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Operating Instructions

1. Oil Quantities It Symbols NM Drain plug V Oil Filling and Vent plug vV Oil level 374 YILMAZ RED KT R 3
2. Oil Ouantities liter Type M1 A B M2 A B M3 A B M4 A B
3. M5 A B M6 A B K 275 276 1 3 0 4 2 0 0 4 2 0 0 4 2 1 0 4 1 3 0 4 1 5 0 4 KR375 376 2 10 0 7 3 3 0 85 3 2 0 7 37707 2 8 0 7 2 4 10 7 K 475 476 52 ero ae 6 0 1 2 CAO 162 59 12 4 8 1 2 K 575 576 6 5 1 2 9 95 1 78 O97 1 2 10 0 1 2 Oz Lot 1 2 K 675 676 150720 190731 19 0 2 0 205 20 17 0 2 0 18 0 2 0 K 775 776 21 2 0 31 0 3 1 29 0 2 0 34 0 2 0 21 0 2 0 25 0 2 0 K 875 876 Symbols 374 YILMAZ RED KT R 37 020 W Drain plug 50 0731 50 0 2 0 60 0 2 0 Oil Filling and Vent plug 33 017720 v 45 0 2 0 Oil level 39 Operating Instruction K Series Lubrication 9 4 Mounting Positions Figured mounting positions of M1 to M6 are determined
4. Oil Ouantities It M1 M2 M3 M4 M5 M6 A B A B A B A B A B A B 21 025 Seon Orr 3 2 0 25 3 11 0 25 2 8 0 25 2 4 10 25 5 0 0 4 6 5 1 5 6 0 0 4 7 0 0 4 5 5 0 4 4 8 0 4 639 05 Fore 9937 05 10 0 0 5 80 053 T9109 15 0 0 9 19 0 4 0 19 0 0 9 20 51 0 9 17 0 1 0 18 0 0 9 210 10 29 0 4 0 29 002150 34 0 1 0 210 10 25 07 10 37 0 2 15 50 0 4 0 50 0 2 15 60 0 2 15 39 0 2 15 45 0 2 15 Symbols W Drain plug V Oil Filling and Vent plug V Oil level 38 YILMAZ RED KT R 4 Operating Instruction K Series Lubrication 9 2 3 Five Six Stage K Series Oil Level Plugs
5. type basic part diagram Parts may differ for special a lications Standard Part List 9 Spacer 17 Bearing 25 Shim Ring 10 Shim Ring 18 Hollow Shaft 26 Bearing 3 Housing 11 Bearing 19 Key 27 Pinion Shaft 4 Girclip 12 Pinion Shaft 20 Key 28 Key 5 Shim Ring 13 Cover Plate 21 Gear 29 Gear 6 Key 14 Bolt 22 Shim Ring 30 Bolt Gear 15 Oil Seal 23 Closing Cap 31 Flange 8 Bearing 16 Circlip 24 Circlip YILMAZ RED KT R 4 Operating Instructions K Series Safety ps Hi b 4 Safety 4 1 Intended Use The gear reducer is designed for use in industrial machines Please refer to our catalogue or our web page for the maximum permitted torques and speeds The most important maximum permitted values are indicated on the nameplate of the product But the all data can be found on our product catalogues Using the product out of the product catalogue nameplate s permitted ranges will cancel the warranty manufacturer declaration and YILMAZ RED KT R 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
6. 26 Assemblingcustomershaftwithshrinkdisk 27 8 Disassembling customer shaftwithshrinkdisk 29 9 Assemblinggearunitwitihtorgucarnm 30 110 FIXING DOIA e e EMA ee een ee 31 7 11 Fitting outputshaftelemenis MMMmA A m A A m Z Z gt mm m 33 12 Correct positionofoutputshaftelemenis 33 Lto FUNG COUPINGS seid tee A AYA APA SAY AP NN 34 8 Maintenance and Inspections 1 00 rr nun nun nun nun nun nun nun nun 35 e MEL ge hp KR e 36 IE OU CS YA A ee eier 36 9 2 Changing the oil A A R YE 254 36 9 3 Oil Quantities It and oil a e i ll ll 36 39 JA b e ge IPOS LION Saunas it ne SAM M RA a AN era 40 10 Troubleshooting CN 2 een alime ama ani y nle konma een 40 N ENE 41 11 DISPOSAL O ie ee ee 44 11 2 Disposal of e SA M Semen eta kemana e netleme ilme alemine int aaa iauuecunedesabeeecd 44 N Disposal Of gt NN NN EN PE Ee 44 BZ N 01 011 e p GE AEN ANE ETA 45 Warranty e gg NE ee 46 Warranty DECIarallONS u uueuuu een 47 374 YILMAZ RED KT R 03 Operating Instructions K Series General Informations 1 How To Use This Manual Take attention to the following safety and warning signs for proper understanding and quick reference H D gt 04 Electric Ha
7. 15 Oil Seal type basic part diagram Parts may differ for special applications 23 Closing Cap 9 Spacer 16 Circlip 24 Circlip 3 Housing 10 Shim Ring 17 Bearing 25 Shim Ring 4 Circlip 11 Bearing 18 Solid Output Shaft 26 Bearing 5 Shim Ring 12 Pinion Shaft 19 Key 27 Pinion Shaft 6 Key 13 Cover Plate 21 Gear 28 Key Gear 14 Bolt 22 Shim Ring 29 Gear YILMAZ RED KT R 4 Operating Instructions K Series Part Designations 3 3 K 02 Type type basic part diagram Parts may differ for special applications Standard KR 02 Standard Part List 9 Spacer 17 Bearing 25 Shim Ring 10 Shim Ring 18 Output Shaft 26 Bearing 3 Housing 11 Bearing 19 Key 27 Pinion Shaft 4 Girclip 12 Pinion Shaft 20 Key 28 Key 5 Shim Ring 13 Cover Plate 21 Gear 29 Gear 6 Key 14 Bolt 22 Shim Ring 30 Bolt Gear 15 Oil Seal 23 Closing Cap 31 Flange 8 Bearing 374 YILMAZ RED KT R 16 Circlip 24 Circlip 09 Operating Instructions K Series Part Designations 3 4 K 03 Type 10 Standard KR 03
