Operating Instructions
Contents
1. Symbol Drain Plug V Oil Filling V Level Breather 26 YILMAZ RED KT R 74 Operating Instructions P R Series Lubrication 9 5 3 Plugs for P Series K Type Mounting position Symbol Drain Plug V Oil Filling Y Oil Level Breather 374 YILMAZ RED KT R 57 Operating Instructions P R Series Lubrication 9 5 4 Plugs for R Series K Mounting position2. Symbol Drain Plug V oil Filling Y Oil Level Breather 60 YILMAZ RED KT R gt 74 Operating Instructions P R Series Lubrication 9 6 Oil Expansion Tank Expansion tanks can be used with Planetary gearboxes according to mounting positions shown on below Mounting Pos Expansion Tank L Type Expansion Tank K Type Not Applicable Not Applicable Not Applicable 374 YILMAZ RED KT R 61 Operating Instructions P R Series Hydraulic Motors 10 Hydraulic Motors All motors must be charged with hydraulic fluid before being operated and during installation You can find the technical information and picture below Performance diagrams or other detailed informations please see the P R series product catalogue or contact YILMAZ REDUKTOR Geometric Displacement V cm Maximum Speed r
3. ZEN L1 L2 L3 N 282 Rad 4 cl Brake Coil Brake Coil M M Delayed Running Brake 4 24 V Sudden Brake 24 V L1 L2 L3 N Brake Coil L1 L2 L3 N Brake Coil MoA L L ik 4 C TE In In 34 YILMAZ RED KT R 74 Operating Instructions P R Series Checking 6 5 Check the mounting position The mounting position must be in accordance with the mounting position mentioned on the AN 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 STOP 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 P 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
4. VY Symbol Drain Plug V Oil Filling Oil Level 58 YILMAZ RED KT R 74 Operating Instructions P R Series Lubrication 9 5 5 Oil Plugs for P Series Gearboxes Combined with E Series Mounting position Symbol Drain Plug V oil Filling V Oil Level Breather 374 YILMAZ RED KT R 59 Operating Instructions P R Series Lubrication 9 5 6 Oil Plugs for R Series Gearboxes Combined with E Series
5. YILMAZ RED KT R 4 Operating Instructions P R Series Lifting 5 1 2 R 01L Types Lifting Positions RV 01L RN 01L YILMAZ RED KT R 27 Operating Instructions P R Series Lifting 9 1 3 R 01K Types Lifting Positions 7 NOT APPLICABLE RV 01K NOT APPLICABLE RT 01K NOT APPLICABLE 28 YILMAZ RED KT R 4 Operating Instructions P R Series Lifting 5 1 4 P Series Combined with E Series Lifting Positions PN
6. 52 YILMAZ RED KT R b74 Operating Instructions P R Series Lubrication 9 4 Oil Quantities liter Mounting position M3 B M4 B Gearbox 1102K R 1102K 1103K R 1103K 1104K R 1104K 1202K R 1202K 1203K R 1203K 1204K R 1204K 1502K R 1502K 1503K R 1503K 1504K R 1504K 1602K R 1602K 1603K R 1603K 1604K R 1604K 1902K R 1902K 1903K R 1903K 1904K R 1904K 2302K R 2302K 2303K R 2303K 2304K R 2304K 2402K R 2402K 2403K R 2403K 2404K R 2404K 2702K R 2702K 2703K R 2703K 2704K R 2704K 2902K R 2902K 2903K R 2903K 2904K R 2904K 3502K R 3502K 3503K R 3503K 3504K R 3504K PV1501K 01 PV1501K 01 11 M1 A bd M1 B PV1501K 01 PV1501K 01
7. 374 YILMAZ RED KT R 53 Operating Instructions P R Series Lubrication 9 4 Oil Quantities liter Mounting position M3 C M4 C 1102 R 1102K 1 25 1 7 1103K R 1103K 1 6 22 1104 R 1104K 24 3 0 1202K R 1202K 1203K R 1203K 1204K R 1204K 1502K R 1502K 1503K R 1503K 1504K R 1504K 1602K R 1602K 1603K R 1603K 1604K R 1604K 1902K R 1902K 1903K R 1903K 1904K R 1904K 2302K R 2302K 2303 R 2303K 2304K R 2304K 2402 R 2402K 2403K R 2403K 2404K R 2404K 2702K R 2702K 2703K R 2703K 2704K R 2704K 2902 R 2902K 2903K R 2903K 2904 R 2904K 3502 R 3502K 3503 R 3503K 3504K R 3504K PV1501K 01 PV1501K 01 Gearbox Te 1 PV1501K 01 PV1501K 01 T
8. 54 YILMAZ RED KT R b74 Operating Instructions P R Series Lubrication 9 5 Oil Plugs 9 5 1 Oil Plugs for P Series L Type Mounting position Single Stage 2 Stages 3 Stages 4 Stages Symbol Drain Plug V Oil Filling V Oil Level Breather 374 YILMAZ RED KT R 55 Operating Instructions P R Series Lubrication 9 5 2 Oil Plugs for R Series L Type Mounting position Single Stage 2 Stages 3 Stages 4 Stages
9. 24 5 1 2 P 01K Types Lifting Positions 26 5 1 3 R 01K Types Lifting Positions 28 5 1 4 P Series Combined with E SeriesliftingPositions 29 5 1 5 R Series Combined with E Series Lifting Positions 30 5 2 Storage T 31 6 Installing The Gear Unit 1 uu 31 6 1 Before you Start u PE A RE A 31 6 2 Check shaft dimensions to fit 32 6 3 Check the ambient temperature au ee ae 32 6 4 Check the voltage supply 32 6 5 Check the mounting sarp 35 6 6 Use of breather 01 10 35 6 7 Check the oil level 35 6 8 Check shaft ends and mounting 35 6 9 Cover abrasive ambient a 35 6 10 Check accessibility to filling breatheranddrainplugs 36 2 YILMAZ RED KT R 74 Operating Instructions P R Series Contents 7 Mechanical Installation a 36 7
10. 11 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 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 A Remedy 64 Gearbox Does Not Start Up Gearbox Does Not Start Up Gearbox Does Not Start Up Gearbox Does Not Start Up Gearbox Does Not Start Up You hear no noise and shaft is not turn ing You are not using any driver fre guency inverter You hear no noise and shaft is not turn ing You are using frequency inverter or driver You hear some noise but both motor shaft and gearbox shaft is not turning You are not using any driver frequency inverter or braked motor You hear some noise but both motor shaft and gearbox shaft is not turning You are using driver or fre quency inverter 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 Still does not work go to ID 100 Please obs
