Oivce0300 1222

OPERATING
INSTRUCTIONS
V Series
Hoist Drum Drive Units
OIVCE0300-1222
Operating Instructions
V Series
Contents
Contents............................................................................................................................. 02
1 - How to Use This Manual.............................................................................................. 04

2 - Unit Designation........................................................................................................... 05
2.1- Detailed Unit Designation........................................................................................ 05

2.2- Nameplate, Unit Designation..................................................................................... 06
3.Standard Type Gearbox Part List.................................................................................... 07
3.1- V... Types................................................................................................................... 07
4- Safety ............................................................................................................................ 08
4.1- Intended Use........................................................................................................... 08

4.2- Improper Use.......................................................................................................... 08
4.3- Safety Instructions................................................................................................... 09
4.3.1- General Safety Instructions............................................................................ 09
4.3.1.1- Working on the Gear Unit.................................................................... 09
4.3.1.2- Operation............................................................................................ 09
4.3.1.3- Maintenance........................................................................................09
4.3.1.4- Lubricant..............................................................................................09
4.3.1.5- Ambient Conditions.............................................................................09
4.4- Tightening Torques..................................................................................................10
4.5- Case of Fire.............................................................................................................10
4.5.1- Suitable Extinguishing Agents......................................................................10
4.5.2- Unsuitable Extinguishing Agents..................................................................10
5 - Things to Check........................................................................................................... 11
5.1- Transportation......................................................................................................... 11
5.2- Storage.................................................................................................................... 12
6- Installing the Gear Unit................................................................................................. 12
6.1- Before You Start...................................................................................................... 12

6.2- Checking splined shaft dimensions ........................................................................ 12
6.3- Checking drum connection flange dimensions........................................................ 14
6.4- Checking ambient temperature............................................................................... 15
6.5- Checking voltage supply......................................................................................... 15
6.6- Checking mounting position.................................................................................... 18
6.7- How to use breather plug........................................................................................ 18
6.8- Checking oil level.................................................................................................... 18
6.9- Checking shaft ends and mounting faces............................................................... 18
6.10- Covering abrasive ambient................................................................................... 19
6.11- Checking accessibility to filling, breather and drain plugs..................................... 19
2 YILMAZ REDÜKTÖR
V Series
Contents
7- Mechanical Installation ................................................................................................ 19
7.1- Installing output shaft elements............................................................................... 20

7.2- Correct position of output shaft elements................................................................ 20
7.3- Coupling connection................................................................................................ 21
8- Maintenance & Inspection ........................................................................................... 22
9- Lubrication .................................................................................................................... 23
9.1- Oil Types................................................................................................................. 23

9.2- Changing the Oil..................................................................................................... 24
9.3- Oil quantities (lt) and plugs...................................................................................... 25
9.4- Mounting Positions.................................................................................................. 26
10- Troubleshooting Guide............................................................................................... 27
11- Disposal....................................................................................................................... 30
11.1- Disposal of oil......................................................................................................... 30

11.2- Disposal of sealing................................................................................................. 30
11.3- Disposal of metal parts........................................................................................... 30
12- Appendix...................................................................................................................... 31
12.1- Warranty conditions................................................................................................ 32

12.2- Warranty paper....................................................................................................... 33
12.3- Service points......................................................................................................... 34
YILMAZ REDÜKTÖR 3
V Series
General Informations
1- How To Use This Manual
Take attention to the following safety and warning signs for proper understanding and quick refer-
ence.
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
EC Machinery Directive:
Within terms of the EC machinery directive 2006/42/EC the gear reducer is not considered an
autonomous machine, but as a component to install in machines. Operation is prohibited within
the area of validity of the EC directive, until it has been determined that the machine, in which
this product is installed, corresponds to the regulations within this directive.
The machine manufacturer or user is responsible for taking the necessary precautions
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 be kept close to the gearbox and must be available in case it
is needed.
This operating instruction is written for V Series gear units and is applicable only for V Series.
If any different type of gearbox is used please ask YILMAZ REDUKTOR for the operating in-
structions 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.
4 YILMAZ REDÜKTÖR
V Series
Type Designations
2- Unit Designation
2.1- Detailed Unit Designation
V R 5 7 3 . 1K - 132S / 4 - L10
Brake
L-230V With Fan
P-24V With Fan
S-230 V Without Fan
Z-24 V Without Fan
00- 5 Nm 10- 100 Nm

01- 10 Nm 20- 200 Nm
02- 25 Nm 30- 300 Nm
04- 40 Nm 40- 400 Nm
05- 50 Nm 50- 500 Nm
Number of Poles
Motor Size
132S / 4
Pole Number
Frame Length
Motor Size
Output Shaft with Spline (DIN5480)