8. A sample name plate for K Series 4 YILMAZ REDUKTOR YILMAZ www yr com tr C RED KT R MADE IN TURKEY Type KR373 00 100L 4a Serial N 10005289 Power 3 kW Ratio 51 05 A Speed 27 rpm M Pos M1 Oi KV Qi Qty 2 4 It Abreviations Serial N Serial Number M Pos Mounting Position Type Designation KR383 00 R Type Shaft Arrangement Viewed from input side L Right Input Left Output R Left Input Right Output YILMAZ RED KT R 4 Operating Instructions K Series Part Designations 3 Standard Type Gearbox Part List 3 1 K 00 Type lications Standard KR 00 type basic part diagram Parts may differ for special a Standard Part List 8 Bearing 15 Oil Seal 23 Closing Cap 9 Spacer 16 Circlip 24 Circlip 3 Housing 10 Shim Ring 17 Bearing 25 Shim Ring 4 Circlip 11 Bearing 18 Hollow Shaft 26 Bearing 5 Shim Ring 12 Pinion Shaft 19 Key 27 Pinion Shaft 6 Key 13 Cover Plate 21 Gear 28 Key Gear 374 YILMAZ RED KT R 14 Bolt 22 Shim Ring 29 Gear 07 Operating Instructions K Series Part Designations 08 3 2 K 01 Type Standard KR 01 Standard Part List 8 Bearing
9. Operating Instruction K Series Lubrication 9 2 2 Four Stage K Series Oil Level Plugs SFr O La Fe et
10. Bolt 3 Bolt 6 Nut 9 Rubber Buffer 574 YILMAZ RED KT R 31 Operating Instructions K Series Mounting 7 10 For the fixing bold position refer to the following dimensions Std b h2 b1 T1 Type KR273 10 KR373 10 KR473 10 KR573 10 KR673 10 KR773 10 KR873 10 32 YILMAZ RED KT R 4 Operating Instructions K Series Mounting 7 11 Fitting output shaft elements Use the following illustration to assemble output shaft units 1 Gear shaft end 2 Thrust bearing 3 Coupling hub 7 12 Correct position of output shaft elements 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 374 YILMAZ RED KT R 33 Operating Instructions K Series Mounting 7 13 Fitting Couplings 7 13 1 By fitting couplings be sure that there is some clearance between the two ele ments 7 13 2 By fitting couplings be sure that there is no eccentricity between the two shafts oo 7 13 3 By fitting coup
11. Standart scope of delivery 2 Lock washer 3 Washer 4 Circlip 5 Spacer 6 Hollow Shaft 7 Customer Shaft 7 4 2 Use the disassembly set from YILMAZ REDUKTOR and fasten the bold as shown bellow to take out the output shaft For disassembly sets look the following pages 1 Retaining bolt 2 Circlip 3 Fixed nut 4 Forcing Washer 5 Hollow Shaft 6 Customer Shaft 24 YILMAZ RED KT R 4 Operating Instructions K Series Mounting 7 5 Shaft Tightening Torgues values are as shown Tightening Torgues Nm 20 40 40 574 YILMAZ RED KT R 25 Operating Instructions K Series Mounting 7 6 Recommended shaft dimensions for KT 00 types b max _b1 b2 b3_ 26 YILMAZ RED KT R 574 Operating Instructions K Series Mounting 7 7 Assembling customer shaft with shrink disk 7 7 1 Loosen the bolts of the shrink disk 7 7 2 Use a solvent available in your market to clean all the dirt an oil from the shaft and shrink disk hollow The surfaces must be free from oil or any dirt The solvent must be re moved from t
12. 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 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 belt coupling chain drive etc the gear unit is only allowed to be used according the nameplate catalogue entries Different speed higher motor power higher radial axial loads etc than nameplate catalogue is not allowed The ambient temperature must be between 5 40 celsius and no abrasive media must attack the paint and seals If different working conditions this mu
13. 120 Working Temperature C Synthetic Grease 100 Working Temperature C 30 36 Energrease LS 3 Energrease SY 2202 Optileb GT 320 Tribol Bio Top 1418 320 Spheerol AP3 Kl bersynth GEM4 100 N Kl beroil 4 UH1 320 N Kl bersynth GEM 2 320 Centoplex 2EP Petamo GHY 133 N Mobil SHC Cibus 320 Mobilux EP 3 Mobiltemp SHC100 Cassida Flu id GL 320 Alvania RL3 Cassida RLS 2 YILMAZ RED KT R 4 Operating Instruction K Series Lubrication 9 2 Changing the oil Refer to the nameplate to find out the correct oil filled inside the gearbox N 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 O Extended intensive contact with oils can lead to skin irritations aS 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 9 2 1 Three Stage K Series Oil Level Plugs