11. L 01 EV125 PN L 01 EN125 PN L 01 ET125 374 YILMAZ RED KT R 29 Operating Instructions P R Series Lifting 5 1 5 R Series Combined with E Series Lifting Positions For P11 To P24 For P27 to P35 NOT APPLICABLE RN L 01 EV125 RN L 01 EN125 NOT APPLICABLE RN L 01 ET125 NOT APPLICABLE 30 YILMAZ RED KT R 74 Operating Instructions P R Series Checking 5 2 Storage Ifthe 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 lik
12. Parts may differ for special applications Standard Part List 45 Shrink Disc 50a Hollow Shaft 54 Oil Plug 46 Bolt 50b Spline Shaft 47 Seal Cover 51 Bearing 48 Seal 52 Spacer 49 Bearing 53 Output Flange 374 YILMAZ RED KT R 09 Operating Instructions P R Series Part Designations 10 3 1 4 Version of Gearbox PV PN PT Gear Size 27 129 35 Output 01 1K 1L 69 68 Parts may differ for special applications Standard Part List 72 71 60 Bolt 64b Spline Output Shaft 69 Nilos Ring 61 Seal Cover 65 Bearing 70 Tab washer 62 Seal 66 Housing 71 Locknuts 63 Key 67 Oil Plug 72 Spacer 64 Output shaft 68 Bearing YILMAZ RED KT R 4 Operating Instructions P R Series Part Designations 3 1 5 Version of Gearbox PV PN PT Gear Size Output Type 27 29 35 05 89 88 87 86 lications Parts may differ for special a Standard Part List 80 Shrink Disc 85 Hollow Shaft 81 Bolt 86 Bearing 82 Seal Cover 87 Spacer 83 Seal 88 Output shaft 84 Bearing 374 YILMAZ RED KT R 89 Plug 11 Operating Instructions P R Series Part Designations 3 1 6 Version of Gearbox PV PN PT Gear Size Output Type 21129138 OK OL lications Parts may differ for special a
13. Standard Part List 95 Bolt 100 Spacer 105 Sun Gear 110 Circlip 108 115 Planetary Gear 96 Seal Cover 101 Output shaft 106 Bearing 111 Pin 116 Circlip 97 Seal 102 Carrier 107 Flange 112 Washer 117 Oil Plug 98 Bearing 103 Washer 108 Bolt 113 Bearing 99 Bearing 104 Internal Gear 12 109 Pin 114 Spacer YILMAZ RED KT R 74 Operating Instructions P R Series Part Designations 3 1 7 Version of Gearbox PV PN PT Gear Size 29138 Output Type 05 Parts may differ for special applications Standard Part List 125 Shrink Disc 130 Bearing 135 Internal Gear 140 Pin 145 Spacer 126 Bolt 131 Spacer 136 Sun Gear 141 Circlip 146 Planetary Gear 127 Seal Cover 132 Output Flange 137 Bearing 142 Pin 147 Circlip 128 Seal 133 Carrier 138 Flange 143 Spacer 148 Oil Plug 129 Bearing 134 Washer 139 Bolt 144 Bearing 374 YILMAZ RED KT R 18 Operating Instructions P R Series Part Designations 3 2 Gear Group 3 2 1 Version of Gearbox PV PN PT RV RN RT Gear Size 11 15 Output Type ALL 155 Parts may differ for special applications Standard Part List 155 Washer 160 Flange 165 Washer 156 Carrier 161 Bolt 157 Washer 162 Pin 158 Sun Gear 163 Needle Roller 159 Internal Gear 164 Planetary Gear 14 YILMAZ RED KT R
14. 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 374 YILMAZ RED KT R 31 Operating Instructions P R Series Checking 6 2 Check the shaft dimensions to fit Hollow Shaft Diameter with Shrink Disc Tolerance H7 Customer Shaft Diameter with Tolerance h6 Solid Output Shaft Diameter Output Shaft Tolerance Shrink Disc 0 03 0 02 42 42 50 0 0 0 03 0 02 52 52 50 0 0 0 03 0 02 75 75 60 0 0 0 03 0 02 75 75 60 0 0 0 04 0 02 90 90 80 0 0 0 04 0 04 0 0 01 0 04 0 04 0 iis 0 01 0 04 0 04 0 TM 0 01 0 04 0 04 0 0 01 0 04 0 04 0 0 02 6 3 Check the ambient temperature The ambient temperature must be between 5 celsius to 40 celsius for standart 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 3kW including 3kW 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 please observe the name plate
15. 74 Operating Instructions P R Series Part Designations 3 2 2 Version of Gearbox PV PN PT RV RN Gear Size 12 16 197 23 24 27 29 35 Output Type ALL Parts may differ for special applications Standard Part List 170 Carrier 175 Bolt 180 Needle Roller 171 Spacer 176 Pin 181 Washer 172 Sun Gear 177 Spacer 173 Internal Gear 178 Planetary Gear 174 Flange 179 Spacer 374 YILMAZ RED KT R 15 Operating Instructions P R Series Part Designations 16 3 2 3 Version of Gearbox PV PN PT RV RN RT 11 12 7 15 16 19 23 24 29 35 ALL Gear Size Output Type 190 lications Parts may differ for special a Standard Part List 190 Bolt 195 Key 200 Bearing 205 Spacer 210 Spacer 191 Seal Cover 196 Shaft 201 Spacer 206 Nilos Ring 211 Circlip 192 Seal 197 Spacer 202 Cover 207 Bearing 212 Washer 193 Bearing 198 Oil Plug 203 Bolt 208 Spacer 213 Circlip 194 Bevel Gear 199 Flange 204 Gear 209 Bearing YILMAZ RED KT R 4 Operating Instructions P R Series Part Designations 3 3 Input Side 3 3 1 Version of Gearbox PV PN RV RN Gear Size 11 12 15 16 19 23 24 29 35 Input IEC B5 Flange Parts may differ for special applications Standard Part List 220 Circlip
