PGR PCS Series User manual

ENMAINTENANCE AND OPERATION INSTRUCTIONS
PCS SERIES
Crane Gear Unts
GEAR UNIT WITH MOTORS / WITHOUT MOTORS
ATEX
Certf cate No: KY3723/05/10-R15
1
Doc. No: PG.AG.KK.008_01
Publcaton Date 0 3 8Rev. / : 6.202 / 0 .2019 TSE 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.

CONTENTS
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GENERAL INFORMATION
1. UNIT
PRODUCT DESCRIPTION
2. UNIT
ASSEMBLY INSTRUCTIONS; PREPARATION, INSTALLATION
3. UNIT
CONTROL AND MAINTENANCE
4. UNIT
Important Warnngs
General Informaton
Correct Use
Safety Informaton
Responsblty
Transportaton
Transportaton and Freghtage
Package Transportaton
Equpment Transportaton
Transport of Gearboxes
Storage
Long Term Storage Suggestons
1.1
1.2
1.3
1.4
1.5
1.6
1.6.1
1.6.2
1.6.3
1.6.4
1.7
1.7.1
5
7
7
8
9
9 - 11
9
10
10
11
12
13
Gear Unt Label
Compatblty Declaraton
Explanatons
2.1
2.2
2.3
14
14
15
Control and Perodc Mantenance
Vsual Inspecton
Check for Runnng Noses
Control of the Lubrcant and Lubrcant Level
Changng the Ol
Ol Plugs Squeezng Torc Chart
Change of the Ventlaton Plug
Temperature Measurement
Checkng the Gear Unt
Checklst
Change of the Ol Seal and Ol Cover
The Bearng Greases
General Overhaul
The Mantenance of the Motor
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.9.1
4.10
4.11
4.12
4.13
27 - 28
29
29
29
30
30
30
31
32
32
32
33
33
33
16 - 18
18 - 20
20
21
21
22
22
23
23
24
24 - 26
3.1
3.2
3.3
3.4
3.5
3.5.1
3.6
3.7
3.8
3.9
3.10
Prerequstes of Assembly
Gear Unt Mountng
Bolt Tghtenng Torque Value
Gear Unt Ventlaton
Temperature Stcker
Vsual Inspecton of the Temperature Stcker
The Mountage of the Connecton Tool to the Output Shaft
The Mountage of the Couplngs
The Mountage of the Standard B5 Motor to the PAM Gear Unt
The Demountage of the Electrcal Motor (PAM)
Gear Unt Operatng

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CONTENTS
Mountng Postons
Termnal Box and Cable Entrance Sdes
Drectons of Manual Arm
5.1
5.2
5.3
34
35
36
Lubrcaton
Lubrcant Fll Quanttes
Lubrcaton Table
6.1
6.2
6.3
37
37
38
Sliding Shaft (DIN 5480) Connection Dimensions and Tolerances
Drum Connecton Flange
Backstop
7.1
7.2
7.3
39
40 - 41
41
5. UNIT MOUNTING POSITIONS
LUBRICATION
6. UNIT
ACCESSORIES
7. UNIT
Product Dsposal
Dsposal
Troubleshootng
8.1
8.1.1
8.2
42
42
43 - 46
Authorzed Servce
9.1 47
Declaraton of Conformty
ATEX Document
10.1
10.2
48
49
TROUBLESHOOTING
8. UNIT
AUTHORIZED SERVICE
9. UNIT
Contact Informaton
11.1 50
CONTACT INFORMATION
11. UNIT
10. UNIT WARRANTY

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CONTENTS
Fgure 2 : Gearbox Nameplate and Explanaton
Fgure 3 : Actvaton of Vent Plug
Fgure 11: Mountng Postons
Fgure 12: Sliding Shaft (DIN 5480) Connection Dimensions and Tolerances
Fgure 1 : Transport of Gearboxes 11
14
21
21
22
23
23
24
26
31
34
39
Fgure 4 : Temperature Stcker 1
Fgure 5 : The Mountage of the Connecton Tool to the Output Shaft
Fgure 6 : The Mountage of the Couplng
Fgure 7 : The Mountage of the Standard B5 Motor to the PAM Gear Unt
Fgure 8 : The Demountage of the Electrcal Motor (PAM)
Fgure 9 : PTC Probe
Fgure 10: Temperature Stcker 2
Lst of llustratons

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CONTENTS
5
6
15
20
27
30
35
36
37
38
39
40 - 41
45
32
46 - 49
50
Table 12: Sliding Shaft (DIN 5480) Connection Dimensions and Tolerances
Table 1 : Safety Alerts and Informaton Sgns
Lst of tables
Table 14: Dsposal Table
Table 15: Troubleshootng
Table 16: Authorzed Servce
Table 2 : General Warnngs
Table 3 : Product Descrpton
Table 4 : Bolt Tghtenng Moments
Table 5 : Control and Perodc Mantenance Board
Table 6 : Ol Plugs Squeezng Torc Chart
Table 7 : Checklst
Table 8 : Termnal Box and Cable Entrance Sdes
Table 9 : Drectons of Manual Arm
Table 10: Lubrcant Fll Quanttes
Table 11: Lubrcaton Table
Table 13: Dmensons of Drum Connecton Flange and Tolerances

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GENERAL INFORMATION 1. UNIT
1.1 Important Warnngs
Take nto consderaton the lsted safety warnngs and nformaton sgns below!
Table 1: Safety Alerts and Informaton Sgns
EXPLOSION !
Indcates an mmedate danger, whch may result n death or serous njury.
Contans mportant nformaton regardng exploson protecton.
NOTE !
Advce and useful nformaton for the user
Ths ndcates that property damage may occur f proper precautons
are not taken.
DANGER !
Harmful stuaton and possble outcome
Damage occurs n the reducers and the envronment.
If proper precautions are not taken, serious damage on the gearbox may
occur, death or serious personal injury will result.
DANGER OF ELECTRICITY !
Electrcal shock hazard and possble outcome
Death and serous njures
DANGER !
Danger and possble outcome
Death and serous njures
ATTENTION !
Dangerous stuaton and possble outcome
Mld or major/mnor njures
Ths ndcates that mnor personal njury may occur f proper
precautons are not taken.