1K Standard
1L Optional
1M Optional ( Only for VR673 )
Stage
3 Stages
Revision Number
Housing Size
2...8
Input Type
R : With Motor
Gearbox Type
V Serie
YILMAZ REDÜKTÖR 5
V Series
Type Designations
2.2- Nameplate, unit designation
A sample name plate for V Series.
YILMAZ REDÜKTÖR
www.yr.com.tr
MADE IN TURKEY
Type: VR473.1K-112M/4-L05
Serial N.: 100348988 M. Pos.: M5
Power: 4 kW Ratio: 61.85
Oil: Min. VG 320 5 lt. Speed: 23 rpm.
Drum Dia.: 200 mm Falls: 4/1
Class.: 5 ton - M5(2m) / ISO4301(FEM1.001/III)
Lift. Sp.: 3.6 m/min. Brake: 50 Nm.
Explanations:
Type : Unit designation
Serial N : Serial number of the gearbox
M. Pos. : Mounting Position
Power : Motor Power
Ratio : Ratio of the gearbox
Oil : Type and quantity of the oil in the gearbox
Speed : Output speed of the gearbox
Drum Dia. : Diameter of the crane’s drum
Falls : It is the ratio between the lifting speed and the
tangential velocity of the rope at the point where it is
wrapping to drum
Class : Class of the crane
Lift. Sp. : Crane’s lifting speed
Brake : Brake torque
6 YILMAZ REDÜKTÖR
V Series
Part Designation
3. Standard Type Gearbox Parts List
3.1- V... Types
18
17
16
15
14
13
20
12
19
21
22
23
24
25
26
27
3
30
29 3
28
4
3
11
10
3
9
8
4
7
1
6
2
3
Standard V... type basic parts diagram. Parts may differ for special applications.
Standard Parts List
1- Housing 10- Bearing 19- Bolt 28- Gear
2- Bolt 11- Cover 20- Side Cover 29- Bearing
3- Plug 12- Bearing 21- Spacer 30- Spacer
4- Screw Bolt 13- Gear 22- Bearing
5- Seal 14- Key 23- Shaft Gear
6- Output Shaft 15- Shaft Gear 24- Key
7- Key 16- Bearing 25- Gear
8- Washer 17- Washer 26- Tube
9- Spacer 18- Tube 27- Bearing
YILMAZ REDÜKTÖR 7
V Series
Safety
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 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 require-
ments of the directive 2006/42/EC. The gearbox must be started up, maintained and oper-
ated according this manual. The gearbox most be incorporated with 2006/42/EC confirming
parts/machines.
A motor connected to the gear unit is only allowed to be operated in the frequency entries
so that the data provided on nameplate/catalogue of the gear unit is not exceeded and is ac-
cordance with the nameplate/catalogue. The speed range will be provided on the name plate
if YILMAZ REDUKTOR is informed that the gear unit will be used with frequency inverter.
If not informed the nameplate will 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 must be informed to YILMAZ
REDUKTOR before ordering.
The gearbox maintenance (oil change / check ) must be done according this manual
4.2- Improper Use
Every usage which exceeds the limits stated above, the nameplate and catalogue of the
product (especially higher torques and speeds) is not compliant with the regulations, and
thus prohibited.
The operation of the gear reducer is prohibited if;
-It was not mounted/installed according to regulations and this manual
-The gear reducer is very soiled
-It is operated without lubricant
-It is operated out of the permitted values provided on catalogues and/or nameplate.
8 YILMAZ REDÜKTÖR
V Series
Safety
4.3- Safety Instructions
4.3.1- General Safety Instructions

4.3.1.1- Working on the gear reducer
- Inappropriately executed work can lead to injury or damage.

Make sure that the gear reducer is only installed, maintained and dismantled by
trained technician.
- 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 sufficient distance and make safeguarding to rotating machinery. See relevant
norms EN349+A1, EN13857.
4.3.1.3- Maintenance
-An unintentional start of the machine during maintenance work can lead to serious
accidents.
Make sure no one can start the machine while you are working on it.
- Even a brief running of the machine during maintenance work can lead to accidents
if the safety devices are not operating.
Make sure that all safety devices are mounted and active.
4.3.1.4- Lubricant
- Extended, intensive contact with oils can lead to skin irritations.
Avoid extended contact with oil, and clean oil off skin thoroughly.
- 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 REDÜKTÖR 9
V Series
Safety
-If the gear unit will be used in outdoor applications the gear unit must be prevented from
rain snow and dust. Entering substances inside the gear unit from seals can damage the
gear unit. Observe the safety instructions for outdoor use EN12100:2010.
4.4- Tightening Torques

All screwed connections for which a tightening torque is specified, must on
principle be tightened with a calibrated torque wrench and checked. Use the
following torques for the threaded bores over the gear unit housing. For
connecting elements refer to the mechanical installation part.
Tightening
Bolt Class
Torque [Nm]
M8 8.8 23
M10 8.8 43
M12 8.8 77
M16 8.8 190
M20 8.8 370
M24 8.8 640
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 easy accessible around the gear unit.
-High temperatures produce irritating steam.