16. using a temperature measuring device under full load If the temp is under 80 Celsius this will make no harm to the gearbox F and is normal All ATEX conforming gearboxes and standard worm gearboxes You are using Worm Gearbox Heating too Much is Up Gear Box and ambi ent tenp is lower than 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 Go to ID 100 If not ATEX confirming check the oil type and oil quantitiy level according your mounting position and check the name plate mounting position If nameplate mounting position does not fit the actual position go to ID 100 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 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 You are using Helical Gear Box Ambient temp is lower than 40 Celsius Gearbo
17. 220 N Mobilgear SHC XMP 220 Enersyn EP XF 150 Alphasyn T 150 Kl bersynth GEM4 150 Mobilgear SHC XMP 150 Kl bersynth GEM4 100 Food Grade Oil NSF H1 Biodegrad CLP able Oil E CLP 40 5 40 Optileb GT 320 Tribol BioTop 1418 320 Kl beroil 4 UH1 320 N Kl bersynth GEM 2 320 Mobil SHC Cibus 320 Cassida Flu id GL 320 Mineral Grease 20 120 Working Temperature Energrease LS 3 Spheerol AP3 Centoplex 2EP Mobilux EP 3 Alvania RL3 Synthetic Grease 30 100 Working Temperature 374 YILMAZ RED KT R Energrease SY 2202 Petamo GHY 133 N Mobiltemp SHC100 Cassida RLS 2 45 Operating Instructions P R Series Lubrication 46 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 3 Extended intensive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin thoroughiy Hot oil can cause scalding When changing oil protect yourself against contacting hot oil 9 3 Mounting Positions YILMAZ R
18. 225 Input Flange 221 Bearing 226 Oil Plug 222 Input Shaft 227 Bolt 223 Bearing 224 Seal 74 YILMAZ RED KT R 17 Operating Instructions P R Series Part Designations 3 3 2 Version of Gearbox PV PN RV RN Gear Size 11 12 15 16 19 237 24 29 35 Input Type C26 M46 input type for Hydraulic motor Parts may differ for special applications Standard Part List 235 Circlip 240 Input Flange 236 Bearing 241 Plug 237 Input Shaft 242 Bolt 238 Bearing 239 Seal 18 YILMAZ RED KT R 74 Operating Instructions P R Series Part Designations 3 3 3 Version of Gearbox PV PN RV RN Gear Size 11 12 15 16 19 238 24 29 35 Input 50110 input shaft Parts may differ special applications Standard Part List 250 Circlip 255 Seal 251 Bearing 256 Input Flange 252 Input Shaft 257 Bolt 253 Key 258 Oil Plug 254 Bearing 374 YILMAZ RED KT R 19 Operating Instructions P R Series Safety 20 Hee BH bi 4 Safety 4 1 Intended Use The gear reducer is designed for use in industrial machines Please refer to our catalogue or our web page for the maximum permitted torques and speeds The most important 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 pe
19. 374 YILMAZ RED KT R 21 Operating Instructions P R Series Safety gt P 22 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 gear unit Observe the safety instructions for outdoor use EN12100 2010 4 4 Tightening Torques All screwed connections for which 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 Bolt Tightening 4 5 Case of Fire The gear reducer itself is not combustible However it usually contains a synthet ic or mineral gear oil Please observe the following if the gear reducer is situated in a burning environ ment 4 5 1 Suitable extinguishing agents Protective equipment Always keep suitable extinguishing protective equipment like carbon dioxide powder foam fog easily accessible around the gear unit High temperature produce irritating steam Use a protective breathing apparatuses 4 5 2 Unsuitable extinguishing agents Do not spray with water YILMAZ RED KT R 74 Operating P R Series Checking as D Instructions 5 Things to Check Before the Gear Unit or Geared Motor is Installed If gear motors are used please also refer to the manua
20. 68 Warranty Conditions u 69 Warranty D claration anne 70 374 YILMAZ RED KT R Operating Instructions P R Series General Informations 1 How To Use This Manual Take attention to the following safety and warning signs for proper understanding and quick reference P P 04 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 the drive or environment Important Information EC Machinery Directive Within terms of the EC machinery directive 2006 42 EC gear reducer is not consid an autonomous machine but as a component to install in machines Operation is prohibited within the area of validity of the 2006 42 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 P R Series gear units and is applicable only for P R 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
21. 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 Lifting and carrying types are indicated on following pages 374 YILMAZ RED KT R 23 Operating Instructions P R Series Lifting 5 1 1 P 01L Types Lifting Positions PV 01L For P11 To P24 PV 01L For P24 To P35 PN 01L For P11 To P24 24 YILMAZ RED KT R 4 Operating Instructions P R Series Lifting 5 1 1 P 01L Types Lifting Positions PN 01L For P11 To P24 PT 01L For P11 To P24 PT 01L For P24 To P35 374 YILMAZ RED KT R 25 Operating Instructions P R Series Lifting 5 1 2 P 01K Types Lifting Positions PV 01K For P11 To P24 PN 01K For P24 To P35 PT 01K For P11 To P24 26 NOT APPLICABLE NOT APPLICABLE NOT APPLICABLE
