Oieex0101 0105

YILMAZ REDÜKTÖR ISO 9001 YILMAZ REDÜKTÖR ISO 9001
Gear Units, E Series
Edition 01/2005
OIEEX 0101/0105
Operating Instructions
Operating Instruction
E Series
Contents
Contents
1 How To Use This Manual.................................................................................... 5
2 Unit Designation................................................................................................... 6
2.a Detailed unit designation................................................................................. 6
2.b Nameplate unit designation............................................................................. 7
3 Part List of Standard Type Gear Units................................................................ 8

3.a E.00.. Type................................................................................................... 8
3.b E.01.. Type................................................................................................... 9
3.c E.02.. Type.................................................................................................. 10
3.d E.03.. Type.................................................................................................. 11
4 Thinks to Check Before the Gear Unit or Geared Motor is Installed.............. 12

4.a Safety notes................................................................................................... 12
4.b Transportation............................................................................................... 13
4.c Storage......................................................................................................... 13
5 Installing The Gear Unit...................................................................................... 14

5.a Before you start............................................................................................. 14
5.b Check Name Plate........................................................................................ 14
5.c Check the ambient conditions and temperature.............................................. 14
5.d Check fitting elements and the shaft dimensions to fit..................................... 14
5.e Check the voltage supply............................................................................... 16
5.f Check the mounting position.......................................................................... 16
5.g Use the breather plug..................................................................................... 16
5.h Check the oil level.......................................................................................... 17
5.i Check shaft ends and mounting faces.............................................................. 17
5.j Cover abresive ambient.................................................................................. 17
5.k Check accessibility to filling, breather and drain plugs...................................... 17
6 Mechanical Installation........................................................................................ 18
6.a Installing gear units in category II2G/D-II3G/D............................................... 18
6.b Fittting outputshaft elements........................................................................... 19
6.c Correct position of otputshaft elements......................................................... 19
6.d Installing customer shaft with shoulder............................................................. 20
6.e Shaft tightening torques................................................................................... 21
6.f Covering all turning parts................................................................................ 22
6.g Recommended shaft dimensions and disassembling nut dimensions................... 23
6.h Assembling gear unit with torque arm............................................................... 24
6.i Fittting Couplings............................................................................................ 26
7 Inspections............................................................................................................. 27
yilmaz redÜktÖr 03
E Series
8 Lubrication.............................................................................................................. 28
8.a Oil Types......................................................................................................... 28
8.b Oil Quantities................................................................................................... 29
8.c Mounting Positions........................................................................................... 29
9 Troubleshooting Guide....................................................................................... 30
10 Decleration by the Manufacturer .................................................................... 34
11 Waranty conditions................................................................................................. 35
12 Waranty................................................................................................................... 36
13 Waranty................................................................................................................... 37
04 yilmaz redÜktÖr
E Series
General Information
1 -How To Use This Manual

Take attention to the following safety and warning signs for proper understanding and quick reference.
Electric Hazard; Can cause severe or fatal injuries.
Mechanical Hazard; Can cause severe or fatal injuries.
Likely to be Hazardous; Can cause minor injuries
Damage Risk; Can damage the drive or environment
Important Information
Important information about explosion protection
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 EN/ET series gear units and is applicable only for these 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 applica-
tion and modified gear units ask YILMAZ REDUKTOR for validity.
The EN/ET Series garboxes are with standard IEC B5/B14 connection flange and without motor. The electric motor
which will be connected to the gearbox must also be in confirmity with the ATEX (94/9/EC) standarts.
All the external parts which will be assembled to the gear unit must conform ATEX (94/9/EC). The product this
decleration refers to must not be put into service until the machinery into which it is to be incorporated has been de-
clared in confirmity with the provisions of the relevant European Directives.
If the gear unit is not operated as informed on this manual the gear unit is no longer ATEX conforming and
YILMAZ REDUKTOR does not take any responsibility.
E Series
Type Designation
2 -Unit Designation
a- Detailed unit designation
Detailed E series gear units designation for ordering

(This Designation is different from the short nameplate designation)
30 - EN063 - B09
Ratio (i) Type Motor Size
EN -Foot mounted type with IEC flange without motor

ET- Foot mounted type with solid inout shaft
B07- IEC 71 B14
B08- IEC 80 B14
B09- IEC 90 B14
B10- IEC 100 B14
B11- IEC 112 B14
B13- IEC 132 B14
Examples
30-EN063-B08
EN63 foot mounted type gearbox with IEC80 B14 motor connection flange.
30-ET063
ET063 i=30 type gear unit with solid input shaft
E Series
Type Designation
b- Nameplate, unit designation
Nameplate unit designation is a short abbreviation from the detailed designation
A sample name plate for EN/ET. Series
YILMAZ REDÜKTÖR A.S.