Use a protective breathing appreciates.
4.5.2- Unsuitable extinguishing agents

Do not spray with water!
10 YILMAZ REDÜKTÖR
V Series
Checking
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 damage.
- The gearbox is stored correctly according the instructions in this manual
- You have the latest product catalogue or you have access to our web page
5.1- Transportation
When the goods arrive, first check for any damage. If some damage observed, im-
mediately 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 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 equipment which is capable to
hold the gear units weight. Refer to the catalogue for various types weights. If the
gearbox is delivered with steel carrying construction use the construction holes for lift-
ing the gear unit. See drawing bellow for hoisting point.
Do not stay beneath / under the lifting/hoisting equipment which may cause serious
injuries 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 / weigh of
your gear unit. Ensure that the load is slowly and carefully handled and placed.
YILMAZ REDÜKTÖR 11
V Series
Checking
5.2- Storage
If the geared unit or geared motor will be stored up to 3 years refer to the following instructions;
With Packing;
-Use corrosion protection oil for the output shaft and connection surfaces 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 areas protect against insect damage.
6- Installing The Gear Unit
6.1- Before you start;

- Observe the gear unit for damages of storage or transportation. If any damage please
contact YILMAZ REDUKTOR.
- Be sure that you have all the equipment necessary for installing like; Spanners, torque
wrench, shims and distance rings, fixing devices for input and output elements, lubricant,
bolt adhesive etc.
- This manual is not for 94/9/EC (ATEX) conforming gear units. For 94/9/EC conforming
gear units refer to the ATEX range manual. ATEX conforming gear units have name plates
indicating the zone and the temperature class and are different from standard type geared
units. Therefore Standard units can not be installed on Potentially explosive atmospheres.
V Series
Installing
6.2- Check Splined Shaft Dimensions and Tolerances
c2 t1
e e1
Ød Ød1
e e1
c1
e1 e1
c
Splined Shaft Dimensions
Type c1
e e1 c d d1 t1
c2
17.5 W35x2x30x16x8f ø40

V273.1K 60 75 50 28
44.5 DIN5480 (h6)
22 W45x2x30x21x8f ø50
V373.1K 55 28
48 DIN5480 (h6)
75 90
22 W40x2x30x18x8f ø43
V373.1L 50 23
43 DIN5480 (h6)
27 W50x2x30x24x8f ø55
V473.1K 60.5 28
51,5 DIN5480 (h6)
95 110
16 W45x2x30x21x8f ø48
V473.1L 48 27
42 DIN5480 (h6)
28 W70x3x30x22x8f ø75
V573.1K 69 35
61 DIN5480 (h6)
115 140
16 W65x2x30x31x8f ø68
V573.1L 56 35
51 DIN5480 (h6)
32 W95x3x30x30x8f ø100
V673.1K 84 45
74 DIN5480 (h6)
17 W75x2x30x36x8f ø78
V673.1L 132.5 157.5 67 44
60 DIN5480 (h6)
21 W90x2x30x44x8f ø92
V673.1M 75 45
68 DIN5480 (h6)
35 W110x4x30x26x8f ø115
V773.1K 110 67
97 DIN5480 (h6)
160 187.5
21 W110x2x30x54x8f ø113
V773.1L 97 67
89 DIN5480 (h6)
41 W120x4x30x28x8f ø130
V873.1K 185 235 124 83
107 DIN5480 (h6)
V Series
Installing
6.3- Check Drum Connection Flange (Optional) Dimensions and Tolerances
Type Drum Connection Flange Dimensions
A
30° 11
14.5 Ø95
V273 +0.03 +0.2 0 30°

+0.01 0 -0.02
Ø118 Ø65 Ø40 Ø31 Ø75 60°
R4
GN25.V27.FK
15 N35x2x30x16x9H A
18 M10
DIN5480
47
A
30° 13
18 Ø115
+0.03 +0.2 0 30°

V373 Ø138 Ø85 Ø50
+0.01
Ø41
0
Ø95
-0.02
60°
R4
GN25.V37.FK
15 N45x2x30x21x9H
M12
A
19 DIN5480
50
A
30° 16
21 Ø130
V473 +0.03 +0.2 0 30°

+0.01 0 -0.02
Ø158 Ø95 Ø55 Ø46 Ø110 60°
R5
GN25.V47.FK
15 N50x2x30x24x9H
M14
A
22 DIN5480
55
A
30° 19
24 Ø165
V573 +0.03 +0.2 0 30°

+0.01 0 -0.02
Ø198 Ø120 Ø75 Ø64 Ø130 60°
R6
GN25.V57.FK
15 N70x3x30x22x9H
M18
A
30 DIN5480
65
V Series
Installing
Type Drum Connection Flange Dimensions
A
30° 21
27 Ø215
V673 +0.04 +0.2 0 30°