22. accordance with your application Check the product catalogue for permitted radial loads and calculation If the output or input shaft is overloaded by radial 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 YILMAZ RED KT R 4 Operating Instructions P R Series Mounting 7 1 Assembling customer shaft with shrink disc 7 1 1 Loosen the bolts of the shrink disc 7 1 2 Use a solvent available in your market to clean all the dirt an oil from the shaft and shrink disc hollow The surfaces must be free from oil or any dirt The solvent must be removed from the surfaces as well 374 YILMAZ RED KT R 37 Operating Instructions P R Series Mounting 7 1 3 Insert the shaft and tighten bolts as shown sure that there is clearance between the shrink disc shoulder and the hollow shaft shoulder of the gearbox Tightening Torque Nm 30 30 59 59 100 38 YILMAZ RED KT R 574 Operating Instructions P R Series Mounting 7 2 Disassembling customer shaft with shrink disc 7 2 1 Loosen the bolts of the shrink disc and take out the shaft 74 YILMAZ RED KT R 39 Operating Instr
23. belt coupling chain drive etc the gear unit is only allowed to be used according 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 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 highest 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 Itis operated out of the permitted values provided on catalogues and or nameplate YILMAZ RED KT R 4 Operating Instructions P R Series Safety P PEP 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 operat
24. 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 fect or damage the sealing lip or output shaft Inside entering substances from the seals can cause serious damage to the gear unit STOP Abrasive material chemicals water positive or negative pressure exceeding 0 2 bar can af 374 YILMAZ RED KT R 35 Operating Instructions P R Series Checking 36 gt P 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 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
25. 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 32 YILMAZ RED KT R 74 Operating Instructions P R Series Checking 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 with out 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 arounded to prevent potential differ ences of earth and gearbox motor Nominal Powers at 400V 50Hz 230V 400 V Y 400V A Pole Number lt 1 5 kW gt 2 2 kW Basic motor connection wiring diagram LI 1 3 L1 L2 230V 230V 400V 71 400V L1 L2 L3 11 L2 1 3 74 YILMAZ RED KT R 33 Operating Instructions P R Series Checking Standard type brakes basic wiring diagram The electric connection must be done by experienced electric technician A The gearbox and the motor must be grounded to prevent potential differences of earth and gearbox motor Delayed Running 220 V Sudden Brake 220 V
26. 1 Assembling customer shaftwithshrinkdisc 37 7 2 Disassembling customer shaft withshrinkdisc 38 7 3 Assemblinggearunitwitihtorgucarm 40 4 Fittingoutputshaftelemenis 42 7 5 Correct position of output shaft elements 42 7 6 Correct position of Splined Shaft output assembling 42 FRING COUPIN GE ae Bere 43 8 Maintenance and Inspections 24 24 44 SERIE e ers 1 E e ee een 45 sak Da RE DEE 45 9 2 Changing he Gan aaa 46 9 3 Mounting Positions ne ke ee lea 46 9 4 Oil Quantities It 51 CI 55 9 6 Oil Expansion 1511 59 10 Hyaraulie NUE seg aan u 60 11 Troubleshooting Guide 155884111012 62 12 DISDOSB I A A 1 22 67 TL AS DIS BO Sell 67 11 2 Disposal of ye M NEED OO 67 11 3 Disposal of 16151 67 13 Top Se
27. 20 140 215 75 115 140 170 1050 1280 840 1024 120 185 751115 120 160 1040 1360 832 1088 95 145 role 100 140 1150 1490 920 1192 78 119 751115 Intermittent operation rating applies to 9010 of every minute 62 70 100 925 1390 YILMAZ RED KT R 4 740 1112 Operating Instructions P R Series Hydraulic Motors 10 1 HE Series flange and Shaft dimensions _ 095 _ 9135 43 6 15 7 2 A fr 7 8 7 24 DIN6885 A T p lp M i 3 Se eee Kas sassa B x sa B 7 1 a L 0 8 0 025 M8x16 9 28 10 2 HG Series flange and Shaft dimensions 095 64 225 22 50 16 a 3 p E k A10x8x46 DIN6885 A 9 gt i 2g 8 alas 8 JE Z d 1 55 5 s H 7 ens N pn 64 0 10 0 036 M12x25 74 YILMAZ RED KT R 63 Operating Instructions ap P R Series Troubleshooting Guide
28. 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 YE Telefon 90 0 212 886 90 01 6hat Fax 90 0 212 886 54 57 Head Office 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
29. ED KT R 4 Operating Instructions P R Series Lubrication 9 3 1 Mounting Position P Series with K Form M1 I M3 gt ee 5 21 5 QI x Co amp Oe 374 YILMAZ RED KT R 47 2 7 i O o lt o 14 6 9 5 5 I 9 3 2 Mounting Positions R Series with K Form S YILMAZ RED KT R 4 48 Operating Instructions P R Series Lubrication 9 3 3 Mounting Position for P Series Combined with Worm Gear 374 YILMAZ RED KT R 49 2 7 i O o0 i o x 6 9 5 3 I 9 3 4 Mounting Position for R Series Combined with Worm Gear YILMAZ RED KT R 74 50 Operating Instructions P R Series Lubrication 9 4 Oil Quantities liter Mounting position M3 M4 Gearbox Type P 1101L R 1101L P 1102L R 1102L P 1103L R 1103L P 1104L R 1104L P 1201L R 1201L P 1202L R 1202L P 1203L R 1203L P 1204L R 1204L P 1501L R 1501L P 1502L R 1502L P 1503L R 1503L P 1504L R 1504L P 1601L R 1601L P 1602L R 1602L P 1603L R 1603L P 1604L R 1604L P 1901L R 1901L P 1902L R 1902L P 1903L R 1903L P 1904L R 1904L P 2301L R 2301L P 2302L R 2302L P 2303L R 2303L P 2304L R 2304L P 2401