Beylikdüzü SAN - BIR Bulvari 1.Bölge 3.Cadde No:18
34900 Büyükçekmece / IST. / TURKEY
Type : EN050-B09 / 2GD

S/N.: 04 / S2251 - EX IP65
P :1,5 kW M2 : 843 Nm
n 1 :1400 rpm n 2 : 16 rpm
F R2 :9542 F
N R1: - N
F A2 :190 N F A1: - N
Oil :VG 220 Qty : 4 lt
M.Pos.: B3 Ta : -20/+40 ºC
II 2GD c,k T4 / T120 ºC
Abreviations:
Type. : Type of gearbox
S/N: Serial Number of gear unit as; year/order no
IP..: Enclosure
P : Max. Allowed Power
M2: Output torque
n1: Input speed
n2: Output speed
FR2: Max. allowed radial load at output shaft
FR1: Max. allowed radial load at input shaft
FA2: Max. allowed axial load at output shaft
FA1: Max. allowed axial load at input shaft
Oil: Filled oil inside the gear unit
Qty.: Oil quantity
M.pos.: Mounting Position.
Ta: Ambient Temp
ATEX sign (EN 13463-1):
o
II 2GD c,k T4 / T120 C
Max. allowed surface temperature
Temperature Class
Ignation Class if applicable.

Catagorie; 2G/3G for Gas, 2D/3D for dust.
Group: Only II, not for underground use
E Series
Part Designation
3- Part List of Standard Type Gear Units

a- E...00... Types
Standard E...00... type basic part diagram. Parts may differ for special applications.
Standard Part List
1- Oil Seal 6- Worm Wheel 11- Closing Cap 16- O-Ring

2- Bolt 7- Bearing 12- Oil Seal 17- Input Flange
3- Side Cover 8- Housing 13- Plug 18- Oil Seal
4- O-Ring 9- Bearing 14- Wormgear 19- Bolt
5- Bearing 10- Circlip 15- Bearing
E Series
Part Designation
b- E...01... Types
Standard E ...01... type basic part diagram. Parts may differ for special applications.
Standard Part List
1- Solid Output Shaft 7- O-Ring 13- Circlip 19- Bearing

2- Key 8- Bearing 14- Closing Cap 20- O-Ring
3- Key 9- Worm Wheel 15- Circlip 21- Input Flange
4- Oil Seal 10- Bearing 16- Oil Seal 22- Oil Seal
5- Bolt 11- Housing 17- Plug 23- Bolt
6- Side Cover 12- Bearing 18- Wormgear
E Series
Part Designation
c- E...02... Types
Standard Part List
1- Bolt 8- Side Cover 15- Circlip 22- O-Ring

2- Output Flange 9- O-Ring 16- Closing Cap 23- Input Flange
3- Output Shaft 10- Bearing 17- Circlip 24- Oil Seal
4- Key 11- Worm-Wheel 18- Oil Seal 25- Bolt
5- Key 12- Bearing 19- Plug
6- Oil Seal 13- Housing 20- Wormgear
7- Bolt 14- Bearing 21- Bearing
E Series
Part Designation
d- E...03... Types
Standard Part List
1- Bolt 7- Bearing 13- Closing Cap 19- Input Flange

2- Output Flange 8- Worm Wheel 14- Oil Seal 20- Oil Seal
3- Oil Seal 9- Bearing 15- Plug 21- Bolt
4- Bolt 10- Housing 16- Wormgear
5- Side Cover 11- Bearing 17- Bearing
6- O-Ring 12- Circlip 18- O-Ring
E Series
Installing
4 -Thinks to Check Before the Gear Unit or Geared Motor is Installed
a) Safety notes for use in potentially explosive atmosphere
Explosive gas mixtures or concentration of dust can lead to severe or fata injuries in conjunc-
tion with hot or moving parts of the gear unit / gearmotor
Before you install the gearbox you have to be sure that the gearbox is arrived with the all necessary
equipment and without damage. Thinks to take into consideration before you start to install the unit;
- You have received the correct operation manual of the your product.
- The gearbox and all its parts are transported without damage.
- The gearbox is stored correctly according the instructions in this manual
- The nameplate is clearly visible and all the data can be read.
- All the regulations and requirements according to the currently valid national/regional regulations.
- The gearbox is used according its intended use
Intended use of gearbox:

The gearboxes covered by this manuel can only be used in ATEX zone 2G,2D,3G,3D and ignation
class IIA/IIB.
The gear units are intended for industrial systems and may only be used in accordance with the
information provided in this manual and the nameplate of the gearbox. They comply with the applica-
ble standards and regulations and meet the requirements of the directive 94/9/EC. The gearbox is
started up, maintained and operated according this manual. The gearbox is incorporated with 94/9/
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 of the gear unit is not exceeded and is accordance with
the nameplate. The input 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 in-
formed the nameplate will have a single fixed input speed and only this input speed is allowed.
The electric motor and frequency inverter must be in accordance with 94/9/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
input speeds (speed range) will be provided. If not mentioned by ordering the gear units input
speed will be a fixes 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 onlt allowed
to be used according the nameplate entries. Diffrent speed, higher motor power, higher
radial/axial loads etc. than nameplate is not allowed.
The ambient conditions must be accordance with the name plate and no agresive media must
attack the paint and seals.
E Series
Installing
The gearbox maintanance (oil change / check ) must be done according this manuel
b) Transportation
When the goods arrive, first check for any damage. If some damage observed, immediately
contact the transport company and inform about the damage. Contact YILMAZ for the
damage and do not start to install the unit until it is agreed that the damage has no affect of
operation.
Use the supplied eyebolts or lifting holes for lifting up the gear unit. The eyebolts are
capable to carry the weight of gearboxes only. Do not hang additional loads.
c) Storage
If the geared unit or gearedmotor will be stored up to 3 years refer to the following instruc-
tions;
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 atmos-
pheric 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.
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.
E Series
Installing
5- Installing The Gear Unit
a) 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.
b) Check nameplate of the gear unit;