+0.02 0 -0.02
Ø248 Ø145 Ø100 Ø89 Ø180 60°
R6
GN25.V67.FK
15 N95x3x30x30x9H
M20
A
41 DIN5480
78
A
22.5° 23
27
Ø265
45°
V773 +0.04
+0.02
+0.2
0
0
-0.02
Ø298 Ø180 Ø115 Ø102 Ø230
R6
GN25.V77.FK
15 N110x4x30x26x9H
51 M22 A
DIN5480
90
22.5° A
26
Ø300
30
45°
V873 +0.04
+0.02
+0.2
0
0
-0.02
Ø348 Ø210 Ø130 Ø112 Ø250
R6 0
GN25.V87.FK -0.14
318 (h9)
20 N120x4x30x28x9H
63 A
DIN5480 M24
111
6.4- Check the ambient temperature;

The ambient temperature must be between +5 celsius to +40 celsius for standard type gear
units. If different contact YILMAZ REDUKTOR for special solutions.
6.5- Check the voltage supply;

The standard geared motors are supplied with 230/400 V 50/60Hz. up to 3kW including 3kW
and 400/690 V 50/60 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 please observe the
name plate of the electric motor and the instructions of the supplier. Check the basic electric
connection diagrams below. Use experienced electric technician.
Using wrong connection or voltage can damage the electric motor or environment.
V Series
Electricity
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 without
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 differences
of earth and gearbox/motor.
Nominal Power at 400V, 50Hz

Pole Number
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
L1 L2 L3 L1 L2 L3
U U U U
(230V) (230V) (400V) (400V)
U U
(230V) (400V)
I1 I2 I3 I1 I2 I3
V1
U2 V1
U
Uph=
Uph=U 3
I
3
V2
Iph=
W2
= I
U1 V2 I ph U2
W1
W2 W1 U1
W2 U2 V2 W2 U2 V2
U1 V1 W1 U1 V1 W1
L1 L2 L3 L1 L2 L3
V Series
Electricity
Standard type brakes basic wiring diagram
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.
Delayed Running Brake( 380 V ) Sudden Brake (380 V)
L1 L2 L3 N L1 L2 L3 N
Brake Coil Brake Coil
3
M M
3
Delayed Running Brake (24 V ) Sudden Brake(24 V)
L1 L2 L3 N Brake Coil L1 L2 L3 N Brake Coil
M
3
M
3
V Series
Installing
6.6- 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 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.
Do not mix synthetic oils with mineral oils which can cause serious damage on the gear
unit.
6.7- Use of breather plug;

Breather plug is delivered with the gearbox together by YILMAZ REDUKTOR. Breather plug
must be on the top of the gearbox according to mounting position.
As shown in the label below, the transport protection rubber must be removed before
operating the gear unit.
TAŞIMA EMNİYET LASTİĞİ

Redüktörü devreye almadan önce
taşıma emniyet lastiğini çıkartınız.
TRANSPORT PROTECTION RUBBER

Remove the transport protection rubber
before operating the gear unit.
Çalıştırmadan önce kullanım kılavuzunu mutlaka okuyunuz.

Please read operation instructions before operating.
Some plug positions are not machined according mounting position. If no mounting position
is mentioned by ordering the standard M5 position plugs are machined.
6.8- Check the oil level;

On the mounting position tables the oil level plug is shown. Please refer to those tables and
be sure that the oil level is correct according the mounting position by screwing half way out
the level plug and see if oil comes out from that plug. If oil comes out tighten the plug again.
If no oil comes out take out the filling plug and add oil until oil comes out from the level plug
and tighten both plugs after finish. Be sure you are using the correct oil mentioned on the
oil tables on this manual.
Do not mix synthetic oils with mineral which can cause serious damage on the gear unit.
6.9- 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.
V Series
Installing
6.10- 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 pres-
sure 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 REDUK-
TOR 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.
6.11- Check accessibility to filling, breather and drain plugs;

The filling, breather and drain plugs must be freely accessible for further checking
and service.
7- Mechanical Installation
The gear unit can only be installed using the supplied connection points like foot and
flange assembling points.
To install the gear unit without the supplied connection points can cause serious
injuries by loosening or braking the gear unit. Even the gear unit is installed totally
correctly according this Manuel, be sure that no one will be harmed by accidentally
brake downs or loosening.
The mounting plate must be rigid enough not allowing torsions, flat enough to prevent
strains by tightening the bolts and stable enough not allowing vibrations. By using chain
drives this becomes much more important because of the polygon effect on chain drives.
According to your connection elements the maximal permitted radial and axial load of
the gear unit must be in 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 all the 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.
V Series
Installing
7.1- Fitting output shaft elements
Use the following illustration to assemble output shaft units
1) Shaft
2) Bearing
3) Coupling Hub
7.2- Correct position of output shaft elements
The Output Shaft unit (transmission elements) must placed as close as possible to
the gear unit so that the radial load is as closest as possible to the gear unit.
1) Hub
V Series
Installing
7.3- Fitting Couplings