30. L R 2401L P 2402L R 2402L P 2403L R 2403L P 2404L R 2404L P 2701L R 2701L P 2702L R 2702L P 2703L R 2703L P 2704L R 2704L P 2901L R 2901L P 2902L R 2902L P 2903L R 2903L P 2904L R 2904L P 3501L R 3501L P 3502L R 3502L P 3503L R 3503L P 3504L R 3504L 374 YILMAZ RED KT R 51 Operating Instructions P R Series Lubrication 9 4 Oil Quantities liter Mounting position M3 A 4 Gearbox P 1102K R 1102K P 1103K R 1103K P 1104K R 1104K P 1202K R 1202K P 1203K R 1203K P 1204K R 1204K P 1502K R 1502K P 1503K R 1503K P 1504K R 1504K P 1602K R 1602K P 1603K R 1603K P 1604K R 1604K P 1902K R 1902K P 1903K R 1903K P 1904K R 1904K P 2302K R 2302K P 2303K R 2303K P 2304K R 2304K P 2402K R 2402K P 2403K R 2403K P 2404K R 2404K P 2702K R 2702K P 2703K R 2703K P 2704K R 2704K P 2902K R 2902K P 2903K R 2903K P 2904K R 2904K P 3502K R 3502K P 3503K R 3503K P 3504K R 3504K PV1501K 01 PV1501K 01 M1 A Tut M1 B PV1501K 01 PV1501K 01
31. RED KT R Additional Information For PN PV RN RV If gearbox unit is PN RN A06 A07 A08 A09 A10 A13 A16 A18 A20 A22 A25 C26 M46 If PN RN t 63 size IEC B5 motor connection flange 71 size IEC B5 motor connection flange 80 size IEC B5 motor connection flange 90 size IEC B5 motor connection flange 100 112 size IEC B5 motor connection flange 132 size IEC B5 motor connection flange 160 size IEC B5 motor connection flange 180 size IEC B5 motor connection flange 200 size IEC B5 motor connection flange 225 size IEC B5 motor connection flange 250 size IEC B5 motor connection flange Flange code C Shaft code 26 HE Hydraulic Motor Flange code M Shaft code 46 HG Hydraulic Motor e gearbox unit connected with hydraulic motor HE330 L Geometric displacement Hydraulic motor type HG or HE If the gearbox unit is PV RV type 905 4 L Number of pole Frame length Motor size 63 250 IF PN RN type gearbox unit coupled with a worm gearbox EV063 71 4b L Iron core length Number of pole Motor size 63 132 Size of worm gearbox 63 125 Worm gearbox type EV With motor EN With motor flange ET Without motor Examples PT1202K 01 Without motor solid output shaft gearbox size 12 2 stages perpendicular input and output shaft with flange PV1902L 01 160M 6 Motor with 11 kW 900 rpm solid output shaft gearbox size 19 2 stages parallel input and output
32. YILMAZ RED KT R ISO 9001 YILMAZ RED KT R 160 9001 w YILMAZ REDUKTOR P R Series Gear Units OIPCE 0100 0312 Operating Instructions Operating Instructions P R Series Contents e gg A A A A A 03 1 How To Use This Manual ee 04 FAUNE eS uu uuu ss bolmak e E uk ne mU 05 2 1 Detailed unit designation 05 2 2 Nameplate unit 651011511011 06 3 Standard type Gearbox Part List un na 07 SW LES 07 3 2 Gear Group 3 3 uuu erene eda earth 16 Salely A M 20 4 1 Intended 056 A ken 21 4 2 ImproperUse renas 21 4 3 Safety MASTERS e 22 4 3 1 General Safety Instruelions ea FE RR PRX ERR RR RM EK ERU KE 21 4 3 1 1 Workingonthegearreducer 21 4 3 1 2 Operation Em 21 4 4 Tightening Torques 22 4 ASS OFFI 22 5 Things to Check Before the Gear Unit or Geared Motor is Installed 23 5 1 Transportation and LING zen 23 5 1 1 P 01L Types Lifting Positions
33. aked motor shock transformators 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 REDUKTOR or with information of YILMAZ REDUKTOR Any change without informing YILMAZ REDUKTOR will cancel the warranty manufacturer declaration and YILMAZ REDUKTOR will take no responsibility Service Required No self solution found 12 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 12 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 12 2 Disposal of Sealings 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 12 3 Disposal of Metal Divide up the remainder of the gear reducer into iron aluminium non ferrous heavy metal if possible Dispose of it according to the valid national guidelines 74 YILMAZ RED KT R 67 Appendix Vy YILMAZ REDUKTOR Warranty Conditions 1 The geared motors and gear units are warranted for two year except t
34. e 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 oil for the output shaft and connection surfaces like flange surface or foot assembling surface If no packing is used and the gearbox is stored without packing the ambient temperature should be between 5 to 60 Celsius degrees The gearbox must be kept under enclosed roof with constant temperature and constant humidity not exceeding 5090 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 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
35. e that there is no eccentricity between the two shafts 7 7 3 By fitting couplings be sure that the two shafts are not angular miss aligned 374 YILMAZ RED KT R 43 Operating Instructions P R Series Checking 44 8 Maintenance 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 Item to check Every 3 000 operating hours Every 20 000 operating or every 6 months Hours or e 3 years eese oe 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 bath temperature Celcius For normal ambient conditions 70 degrees Celsius oil bath temperature should be taken as reference For P R series Synthetic oil is used unless it is differently ordered For oil type and quantities refer to the following tables YILMAZ RED KT R 574 Operating Instructions P R Series Lubrication 9 Lubrication 9 1 Oil Types Ambient DIN Temperature C Petroleum Castrol Kl ber Lubrication Mobil Lubricant 51517 3 Dip Lubrication Forced Lubr