- ATEX conforming gear gear units have a nameplate indicating the “EX” sign shown on the left side
and the following information;
- Equipment group
- Ex category
- Ex zone
- Temprature class
- Maximum surface temperature
If you can not see this sign and values, your gearbos is not intended for use on potentially explosive
atmosphere. If some of the data can not be read because of some reason, please contact YILMAZ
REDUKTOR.
c) Check the ambient conditions and temperature;

Have measures been taken to ensure that no potentially explosive atmosphere, oils, acids, gases,
vapors or radiated interference are present when the gear unit is being installed.
The ambient temperature must be in accordance with the oil tables given on the manual. If different
contact YILMAZ REDUKTOR for special solutions.
The ambient air temperature must not exceed 40 degrees celcius as mentioned on the name-
plate. The cooling air surrounding the gear unit must bellow 40 degrees and the gear unit
must not subject to heating from external sources. The gear unit surface must be kept clean
and sufficiently ventilated.
d) Check fitting elements and the shaft dimensions to fit;
All external elements that will be fitted to the gear unit must be ATEX confirming.
The shaft/flange dimention are shown bellow. Use correct tolerances to fit external elements. Ob-
serve the assemly instructions provided in this manual.
E Series
Installing
Only belts with sufficient shunt resistance <10^9 ohm are allowed
Never strike belt pulleys, coupling, pinions etc. with a hammer when pulling them onto the
shaft end. This could result in damage to bearings, the housing and the shaft.
Power transmision elements must be balanced after fitting and must not give rise to any imper-
missible radial or axial forces.
Observe the name plate for maximum allowed radial and axial load. The external radial
and axil load must not exceed the provided values on the nameplate.
Output Shaft Flange

Hollow Shaft Hollow Shaft Output Shaft Centering Shoulder
Type Tolerance (DIN748) Centering Shoulder Tolerance
Diameter Tolerance (H8) Diameter Up to 50mm k6
Over 50mm m6
Diameter ( g6 )
+0.03 +0.01 -0.01

E...030.. 14 14 50
0 0 -0.03
+0.03 +0.01 -0.01
E...040... 18 18 60
0 0 -0.03
+0.04 +0.02 -0.01
E...050... 25 25 110
0 0 -0.04
+0.04 +0.02 -0.01
E...063... 25 25 115
0 0 -0.04
+0.04 +0.02 -0.02
E...080... 35 35 180
0 +0.00 -0.04
+0.04 +0.02 -0.02
E...100... 42 42 180
0 +0.00 -0.04
+0.04 +0.02 -0.02
E...125... 45 45 230
0 +0.00 -0.05
E Series
Installing
e) Check the voltage supply;

ATEX Conforming gear units are supplied by YILMAZ without motor. The motor that will be fitted
must have ATEX certificate and the instruction manual of the electric motor provider must be ob-
served. Observe the name plate of the electric motor and the instructions of the supplier. Check the
basic electric connection diagrams below. Use experienced electric technician. The gearbox and the
motor must be grounded to prewent potential differences of earth and gearbox/motor.
Using wrong connection or voltage can damage the electric motor or environment.
The elctric connection must be done by experienced electric technician.
f) Check the mounting position;

The mounting position must be in accordance with the mounting position mentioned on the
name plate. If different please contact YILMAZ REDUKTOR for possibilities of using in a
different mounting position. Different use of mounting position than indicated on the name plate
without informing YILMAZ REDUKTOR will cancel the ATEX confirmity and YILMAZ does not
take any responsibility.
Do not mix synthetic oils with mineral oils which can cause serious damage on the gear unit.
g) Use of breather plug;

Breather plugs are supplied as a standard part for ATEX conforming gear units. The breather plug is
attached to the gear unit and must be changed with the most top plug according to the mounting
position.Take out the plug over the gear box and replace it with the supplied breather plug after
assembling to its place and before start-up.
All plug points are not machined. Only plugs according mounting position is machined. If no
mounting position is mentioned by ordering the standard B3 position plugs are machined.
E Series
Installing
h) 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. Use a wire as shown below for checking
the oil level entering from the level plug. The oil level must be within 3mm from the plugs entering
point as shown below. If you need to adjust the oil level refer to the oil tables given on this manuel
and be sure you are using the correct oil. Observe the nameplate for the correct oil.
Do not mix synthetic oils with mineral which can cause serious damage on the gear unit.
i) 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.
j) 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 for solutions.
Abrasive material, chemicals, water, positive or negative pressure exceeding 0,2 bar can
affect or damage the sealing lip or output shaft. Inside entering substances from the seals
can cause serious damage to the gear unit.
k) Check accessibility to filling, breather and drain plugs;