7.3.1- By fitting couplings be sure that there is some clearance between the two
elements
7.3.2- By fitting couplings be sure that there is no eccentricity between the two shafts.
7.3.3- By fitting couplings be sure that the two shafts are not angular miss-aligned
V Series
Maintenance and Inspections
8- Maintenance and Inspections
Under normal ambient and working conditions the gear unit should be checked according the
following intervals. (For definition of normal working conditions refer to the product catalogue:
“Selecting Gearbox” section);
Every 3.000 working hours Every 4.000 working Every 10.000 working Every 25.000
Item to check / replace
or every 6 months hours hours or every 3 years working hours
x
Check for oil leakage
x
Check for oil level
Check oil leakage from x

seal
x (Change if necessary)
Check Rubber buffer
x (Change if necessary)
Check Bearings Noise
x (See Below for details)

Change Mineral Oil
x (See Below for

Change Synthetic-PAO Oil details)
x
Change Sealing
x
Change Bearing Grease
x
Change Bearings
x
Check for noise Changes
45000
Oil change interval [Hours]
40000
35000
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 Celsius oil bath temp. Should be taken as
reference
* For V Series mineral oil is used unless it is differently ordered. For oil type and quantities
refer to the following tables.
V Series
Lubrication
9- Lubrication
9.1- Oil Types
Beyond Klüber
Ambient Temp. [ºC] Aral Petroleum Castrol Lubrication Mobil Shell Total
Lubricant DIN ISO VG
51517-3
Dip Lubrication
Degol Energol Alpha Klüberoil Mobilgear Omala S2 Carter

0 ... +50 680
BG 680 GR-XP 680 SP 680 GEM 1-680 N XMP 680 GX 680 EP 680

-5 ... +45 460

-10 ... +40 320
Mineral Oil
CLP
-15 ... +30 220

-20 ... +20 150

-25... +10 100
Degol Energsyn Klübersynth Mobil Omala S4 Carter

-10 ... +60 680 –
GS 680 SG-XP 680 GH 6 -680 Glygoyle 680 WE 680 SY 680
Degol Energsyn Alphasyn Klübersynth Mobil Omala S4 Carter

-20 ... +50 460
GS 460 SG-XP 460 PG 460 GH 6 -460 Glygoyle 460 WE 460 SY 460

-25 ... +40 320
CLP PG
-30 ...+30 220

-35 ... +20 150
Klübersynth Mobil
Synthetic Oil -40 ... +10 100 – – – – –
GH 6 -100 Glygoyle 100
Mobil
Klübersynth Omala S4 Carter
-10 ... +60 680 – – – SHC Gear
GEM 4-680 N GXV 680 SH 680
680
Mobil
Degol Enersyn Alphasyn Klübersynth Omala S4 Carter
-20 ... +50 460 SHC Gear
PAS 460 EP-XF 460 T 460 GEM 4-460 N GXV 460 SH 460
460
Mobil
-30 ... +40 320 SHC Gear
320
Mobil
-40 ... +40 220 SHC Gear
CLP HC PAS 220 EP-XF 220 T 220 GEM 4-220 N GXV 220 SH 220
220
-40 ... +40 150 –
Klübersynth
-40 ... +40 100 – – – – – –
GEM 4-100 N
Mobil
CLP Optileb Klüberoil Nevastane
Food Grade Oil -30 ... +25 220 – – SHC –
NSF H1 GT 220 4 UH1-220 N SL 220
Cibus 220
Tribol BioTop Klübersynth Carter

Biodegradable Oil CLP E -25 ... +40 320 – – – –
1418-320 GEM 2-320 Bio 320
Product Code Working Temp. [ºC] NLGI Grade Base Oil Colour
Mineral Grease Mobil XHP 223 -20 ... +140 NLGI 3 ISO VG220 Blue
Mobil SHC Grease 460 WT -30 ... +150 NLGI 1.5 ISO VG460
Synthetic Grease Red
Mobilith SHC 100 -40 ... +150 NLGI 2 ISO VG100
Mobil SHC Polyrex 222 -30 ... +170 NLGI 2 ISO VG220
Food Grade Grease NSF H1 White
Castrol Optileb™ GR 823-2 -30 ... +120 NLGI 2 ISO VG192
Liquid Grease (Mineral) Shell Gadus S2 V 220 00 -20 ... +100 NLGI 00 ISO VG220 Brown
V Series
Lubrication
9.2- Changing the Oil

Refer to the nameplate to find out the correct oil type filled inside the gearbox.
- Do not mix synthetic oils with mineral oils which will cause serious damage to the
gear unit. The oil change must be done by using the filling, draining and level plugs
according the mounting position illustrated at oil plugs tables.
- Extended, intensive contact with oils can lead to skin irritations. Avoid extended contact
with oil, and clean oil off skin immediately.
- Hot oil can cause scalding. When changing oil, protect yourself against contacting hot oil,
use protective gloves.
V Series
Lubrication
9.3- Oil Levels,Plugs and Quantities
M1 M3
M5 M6
Oil Quantities (lt)
V Series Oil Quantities (lt)