36. erve the frequency inverter driver manual Chech the motor by supplying direct voltage to see ifthe problem is on your driver frequency inverter Still does not work go to ID 001 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 mo tor power is needed For monophaze motors check the start ing up compensator and running condensate 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 sup ply 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 manufac turers manuel If brake is supplied from YILMAZ observe this manuel for correct brake wiring diagram If still not work sup ply the brake with voltage according its nameplate directly For example 198V DC You will hear a clicking noise explaining that the brake is opening If
37. f still same problem go to ID 100 Observe exactly where the oil is coming out It could be seal or plug point where it comes out and leakes over the housing If this is your case goto 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 the cover and put new sealing liquid Assemble the cover and tighten the bolts If still same prob lem go to ID 100 The movement of gear box is because of the run out of the shaft which you assemble the gearbox This has no bad affect 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 clearance of the shaft which you assemble the gearbox Check the clearance of the assembling shaft and the clearances on your machine This has no bad affect or harm to the gearbox unless you are using torque arm 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 If 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 YILMAZ RED KT R 4 Operating Instructions P R Series Troubleshooting Guide Motor is running but Gear box shaft does not turn Scratching noi
38. he 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 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 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 manufact
39. ication bp ie Castrol LUBRICATION Mobil 0 50 Energol GR XP 680 Alpha SP 680 Kl beroil GEM 1 680 N Mobilgear XMP 680 5 45 Energol GR XP 460 Alpha SP 460 Kl beroil GEM 1 460 N Mobilgear XMP 460 10 40 Energol GR XP 320 Alpha SP 320 Kl beroil GEM 1 320 N Mobilgear XMP 320 Mineral Oil 30 Energol GR XP 220 Alpha SP 220 Kl beroil GEM 1 220 N Mobilgear XMP 220 20 Energol GR XP 150 Alpha SP 150 Kl beroil GEM1 150 N Mobilgear XMP150 10 Energol GR XP 100 Alpha SP 100 Kl beroil GEM 1 100 N 60 Energsyn SG XP 680 Kl bersynth GH 6 680 Mobil Glygoyle 680 50 Energsyn SG XP460 Aphasyn PG460 Kl bersynth GH 6 460 Mobil Glygoyle 460 40 Energsyn SG XP320 Aphasyn PG320 Kl bersynth GH 6 320 Mobil Glygoyle 320 30 Energsyn SG XP 220 Aphasyn PG 220 Kl bersynth GH 6 220 20 Energsyn SG XP 150 Aphasyn PG 150 Kl bersynth GH 6 150 10 Kl bersynth GH 6 100 Kl bersynth GEM4 680 N Mobilgear SHCXMP680 Synthetic Enersyn EP XF 460 Alphasyn T 460 Kl bersynth GEM4 460 N Mobilgear SHC XMP460 Oil Enersyn EP XF 320 Alphasyn T 320 Kl bersynth GEM4 320 N Mobilgear SHC XMP 320 Enersyn EP XF 220 Alphasyn T 220 Kl bersynth GEM4
40. ion 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 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 ac cidents Make sure no one can start the machine while you are working on it Even a brief running of the machine during maintenance work can lead to accidents if the safety devices are not operating Make sure that all safety devices are mounted and active 4 3 1 4 Lubricant Extended intensive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin thoroughly Hot oil can cause scalding When changing oil protect yourself against contacting hot oil 4 3 1 5 Ambient Conditions Standard gearboxes are allowed to work in ambient temperatures between 5 to 40 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
41. l 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 be fore 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 imme diately contact the transport company and inform about the damage Contact YILMAZ REDUKTOR for the damage and do not start to install the unit until it is agreed that the damage has no effect of operation Please use the rope for lifting and carrying by wrapping around the gearbox or use the eyebolt indicated position as shown on next pages If you can not find lifting adequate pictures for your product please contact YILMAZ REDUKTOR The eyebolts should be capable to carry the weight of gearboxes Do not hang additional loads on the gearbox by lifting Use suitable hoisting equipment which is capable to hold the gear units weight Refer to the catalogue for various types weights Do not stay beneath under the lifting hoisting equipment which may cause serious injuries by falling down objects accidental movements unexpected
42. ng your speed Oil Leakage from Seal Oil Leakage from Plug Oil Leakage from Housing Oil Leakage from Cover You are using Torque Arm You are using Torque Arm Motor is running over its nominal current Ambient is dusty Remedy Check Your moving parts for noise Disassemble the gearbox 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 out the output shaft element and run without load If you still hear the noise one of the gears has run out problem Go to ID 100 Low randomly clicking noise may come from the brake disc which is normal If noise level is disturbing the brake may be defect or brake clearance is not adjusted Go to ID 100 The frequency inverter parameters are not optimized for the frequency range or motor you are using Observe the frequency inverters manual If still same problem change the ratio of gearbox Go to ID 100 If ambient Temp is over 40 Celsius or none stop work over 16 hours please change the top plug with a breather plug Observe this manual for using breath er 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 position The plug may be not tight enough There are some particles under the plug rubber surface Clean and tighten the plug I