The filling, breather and drain plugs must be freely accessible for further checking and service.
E Series
Installing
6- Mechanical Installation
The mounting plate must be rigid enough not allowing torsions, flat enough to prevent strains by tighten-
ing 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.
All bolts are locked by use of locktide adhesives or gear-shims on the gearbox. By assembling the gear
unit locktides adhesives or gear-shims must be used to prevent loosening of 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.
Only ATEX-approved input and output elements are allowed to be used, assum-
ing the elements are subject to Directive 94/9/EC
a- Installing gear units in category II2G/D-II3G/D
Explosion-proof gear units comply with the design requirements for unit group II,
catagory 2G,2D,3D,3G. These units are intended for use in zones 1 and 21.
The gear units in catagory II2D must be used in ambient teperature between -20
C to +40 C only. If different ambient conditions this must be inforned before
order and the name plate must be in accordance with the ambient conditions.
The temperature class depends on the speed, type and mounting position of the
gearbox and is indicated on the name plate. Temperature classes from T4 to T6
are provided by YILMAZ REDUKTOR.
The surface temperature of the gearbox must not exceed the provided max. sur-
face temperature on the name plate. After all installations finished and the gear-
box is started up according this manual let the gear unit run 4 hours at full load
and check the surface temperature from the shown point bellow and the ambient
temperature. Check the following;
(40-Ta)+Tw < Tmax. of nameplate ( Ta: Ambient Temp., Tw: Surface Temp)
E Series
Installing
If the result is higher then Tmax, immidiately stop the system and contact YILMAZ
REDUKTOR.
b- Fittting outputshaft elements

Use the following ilustration to assemble output shaft units
1) Gear shaft end

2) Thrust bearing
3) Coupling hub
c- Correct position of otputshaft elements

The Output Shaft unit (transmision 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
E Series
Installing
d- Installing customer shaft with shoulder

d1- Use anti-seize assembling paste available on your market. Use a brush to apply the paste.
d2 -Fasten the bold as shown below.
E Series
Installing
e- Shaft tightening torques

Use the following table for shaft tightening torques.
Tightening torque
Type Bolt
[Nm]
E.030... M5 5
E.040... M6 8
E.050... M10 20
E.063... M10 20
E.080... M12 30
E.100... M16 40
E.125... M16 40
E Series
Installing
f- Covering all turning parts

All open turning parts must be covered. The Closing caps for oposide shaft output are provided
by YILMAZ REDUKTOR and are assembled as shown bellow. The Output shaft side must also
be covered by the machine manufacturer.
E Series
Installing
g- Recomended shaft dimensions and disassembling nut dimensions

Use the following part number for ordering the disassembling nut.
B3 G1 B3
B1 G1 B1
B B
B2 B2
h6
h6
h6
b1
d
d
t1
M M
1 3
L1 L2
G1 B3
G1 B1 5
B2
B
4
2
Part no example: GN10.DR33
k6
k6
b1
d
d
t1
M M
L
L3
Montaj Ölçüleri Ağırlıklar

TiPi M ounting Dim ensions Weight [kg]
TYPE Befestigungsmaße Gewicht
TYP
d B B1 B2 B3 G1 L L1 L2 L3 M b1 t1 1 2 3 4 5
EV030 14 30 34 30 51.5 66 103 134 169 120.5 M5 5 16 0.18 0.20 0.35 0.27 0.15
EV040 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
EV050 25 50 55 50 70.5 98 158 208 239 173 M10 8 28 0.70 0.50 0.90 0.60 0.30
EV063 25 50 55 50 72 122 182 232 266 199 M10 8 28 1.10 0.90 1.40 1.00 0.40
EV080 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
EV100 40 80 87 80 114 156 249 330 384 276 M16 12 43 5.10 3.90 6.50 4.50 3.65
EV125 45 100 107.5 100 142 185 300 400 469 335 M16 14 48.5 8.70 6.50 10.60 7.40 6.80
E Series
Installing
h- Assembling Gear Unit with Torque Arm

h1- The following connecting possibilities are avaliable. Use one position which is the most suitable.
A B C
E Series
Installing
h2-Assemble the parts as shown bellow
1- Bolt 4- Torque Arm

2- Washer 5- Mashine Fixing Arm
3- Bolt 6- Nut
h3-For the fixing bold position refer to the following dimensions
h
d
b e
R
Tipi Parça No.

Type b e d h R Part No.
Typ Teil Nr.
EN030 22 14 10 85 15 10E030
EN040 31 14 10 100 18 10E040
EN050 38 16 10 100 18 10E050
EN063 49.5 16 10 150 30 10E063
EN080 49.5 25 20 200 30 10E080
EN100 57.5 35 25 250 35 10E100
EN125 69.5 35 25 300 35 10E125
E Series
Installing
i- Fittting Couplings
n1-By fitting couplings be sure that there is some clearanve between the two elements
i2-By fitting couplings be sure that there is no exantricity between the two shafts.
i3-By fitting couplings be sure that the two shafts are not angular miss-aligned.
E Series
Inspection
7- Inspections
Under normal ambient and working conditions the gear unit should be checked according the
following intervals. (For definition of normal working conditions refer to the product catalogue:
“Selecting Gearbox” section);
Every 3.000 working
Every 4.000 working Every 10.000 working Every 25.000 working
Item to check / replace hours
hours hours or every 3 years hours
or every 6 months
Check for oil leakage x
Check for oil level x
Check oil leakage from seal x
Check Rubber buffer x (Change if necessary)
Check Bearings Noise x (Change if necessary)
Change Mineral Oil x (See Below for details)
Change Synthetic-PAO Oil x (See Below for details)
Change Sealing x
Change Bearing Grease x
Change Bearings x
Check for noise Changes x
45000
40000
35000
Oil change interval
30000
Mineral
25000
Synthetic PAO
20000
Synthetic PG
15000
10000
5000
0
70 80 90 100 110 120 130 140 150 160
Oil bath temperature (Celcius)
For normal ambient conditions 70 degrees Celcius Should be taken as referance
* For K series Mineral oil is used unless it is differently ordered. For oil type and quantities
refer to the following tables.
E Series
Lubrication
8- Lubrication
a- Oil Types
Yağ Cinsi ISO Vizkozite Sınıfı

