YILMAZ REDÜKTÖR E Series Operating Instructions Manual Download Page 11

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Part Designation

3.5- E...04 Types

1- Key

7- Bearing

13- Bearing

19- Bearing

2- Solid Output

Shaft

8- Worm Wheel 14- Circlips

20- O-Ring

3- Seal

9- Bearing

15- Washer

21- Input Flange

4- Bolt

10- Housing

16- Seal

22- Bolt

5- Side Cover

11- Closing Cap 17- Oil Plug

23- Seal

6- O-Ring

12- Circlips

18- Worm Gear

22 23

Standard E...04... type basic part diagram. Parts may differ for special applications.

Standard Part List

Operating Instructions

E Series

Summary of Contents for E Series

Page 1: ...E Series Worm Gearboxes OPERATING INSTRUCTIONS OIECE0302 0422 ...

Page 2: ...ety Instructions 22 4 3 1 1 Working on gear reducer 22 4 3 1 2 Operation 22 4 3 1 3 Maintenance 22 4 3 1 4 Lubricant 22 4 3 1 5 Ambient Conditions 22 4 4 Tightining Torques 23 4 5 Case of Fire 23 4 5 1 Suitable extinguishing agents protective equipment 23 4 5 2 Unsuitable extinguishing agents 23 5 Thinks to Check Before the Gear Unit or Geared Motor is Installed 24 5 1 Transportation 24 5 2 Storag...

Page 3: ...unit with torque arm 34 7 5 Fitting output shaft elements 37 7 6 Correct position of output shaft elements 37 7 7 Fitting couplings 38 8 Maintenance Inspection 39 9 Lubrication 40 9 1 Oil types 40 9 2 Changing the oil 41 9 3 Mounting Positions 41 9 4 Oil Quantities 42 10 Troubleshooting Guide 43 11 Disposal 46 11 1 Disposal of oil 46 11 2 Disposal of sealing 46 11 3 Disposal of metal 46 12 Appendi...

Page 4: ...ing the necessary pre cautions on the machine or at the place where the gearbox will be used in order to prevent injury and life threatening risks by taking into account the shaft gear failures etc that may occur in the gearboxes The operating instructions contain important information to ensure Trouble free operation Fulfilment of any rights to claim under guarantee The operating instruction must...

Page 5: ...nge 03 Flanged and Hollow Shaft Output 04 With Double Shaft Output 05 Double Flanged and Double Output Shaft 06 With Shaft Extension on the Motor Fan Cover Side 07 With Double Input Shaft 08 Double Flanged and Hollow Output Shaft E V 063 01 90S 4 L05 10 100Nm 20 200 Nm 30 300 Nm 40 400 Nm Motor Size For EV types 90S 4 Pole Number Frame Lenght Motor size A06 63 B5 A10 100 B5 A20 200 B5 B06 63 B14 B...

Page 6: ...ies Abreviations Serial N Serial Number M Pos Mounting Position Type Designation Type EV080 00 90S 4 Output Shaft Motor Type Type Designations M Pos Oil Ratio Type rpm Speed Power kW www yr com tr MADE IN TURKEY Serial N YILMAZ REDÜKTÖR Oil Qty lt EV080 00 90S 4 100536041 1 1 62 23 M1 ISO VG320 Synthetic Oil 0 5 6 Operating Instructions E Series ...

Page 7: ...g 14 Worm Gear 3 Side Cover 9 Closing Cap 15 Bearing 4 O ring 10 Circlips 16 O Ring 5 Bearing 11 Bearing 17 Input Flange 6 Worm Wheel 12 Seal 18 Bolt Standard E 00 type basic part diagram Parts may differ for special applications Standard Part List 1 2 3 4 5 6 7 8 11 10 9 12 13 14 15 16 17 18 19 7 Operating Instructions E Series ...

