberi    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    z     the plate you assemble the gearbox is rigit enough  Check if you  Gearbox Housing is You are using chain drive or             are using the correct diameter of chain drive and you are not  Defect pinion gear     m  exceeding max  allovved radial load  Check the position of your  output element and re calculate your radyal load and check if this  fit to the maximum allovved radial load  Goto ID 100   The radial load or poligon effect of the chain may have caused       the damage  Check also if the assembiy bolts are loosened or      MER 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  7 g 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 diagra
23. d vvith Flange   03  Flanged and Hollow Shaft Output   04 With Double Shaft Output   05  Double Flanged and Double Output Shaft     06  With Shaft Extension on the Motor Fan Cover Side      07  With Double Input Shaft  08   Double Flanged and Hollow Output Shaft    Housing Size  E 030  E 040  E 050  E063  E 075  E 080  E 100  E 125     Input Type                 A13  132 B5  B08  80 B14                06 code is optional input shaft types for EN and EV types  Can be    shovvn as EN050 00 07    ET050 00 07      07 Code is optional input shaft types for ET Types  Can be shown as    N   EC B5 1 B14 Flange without Motor  V  IEC B5  B14 Flange with Motor  T  Without Motor    Gearbox Type  E serie    YILMAZ RED  KT  R 74    Operating Instructions    E Series  Type Designations    2 2  Nameplate  unit designation    Nameplate unit designation is a short abbreviation from the detailed designation    A sample name plate for E Series       YILMAZ REDUKTOR    www yr com tr C      MADE IN TURKEY       Type      080 00 905 4  Serial N   10053604             Power  1 1 kW Ratio  60 8    Speed  23 rpm  M  Pos   m1    Oil   nara      QW  64   t                             Abreviations     Serial N    Serial Number  M Pos    Mounting Position    Type Designation   EV080 00 90S 4    Type  Output Shaft    Motor Type    374 YILMAZ RED  KT  R    Operating Instructions  E Series    Part Designation    3  Part List of Standard Type Gear Units    3 1  E    00 Types          Standard E   00    t    e
24. e a single fixed speed and only this speed is allowed   The electric motor and frequency inverter must be in accordance with 2006 42 EC     If the gear units input is used with variable speed gear unit  this must be informed to YILMAZ  REDUKTOR _before ordering and on the nameplate the allowed maximum and minimum  speeds  speed range  will be provided  If not mentioned by ordering the gear units speed  will be a fixed single input speed and only this speed is allowed     If the gear unit will be driven by belt   coupling   chain drive etc  the gear unit is only allowed  to be used according the nameplate catalogue entries  Different speed  higher motor power   higher radial axial loads etc  than nameplate catalogue is not allowed     The ambient temperature must be between  5    40  C and no abrasive media must attack  the paint and seals  If different working conditions this must be informed to YILMAZ before  ordering     The gearbox maintenance  oil change   check   must be done according this manual     4 2  Improper Use  Every usage 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 catalogue
25. e 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    74 YILMAZ RED  KT  R       Check Your moving parts for noise  Disassemble the gearbox and run  without load  If you hear still the noise the oil may has some particles  inside  Change the oil and look for small particles  If metal particles are    found the gearbox may have some demage  Goto ID 100       45    Operating Instruction  E Series  Hata Tespit Rehberi                                              46    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 yo
26. 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 4    Operating Instructions    E Series  Mounting    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 correct
27. 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 E series gear units and is applicable only for E  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     374 YILMAZ RED  KT  R 5    Operating Instructions  E Series    Type Designations       2  Unit Designation    2 1  Detailed unit designation    Detailed E series gear units designation for ordering  This Designation is different from the short nameplate designation       E V 063 01   90S 4   L05    Brake   L 220V With Fan  P 24V With Fan  S 220 Without Fan  Z 24 V Without Fan                                01 10 Nm 10 100Nm  02 25 Nm 20 200 Nm  04 40 Nm 30 300 Nm  05 50 Nm 40 400 Nm  Motor Size  For EV types  For EN Types  905 4 A06  63        A10  100        A20  200 B5     63B14   B10  100 B14   A22  225 B5   Pole Number A11  112        A25  250 B5  Frame Lenght B11  112 B14   A28  280 B5  Motor size R    Output Shaft Option  00  Hollovv Shaft Output    01  Solid Output Shaft   02  Solid Output Shaft an