Tip
M1 M3 M5 M6
V273 1,8 2,2 1,45 1,4
V373 3,3 4,0 2,6 2,5
V473 4,5 6,9 4,3 4,1
V573 9,7 12,5 9,2 9,0
V673 16,3 21 16 15,8
V773 30 18 21 20,5
V873 49,5 30 35 34
Symbols : :Oil filling :Drain plug :Oil level :Vent Plug
V Series
Mounting Positions
9.4- Mounting Positions
V Series
M1
M5
M6
M3
Indicated mounting positions are determined as reference directional position of the gearbox.
Mounting surfaces are not binding.
V Series
Troubleshooting Guide
10- Troubleshooting Guide

All the operations bellow must be done by authorized and skilled mechanician /electrician.
Inform YILMAZ REDUKTOR before making any change to the gearbox. Only oil change is
allowed to change without information. Do not make anything if you are not sure what you are
doing and contact YILMAZ REDUKTOR. 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.
ID Problem Observation Remedy
You hear no noise and shaft Please Check the voltage supply and frequency of your electric
Gearbox Does is not turning. You are not connection. They must be in accordance with the nameplate of
001
Not Start Up using any driver or the motor. Observe motor manufacturers start up manual. Still
frequency inverter. does not work go to ID 100
You hear no noise and shaft Please observe the frequency inverter/driver manual. Check the
002 Gearbox Does
is not turning. You are using motor by supplying direct voltage to see if the problem is on your
Not Start Up
frequency inverter or driver. driver/frequency inverter. Still does not work go to ID 001.
Please Check the voltage supply and frequency of your electric

connection. They must be in accordance with the nameplate of
You hear some noise
the motor. Observe motor manufacturers start up manual. Still
but both motor shaft and
same problem, the load may be too high for the chosen motor.
003 Gearbox Does gearbox shaft is not turn-
Loosen the gearbox from the load/torque.
Not Start Up ing. You are not using any
If it works than the starting torque is insufficient and higher motor
driver /frequency inverter or
power is needed. For mono phase motors, check the starting up
braked motor.
condensator and running condensator as well. If nothing helps go
to ID 100
You hear some noise but Please observe the frequency inverters or drivers manual. To see
Gearbox Does both motor shaft and gear- if the problem is on your driver or frequency inverter take out the
004
Not Start Up box shaft is not turning. You driver/frequency inverter and make direct voltage supply to the
are using driver or frequen- motor according the motors nameplate. Still does not work go to
cy inverter. ID 100
Please Check the voltage supply and frequency of your electric

connection. They must be in accordance with the nameplate of
the motor. Observe motor manufacturers start up manual. Be
sure that the brake is working. Observe the brake manufacturers
manuel. If brake is supplied from YILMAZ observe this manuel for
You hear some noise but correct brake wiring diagram. If still not work supply the brake with
Gearbox Does both motor shaft and gear- voltage according its nameplate directly. For example 198 V DC.
005
Not Start Up box shaft is not turning. You You will hear a clicking noise explaining that the brake is opening.
are using braked motor If you hear no noise the brake or rectifier is defect. If you hear the
clicking noise the brake is working. You should this clicking noise
by your normal electric connection as well. By supplying direct
supply to the brake you hear the 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.
V Series
For very low speeds the frequency inverters frequency is lower-

ing down. For very low frequencies the inverter parameter and
Gearbox Does motor parameter must be optimise. Also for low speeds the
Not Work in Low You are using frequency efficiency of the gearbox may vary too much. Specially for worm-
006
speeds / inverter. gearboxes. The recommended frequency range is 20-70 Hz
Frequencies. for worm-gearboxes and 10-70 Hz for Helical Gear Boxes. Use
Higher motor power and Frequency inverter or change ratio of
gearbox to work inside the recommended range.
Gearbox Does Not The oil is not in accordance with your working conditions. Change
007 Start Mornings or Ambient Temperature is to lower viscosity oils. Observe this manual for using the correct
After Long Time below +5 Celsius oil. Working in higher ambient temperatures is an other solution if
Stop. 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 and is normal. All ATEX conform-
ing gearboxes and standard worm gearboxes are designed to
You are using Worm
work under max. +120 Celsius. If higher than +120 Celsius and
008 Gearbox is Heating Gear Box and ambient
using ATEX conforming gear box immediately stop the system
Up too Much temperature is lower
and contact YILMAZ REDUKTOR. Go to ID 100. If not ATEX
than +40 Celsius
confirming check the oil type and oil quantity/level according your
mounting position and check the nameplate mounting position. If
nameplate mounting position does not fit the actual position go to
ID 100.
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 conform-
ing gearboxes are designed to work under max. +120 Celsius. If
You are using Helical
higher than +120 Celsius and using ATEX conforming gear box
009 Gearbox is Heating Gear Box. Ambient temp
immediately stop the system and contact YILMAZ REDUKTOR.
Up too Much is lower than +40 Cel-
If not ATEX gearbox the gearbox is designed to work under max.
sius
+80 Celsius. If higher than +80 Celsius check the oil type and oil
quantity/level according your mounting position and check the
nameplate mounting position. If nameplate mounting position
does not fit the actual position go to ID 100
Standard Gearboxes are designed to work under +40 Celsius.