Page 8: ...5 Seal 21 Bolt 4 Bolt 10 Housing 16 Oil Plug 22 Seal 5 Side Cover 11 Closing Cap 17 Worm Gear 6 O ring 12 Circlips 18 Bearing Standard E 01 type basic part diagram Parts may differ for special applications Standard Part List 3 4 5 6 7 8 9 10 13 12 11 15 16 17 18 19 20 21 22 14 1 2 1 Part Designation 8 Operating Instructions E Series ...

Page 9: ...ring 15 Bearing 21 O Ring 4 Flange 10 Worm Wheel 16 Circlips 22 Motor Flange 5 Seal 11 Bearing 17 Seal 23 Bolt 6 Bolt 12 Housing 18 Oil Plug 24 Seal 4 3 2 11 10 5 6 7 8 9 12 15 14 13 17 18 19 20 21 22 23 24 16 1 1 Standard E 02 type basic part diagram Parts may differ for special applications Standard Part List 9 Operating Instructions E Series ...

Page 10: ...l Plug 21 Seal 4 Bolt 10 Housing 16 Worm Gear 5 Side Cover 11 Closing Cap 17 Bearing 6 O Ring 12 Circlips 18 O Ring 2 1 9 8 3 4 5 6 7 10 13 12 11 14 15 16 17 18 19 20 21 Standard E 03 type basic part diagram Parts may differ for special applications Standard Part List Part Designation 10 Operating Instructions E Series ...

Page 11: ...ng 15 Washer 21 Input Flange 4 Bolt 10 Housing 16 Seal 22 Bolt 5 Side Cover 11 Closing Cap 17 Oil Plug 23 Seal 6 O Ring 12 Circlips 18 Worm Gear 20 21 22 23 2 1 1 1 15 14 3 4 5 6 7 8 9 10 13 12 11 16 17 18 19 Standard E 04 type basic part diagram Parts may differ for special applications Standard Part List 11 Operating Instructions E Series ...

Page 12: ...Side Cover 14 Closing Cap 20 Worm Gear 3 Circlips 9 O Ring 15 Circlips 21 Bearing 4 Bolt 10 Bearing 16 Bearing 22 O Ring 5 Flange 11 Worm Wheel 17 Circlips 23 Input Flange 6 O Ring 12 Bearing 18 Seal 24 Bolt Standard E 05 type basic part diagram Parts may differ for special applications Standard Part List Part Designation 12 Operating Instructions E Series ...

Page 13: ...ut Flange 2 Output Flange 8 Worm Wheel 14 Seal 20 Bolt 3 Seal 9 Bearing 15 Oil Plug 21 Seal 4 Bolt 10 Housing 16 Worm Gear 5 Side Cover 11 Closing Cap 17 Bearing 6 O Ring 12 Circlips 18 O Ring Standard E 08 type basic part diagram Parts may differ for special applications Standard Part List 13 Operating Instructions E Series ...

Page 14: ...eel 12 Seal 18 Flange 3 Side Cover 7 Bearing 13 Oil Plug 19 Bolt 4 O ring 8 Housing 14 Worm Gear 20 Seal 5 Bearing 9 Closing Cap 15 Key 6 Worm Wheel 10 Circlips 16 Bearing Standard ET 00 type basic part diagram Parts may differ for special applications Standard Part List Part Designation 14 Operating Instructions E Series ...

Page 15: ...ring 15 Seal 21 Giriş Flange 4 Bolt 10 Housing 16 Oil Plug 22 Bolt 5 Side Cover 11 Closing Cap 17 Worm Gear 23 Seal 6 O Ring 12 Circlips 18 Key Standard ET 01 type basic part diagram Parts may differ for special applications Standard Part List 17 19 20 21 23 18 22 3 4 5 6 7 8 9 10 13 12 11 15 16 14 1 2 1 15 Operating Instructions E Series ...