14. 60 Hz over 3kW and is indicated on the motors name plate unless it is differently ordered In case of only gear unit is supplied from YILMAZ RED KT R please observe the name plate of the electric motor and the instructions of the supplier Check the basic electric connection diagrams below Use experienced 16 U electric technician YILMAZ RED KT R 4 sing wrong connection or voltage can damage the electric motor or environment Operating Instructions K Series AN 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 grounded to prevent potential differ ences of earth and gearbox motor A Nominal Powers at 400V 50Hz enua Nominal Powers at 400v 50Hz 230V A 400V Y 400V A kW SSM ee ee Direct Direct or Y A Principle Basic motor connection wiring diagram LI L2 L3 LI gt L3 230V 230V 400V 400V 230V 400V 1 y 12 I 13 Il J 12 1 I3 J ip a a r LI L2 L3 A Y 574 YILMAZ RED KT R 17 Operating Instructions B Series Checking Standard type brakes basic wiring diagram
15. Mounting 7 2 Installing customer shaft without shoulder 2 1 Use anti seize assembling paste available on your market Use a brush to ap ply the paste 7 2 2 Fasten the bold as shown indicated 22 1 Short retaining bolt Standart scope of delivery 2 Lock washer 3 Washer Circlip 5 Spacer Customer Shaft YILMAZ RED KT R 4 Operating Instructions K Series Mounting 7 3 Disassembling customer shaft with shoulder 7 3 1 Disassemble the bolt and take out the parts as shown 1 Short Retaining Bolt 2 Lock Washer 3 Washer 4 Circlip 5 ollow Shaft 6 Customer Shaft 7 3 2 Use the disassemble set from YILMAZ RED KT R and fasten the bold as shown bellow to take out the output shaft For disassemble sets look the following pages 1 Retaining Bolt 2 Circlip 3 Fixed Nut 4 Forcing Washer 5 Delik Mil 6 Customer Shaft 574 YILMAZ RED KT R 23 Operating Instructions K Series Mounting 7 4 Disassembling customer shaft without shoulder 7 4 1 Disassembly the bolt and take out the parts as shown 1 Short retaining bolt 5
16. The electric connection must be done by experienced electric technician The gearbox and the motor must be grounded to prevent potential differences of earth and gearbox motor A Delayed Running Brake 220V Sudden Brake 220 V L1 L2 L3 N L1 L2 L3 N L e u o Brake Coil Brake Coil M M ar Delayed Running Brake 24 V Sudden Brake 24 V L1 L2 L3 N Brake Coil L1 L2 L3 N Brake Coil IIIT E f gt 4 do I pe 18 YILMAZ RED KT R 74 Operating Instructions K Series Checking N 6 5 Check the mounting position The mounting position must be in accordance with the mounting position mentioned on the A 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
17. as reference of directional position of the gearbox Mounting surfaces are not binding 40 YILMAZ RED KT R 4 Operating Instructions K Series Troubleshooting Guide 10 Troubleshooting Guide All the operations bellow must be done by authorized and skilled mechanician electrician gt Inform YILMAZ REDUKTOR before making any change to the gearbox Only oil change is al lowed to change without information Do not make anything if you are not sure what you are doing and contact YILMAZ RED KT R Any change or operation done without the informa tion of YILMAZ REDUKTOR is in your own risk and responsibility and YILMAZ REDUKTOR does not take any responsibility Gearbox Does el Not Start Up 002 Gearbox Does Not Start Up 003 Gearbox Does Not Start Up Gearbox Does Not Start Up Gearbox Does gt Not Start Up You hear no noise and shaft is not turning You are not using any driver or reguency inverter You hear no noise and shaft is not turning You are using frequency inverter or driver You hear some noise but both motor shaft and gearbox shaft is not turn ing You are not using any driver frequency inverter or braked motor You hear some noise but both motor shaft and gearbox shaft is not turn ing You are using driver or frequency inverter You hear some noise but both motor shaft and gearbox shaft is not turning You are using braked motor 574 YILMAZ RED KT R Please Che
18. 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 If 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 leaks over the housing If this is your case go to ID 018 019 If you are sure oil comes out from housing than housing has some micro split crack Go to ID 100 The sealing liquid under cover is split defect Disassemble 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 ofthe 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 e