Kullanım Sıcaklığı
Lubricant ISO Viscosity Class
Usage Temparature
Art des Vizkozitäts Klasse
Gebrauchstemperature
Schmierstoffes ISO
Degol Energol Spartan Mobilgear Omala Alpha SP

0 ... +100 ISO VG 680
BG 680 GR-XP680 EP 680 636 680 680
Degol Energol Spartan GEM 1 680 Mobilgear Omala Alpha SP

0 ... +100 ISO VG 460
BG 460 GR-XP460 EP 460 634 460 460
GEM 1 460
0 ... +100 ISO VG 320
Mineral Yağlar BG 320 GR-XP320 EP 320 GEM 1 320 632 320 320
Mineral Oil
Mineralöl Degol Energol Spartan GEM 1 220 Mobilgear Omala Alpha SP
-5 ... +100 ISO VG 220
BG 220 GR-XP220 EP 220 630 220 220
GEM 1 150
-5...+100 ISO VG 150
BG 150 GR-XP150 EP 150 GEM 1 100 629 150 150

-5...+100 ISO VG 100
BG100 GR-XP100 EP 100 627 100 100
Degol Enersyn Syntheso Gylgoyle

-20 ... +140 ISO VG 680 GS 680 SG-XP680 D 680 EP HE 680
Degol Enersyn Glycolube Syntheso Gylgoyle Tivela Alphasyon

-20 ... +140 ISO VG 460 GS 460 SG-XP460 460 D 460 EP HE 460 SD PG 460
Degol Enersyn Glycolube Syntheso Gylgoyle Alphasyon

-25 ... +140 ISO VG 320 GS 320 SG-XP320 320 D 320 EP HE 320 PG 320
Sentetik Yağlar
Synthetic Oil
Degol Enersyn Syntheso Gylgole Tivela Alphasyon
Synthetisch Öl -25 ... +140 ISO VG 220 GS 220 SG-XP220 D 220 EP HE 220 WB PG 220
Degol Enersyn Syntheso Alphasyon

-30 ... +140 ISO VG 150 GS 150 SG-XP 150 D 150 EP PG 150
Syntheso
-30 ... +140 ISO VG 100 Enersyn D 150 EP
SG-XP 100
Mineral Gresler /
Aralup Energrease Beacon Centoplex Mobilux Alvania Spheerol
Minaral Grease / -20 ... +120
HL 3 LS 3 3 2 2 R3 APT 3
Mineral Fett
Sentetik Gresler / ISOFLEX

Mobiltemp Cassida
Synthetic Grease -30 ... +100 Topas
SHC 100 RLS 00
/ Synthetisch gres L152
E Series
Oil Quantities
b- Oil Quantities. (lt)
Gövde büyüklüğüne ve çalışma

Quantities according to working Ölmengen Abhängig von Grtriebe Baugröße und
pozisyonlarına göre yağ miktarları
pozitions and gear size (lt) Arbeitzpositionen (lt)
(lt)
Redüktör Tipi
Gear Unit Type
Getriebe Typ
B3-B5 B6-B7 B8 V1-V3 V5 V6
EV30 0,025 0,04 0,02 0,04 0,04 0,04

EV40 0,070 0,20 0,12 0,20 0,20 0,20
EV50 0,150 0,30 0,18 0,30 0,30 0,30
EV63 0,300 0,60 0,26 0,40 0,40 0,40
EV80 0,600 0,80 0,50 0,80 0,80 0,80
EV100 1,710 2,1 1,2 2,1 2,1 2,1
EV125 3,140 3,6 2 3,6 3,6 3,6
c- Mounting Positions
V1
V3
V5 V6
B8
B6
B3 B5
E Series
Oil Quantities
9- Troubleshooting Guide
All the operations bellow must be done by experienced mechanichan/electrican. Do not make anythink
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.
ID Problem Observation Remedy