Page 16: ...19 Worm Gear 25 Seal 2 Solid Output Shaft 8 O Ring 14 Circlips 20 Key 3 Bolt 9 Bearing 15 Bearing 21 Bearing 4 Flange 10 Worm Wheel 16 Circlips 22 O Ring 5 Seal 11 Bearing 17 Seal 23 Input Flange 6 Bolt 12 Housing 18 Oil Plug 24 Bolt 5 6 7 8 9 12 15 14 13 17 18 16 4 3 2 11 10 1 1 19 21 22 23 25 20 24 Part Designation 16 Operating Instructions E Series ...

Page 17: ...9 Bearing 15 Oil Plug 21 Bolt 4 Bolt 10 Housing 16 Worm Gear 22 Seal 5 Side Cover 11 Closing Cap 17 Key 6 O Ring 12 Circlips 18 Bearing Standard ET 03 type basic part diagram Parts may differ for special applications Standard Part List 3 4 5 6 7 10 13 12 11 14 15 2 1 9 8 16 18 19 20 22 17 21 17 Operating Instructions E Series ...

Page 18: ...Key 2 Solid Output Shaft 8 Worm Wheel 14 Circlips 20 Bearing 3 Seal 9 Bearing 15 Washer 21 O Ring 4 Bolt 10 Housing 16 Seal 22 Input Flange 5 Side Cover 11 Closing Cap 17 Oil Plug 23 Bolt 6 O Ring 12 Circlips 18 Worm Gear 24 Seal 3 4 5 6 7 8 9 10 13 12 11 16 17 2 1 1 1 15 14 18 20 21 22 24 19 23 Part Designation 18 Operating Instructions E Series ...

Page 19: ...Plug 25 Bolt 2 Solid Output Shaft 8 Side Cover 14 Closing Cap 20 Worm Gear 26 Seal 3 Circlips 9 O Ring 15 Circlips 21 Key 4 Bolt 10 Bearing 16 Bearing 22 Bearing 5 Output Flange 11 Worm Wheel 17 Circlips 23 O Ring 6 Seal 12 Bearing 18 Seal 24 Input Flange 6 7 8 9 13 16 15 14 18 19 5 4 4 5 17 1 1 1 3 12 11 2 10 20 22 23 24 26 21 25 19 Operating Instructions E Series ...

Page 20: ...ng 13 Bearing 19 O Ring 2 Output Flange 8 Worm Wheel 14 Seal 20 Input Flange 3 Seal 9 Bearing 15 Oil Plug 21 Bolt 4 Bolt 10 Housing 16 Worm Gear 22 Seal 5 Side Cover 11 Closing Cap 17 Key 6 O Ring 12 Circlips 18 Bearing 3 4 5 6 7 10 13 12 11 14 15 2 1 9 8 1 2 16 18 19 20 22 17 21 Part Designation 20 Operating Instructions E Series ...

Page 21: ...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 ...

Page 22: ...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 ...

Page 23: ... 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 High temperature produce irritating steam Use a protective breathing apparatuses 4 5...

Page 24: ...ely contact the transport company and inform about the damage Contact YILMAZ for the damage and do not start to install the unit until it is agreed that the damage has no affect of operation Use the supplied eyebolts or lifting holes for lifting up the gear unit The eyebolts are capable to carry the weight of gearboxes only Do not hang additional loads Use suitable hoisting equipment which is capa...

Page 25: ...C The gearbox must be kept under enclosed roof with constant temperature and constant humidity not exceeding 50 The storage should be free of dust and dirt and ventilated with filter If the gearbox is stored without packing it is recommended not to store more than 2 years and regular check dur ing this time is recommended If stored in open protect against insect damage 6 Installing The Gear Unit 6...

Page 26: ...he instructions of the supplier Check the basic electric connection diagrams below Use experienced electric technician Using wrong connection or voltage can damage the electric motor or environment Type Hollow Shaft Diameter Hollow Shaft Tolerance H8 Output Shaft Diameter Output Shaft Tolerance DIN748 Up to 50mm k6 Over 50mm m6 Flange Centering Sho ulder Diameter Centering Shoulder Tolerance g6 H8...