19. during the warranty time and it is not possible to repair it the product will be changed with a new one according to the report from our service department mentioning that the hazard can not be repaired 6 Costumers must inform the manufacturer if there are some problems after the service and repair of the failed product 7 The extra costs like stopped plant physical or mental injuries etc by the costumer side are not covered by this warranty except the product itself YILMAZ REDUKTOR San ve Tic A S Head Office Maltepe Gumussuyu Cad Bestekar Medeni Aziz Efendi Sok No 54 P K 34020 Topkapi Istanbul TURKEY Phone 90 0 212 567 93 82 83 Fax 90 0 212 567 99 75 Factory YILMAZ REDUKTOR Sanayi ve Ticaret A S ATATURK Mah Lozan Cad No 17 P K 34522 Esenyurt stanbul TURK YE Telefon 90 0 212 886 90 01 8 line Fax 90 0 212 886 54 57 xy YILMAZ REDUKTOR 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 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
20. sufficient distance and make safeguarding to rotating machinery See relevant norms EN349 A1 EN 13857 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 YILMAZ RED KT R 4 Operating Instructions K Series Safety f 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 Torgu
21. the gear unit 6 6 Use of breather plug Breather plugs are not needed for K Series under normal ambient and working conditions Up to 30 degree Celsius ambient temperature and up to 8 hours per day If heavy ambient conditions and long time working hours then breather plug are recommended by YILMAZ REDUKTOR and delivered with the gearbox together Replace the breather plug with the most top plug according to your mounting position Some plug positions are not machined according mounting position If no mounting position is mentioned by ordering the standard M1 position plugs are machined 6 7 Check the oil level On the mounting position tables the oil level plug is snown 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 elements are free of oil and dust The output shaft may be protected by anti corrosion oil Please remove this using available solvents on y
22. Lubricant Bin 51517 3 Dip Forced Lubrication Lubrication ISO VG 68 GR XP 680 Energol Kl beroil Mobilgear Beyond Castrol Kl ber Petroleum Lubrication bp pyar LELE GEM 1 680 N XMP 680 Energol Kl beroil Mobilgear GR XP 460 GEM 1 460 N XMP 460 Energol Kl beroil Mobilgear CLP GR XP 320 GEM 1 320 N XMP 320 Energol Kl beroil Mobilgear GR XP 220 GEM 1 220 N XMP 220 Energol Kl beroil Mobilgear GR XP 150 GEM1 150 N XMP150 Energol Kl beroil GR XP 100 GEM 1 100 N 7 Energsyn Klubersynth Mobil SG XP 680 p GH 6 680 Glygoyle 680 Energsyn Aphasyn Kl bersynth Mobil SG XP460 PG460 GH 6 460 Glygoyle 460 Energsyn Aphasyn Kl bersynth Mobil SG XP320 PG320 GH 6 320 Giygoyle 320 Energsyn Aphasyn Kl bersynth CLP SG XP 220 PG 220 GH 6 220 u PG Energsyn Aphasyn Kl bersynth SG XP 150 PG 150 GH 6 150 Klubersynth u u GH 6 100 Kl bersynth Mobilgear u u GEM4 680 N SHCXMP680 Enersyn Alphasyn Kl bersynth Mobilgear Synthetic EP XF 460 T 460 GEM4 460 N 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 220 N Mobilgear SHC XMP 220 CLP HC Enersyn EP XF 150 Alphasyn T 150 Kl bersynth GEM4 150 N Mobilgear SHC XMP 150 Food CLP Grade Oil NSF H1 Biodegrad CLP able Oil E Mineral Grease 20
23. Unit nun nun nnnn nun ann nun nun nun nenn 15 6 1 Before you iss PA ee ee een 15 6 2 Check the shaft dimensions to fit MMAm A A A A A A A A A A A A A A lt gt nenn nenn nennen 16 6 3 Checkitiheambienttemperature 16 6 4 Checkthevoltagesupply m m gt nenn nennen 16 6 5 Check the mounting position 19 6 6 Use of breather Di MN net AM ARMAN A N NA 19 6 Checktheoillevel NNMMMMMAMA A A A A gt gt gt Z gt Z Z Z I mm ann nnnn nenn anne nennen 19 6 8 Check shaftendsandmountingtaces 19 6 9 Cover abrasive ambient u rennen 19 2 YILMAZ RED KT R 4 Operating Instructions K Series Contents 6 10 Check accessibility tofilling breatheranddrainplugs 20 T Mechanical Installation aaa aaa aaa nun nun nnnnen 20 7 1 Installing customer shaftwithshoulder mmm lt lt lt lt 21 7 2 Installing customer shaftwithoutshoulder nennen 21 3 Disassembling customer shaft withshoulder 22 4 Disassembling customer shaft withoutshoulder 24 l Shaft tig tening CON UC Sey gi ee lll 25 7 6 RecommendedshaftdimensionsforKTl 00types
24. YILMAZ RED KT R ISO 9001 YILMAZ REDUKTOR ISO 9001 v YILMAZ RED KT R K Series Gear Units Edition OIKCE 0201 0312 Operating Instructions Operating Instructions K Series Contents CONTES rsin EAE era anne Range 03 1 Howlo UselhisManual nun nun ann nun ann nun nn nnn ann nenn 04 2 Unit DESIGNAU ON nase ir eu lll 05 2 1 Detailed unit designation 2 05 2 2 Nameplate unit designation u2 z020020000000000 000 nnn nun nnnn nn nnnn ann nnnn nn 06 3 StandardtypeGearboxPartlist eee 07 Oe ie DES emilme emme sab bi emaili ni iisl e belen sini lil ni bni diei bii eo kaldi 07 PF Ta A en ee ne 08 3 3 KR 3 02 IOC ME ARAN EREN E MAY EA PEP MEME PMPA 09 SA RR 29303 VY OC Ser ral peni elele male 10 e ig A RR EMAY 11 4 1 Intended WSC die so ee A YAY YAY A ANY 11 Za 2 IDEODE de NE O ER E 11 4 3 Safety MINS UNG NR A 12 4 3 1 GeneralSafetyiInstructions 12 4 3 1 1 Workingonthegearreducer 12 4 3 1 2 Operation KK ME MM NE MA sehen 12 44 Tighteninglorgues m m nenn nnn nennen enenennnenenennenn 13 4 5 Case of e YP KE A EE A RE 13 5 Things to Check Before the Gear Unit or Geared Motor is Installed 14 5 1 Transportation EE AE ER A PAN YP 14 9 2 OAE a EREM ee ME KE PE EEE ERON ere 15 6 installiinglheGear
