PGR PA-PF Series User manual

PA-PF / PD-PM / PKD / PSH SERIESHelcal Gear UntsParallel Shaft Mounted Gear UntsHelcal Bevel Gear UntsHelcal Worm Gear UntsGEAR UNIT WITH MOTORS / WITHOUT MOTORSENMAINTENANCE AND OPERATION INSTRUCTIONSCertf cate No: KY3723/05/10-R151Doc. No: PG.AG.KK.006_01Publcaton DateRev. / : 09.2021 / 04.2019TSE K 558

The copyrghts of the usage Mantenance nstructon are belong to PGR company. Usage gude could not be used partally or fully wthout our permsson to the purpose of competton and not submtted to the use of thrd partes.The rght of changng nformatons whch stated n the usage mantenance nstructon partally or fully wthout gvng any notce before or rght of full changng and abolshment are kept reserved by us.

CONTENTSwww.pgr.com.tr < 01PRODUCT DESCRIPTION2. UNITGear Unt LabelExplanatonsAbbrevatons2.12.22.32021 - 2425 - 28ASSEMBLY INSTRUCTIONS; PREPARATION, INSTALLATION3. UNITPrerequstes of AssemblyGear Unt MountngBolt Tghtenng Torque ValueGear Unt VentlatonRetrospectve PantworkThe Operatng of the Automatc Lubrcatng SensorThe Mountage of the Connecton Tool to the Output ShaftThe Mountage of the CouplngsThe Mountage of the Standard B5 Motor to the IEC Gear UntThe Mountage of the Standard B5 Motor to the PAM Gear UntThe Demountage of the Electrcal Motor (IEC, PAM)Gear Unt Operatng3.13.23.33.43.53.63.73.83.93.103.113.1229303131323232 - 333333343434CONTROL AND MAINTENANCE4. UNITControl and Perodc MantenanceVsual InspectonCheck for Runnng NosesControl of the Lubrcant and Lubrcant LevelAddtonal Lubrcaton Wth GreaseChangng the OlOl Plugs Squeezng Torc ChartChange of the Ventlaton PlugChange of the Ol Seal and Ol CoverThe Bearng GreasesThe Changng of the Automatc Lubrcatng SensorGeneral OverhaulThe Mantenance of the Motor4.14.24.34.44.54.64.74.84.94.104.114.124.13353636363636 - 3737373738383838GENERAL INFORMATION1. UNITImportant WarnngsGeneral InformatonCorrect UseSafety InformatonResponsbltyTransportatonTransportaton and FreghtagePackage TransportatonEqupment TransportatonTransport of GearboxesStorageLong Term Storage Suggestons1.11.21.31.41.51.61.6.11.6.21.6.31.6.41.71.7.1566677 - 187789 - 181919

5. UNITMOUNTING POSITIONSAddtonal Ol Volume and Ol Tank for the M4 Mountage PostonMountng PostonsTermnal Box and Cable Entrance Sdes5.15.25.339 - 4041 - 5845 - 59LUBRICATION6. UNITLubrcatonLubrcant Fll QuanttesLubrcaton Table6.16.26.36060 - 6768ACCESSORIES7. UNITShrnk Dsc (PD / PM, PKD, PSH)Mountng Poston of the Shrnk Dsc (PD / PM, PKD, PSH)Demountng Poston of the Shrnk Dsc (PD / PM, PKD, PSH)Cleanng of the Shrnk Dsc (PD / PM, PKD, PSH)The Mountng of the Protecton Caps (PD / PM, PKD, PSH)Fxng Kt (PD, PKD, PSH)Assemblng of the Fxng Kt (PD, PKD, PSH)Dsassemblng of the Fxng Kt (PD, PKD, PSH)Torque Arm and Torque Arm Platform (PKD, PSH)Rubber Buffer (PD / PM)The Rubber Wedge Mountng Row (PD / PM)The Rubber Wedge Demountng Row (PD / PM)BackstopAr - Ol Cooled (PA / PF, PD / PM, PKD)Water Cooled (PD / PM, PKD)7.17.1.17.1.27.1.37.27.37.3.17.3.27.47.57.5.17.5.27.67.77.8696970707071 - 73737374 - 757676767677 - 7878 - 79THE ELECTRICAL MOTOR AND BRAKE CONNECTION8. UNITThe Electrcal Motor And Brake ConnectonThe Electrcal Motor Connecton SchemaStandard Type Brake Anchorage Schema8.18.28.3808182TROUBLESHOOTING9. UNITProduct DsposalDsposalTroubleshootng9.19.1.19.2838384 - 87AUTHORIZED SERVICE10. UNITAuthorzed Servce10.188CONTACT INFORMATION11. UNITContact Informaton12.189CONTENTSwww.pgr.com.tr 02 >