Page 27: ...otor and the brake must be grounded to prevent potential differences of earth and gearbox motor Pole Number Nominal Powers at 400V 50Hz 230V D 400 V Y 400V D 2 or 4 3 kW 4 kW 6 2 2 kW 3 kW 8 1 5 kW 2 2 kW Starting Principle Direct Direct or Y D Basic motor connection wiring diagram I L2 L1 U1 W2 W2 p h U1 W1 V1 L3 W1 V2 U2 V2 230V U2 I1 I 3 U L1 230V U U U I2 V1 I3 ph 230V U L2 L3 V2 L1 L2 U1 V1 I...

Page 28: ...arbox and the motor must be grounded to prevent potential differences of earth and gearbox motor Delayed Braking 220 V Sudden Braking 220 V Delayed Running Brake 24 V Sudden Brake 24 V Mounting M 3 R S T Fren Bobini Fren Bobini M 3 R S T N N M 3 R S T Fren Bobini M 3 S R N T Fren Bobini 28 Operating Instructions E Series ...

Page 29: ... 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 tha...

Page 30: ...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 loa...

Page 31: ...Installing customer shaft with shoulder 7 1 1 Use anti seize assembling paste available on your market Use a brush to ap ply the paste 1 Retaining Bolt 2 Lock Washer 3 Washer 4 Circlips 5 Hollow Shaft 6 Customer Shaft 31 Operating Instructions E Series ...

Page 32: ...s Use the following table for shaft tightening torques Type Bolt Tightining Torque Nm E 030 M5 5 E 040 M6 8 E 050 M10 20 E 063 M10 20 E 075 M12 30 E 080 M12 30 E 100 M16 40 E 125 M16 40 Mounting 32 Operating Instructions E Series ...

Page 33: ... 0 15 E 040 18 40 44 5 40 66 82 130 171 214 151 5 M6 6 20 5 0 35 0 30 0 55 0 40 0 20 E 050 25 50 55 50 70 5 98 158 208 239 173 M10 8 28 0 70 0 50 0 90 0 60 0 30 E 063 25 50 55 50 72 122 182 232 266 199 M10 8 28 1 10 0 90 1 40 1 00 0 40 E 075 35 65 72 65 116 120 197 264 352 235 M12 10 38 2 10 1 50 3 15 1 90 0 70 E 080 35 65 72 65 103 5 133 210 277 340 241 5 M12 10 38 2 25 1 60 3 00 2 00 0 90 E 100 ...

Page 34: ...7 4 Torque Arm Connection 7 4 1 Use the torque arm connection according the following drawing L1 L2 L3 R1 R2 R3 Mounting 34 Operating Instructions E Series ...

Page 35: ...Mounting 7 4 2 Assemble the parts as shown bellow 1 Bolt 4 Torque arm 2 Washer 5 Machine Connection Arm 3 Bolt 6 Nut 35 Operating Instructions E Series ...

Page 36: ... Type b e d h R Part No E 030 22 14 10 85 25 9E030 E 040 31 14 10 100 25 9E040 E 050 38 16 10 100 32 9E050 E 063 49 5 16 10 150 36 9E063 E 075 49 5 25 20 200 45 9E075 E 080 49 5 25 20 200 45 9E080 E 100 57 5 30 25 250 50 9E100 E 125 72 30 25 300 55 9E125 36 Operating Instructions E Series ...

Page 37: ...nits 7 6 Correct position of output shaft elements The Output Shaft unit transmission elements must placed as close as possible to the gear unit so that the radial load is as closest as possible to the gear unit 1 Gear shaft end 2 Thrust bearing 3 Coupling hub 1 Hub 37 Operating Instructions E Series ...

Page 38: ... there is some clearance between the two elements 7 7 2 By fitting couplings be sure that there is no eccentric between the two shafts 7 7 3 By fitting couplings be sure that the two shafts are not angular miss aligned Mounting 38 Operating Instructions E Series ...