28. f the gear reducer into iron  aluminium  non ferrous havy metal if possible  Dispose of it according to the valid national guidelines     374 YILMAZ RED  KT  R 47    Appendix         YILMAZ    RED  KT  R    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 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  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 war
29. ge 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 Istanbul TURKEY   Phone   90  0  212 567 93 82 83   Fax   90  0  212 567 99 75   Factory   Ataturk Mah  Lozan Cad  No  17 P K  34522 K  rac Esenyurt Istanbul TUR   KEY   Phone   90  0  212 886 90 00   PBX 10lines   Fax   90  0  212 886 54 57    Stamp and Signature    Supplier   End User    With signing this part and sending this back to our company your warranty period  will be started and you are accepting that you have received the operating in   struction of the product     Name    Billing Date  Bill No    Start Up Place   Date   Address    Phone   Fax     Supplier  End User Stamp and Signature    Service Contact Points     Main Service Point   YILMAZ REDUKTOR A S   Ataturk Mah  Lozan Cad  No  17 P K  34522 Esenyurt   Istanbul   TURKEY    Head Office   Tel    90  0 212 567 93 82  2 line    90 0  212 567 06 03   90 0  212 567 40 78   90 0  212 567 04 11   90 0  212 567 45 07   90 0  212 567 00 70  Fax   90 0  212 567 99 75  E mail  yilmaz yr com tr  Web  www yr com tr                           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  
30. inguishing  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     YILMAZ RED  KT  R KY    Operating Instructions    E Series    Safety    as  A        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 company and inform about the damage  Contact YILMAZ for the damage and do not  start to install the unit until it is agreed that the damage has no affect of operation     Use the supplied eyebolts or lifting holes for lifting up the gear unit  The eyebolts are capable to  carry the weight of gearboxes only  Do not hang additional loads  Use su
31. itable 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 25    Operating Instruction    E Series    Control    26    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 container should be kept under  roof which protects from snow and rain  Under this condition the gear unit can be stored  up to 3 year with regular check  The ambient temperature should be between  5 to 60   C     Without Packing     Use protection oil for the output shaft and connection surfaces like flange surface or foot  assembling surface  If no packing is used and the
32. king 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 KY    Operating Instruction  E Series  Troubleshooting Guide    Problem    Observation    Remedy       Gearbox Does Not  Work in Low Speeds   freguencies     You are using  freguency inverter     For very low speeds the frequency inverters frequency is lowering down   For very low frequencies the inverter parameter and motor parameter  must be optimized  Also for low speeds the efficiency of the gearbox may  varry too much  Specially for worm gearboxes  The recomended frequ   ency range is 20 70 Hz for worm gearboxes and 10 70 Hz for Helical  Gear Boxes  Use Higher motor power and Frequency inverter or change  ratio of gearbox to work inside the reccomended range        Gearbox Does Not  Start Mornings or Af   ter Long Time Stop     Ambient Temperature  is below  5 Celsius    The oil is not in accordance with your working conditions  Change to lo   wer viscosity oils  Observe this manuel for using the correct oil  Working  in higher ambient temperatures is an other solution if po
33. ly 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     ack 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     374 YILMAZ RED  KT  R 31    a    Operating Instruction    E Series    Mounting    7 1  Installing customer shaft with shoulder    7 1 1  Use anti seize assembling paste available on your market  Use a brush to ap     ply the paste                             7 1 2  Fasten the bold as shown below                                                                 1  Retaining Bolt  2  Lock Washer    3  Washer  4  Circlips       5  Hollow Shaft                            6  Customer Shaft       YILMAZ RED  KT  R   4    
34. m  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 Reguired No self solution found                11  Disposal   If your product is no longer of use and you wish to dispose of it  refer to the instructions here  If you  have any questions regarding ecological disposal methods  please consult our service points given on  the backside of this manuel    11 1  Disposal of Oil    Lubricants  oil and greases  are hazardous substances  which can contaminate soil and water   Collect drained lubricant into suitable receptacles and dispose of it according to the valid national guid   lines    11 2  Disposal of Sealings   Remove the sealing rings from the gear reducer  and clean them of oil and grease resudies    Dispose of the sealings as composite material  metal plastic    11 3 Disposal of Metal   Divide up the remainder o