43. or standard type geared units of YILMAZ REDUK TOR 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 contact YILMAZ REDUKTOR YILMAZ RED KT R 74 Operating Instructions P R Series Unit Designation 2 Unit Designation 2 1 Detailed Unit Designation Detailed P Series gear units designation for orderin nameplate designation This Designation is different from the short PN 11 0 2 1 01 Additional Information Output Shaft Properties 01 Solid Output Shaft Splined Hollow Shaft DIN 5480 OL Splined Hollow Shaft DIN 5482 05 Shrink Disc 1 Splined Solid Shaft DIN 5480 1L Splined Solid Shaft DIN 5482 Optional for 24 10 Solid Output Shaft Splined Hollow Shaft DIN 5480 10 Splined Hollow Shaft DIN 5482 50 Shrink Disc K1 Splined Solid Shaft DIN 5480 L1 Splined Solid Shaft DIN 5482 Shaft Condition L Input and Output Shafts on Same Axis K Input and Output Shafts Perpendicular Number of Stage Single Stage Two Stage Three Stages Four Stages AONO Revision Number Gearbox Sizes 11 12 15 16 19 23 24 27 29 35 Version of Gearbox Vier With Electric or Hydraulic Motor Motor Connection Flange IEC C26 M46 T Solid Input Shaft Serie of Gearbox P Planetary Gearbox with Flange Mounted R Planetary Gearbox with Foot Mounted 374 YILMAZ
44. 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 STOP 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
45. pm 930 1160 Max Oil Flow O l min Max Pressure Difference Bar 140 190 Max Supply Pressure bar cont int Maximum Torque Nm 25 70 Maximum Power kW Min Starting Torque Nm 44152 810 990 140 190 70 100 44 164 725 935 140 175 90 115 72192 705 940 140 175 125 160 100 128 560 750 140 175 160 200 128 160 470 630 140 175 190 240 1521192 350 470 140 175 255 320 204 256 280 375 140 175 310 395 248 316 235 315 140 175 390 480 312 384 265 330 120 150 380 480 304 384 230 290 110 140 400 525 320 420 200 255 100 130 410 520 328 416 185 235 100 120 430 530 344 1 424 150 200 95 110 467 558 373 446 152 190 530 710 75 100 85 100 200 280 435 540 400 545 348 432 320 436 440 575 751100 200 280 485 670 388 536 380 510 751100 200 280 560 770 448 616 320 420 751100 200 280 685 945 548 756 270 350 751100 200 280 800 1100 640 880 225 1290 75 100 200 280 980 1350 784 1080 185 245 75 100 170 240 960 1350 768 1080 160 240 75 115 140 200 960 1400 768 11
46. rink Disc Splined Solid Shaft DIN 5480 Splined Solid Shaft DIN 5482 YILMAZ RED KT R 74 Operating Instructions P R Series Part Designations 3 Standard Gearbox Part List 3 1 Output Group 3 1 1 Version of Gearbox RV RN RT Gearbox Size 11 12 15 16 19 23 24 27 29 35 Output 01 1K 1L 14 13 12 11 10 Parts may differ for special applications Standard Part List 1 Bolt 5b Splined Output shaft 10 Bearing 2 Seal Cover 6 Bearing 11 Nilos Ring 3 Seal 7 Oil Plug 12 Tab washer 4 Key 8 Footed output 13 Locknuts 5a Output Shaft 9 Lifting Bolts 14 Spacer 374 YILMAZ RED KT R 07 Operating Instructions P R Series Part Designations 3 1 2 Version of Gearbox PV PN PT Gear Size 117127 15 1 16 19 23 24 Output 01 1K 1L 37 36 35 34 33 Parts may differ for special applications Standard Part List 25 Bolt 29b Spline Output Shaft 34 Nilos Ring 26 Seal Cover 30 Bearing 35 Tab washer 27 Seal 31 Output Flange 36 Locknuts 28 Key 32 Oil Plug 37 Spacer 29a Output Shaft 33 Bearing 08 YILMAZ RED KT R Operating Instructions P R Series Part Designations 3 1 3 Version of Gearbox PV PN PT Gear Size 11 12 15 16 19 23 24 Output Type 08 OK OL 54 53 52 51 46
47. rmitted ranges will cancel the warranty manufacturer declaration and YILMAZ REDUKTOR 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 must 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 accordance with the nameplate catalogue The speed range will be provided on the name plate if YILMAZ REDUKTOR is informed that the gear unit will be used with frequency inverter If not informed the nameplate will have a single fixed speed and only this speed is allowed The electric motor and frequency inverter must be in accordance with 2006 42 EC If the gear units input is used with variable speed gear unit this must be informed to YILMAZ REDUKTOR before ordering and on the nameplate the allowed maximum and minimum speeds speed range will be provided If not mentioned by ordering the gear units speed will be a fixed single input speed and only this speed is allowed If the gear unit will be driven by
48. se comes out Some part key gear may be defect inside gearbox Go to ID The radial load or polygon effect of the chain may have caused the damage Check also ifthe assembly bolts are loosened or the plate you assemble the gearbox is rigid enough Check if you are using the correct diameter of chain drive and you are not exceeding max Allowed radial 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 You are using chain drive or Gearbox Housing is Defect ne pinion gear 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 rigit enough Check if you are using the correct diameter of chain drive and you are not exceeding max allowed radial load Check the position of your output element and re calculate your overhung load and check if this fit to the maximum allowed load Go to ID 100 You are using chain drive or Output Shaft is Defect ns pinion gear 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 braking For sudden braking check the wiring diagram Gearbox is stopping toolate You are using braked motor For fast opening of big brakes over 100Nm you may need Gearbox is starting too late You are using br