Page 39: ...20000 25000 30000 35000 40000 45000 70 80 90 100 110 120 130 140 150 160 Oil change interval Hours Oil bath temperature Celcius Mineral SyntheticPAO SyntheticPG Item to check Replace Every 3 000 working hours or every 6 months Every 4 000 working hours Every 10 000 working hours or every 3 years Every 25 000 working hours Check for oil leakage x Check for oil level x Check oil leakage from seal x ...

Page 40: ...Alphasyn PG 220 Klübersynth GH 6 220 Mobil Glygoyle 30 Omala S4 WE 220 Carter SY 220 35 20 150 Degol GS 150 Energsyn SG XP 150 Alphasyn PG 150 Klübersynth GH 6 150 Mobil Glygoyle 22 Omala S4 WE 150 Carter SY 150 40 10 100 Klübersynth GH 6 100 Mobil Glygoyle 100 CLP HC 10 60 680 Klübersynth GEM 4 680 N Mobil SHC Gear 680 Omala S4 GXV 680 Carter SH 680 20 50 460 Degol PAS 460 Enersyn EP XF 460 Alpha...

Page 41: ...ng the mounting position illustrated in section 9 4 Extended intensive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin thorough Hot oil can cause scalding When changing oil protect yourself against contacting hot oil 9 3 Mounting Positions Figured mounting positions of M1 to M6 are determined as reference of directional position of the gearbox ...

Page 42: ... E 50 0 15 0 17 0 15 0 17 0 17 0 17 E 63 0 30 0 40 0 30 0 40 0 40 0 40 E 75 0 45 0 60 0 50 0 60 0 60 0 60 E 80 0 50 0 80 0 70 0 80 0 80 0 80 E 100 1 7 1 8 1 2 2 1 2 0 2 0 E 125 3 3 3 6 2 5 3 6 3 8 3 8 Oil Quantities 9 4 Oil Quantities M1 M4 M5 M6 M2 M3 Lubrication 42 Operating Instructions E Series ...

Page 43: ... 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 100 005 Gearbox Does Not Start Up You hear some noise but both motor shaft and gearbox shaft is not turning You are using braked motor Please Check the voltage supply and frequency of your electric connectio...

Page 44: ...osition and check the nameplate mounting position If nameplate mounting position does not fit the actual position go to ID 100 009 Gearbox is Heating Up too Much You are using Helical Gear Box Ambient temp is lower than 40 Celsius Measure the surface temp using a temperature measuring device under full load If the temp is under 80 Celsius this will make no harm to the gearbox and is normal All ATE...

Page 45: ... There are some particles under the plug rubber surface Clean and tifgten the plug If still same problem go to ID 100 019 Oil is Leaking Oil Leakage from Housing Observe exactly where the oil is comming 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 c...

Page 46: ...ed from our factory is set to delayed braking For sudden braking check the wiring diagram 029 Gearbox is starting too late You are using braked motor A 24V shock transformer is recommended for fast opening of big brakes 200 Nm and shock rectifier is recommended for smaller brakes 200 Nm Go to ID 100 100 Service Required No self solution found Please contact YILMAZ REDUKTOR Service point See on the...

Page 47: ...Appendix ...

Page 48: ...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...

Page 49: ... 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 Ataturk Mah Lozan Cad No 17 P K 34522 Kırac Esenyurt Istanbul TURKEY Phone 90 0 212 886 90 00 PBX 10lines Fax 90 0 212 886 54 57 Stamp and Signature Supplier End User With signing this part and send...

Page 50: ...Notlar ...

Page 51: ...Notlar ...

Page 52: ...ational Services If you call the above service point you will be directed to our nearest service Domestic Service Tel 90 212 886 90 00 Int 1223 1228 1287 Whatsapp 90 554 713 71 02 E Mail servis yr com tr Spare Parts Tel 90 212 886 90 00 Int 1224 1277 Whatsapp 90 506 774 44 35 E Mail yedekparca yr com tr IS O 1 4 0 0 1 IS O 4 5 0 0 1 YEARS WARRANTY ...

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