010 Gearbox is Heating Ambient Temp is over
ambient temperature. If ambient temp is higher than +40 Celsius
Up too Much +40 Celsius
special solutions/gearboxes are required. Please contact YILMAZ
Noise is regular Check Your moving parts for noise. Disassemble the gearbox
011 Gearbox is noisy
continuous and run without load. If you still hear the noise motor bearings or
gearbox bearings are defect. Change bearings. Go to ID 100
Check Your moving parts for noise. Disassemble the gearbox

and run without load. If you hear still the noise the oil may has
012 Gearbox is noisy Noise is random
some particles inside. Change the oil and look for small particles.
If metal particles are found the gearbox may have some damage.
Goto ID 100
V Series
Check Your moving parts for noise. Disassemble the gearbox

013 Gearbox is noisy Regular knocking noise 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

Regular up and down out the output shaft element and run without load. If you still
noise hear the noise one of the gears has run out problem. Go to ID
100
Gearbox is with braked

Low randomly clicking noise may come from the brake disk
motor and noise is coming
015 Gearbox is noisy which is normal. If noise level is disturbing the brake may be
from the brake side ran-
defect or brake clearance is not adjusted. Go to ID 100
domly.
You are using frequency The frequency inverter parameters are not optimise for the
inverter and the noise frequency range or motor you are using. Observe the frequency
level is changing inverters manual. If still same problem change the ratio of gear-
according your speed. box. 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
017 Oil is Leaking Oil Leakage from Seal
this manual for using breather plug. If this is not your case the
seal could be damaged. Go to ID 100
If you are using breather plug be sure it is in the correct place.

This is the most top plug position according your mounting posi-
018 Oil is Leaking Oil Leakage from Plug tion. The plug may be not tight enough. There are some parti-
cles 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
019 Oil is Leaking Oil Leakage from Housing 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

020 Oil is Leaking Oil Leakage from Cover the cover and put new sealing liquid. Assemble the cover and
tighten the bolts. If still same problem go to ID 100
Gearbox is mov- The movement of gear box is because of the run out of the
021 ing regularly on its You are using Torque Arm shaft which you assemble the gearbox. This has no bad af-
mounting point fect 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 clear-
Gearbox is mov-
ance of the shaft which you assemble the gearbox. Check the
022 ing randomly on its You are using Torque Arm
clearance of the assembling shaft and the clearances on your
mounting point
machine. This has no bad affect or harm to the gearbox unless
you are using torque arm.
Motor is running over its

023 Motor is heating up The motor power is not enough or some overload to the motor
nominal current
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
024 Motor is heating up Ambient is dusty
are using frequency inverter in low speeds and you do not have
forced external fan, you may need forced external fan. Go to ID
100
V Series
Motor is running but Gear- Some part (key, gear) may be defect inside gearbox.
025 Scratching noise comes out
box shaft does not turn Go to ID 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
You are using chain drive or enough. Check if you are using the correct diameter of
026 Gearbox Housing is Defect
pinion gear chain drive and you are not exceeding max. allowed ra-
dial 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
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
You are using chain drive or enough. Check if you are using the correct diameter of
027 Output Shaft is Defect
pinion gear chain drive and you are not exceeding max. allowed ra-
dial 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
Please check the wiring diagram of the brake. There are

Gearbox is stopping too two different kind of brake wiring diagram. The standard
028 You are using braked motor
late gearbox delivered from our factory is set to delayed brak-
ing. For sudden braking check the wiring diagram.
A 24V shock transformer is recommended for fast opening

029 Gearbox is starting too late You are using braked motor of big brakes (≥ 200 Nm) and shock rectifier is recommen-
ded for smaller brakes (< 200 Nm). 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 REDUK-
100 Service Required No self solution found TOR or with information of YILMAZ REDUKTOR. Any
change without informing YILMAZ REDUKTOR will can-
cel the warranty, manufacturer declaration and YILMAZ
REDUKTOR will take no responsibility.
11- Disposal
If your product is no longer of use and you wish to dispose 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 manual.
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 Sealing

Remove the sealing rings from the gear reducer, and clean them of oil and grease residues.
Dispose of the sealing as composite material (metal/plastic)
11.3- Disposal of Metal