25. aking For sudden braking check the wiring diagram Gearbox is stopping too late You are using braked motor For fast opening of big brakes over 100 Nm you may need Gearbox is starting too late You are using braked motor shock transformators which is supplied by YILMAZ RED KT R 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 declara tions and YILMAZ REDUKTOR will take no responsibility Service Required 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 guidelines 11 2 Disposal of Sealings Remove the sealing rings from the gear reducer and clean them of oil and grease residues Dispose of the sealings as composite material metal plastic 11 3 Disposal of Metal Divide up the remainder of the gear reducer into iron aluminium non ferrous hea
26. ck the voltage supply and freguency of your electric con nection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Still does not work go to ID 100 Please observe the freguency inverter driver manual Check the motor by supplying direct voltage to see if the problem is on your driver fre guency inverter Still does not work go to ID 001 Please Check the voltage supply and freguency of your electric con nection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Still same problem the load may be too high for the chosen motor Loosen the gearbox from the load torque If it works than the starting torque is insufficient and higher motor power is needed For monophaze motors check the starting up condansator and running condansator as well If nothing helps go to ID 100 Please observe the frequency inverters or drivers manual To see ifthe problem is on your driver or frequency inverter take out the driver fre guency inverter and make direct voltage supply to the motor according the motors nameplate Still does not work go to ID 100 Please Check the voltage supply and freguency of your electric con nection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Be sure that the brake is working Observe the brake manufacturers Manuel If brake is supplied from YILMAZ RED KT R obse
27. e 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 Gearbox is Heating Up too Much Gearbox is Standard Gearboxes are designed to work under 40 Celsius ambient tem Ambient Temp is i i l Heating Up averso Celtis perature If ambient temp is higher than 40 Celsius special solutions gear too Much boxes are required Please contact YILMAZ RED KT R Gearbox is Nois is regular con Check Your moving parts for noise Disassemble the gearbox and run without noisy tinious 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 Nois is random 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 is noisy 42 YILMAZ RED KT R 4 Operating Instructions K Series Troubleshooting Guide Gearbox is noisy Gearbox is noisy Gearbox is noisy Gearbox is noisy Oil is Leaking Oil is Leaking Oil is Leaking Oil is Leaking Gearbox is moving regularly on its mounting point Gearbox is moving ran domly on its mounting point Motor is heat ing up Motor is heat ing up CH Regular nocking
28. eared unit or geared motor will be stored up to 3 years refer to the following instructions With Packing Use corrosion protection oil for the output shaft and connection surfaces like flange surface or foot assembling surface Seal the unit in a plastic wrap and pack it in container A moisture indicator should be placed around the container to observe the moisture Relative atmospheric humidity should not exceed 50 The container should be kept under roof which protects from snow and rain Under this condition the gear unit can be stored up to 3 year with regular check The ambient temperature should be between 5 to 60 Celsius degrees Without Packing Use protection 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 50 The storage should be free of dust and dirt and ventilated with filter If the gearbox is stored without packing it is recommended not to store more than 2 years and regular check during this time is recommended If stored in open 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 yo