49. shaft with flange RV1502L 00 90S 6 Motor with 0 75 kW 900 rpm hollow output shaft gearbox size 15 2 stages parallel input and output shaft with foot PN1102L 01 EV063 71 4b Motor with 0 37 kW 1400 rpm connected with worm gearbox size 63 solid output shaft 2 stages parallel input output shaft planetary gearbox size 11 with flange Operating Instructions P R Series Designation 2 2 Nameplate unit designation Nameplate unit designation is a short abbreviation from detailed designation A sample name plate for P R Series YILMAZ RED KT R b 4 WWW yr com tr YILMAZ Made in Turkey RED KT R PV1902L 01 132M 4 Serial N 100109820 Power 7 5 Ratio 56 25 Speed 16 rpm M Positon M1 Oil ISO VG 320 Synthetic Oil Oil Quantity 2 0 It Abbreviations Serial N Serial Number M Position Mounting Position Type Designation PV1902 L 01 132M 4 Motor Type Type Output Shaft Properties Optional for P24 01 Solid Output Shaft 10 Solid Output Shaft Splined Hollow Shaft DIN 5480 KO OL Splined Hollow Shaft DIN 5482 LO 05 Shrink Disc 50 Splined Solid Shaft DIN 5480 K1 1L 5 Solid Shaft DIN 5482 L1 Shaft Arrangement L Input and Output shafts are on same axis K Input and Output shafts are perpendicular each other 06 Splined Hollow Shaft DIN 5480 Splined Hollow Shaft DIN 5482 Sh
50. uctions P R Series Mounting 7 3 Assembling Gear Unit with Torque Arm 7 3 1 Dimensions Torque arm dimension shown on below according to size of planetary gearbox 176 011 8 176 011 8 195 013 10 195 013 10 250 280 015 12 295 17x10 324 13x12 370 400 17x25 sn 415 450 17x28 40 YILMAZ RED KT R 574 Operating Instructions P R Series Mounting 7 3 2 Assemble the parts as shown bellow 1 Nut 4 Torque arm 2 Rubber buffer 5 Bolt 3 Spacer 6 Gearbox 74 YILMAZ RED KT R 41 Operating Instructions P R Series Mounting 7 4 Fitting output shaft elements Use the following illustration to assemble output shaft units 1 Gear shaft end 2 Thrust bearing 3 Coupling hub 7 5 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 1 Hub 7 6 Correct position of splined shaft output mounting positions Please refer the following mounting tolerances for splined output Be sure that there is no eccentricity between axis 110 1 100 42 YILMAZ RED KT R 574 Operating Instructions P R Series Mounting 7 7 Fitting Couplings 7 7 1 By fitting couplings be sure that there is some clearance between the two ele ments 7 7 2 By fitting couplings be sur
51. urer 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 P K 34522 Esenyurt istanbul TURKIYE Telefon 90 0 212 886 90 01 8 line Fax 90 0 212 886 54 57 Vy YILMAZ REDUKTOR Warranty Declaration 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 ac knowledgement 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 Atat rk Mah Lozan Cad No 17 P K 34522 Esenyurt istanbul TURK YE Telefon 90 0 212 886 90 01 8 line Fax
52. x is Heating Up too Much Gearbox Heating too Much Standard Gearboxes are designed to work under 40 Celsius ambient tem perature If ambient temp is higher than 40 Celsius special solutions gear boxes are required Please contact YILMAZ Ambient Temp is over 40 Celsius Gearbox noisy Nois is regular con tinious 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 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 damage Go to ID 100 Gearbox Nois is random noisy 374 YILMAZ RED KT R 65 Operating Instructions P R Series Troubleshooting Guide Gearbox is Gearbox is noisy Gearbox is noisy Gearbox is noisy Oil is Leaking Oil is Leaking Oil is Leaking Gearbox is mov ing regularly on its mounting point Gearbox is moving randomly on its mounting point Motor is heating up Motor is heating up Oil is Leaking 66 Regular nocking noise Regular up and down noise Gearbox is with braked motor and noise is coming from the brake side ran domly You are using fre quency inverter and the noise level is changing accordi
53. 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 chosen motor Go to ID 003 YILMAZ RED KT R 4 Operating Instructions P R Series Troubleshooting Guide For very low speeds the frequency inverters frequency is lowering down For very low frequencies the inverter parameter and motor parameter must be op timized 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 mo tor power and Frequency inverter or change ratio of gearbox to work inside the recommended range Gearbox Does Not Work in Low Speeds frequencies You are using fre quency inverter Gearbox Does Not Start Mornings or After Long Time Stop The oil is not in accordance with your working conditions Change to lower viscosity oils Observe this manuel for using the correct oil Working in higher ambient temperatures is an other solution if possible If still same problem you need higher motor power Ambient Temperature is below 5 Celsius Measure the surface temp
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