35. ng 15  Seal 21  Giri   Flange       4  Bolt 10  Housing 16  Oil Plug 22  Bolt       5  Side Cover 11  Closing Cap 17  Worm Gear  23  Seal       6  O ring 12  Circlips 18  Key                16 YILMAZ RED  KT  R   4    Operating Instructions  E Series  Part Designation    3 10  ET   02 Types          Standard ET  02    type basic part diagram  Parts may differ for special applications   Standard Part List     1  Key 7  Side Cover 13  Closing Cap 119  Worm Gear 125  Seal       2  Solid Output Shaft   8  O Ring 14  Circlips 20  Key       3  Bolt 9  Bearing 15  Bearing 21  Bearing       4  Flange 10  Worm Wheel   16  Circlips 22  O Ring       5  Seal 11  Bearing 17  Seal 23  Input Flange                      6  Bolt 12  Housing 18  Oil Plug 24  Bolt    374 YILMAZ RED  KT  R 17    Operating Instructions  E Series  Part Designation       3 11  ET    03    Types          Standard ET   03    type basic part diagram  Parts may differ for special applications   Standard Part List     7  Bearing 13  Bearing 19  O Ring       8  Worm Wheel 14  Seal 20  Motor Flange       9  Bearing 15  Oil Plug 21  Bolt       10  Housing 16  Worm Gear 22  Seal       5  Side Cover 11  Closing Cap 17  Key                   6  O Ring 12  Circlips 18  Bearing    18 YILMAZ RED  KT  R      4    Operating Instruction  E Series  Part Designation    3 12  ET   04 Types       e basic part diagram  Parts may differ for special applications        Standard ET   04    t  Standard Part List    1  Key    7  Bearing    1
36. ranty 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    Merkez  Maltepe G  m    suyu Cad  Bestekar Medeni Aziz Efendi Sok  No 54  P K 34020 Topkap     stanbul T  rkiye   Telefon   90  0  212 567 93 82 83   Faks   90  0  212 567 99 75   Fabrika   YILMAZ RED  KT  R Sanayi ve Ticaret A S    ATAT  RK Mah  Lozan Cad  No 17 P K 34522 Esenyurt   stanbul  T  RK  YE  Telefon   90  0  212 886 90 01  8 Hat    Faks   90  0  212 886 54 57       4    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 char
37. s and or nameplate     YILMAZ RED  KT  R      4    Operating Instruction    E Series  Safety    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 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      
38. se dl File AA K   geneli in   l   d AA        24  4 5 1 Suitable extinguishing agents  protective equipment                             24  4 5 2 Unsuitableextinguishingagenis                           24  5 Thinks to Check Before the Gear Unit or Geared Motor is Installed                    25  8 1  EE   L ai a   af daa ai nike m haaa 25  27 SID  6 MA RE 26  6 Installing The Gear Unit    26     Bef  re you Stan a  a en ee ee een 26  6 2 Check the shaft dimensions oh    eee 27  6 3Checktheambienitemperature                                     ne 27  6 4 Check the voltage Supply    27  6 5 Check the mounting POSINON            ee  30  6 6 Use the breather                 een 30  6 7 Check the oil level    eee 30  6 8 Check shaft ends and mounting faces    sese 30    374 YILMAZ RED  KT  R    Operating Instructions       E Series  Contents  5 9   Cover abrasive ambi  nt RM een 30  6 10 Check accessibility to filling  breather and drain plugs                                  31  7 Mechanical    5                                       2                                                                    31  7 1 Installing customer shaft with shoulder    32  7 2 Shaft tightening torques sense 31  7 3 Recommended shaft dimensions and disassembling nut dimensions            34  7 4 Assemblinggearunitwithtorgucarm                36  7 5 Fitting output shaft elemenis n  n ae 35  r    Fitting ee           EM NM ee EM ee 39  8 Maintenance  amp    nspection                          el  s  
39. ssible  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        Gearbox is Heating  Up too Much    You are using Helical  Gear Box  Ambient  temp is lower than  40  Celsius    Measure the surface temp  using a temperature measuring device  under full load  If the temp is under  80 Celsius this will make no harm  to the gearbox and is normal  All ATEX conforming gearboxes are  designed to work under max   120 Celsius  If higher than  120 Celsi   us and using ATEX conforming gear box immidiately stop the system  and contact YILMAZ REDUKTOR  If not ATEX gearbox the gearbox is  designed to work under max   80 Celsious  If higher than  80 Celsius  check the oil type and oil guantitiy level according your mounting positi   on and check th
40. u 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      The freguency inverter parameters are not optimized for the fregu   You are using frequency inver                        range or motor you are using  Observe the frequency inverters  016 Gearbox is noisy   ter and the noise level is chan           manual  If still same problem change the ratio of gearbox  Goto ID  ging according your speed   100  If ambient Temp is over  40 Celsious or none stop work over 16  Er     hours please change the top plug with a breather plug  Observe this  017 Oil is Leaking Oil Leakage from Seal   m  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       plug point where it comes out and leakes over the housing  If this is  019 Oil is Leaking Oil 
41. ust 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  Still does not  work go to ID 100       44       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 clic
    
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