CONTENTSwww.pgr.com.tr < 039 - 1415 - 16171820313232333439404041 - 4447 - 5053 - 5557 - 58697071747475757676777777788182Fgure 14: Mountng Postons (PA / PF)Fgure 15: Mountng Postons (PD / PM)Fgure 16: Mountng Postons (PKD)Fgure 17: Mountng Postons (PSH)Fgure 18: Shrnk Dsc (PD / PM, PKD, PSH)Fgure 19: Protecton Cover (PD / PM, PKD, PSH) Fgure 21: PKDTorque Arm ()Fgure 20: Fxng Kt (PD, PKD, PSH)Fgure 22: (PKD)Torque Arm PlatformFgure 23: (PKD)Torque Arm PlatformFgure 24: PSHTorque Arm ()Fgure 25: (PD / PM)Rubber Buffer Fgure 26: Rubber Buffer (PD / PM)RenforcedFgure 27: Cooled (Ar-Ol) PA / PFFgure 28: Cooled (Ar-Ol) PD / PMFgure 29: Cooled (Ar-Ol) PKDFgure 30: Cooled (Radator)Fgure 31: The Electrcal Motor Connecton SchemaFgure 32: Standard Type Brake Anchorage SchemaFgure 2 : Transport of Gearboxes (PD / PM)Fgure 3 : Transport of Gearboxes (PKD)Fgure 4 : Transport of Gearboxes (PSH)Fgure 5 : Gearbox Nameplate and ExplanatonFgure 6 : Actvaton of Vent PlugFgure 7 : The Automatc Lubrcatng SensorFgure 8 : The Mountage of the Connecton Tool to the Output ShaftFgure 9 : The Mountage of the CouplngFgure 10: The Demountage of the Electrcal Motor (IEC, PAM)Fgure 11: The Ol Level Tank and Ol Level Control (PA / PF)Fgure 12: The Ol Level Tank and Ol Level Control (PD / PM)Fgure 1 : Transport of Gearboxes (PA / PF)Fgure 13: The Ol Level Tank and Ol Level Control (PKD)Lst of llustratons

www.pgr.com.tr 04 >CONTENTSLst of tablesTable 14: Termnal Box and Cable Entrance Sdes (PF)Table 15: Termnal Box and Cable Entrance Sdes (PD)Table 16: Termnal Box and Cable Entrance Sdes (PM)Table 17: Termnal Box and Cable Entrance Sdes (PKD)Table 18: Termnal Box and Cable Entrance Sdes (PSH)TableLubrcant Fll Quanttes (PA) 19: TableLubrcant Fll Quanttes (PF) 20: TableLubrcant Fll Quanttes (PD / PM) 21: TableLubrcant Fll Quanttes (PKD) 22: TableLubrcant Fll Quanttes (PSH) 23: Table 24: Lubrcaton Table Table 25: Lubrcaton Schedule Whle Cleanng of Shrnk DscTable 2 : Product Descrpton (PA / PF)Table 3 : Product Descrpton ()PD / PMTable 4 : Product Descrpton ()PKDTable 5 : Product Descrpton () PSHTable 6 : Abbrevatons (PA / PF)Table 7 : Abbrevatons (PD / PM)Table 8 : Abbrevatons (PKD)Table 9 : Abbrevatons (PSH)Table 10: Bolt Tghtenng MomentsTable 11: Control and Perodc Mantenance Ranges - WorksTable 12: Ol Plugs Squeezng Torc ChartTable 1 : Safety Alerts and Informaton Sgns Table 13: Termnal Box and Cable Entrance Sdes (PA)Table 30: Table Shows that Sutablty of Water Coolng for Whch Mountng Postons (PD / PM)Table 26: Fxng Kt Dmensons (PD)Table 31: Table Shows that Sutablty of Water Coolng for Whch Mountng Postons (PKD)Table 27: Fxng Kt Dmensons (PKD - DA)Table 32: Dsposal TableTable 28: Fxng Kt Dmensons (PKD - DG)Table 33: TroubleshootngTable 29: Fxng Kt Dmensons (PSH - DG)Table 34: Authorzed Servce5212223242526272831353745465152565960 - 6161 - 6263 - 6465 - 666768707273797172798384 - 8788