You hear no noise and Please Check the voltage supply and frequency of your
Gearbox Does shaft is not turning. You electric connection. They must be in accordance with the
001
Not Start Up are not using any driver or nameplate of the motor. Observe motor manufacturers start
frequency inverter. up manual. Still does not work go to ID 100
You hear no noise and Please observe the frequency incerter/driver manual. Chech
Gearbox Does shaft is not turning. You the motor by supplying direct voltage to see if the problem is
002
Not Start Up are using frequency on your driver/frequency inverter. Still does not work go to
inverter or driver. ID 001.
Please Check the voltage supply and frequency of your
electric connection. They must be in accordance with the
You hear some noise but
nameplate of the motor. Observe motor manufacturers start
both motor shaft and
up manual. Still same problem, the load may be too high for
Gearbox Does gearbox shaft is not
003 the choosen motor. Loosen the gearbox from the load/torque.
Not Start Up turning. You are not using
If it works than the starting torque is insufficient and higher
any driver /frequency
motor power is needed. For monophaze motors, check the
inverter or braked motor.
starting up condansator and running condansator as well. If
notting helps go to ID 100
You hear some noise but
Please observe the frequency inverters or drivers manual. To
both motor shaft and
see if the problem is on your driver or frequency inverter take
Gearbox Does gearbox shaft is not
004 out the driver/frequency inverter and make direct voltage
Not Start Up turning. You are using
supply to the motor according the motors nameplate. Still
driver or frequency
does not work go to ID 100
inverter.
Please Check the voltage supply and frequency of your
electric connection. They must be in accordance with the
nameplate of the motor. Observe motor manufacturers start
up manual. Be sure that the brake is working. Observe the
brake manufacturers manuel. If brake is supplied from
YILMAZ observe this manuel for correct brake wiring
You hear some noise but diagram. If still not work supply the brake with voltage
both motor shaft and according its nameplate directly. For example 198V DC. You
Gearbox Does
005 gearbox shaft is not will hear a clicking noise explaining that the brake is opening.
Not Start Up
turning. You are using If you hear no noise the brake or rectifier is defect. If you
braked motor 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 choosen motor. Goto ID
003.
E Series
Mounting Positions

For very low speeds the frequency inverters frequency is
lowering down. For very low frequencies the inverter
parameter and motor parameter must be optimized. Also for
Gearbox Does
low speeds the efficiency of the gearbox may varry too much.
Not Work in Low You are using frequency
006 Specially for worm-gearboxes. The recomended frequency
Speeds/frequenci- inverter.
range is 20-70 Hz for worm-gearboxes and 10-70 Hz for
es.
Helical Gear Boxes. Use Higher motor power and Frequency
inverter or change ratio of gearbox to work inside the
reccomended range.
The oil is not in accordance with your working conditions.
Gearbox Does
Change to lower viscosity oils. Observe this manuel for using
Not Start Ambient Temperature is
007 the correct oil. Working in higher ambient temperatures is an
Mornings or After below +5 Celsius
other solution if possible. If still same problem you need
Long Time Stop.
higher motor power.
Measure the surface temp. using a temperature measuring
device under full load. If the temp is under +80 Celsius this
will make no harm to the gearbox and is normal. All ATEX
conforming gearboxes and standart worm gearboxes are
designed to work under max. +120 Celsius. If higher than
Gearbox is You are using Worm Gear
+120 Celsius and using ATEX conforming gear box
008 Heating Up too Box and ambient tenp is
immidiately stop the system and contact YILMAZ
Much lower than +40 Celsius
REDUKTOR. Go to ID 100. If not ATEX confirming check
the oil type and oil quantitiy/level according your mounting
position and check the nameplate mounting position. If
nameplate mounting position does not fit the actual position
goto ID 100.
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
Gearbox is You are using Helical Gear
conforming gear box immidiately stop the system and contact
009 Heating Up too Box. Ambient temp is
YILMAZ REDUKTOR. If not ATEX gearbox the gearbox is
Much lower than +40 Celsius
designed to work under max. +80 Celsious. If higher than
+80 Celsius check the oil type and oil quantitiy/level
according your mounting position and check the nameplate
mounting position. If nameplate mounting position does not fit
the actual position goto ID 100
Standart Gearboxes are designed to work under +40 Celsius.
Gearbox is
Ambient Temp is over ambient temperature. If ambient temp is higher than +40
010 Heating Up too
+40 Celsius Celsius special solutions/gearboxes are required. Please
Much
contact YILMAZ
Check Your moving parts for noise. Disassemble the gearbox
and run without load. If you still hear the noise motor
011 Gearbox is noisy Nois is regular continious
bearings or gearbox bearings are defect. Change bearings.
Goto ID 100
and run without load. If you hear still the noise the oil may
012 Gearbox is noisy Nois is random has some particles inside. Change the oil and look for small
particles. If metal particles are found the gearbox may have
some demage. Goto ID 100
E Series
Oil Quantities