29. ed unit designation Detailed K Series gear units designation for orderin This Designation is different from the short nameplate desiqnation 3 0 27 48 86 KR3 3 00 100L 4b L02 Power kW Ratio Type Output Type Motor Size Brake Speed rpm _ KR Direct Motor Coupled L 220V KT Without Motor With Fan KV With motor and B5 flanged P 24V KN Ohne Motor With Fan S 220 V Without Fan Z 24V Without Fan 00 Hollow shaft output 01 10 Nm 01 Solid output shaft a 20 2 02 Solid shaft output with IEC B5 14 Flange en AT g m 03 Flanged and hollow shaft output ie dik ane 05 50 Nm 04 With Double shaft output ypes 10 100 Nm 05 Double flanged and double output shaft B07 71B14 20 200 Nm 08 Double flanged and hollow output shaft A08 80 B5 30 300 Nm 0S Shrink disk output B08 80 B14 40 400 Nm OE Extruder output A09 90 B5 B09 90 B14 A10 100 B5 B10 100 B14 A11 112 B5 B11 112 B14 A13 132 B5 B13 132 B14 0 75 24 58 09 KV 373 01 100L 4b 0 75 kW 1500 rom geared motor with and solid output shaft KV 373 gearbox type 10 15 KN373 01 B08 KN373 i 10 15 geared unit with 80 type B14 flange and output shaft 10 15 K 1373 01 KT373 i 10 15 geared unit with input shaft and output shaft 374 YILMAZ RED KT R 05 Operating Instructions K Series Type Designation 06 2 2 Nameplate unit designation Nameplate unit designation is a short abbreviation from the detailed designation
30. ening The mounting plate must be rigid enough not allowing torsions flat enough to prevent strains by tightening the bolts and stable enough not allowing vibrations By using chain drives this becomes much more important because of the polygon effect on chain drives According to your connection elements the maximal permitted radial and axial load of the gear unit must be in accordance with your application Check the product catalogue for permitted radial loads and calculation If the output or input shaft is overloaded by radial or axial loads it can cause serious damage to the gear unit Secure the gear unit using 8 8 or higher quality bolts Cover allthe turning parts from human entering or touching Turn ing parts can cause severe or fatal injuries For different kind of basic installations refer to the following illustrations YILMAZ RED KT R 4 Operating Instructions K Series Mounting 7 1 Installing customer shaft with shoulder 1 1 Use anti seize assembling paste available in your market Use a brush to apply the paste 7 1 2 Fasten the bold as shown below Er 1 Short retaining bolt Standart scope of delivery 2 Lock washer Washer 4 Circlip Hollow Shaft Customer Shaft in D 374 YILMAZ RED KT R 21 Operating Instructions K Series
31. es All screwed connections for which a tightening torgue is specified must on principle be tightened with a calibrated torgue wrench and checked Use the following torgues for the threaded bores over the gear unit housing For con necting 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 synthetic or mineral gear oil Please observe the following if the gear reducer is situated in a burning environment 4 5 1 Suitable extinguishing agents Protective equipment Always keep suitable extinguishing protective equipment like carbon dioxide powder foam fog easily accessible around the gear unit N High temperature produce irritating steam Use a protective breathing apparatus 4 5 2 Unsuitable extinguishing agents N Do not spray with water 374 YILMAZ RED KT R 13 Operating K Series Checking 14 nstructions 5 Things to Check Before the Gear Unit or Geared Motor is Installed If gear motors are used please also refer to the manual of the motor manufacturer Before you install the gearbox you have to be sure that the gearbox is arrived with the all necessary equipment and without damage Thinks to take into consideration before you start to install the unit You have received the correct operation manual of the your product The gearbox and all its parts are transported without dama