Important WarnngsTake nto consderaton the lsted safety warnngs and nformaton sgns below!1.1NOTE !Advces and necessary nformatons for the userDANGER !Harmful poston and possble resultDamage n gear unt and envronmentDANGER OF ELECTRICITY !Danger of electrcal shock and possble resultDeath and heavy woundngsDANGER !Danger possble resultDeath and heavy woundngsATTENTION !Dangerous poston and possble resultSlght and unmportant woundngsTable 1: Safety Alerts and Informaton Sgns GENERAL INFORMATION1. UNITwww.pgr.com.tr < 05

1. 21.31.4General InformatonThs user gude s prepared by our frm to provde nformaton about safety transportaton of gear unt/gear unt wth motors, storage, nstallon/ mountng, connecton, operatng, mantenance and repar processes. All the purchase andtechncal datas are postonedat productcatalogu es. Besde eng neerng applca tons, the nformatons whch placed n ths nstructon, should be well read and applcated. The documents must be protected and to get ready for controllng by authorzed person. The nformaton about electrcal motor could be found by gudance whch prepared by motor- producng frm.Correct UsePGR The products are desgned to use n commercal plants and are operated convenentto the current standards and drectons. Techncal datas and allowed usage condtons are placed n product's power tab and usage gudance. Should be conformed to all the values.Ths usage gudance s prepared by our firm accordng to 2006/42/EC The European Unon Machnery SafetyInstructons and s not be n placed 2014/34/EU ''The drecton about tools used n possble explosve envronment and protectve systems''.Safety InformatonIn gear unts/ gear unts wth motors and motors, there could be peces subjected to voltage, movable peces and hot areas. Durng all the works to be done; transportaton, storage, placng, mountage, connecton, operatng, mantenance -repar processes could be mplemented by qualfied employees and responsble managers.All the processes to be mplemented durng the workng perod;● Related usage and mantenance nstructons,● Warnng and Safety Tags n gear unt/gear unt wth motor,● Instructons and Requrements related to the system,● Local and Internatonal requrements for safety and accdental protecton.Our Frm s not responsble where the lsted tems are mplemented below:● Volaton of work health and safety rules n gear unt /gear unt wth motors,● Improper usage (The usage whch stated out of bounds n gudance and all the usages except tag/catalogue values especally usage n hgh moment and dfferent cycle) and msmountng and msusage of gear unt/ gear unt wth motor n plant,● Extremely drty and mantenance free of gear unt/gear unt wth motor,● ,Unlubrcated usage● ,Usage of product other than out of tag/catalogue values● ,Wrong motor selecton● ,Take out of the necessary protectve plugs ● ,Dsuse of orgnal peces n gear unt/gear unt wth motor● The usng, mountng, mantanng and takng place of the uneducated, unauthorzed and unqualfied 3. persons.GENERAL INFORMATION1. UNITwww.pgr.com.tr 06 >