013 Gearbox is noisy Regular nocking noise and run without load. If you still hear the noise one of the
gears inside is defect. Goto ID 10
Check the output-shaft connection alements for runout. Take
Regular up and down out the output shaft element and run without load. If you still
014 Gearbox is noisy
noise (Sinosial noise) hear the noise one of the gears has runout problem. Goto ID
10
Gearbox is with braked
Low randomly clicking noise may come from the brake disk
motor and noise is
015 Gearbox is noisy which is normal. If noise level is disturbing the brake may be
comming from the brake
defect or brake clearance is not adjusted. Goto ID 100
side randomly.
You are using frequency The frequency inverter parameters are not optimized for the
inverter and the noise level frequency range or motor you are using. Observe the
016 Gearbox is noisy
is changing according your frequency inverters manual. If still same problem change the
speed. ratio of gearbox. Goto ID 100
If ambient Temp is over +40 Celsious or none stop work
over 16 hours please change the top plug with a breather
017 Oil is Leaking Oil Leakage from Seal
plug. Observe this manual for using breather plug. If this is
not your case the seal could be damaged. Goto ID 100
If you are using breather plug be sure it is in the correct
place. This is the most top plug position according your
018 Oil is Leaking Oil Leakage from Plug mounting position. The plug may be not tight enough. There
are some particles under the plug rubber surface. Clean and
tifgten the plug. If still same problem goto ID 100
Observe exactly where the oil is comming out. It could be
seal or plug point where it comes out and leakes over the
019 Oil is Leaking Oil Leakage from Housing 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. Goto ID 100
The sealing liquit under cover is split/defect. Disassemle the
020 Oil is Leaking Oil Leakage from Cover cover and put new sealing liquit. Assemle the cover and
tighten the bolts. If still same problem goto ID 100
The movement of gear box is because of the runout of the
Gearbox is moving
shaft which you assemle the gearbox. This has no bad affect
021 regularly on its You are using Torque Arm
or harm to the gearbox and is normal unless you are using
mounting point
torque arm.
The movement of gear box is because of the runout and
Gearbox is moving clearance of the shaft which you assemle the gearbox. Check
022 randomly on its You are using Torque Arm the clearance of the assemling shaft and the clearances on
mounting point your machine. This has no bad affect or harm to the gearbox
unless you are using torque arm.
Motor is heating Motor is running over its The motor power is not enough or some overload to the
023
up nominal current motor is possible. The motor may be defect. Goto 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
Motor is heating
023 Ambient is dusty working. If you are using frequency inverter in low speeds
up
and you do not have forced external fan, you may need
forced external fan. Goto ID 100
E Series
Mounting Positions

Motor is running
Scratchinh noise comes Some part (key, gear) may be defect inside gearbox. Goto
024 but Gearbox shaft
out ID 10
does not turn
The radial load or poligon effect of the chain may have
caused the damage. Check also if the assembly bolts are
loosened or the plate you assemble the gearbox is rigit
Gearbox Housing You are using chain drive enough. Check if you are using the correct diameter of chain
025
is Defect or pinion gear drive and you are not exceeding max. allowed radial load.
Check the position of your output element and re-calculate
your radyal load and check if this fit to tha maximum allowed
radial load. Goto ID 100
The radial load or poligon 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
Output Shaft is You are using chain drive enough. Check if you are using the correct diameter of chain
026
Defect or pinion gear drive and you are not exceeding max. allowed radial load.
Check the position of your output element and re-calculate
your radyal load and check if this fit to tha maximum allowed
radial load. Goto ID 100
Please check the wiring diagram of the brake. There are two
Gearbox is You are using braked different kind of brake wiring diagram. The standart gearbox
027
stopping too late motor delivered from our factory is set to delayed braking. For
sudden braking check the wiring diagram.
For fast opening of big brakes (over 100Nm), you may need
Gearbox is starting You are using braked
028 shock transformators which is supplied by YILMAZ. Goto
too late motor
ID 100
Please contact YILMAZ REDUKTOR Service point. See on
100 Service Required No self solution found
the back side of this manual
Yılmaz Redüktör San. ve Tic. A.Ş.
Head Office: Maltepe Gümüşsuyu Cad. Bestekar Medeni Aziz Efendi Sok. No:54 P.K.34020 TOPKAPI-İSTANBUL-TÜRKEY
Tel: +90 (0) 212 567 93 82/83 , Fax: +90 (0) 212 567 99 75
Factory: Beylikdüzü San-Bir Bulv. 1.Bölge 3.Cad. No:18 BÜYÜKÇEKMECE-İSTANBUL-TÜRKEY
Tel: +90 (0) 212 886 52 82/83 , Fax: +90 (0) 212 886 54 57
DECLARATION BY THE MANUFACTURER

(According 94/9/EC, Anex VIII)
We YILMAZ REDÜKTÖR Sanayi ve Ticaret A.Ş.

Beylikdüzü San-Bir. Bulvarı 1.Bölge 3.Cadde No:18
Büyükçekmece/Istanbul/ TURKEY
herewith declare, on our own responsibility, that the following products
EN/ET Series Gear Units

o
II 2GD c,k T4 / T120 C
in catagorie 2G and 2D that are subject to this decleration are meeting the requirements set
forth in
Directive 94/9/EC
Applicable standarts: EN 1127-1, EN 13463-1, EN 13463-5, EN 13463-8
The product this declaration refers to must not be put into service until the machinery
into which it is to be incorporated has been declared in confirmity with the provisions
of the relevant European Directives.
YILMAZ REDUKTOR will archive the documents required according to 94/9/EC, Appendix VIII
at the following location
TÜV Product Service No: 0123

with file No: Ex 9 05 04 54878 014
TURKEY / Istanbul Authorized Person

Date :01.01.2005 Re-Search Manager
Metin YILMAZ
This declaration is not guarantee of charecteristics in the sense of the product liability law. The
safety regulations of the maintenance instructions have to be observed.
Warranty Conditions:
1. The geared motors and gear units are warranted for two year except the electric
motor. 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 haz-
ard can not be repaired.
6. Costumers must inform the manufacturer if there are some problems after the ser-
vice 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.
Yılmaz Redüktör San. ve Tic. A.Ş.