32. ge The gearbox is stored correctly according the instructions in this manual You have the latest product catalogue or you have access to our web page 5 1 Transportation When the goods arrive first check for any damage If some damage observed im mediately contact the transport company and inform about the damage Contact YILMAZ RED KT R for the damage and do not start to install the unit until it is agreed that the damage has no affect of operation Use the upper foot connection holes for lifting up the gear unit by using eyebolts The eyebolts should be capable to carry the weight of gearboxes Do not hang additional loads on the gear box by lifting Use suitable hoisting eguipment which is capable to hold the gear units weight Refer to the catalogue for various types weights If the earbox is delivered with steel carrying construction use the construction holes for lifting the gear unit See drawing bellow for hoisting point Do not stay beneath under the lifting hoisting eguipment which may cause serious iniuries by falling down objects accidental movements unexpected accidents Falling or hard placement can damage the gear unit Only use hoisting and securing equipment which is permitted for the size weight of our gear unit Ensure that the load is slowly and carefully handled and placed YILMAZ RED KT R 4 Operating Instructions K Series Checking 5 2 Storage If the g
33. he surfaces as well 374 YILMAZ RED KT R 21 Operating Instructions K Series Mounting 7 7 3 nsert the shaft and tighten the bolts as shown Be sure that there is a clearance between the shrink disk shoulder and the hollow shaft shoulder of the gearbox 2 5 1 Welle von Kunde Ringaus bronze ohlwell 4 Schrumpscheibe Tightening Torque Nm 30 30 30 60 28 YILMAZ RED KT R 4 Operating Instructions K Series Mounting 7 8 Disassembling customer shaft with shrink disk 7 8 1 Loosen the bolts of the shrink disk and take out the shaft 574 YILMAZ RED KT R 29 Operating Instructions K Series Mounting 7 9 Assembling Gear Unit with Torque Arm 7 9 1 The following connecting possibilities are available Use one position which is the most suitable 30 YILMAZ RED KT R 4 Operating Instructions K Series Mounting 7 9 2 Assemble the parts as shown bellow Nu 00 6 7 a P LO 1 Gear Unit 4 Spacer Ring Spacer Ring 10 Torgue Arm 2 Assembled Shaft 5 Machine Extension 8 Nut 11
34. l for using the correct oil Working in higher is below 5 Celsius ambient temperatures is an other solution if possible If still same problem you need higher motor power Measure the surface temp using a temperature measuring device under full load If the temp is under 80 Celsius this will make no harm to the gearbox a WiGRn and is normal All ATEX conforming gearboxes and standard worm gearboxes Gearbox is g are designed to work under max 120 Celsius If higher than 120 Celsius 008 Gear Box and ambi l i Heating Up Si lower han and using ATEX conforming gear box immediately stop the system and contact too Much pl YILMAZ REDUKTOR Go to ID 100 If not ATEX confirming check the oil type 40 Celsius l l a and oil guantity 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 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 guantitiy level according your mounting position and check th
35. lings be sure that the two shafts are not angular miss aligned 34 YILMAZ RED KT R 4 Operating Instructions K Series Checking 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 cata logue Selecting Item to check replace Check for oil leakage Check for oil level Check oil leakage from seal x Change if neces Check Rubber buffer Check Bearings Noise Change Mineral Oil Gearbox section Every 3 000 work ing hours or every 6 Every 4 000 work ing hours x See Below for details Every 10 000 working hours or every 3 years hours Every 25 000 working Pr x See Below for details 45000 40000 35000 30000 25000 20000 15000 10000 Oil change interval Hours 5000 70 80 90 100 110 120 130 140 Oil bath temperature Celcius 150 160 Mineral Synthetic PAO Synthetic PG reference il For normal ambient conditions 70 degrees Celsius oil bath temp should be taken as For K series Mineral oil is used unless it is differently ordered For oil type and quantities refer to the following tables 574 YILMAZ RED KT R 35 Operating Instruction K Series Lubrication 9 Lubrication 9 1 Oil Types E Temperature E ay
36. 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 according 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 574 YILMAZ RED KT R 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 disk 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 optimised 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
37. our 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 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 19 Operating Instructions K Series Checking 20 gt 8 D as 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 manual be sure that no one will be harmed by accidentally brake downs or loos