1.5 1.6.21.6 1.6.1TransportatonTransportaton and Freghtage;● Take nto consderaton of the artcle stated on package durng the product delvery.● Durng the delvery, product should be controlled about possble damages n carryng perod.● The firm should be nformed about possble damages.● The damaged products should not be put nto use.● Lftng flanged eyebolts must be tghtened.These flanged eyebolts szed to carry the weght of only gear unt/ gear unt wth motor. The addtonal weght should not be added. The flanged eyebolts must be sutable to the DIN 580 norm. ● If there are 2 lftng flanged eyebolts n gear unt wth motor, both of them could be used n carryng process upon the sze of gear unt and motor. In necessary stuatons, the sutable and adequated-sze carrer should be used.● Carryng safetes should be removed before the start of operatng.● The weghts of the movable gear unts/gear unts wth motors are placed n product catalogues.● The dangerous area should be got nto the secure to prevent damage to the persons. ● Durng the carryng process, to stand under the gear unt could cause danger of death.● The damage of gear unt must be prevented. The crushes to the free nput shafts could damaged nto the gear unt.Package Transportaton;● There could be no loads on packages or the shelved surfaces should be prepared.● The necessary carryng equpments should be prepared. ● The carryng and lftng equpments should be larged- enough to the sufficent capacty. ● The calculatons should be made to the connecton ponts and center of gravty. ● If necessary, ths nformaton should be wrtten on the package. ● The carryng equpments (steel rope, belt, chan etc.) must be robust and sutable to the appled weght.● Durng the carryng process, the load centerng could be done wthout oscllaton.The configuratons provded n the catalogue of the unt are the only ones allowed. Do not use the product n contrastwth the ndcatons provded n t. The nstructons provded n ths manual do not replace but compensate the oblgatons of current laws concernng safety regulatons.ATTENTION !ResponsbltyPGR, declnes any responsblty n case of: Use of the reducer not complant wth natonal laws on safety and accdent preventon,● Work done by unqualfied personnel,● Incorrect nstallaton,● Tamperng wth the product,● Incorrect or falure to follow the nstructons n the manual,● Incorrect or falure to follow the ndcatons marked on the dentficaton labels fixed on the unts,● For motor gearboxes, wrong delvery of electrcal power,● Incorrect connectons and/or use of temperature sensors (when present),● Use of gearbox under unlubrcated condtons,● ●The contents of ths manual were revewed to ensure consstency wth the catalogues and etc. documents. We cannotguarantee full consstencysnce the changes cannot be completely prevented. However, the nformatons n ths manual are revewed regularly and necessary revsons are made n next edtons.The products suppled by PGR are ntended to be ncorporated nto "complete machnes", so t s prohbted to put them nto servce untl the entre machne has not been declared complant.GENERAL INFORMATION1. UNITwww.pgr.com.tr < 07

Equpment Transportaton;● The connecton carryng pont should be apponted.● The carryng equpments (hook, chan, belt) must be prepared.To the alternatve, pallet must be used for the load- lftng.● If the Crane wll be used, t could be lfted perpendcular from nsde to the outsde of the package.● If the forklft or palletzed carryng equpment wll be used, the product whch removed from package should be placed on the pallet. ● The fork of the equpment should be carred out the way that grpped the pallet.● The weght must be lfted both wth slowly and constant speed and must take measure to the sudden oscllaton.1..3 6X
Durng the carryng process, the fixngs lke the lftng lug, hook, belt, rope, locked hook must be sufficent to the load and have conformty certficate.The weghts of the movable gear unt/gear unt wth motor have gven n product cataloque.ATTENTION !In all carryng processes, there should be avoded from both sudden movements and sudden lftngs.NOTE !If the connecton tool s couplng between electrc motor and gear unt, lftng eyebolt should not be used.ATTENTION !GENERAL INFORMATION1. UNITwww.pgr.com.tr 08 >

www.pgr.com.tr < 09Transport of Gearboxes; 1..4 6Fgure 1: Transport of Gearboxes (PA / PF)SINGLE STAGEGENERAL INFORMATION1. UNITIEC / WMOTOR / PAMPAAABAABABAABA
15°15°
MAX
Screw hookLoad hookHoop equpped (swab)AHoop equpped (chan)BLocked hookLftng eyebolts Manuel lftng (Weght ≤ 15 kg) (ref. ILO Contract)Not vald for the contnuous carryng.The allowable maxmum slope s 15 degree.