Divide up the remainder of the gear reducer into iron, aluminium, non-ferrous heavy metal if pos-
sible. Dispose of it according to the valid national guidelines.
Appendix
Warranty Conditions:
1. The geared motors and gear units are warranted for two year except the electric mo-
tor. For motor warranty please refer to the manual of the electric motor manufacturer
or the warranty document of the motor manufacturer. This warranty is valid only if the
gearbox is assembled and started up according our operating instructions and is used
under the allowed conditions for the appropriate gearbox type in our catalogue. Special
Gearbox parts made according customer request are not covered by this warranty.
2. The warranty time starts from the start up time written on the warranty document and
last for two years. If the start-up time is more then three months after the billing time,
the total warranty time is limited to 27 months starting from billing time. If the warranty
document is not send to our company after start-up, the total warranty time will be limited
to 24 months after the billing time.
3. Any time during the warranty for maintenance, repair or change will be added to the
warranty time. This time starts from the date which the company or representative was
made aware of the problem and ends on the date of the re-start-up.
4. If the product fails to operate because of a manufacturing or assembly failure during

the warranty time, the product will be repaired free of charge.
5. If the product fails to operate because of a manufacturing or assembly failure during

the warranty time and it is not possible to repair it, the product will be changed with a
new one according to the report from our service department mentioning that the hazard
can not be repaired.
6. Costumers must inform the 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 REDÜKTÖR San. ve Tic. A.S.

ATATÜRK Mah. Lozan Cad. No:17 P.K.:34522 Esenyurt-İstanbul-TÜRKİYE
Phone: +90 (0) 212 886 90 00 (8 Lines)
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 refer the back side of this page.
Serial No:
Type:
Manufacturer:
Company : YILMAZ REDUKTOR Sanayi ve Ticaret A.S.
Address : ATATÜRK Mah. Lozan Cad. No:17 P.K.34522 Esenyurt-Ýstanbul- TURKÝYE
Telefon : +90 (0) 212 886 90 00 (8 Lines)
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:
Supplier/ End User Stamp and Signature

WARRANTY
IS IS
O 1400 O 4500
1
1
YEARS
Domestic Service Spare Parts

Tel: +90 212 886 90 00 Tel: +90 212 886 90 00
Int: 1223, 1228, 1287 Int: 1224, 1277
Whatsapp: +90 554 713 71 02 Whatsapp: +90 506 774 44 35
E-Mail: servis@yr.com.tr E-Mail: yedekparca@yr.com.tr
International Services
If you call the above service point, you will be directed to our nearest service.
Yılmaz Redüktör Sanayi ve Ticaret A.Ş.

Atatürk Mah. Lozan Cad. No: 17, 34522 Esenyurt - İstanbul / Turkey
Tel: +90 212 886 90 00 | E-Mail: yilmaz@yr.com.tr

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OPERATING

1 - How to Use This Manual.............................................................................................. 04

2.1- Detailed Unit Designation........................................................................................ 05

3.Standard Type Gearbox Part List.................................................................................... 07

3.1- V... Types................................................................................................................... 07

4.1- Intended Use........................................................................................................... 08

6- Installing the Gear Unit................................................................................................. 12

6.1- Before You Start...................................................................................................... 12

7.1- Installing output shaft elements............................................................................... 20

8- Maintenance & Inspection ........................................................................................... 22

9.1- Oil Types................................................................................................................. 23

10- Troubleshooting Guide............................................................................................... 27

11.1- Disposal of oil......................................................................................................... 30

12.1- Warranty conditions................................................................................................ 32

Electric Hazard; Can cause severe or fatal injuries.

Mechanical Hazard; Can cause severe or fatal injuries.

Likely to be Hazardous; Can cause minor injuries

The operating instructions contain important information to ensure;

00- 5 Nm 10- 100 Nm

Output Shaft with Spline (DIN5480)

2.2- Nameplate, unit designation

A sample name plate for V Series.

Standard Parts List

1- Housing 10- Bearing 19- Bolt 28- Gear

2- Bolt 11- Cover 20- Side Cover 29- Bearing

3- Plug 12- Bearing 21- Spacer 30- Spacer

4- Screw Bolt 13- Gear 22- Bearing

5- Seal 14- Key 23- Shaft Gear

6- Output Shaft 15- Shaft Gear 24- Key

7- Key 16- Bearing 25- Gear

8- Washer 17- Washer 26- Tube

9- Spacer 18- Tube 27- Bearing

4.1- Intended Use

4.3- Safety Instructions

4.3.1- General Safety Instructions

- Inappropriately executed work can lead to injury or damage.

- Hot oil can cause scalding.

4.3.1.5- Ambient Conditions

4.4- Tightening Torques

M16 8.8 190

M20 8.8 370

M24 8.8 640

4.5- Case of Fire

4.5.1- Suitable extinguishing agents, Protective equipment

-High temperatures produce irritating steam.

4.5.2- Unsuitable extinguishing agents

5 -Things to Check Before the Gear Unit or Geared Motor is Installed

Falling or hard placement can damage the gear unit.

If stored in open areas protect against insect damage.

6- Installing The Gear Unit

6.1- Before you start;

6.2- Check Splined Shaft Dimensions and Tolerances

Splined Shaft Dimensions

17.5 W35x2x30x16x8f ø40

Type Drum Connection Flange Dimensions

V273 +0.03 +0.2 0 30°

+0.03 +0.2 0 30°

V473 +0.03 +0.2 0 30°

V573 +0.03 +0.2 0 30°