38. 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 stanbul TURK YE Telefon 90 0 212 886 90 01 8 line Fax 90 0 212 886 54 57 Stamp and Signature Supplier End User With signing this part and sending this back to our company your waranty 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 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 0 0 0 0 0 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
39. rve this Manuel for correct brake wir ing diagram If still not work supply the brake with voltage according its nameplate directly For example 198V DC You will hear a clicking noise explaining that the brake is opening f you hear no noise the brake or rectifier is defect If you hear the clicking noise the brake is working You should this clicking noise by your normal electric connection as well By supplying direct supply to the brake you hear the clicking noise and at same time you supply the motor with direct voltage according to its name plate and still same problem the load may be too high for the chosen motor Go to ID 003 41 Operating Instructions K 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 timise 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 You are using fre Low Speeds guency inverter frequencies Gearbox Does Not Start Mornings or After Long Time Stop The oil is not in accordance with your working conditions Change to lower Ambient Temperature viscosity oils Observe this Manue
40. st be informed to YILMAZ RED KT R 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 It is operated out of the permitted values provided on catalogues and or nameplate 374 YILMAZ RED KT R 11 Operating Instructions K Series Safety 12 gt BPP PE BE EB 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 techniclans Foreign bodies spinning through the air can cause grave Injury Before putting the gear reducer into operation check that there are no foreign bodies or tools near the gear reducer 4 3 1 2 Operation Touching hot surfaces can lead to burns Do not touch the gear reducer if their operation temperatures are too high or use suit able safety equipment like gloves Rotating machinery can lead to injuries There is danger of being trapped or pulled in Keep a
41. u 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 374 YILMAZ RED KT R 15 Operating Instructions K Series Checking 6 2 Check the shaft dimensions to fit Hollow Shaft Diameter Hollow Shaft Tolerance H8 Output Shaft Diameter Output Shaft Tolerance DIN748 Up to 50mm k6 Over 50mm m6 Flange Centering Shoulder Diameter Centering Shoulder Tolerance g6 0 02 0 0 01 0 04 0 02 O 0 02 0 04 0 02 0 0 02 0 05 0 03 0 01 0 02 0 05 0 03 0 01 0 02 0 05 0 04 0 02 0 02 0 06 6 3 Check the ambient temperature 0 04 0 02 0 02 0 06 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 60Hz up to 3kW includ ing 3kW and 400 690 V 50
42. vy metal if possible Dispose of it according to the valid national guidelines 44 YILMAZ RED KT R 4 Appendix amp V YILMAZ REDUKTOR Warranty Conditions 1 The geared motors and gear units are warranted for two year except the electric mo tor For motor warranty please refer to the manual of the electric motor manufacturer or the warranty document of the motor manufacturer This warranty is valid only if the gearbox is assembled and started up according our operating instructions and is used under the allowed conditions for the appropriate gearbox type in our catalogue 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
43. xternal fan you may need forced external fan Go to ID 100 43 Operating Instructions K Series Troubleshooting Guide o rem nem Motor is running but Gear Scratching noise comes Some part key gear may be defect inside gearbox Go to ID box shaft does not turn out 10 The radial load or polygon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigid 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 Gearbox Housing is Defect nn or pinion gear The radial load or polygon effect of the chain may have caused the damage Check also if the assembiy 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 Output Shaft is Defect y or 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 br
44. zard 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 the gear reducer is not consid ered 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 K Series gear units and is applicable only for K 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 YILMAZ RED KT R 4 Operating Instructions K Series Contents 2 Unit Designation 2 1 Detail

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