Head Office: Maltepe Gümüşsuyu Cad. Bestekar Medeni Aziz Efendi Sok. No:54
P.K.34020 TOPKAPI-İSTANBUL-TURKEY Phone: +90 (0) 212 567 93 82/83 , Fax: +90
(0) 212 567 99 75
Factory : Beylikdüzü San-Bir Bulv. 1.Bölge 3.Cad. No:18 BÜYÜKÇEKMECE-
İSTANBUL- TURKEY
Phone: +90 (0) 212 886 90 00 - PBX 10lines , Fax: +90 (0) 212 886 54 57
Warranty
YILMAZ REDÜKTÖR products are warranted for 2 (Two) years covering all parts and mate-
rials used in products and their production errors unless they are started-up and used according
our service manual and is not modified or disassembled without an acknowledgement from our
company.
The warranty covers all costs like repair, service, spare parts etc. and no charge will be asked
under any name. The time for repair, service will be added to the warranty time.
For detailed warranty conditions please refer the back side of this page.
Serial No:
Type:
Manufacturer:
Company : YILMAZ REDÜKTÖR SANAYİ VE TİCARET A.Ş.
Address : Gümüşsuyu Cad. Bes.Medeni Aziz Efendi Sok. No:54
Topkapı / Maltepe / İsyanbul / TURKEY
Phone : +90 (0) 212 567 93 82 / 83 - +90 (0) 212 886 50 43/44
Fax : +90 (0) 212 567 99 75 - +90 (0) 212 886 54 57
Stamp and Signature
Supplier / End User:

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 REDÜKTÖR A.S.
Beylikduzu San-Bir Bulv. 1. Bolg. 3. Cad. No: 18
PK 34900
Büyükcekmece/Istanbul/TURKEY
Head Office:
Tel: +90 (0)212 567 93 82 (2 line),
+90(0) 212 567 06 03,
+90(0) 212 567 40 78
+90(0) 212 567 04 11
+90(0) 212 567 45 07
+90(0) 212 567 00 70
Fax: +90(0) 212 567 99 75
e-mail: [email protected]
web: www.yr.com.tr
Factory:
Tel: +90(0) 212 886 61 92 (5lines)
+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: [email protected]
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

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YILMAZ REDÜKTÖR ISO 9001 YILMAZ REDÜKTÖR ISO 9001

Gear Units, E Series

1 How To Use This Manual.................................................................................... 5

3 Part List of Standard Type Gear Units................................................................ 8

4 Thinks to Check Before the Gear Unit or Geared Motor is Installed.............. 12

5 Installing The Gear Unit...................................................................................... 14

10 Decleration by the Manufacturer .................................................................... 34

1 -How To Use This Manual

Electric Hazard; Can cause severe or fatal injuries.

Mechanical Hazard; Can cause severe or fatal injuries.

Likely to be Hazardous; Can cause minor injuries

Damage Risk; Can damage the drive or environment

Important information about explosion protection

The operating instructions contain important information to ensure;

Detailed E series gear units designation for ordering

EN -Foot mounted type with IEC flange without motor

b- Nameplate, unit designation

Nameplate unit designation is a short abbreviation from the detailed designation

A sample name plate for EN/ET. Series

YILMAZ REDÜKTÖR A.S.

Type : EN050-B09 / 2GD

Ignation Class if applicable.

3- Part List of Standard Type Gear Units

Standard Part List

1- Oil Seal 6- Worm Wheel 11- Closing Cap 16- O-Ring

Standard Part List

1- Solid Output Shaft 7- O-Ring 13- Circlip 19- Bearing

Standard Part List

1- Bolt 8- Side Cover 15- Circlip 22- O-Ring

Standard Part List

1- Bolt 7- Bearing 13- Closing Cap 19- Input Flange

4 -Thinks to Check Before the Gear Unit or Geared Motor is Installed

a) Safety notes for use in potentially explosive atmosphere

Intended use of gearbox:

If stored in open protect against insect damage.

5- Installing The Gear Unit

a) Before you start;

b) Check nameplate of the gear unit;

c) Check the ambient conditions and temperature;

d) Check fitting elements and the shaft dimensions to fit;

Output Shaft Flange

+0.03 +0.01 -0.01

e) Check the voltage supply;

f) Check the mounting position;

g) Use of breather plug;

h) Check the oil level ;

i) Check shaft ends and mounting faces;

j) Cover abrasive ambient;

k) Check accessibility to filling, breather and drain plugs;

Secure the gear unit using 8.8 or higher quality bolts.

For different kind of basic installations refer to the following illustrations.

a- Installing gear units in category II2G/D-II3G/D

b- Fittting outputshaft elements

1) Gear shaft end

c- Correct position of otputshaft elements

d- Installing customer shaft with shoulder

d2 -Fasten the bold as shown below.

e- Shaft tightening torques

f- Covering all turning parts