www.pgr.com.tr 10 >SINGLE STAGEGENERAL INFORMATION1. UNITIEC / WABAAABMOTOR / PAMPFAABAAB
MAX
15°15°
Screw hookLoad hookHoop equpped (swab)AHoop equpped (chan)BLocked hookLftng eyebolts Manuel lftng (Weght ≤ 15 kg) (ref. ILO Contract)Not vald for the contnuous carryng.The allowable maxmum slope s 15 degree.

www.pgr.com.tr < 11DOUBLE STAGEGENERAL INFORMATION1. UNITABAABAMOTOR / PAMPAABAABAIEC / W
MAX
15°15°
Screw hookLoad hookHoop equpped (swab)AHoop equpped (chan)BLocked hookLftng eyebolts Manuel lftng (Weght ≤ 15 kg) (ref. ILO Contract)Not vald for the contnuous carryng.The allowable maxmum slope s 15 degree.

www.pgr.com.tr 12 >DOUBLE STAGEGENERAL INFORMATION1. UNITABAAABIEC / WMOTOR / PAMPFAABAAB
MAX
15°15°
Screw hookLoad hookHoop equpped (swab)AHoop equpped (chan)BLocked hookLftng eyebolts Manuel lftng (Weght ≤ 15 kg) (ref. ILO Contract)Not vald for the contnuous carryng.The allowable maxmum slope s 15 degree.

www.pgr.com.tr < 13TRIPLE STAGEGENERAL INFORMATION1. UNITMOTOR / PAMPAABAABAIEC / WAAABAB
MAX
15°15°
Screw hookLoad hookHoop equpped (swab)AHoop equpped (chan)BLocked hookLftng eyebolts Manuel lftng (Weght ≤ 15 kg) (ref. ILO Contract)Not vald for the contnuous carryng.The allowable maxmum slope s 15 degree.

www.pgr.com.tr 14 >TRIPLE STAGEGENERAL INFORMATION1. UNITAABABAIEC / WMOTOR / PAMPFABAABA
MAX
15°15°
Screw hookLoad hookHoop equpped (swab)AHoop equpped (chan)BLocked hookLftng eyebolts Manuel lftng (Weght ≤ 15 kg) (ref. ILO Contract)Not vald for the contnuous carryng.The allowable maxmum slope s 15 degree.

www.pgr.com.tr < 15GENERAL INFORMATION1. UNITFgure 2: Transport of Gearboxes (PD / PM)DOUBLE STAGETRIPLE STAGE
MAX
15°15°
AHoop equpped (swab)Load hookScrew hookLocked hookHoop equpped (chan)BManuel lftng (Weght ≤ 15 kg) (ref. ILO Contract)Not vald for the contnuous carryng.The allowable maxmum slope s 15 degree.IEC / WABABAMOTOR / PAMPDABABAAA

www.pgr.com.tr 16 >GENERAL INFORMATION1. UNITDOUBLE STAGETRIPLE STAGE
15°
MAX
15°
AHoop equpped (swab)Load hookScrew hookLocked hookHoop equpped (chan)BManuel lftng (Weght ≤ 15 kg) (ref. ILO Contract)Not vald for the contnuous carryng.The allowable maxmum slope s 15 degree.MOTOR / PAMPMIEC / WABABABABAAAA

www.pgr.com.tr < 17Fgure 3: Transport of Gearboxes (PKD)GENERAL INFORMATION1. UNITMOTOR / PAM / IEC / WPKD - DGMOTOR / PAM / IEC / WPKD - DABABABABABABABABA
MAX
15°15°
AHoop equpped (swab)Load hookScrew hookLocked hookHoop equpped (chan)BManuel lftng (Weght ≤ 15 kg) (ref. ILO Contract)Not vald for the contnuous carryng.The allowable maxmum slope s 15 degree.

www.pgr.com.tr 18 >Fgure 4: Transport of Gearboxes (PSH)GENERAL INFORMATION1. UNITMOTOR / PAM / IEC / WPSH - DGMOTOR / PAM / IEC / WPSH - DABABABABABABABABA
MAX
15°15°
AHoop equpped (swab)Load hookScrew hookLocked hookHoop equpped (chan)BManuel lftng (Weght ≤ 15 kg) (ref. ILO Contract)Not vald for the contnuous carryng.The allowable maxmum slope s 15 degree.