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GENERAL INFORMATION1. UNIT
ISO ANSI WARNINGS
---
---
---
Warnng - Dangerous Electrcal Voltage
Warnng - Explosves
Warnng - Jammng Hazard
Warnng - Hot Surfaces
Warnng - Irrtant or Harmful Substances
--- Warnng - Corrosve Substance Hazard
--- Warnng - Suspended Load
--- Warnng - Hand Injures
ATEX Certficate
Table 2: General Warnngs

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GENERAL INFORMATION 1. UNIT
1.2 General Informaton
Th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 and techncal datas are postoned at product catalogu 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.
In case of loss of usage gude or becomng n unusable poston t could be redemanded from PGR.
All the nformatons those boxes nclude would only state proper goods to the nstructon of
ATEX 2014/34/EU.
Processes whch related to these regulatons should only be made by personnel (qualfied)
who has expertse regardng securty n the fields that has the probablty of beng exploded.
EXPLOSION !
Correct Use1.3
These gear unts generate a rotatonal movement and are ntended for use n commercal systems. They satsfy
the exploson protecton requrements of Drectve 2014/34/EU for the product category ndcated on the type
plate. No mxture from categores IID and IIG may be present durng operaton. The ATEX approval s vod n
case of a hybrd mxture.
Commssonng (start of proper operaton) s prohbted untl t has been establshed that the machne comples
wth the local laws and drectves. The EMC Drectve and the Machnery Drectve 2006/42/EC n 2014 /30/EU
ther currently vald scope of applcaton must be compled wth n partcular.
Only components whch comply wth the applcable regulatons of Drectve 2014/34/EU may
be fitted and operated.
Observe the Declaraton of Conformty and all safety nformaton for the components.
EXPLOSION !
Danger to persons:
Approprate safety measures must be taken n the case of applcatons n whch falure of a
gear unt or geared motor may cause a hazard to persons.
Safeguard a wde area around the hazard zone.
DANGER !

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1. 4 Safety Informaton
Safety nformaton
In 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fed employees and responsble
managers.
All the processes to be mplemented durng the workng perod;
● Related Use and Mantenance Instructons / catalog data of the relevant product,
● 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,
● Dsassembly of gearbox should only be made by authorzed personnels.
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,
● Addtonal dangers that could be generated durng power cut can be prevented by materals such as brake/
key.
GENERAL INFORMATION1. UNIT
Exploson hazard: Falure to comply may cause severe, or even fatal njures.
All work, e.g. transportaton, storage, nstallaton, electrcal connecton, commssonng,
servcng and mantenance must be performed n a non-explosve atmosphere.
EXPLOSION !
In envronments wth potentally explosve atmospheres, only ATEX unts are allowed, after
verfyng ther certficaton lmts. In case of non-ATEX unts, or ATEX unts wth certficaton
non-complant wth envronmental condtons, t s compulsory to dsconnect the unt power
supply. Adopt all the necessary measures of envronmental safety.
EXPLOSION !
1. 4

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GENERAL INFORMATION 1. UNIT
1.5
Only the configuratons found n the product catalog are allowed. Do not use the product
contrary to the ndcatons gven n the product. The nstructons gven n ths manual do
not replace the oblgatons of current laws regardng safety regulatons and do not
compensate for any damages.
DANGER !
Responsblty
PGR accepts no lablty f the followng occurs:
● Use of reducers that do not comply wth natonal laws on safety and accdent preventon,
● Work done by unqualfied personnel,
● Wrong nstallaton,
● Tamperng wth the product (makng changes),
● It does not accept any lablty for non-observance or naccuracy of the nstructons n the manual, for
damage or malfunctons resultng from non-observance of these operatng nstructons.
● To follow the sgns ndcated on the product labels of the reducers ncorrectly or napproprately,
● Wrong electrcal energy for geared motor reducers,
● Incorrect connectons and/or use of temperature sensors (f any),
● Ol-free use of the reducer,
● The content of ths gude has been revewed to ensure consstency wth the documents such as catalog etc.
We cannot guarantee full consstency, as dynamc requred by the system cannot be completely blocked.
However, the nformaton n ths manual s regularly revewed and correctons are made n subsequent
edtons.
Snce products suppled by PGR are desgned to be ncluded n "complete machnes", commssonng them s
prohbted untl the full machne has been declared compatble.
Restartng the reducer:
When nstallng the reducer on machnes or systems, the machne or system manufacturers must ensure that
the regulatons, notes and descrptons contaned n ths operatng manual are ncluded n ther operatng
manual.
1.6
1.6.1
Transportaton
Transportat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.

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GENERAL INFORMATION1. UNIT
1.6.2
1.6.3
X
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.
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.
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 !

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GENERAL INFORMATION 1. UNIT
Transport of Gearboxes;
Fgure 1: Transport of Gearboxes
1.6.4
PCS 1-3-5-10-20 PCS 25-40-50-60 PCS 25-40-50-60
AA
B
A
PCS
Screw hook
Load hook
Hoop equpped (swab)
A
Hoop equpped (chan)
B
Locked hook
Lftng eyebolts
Manuel lftng (Weght ≤ 15 kg)
(ref. ILO Contract)
Not vald for the contnuous carryng.

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1.7
GENERAL INFORMATION1. UNIT
Storage
The certan suggestons have gven about the storage condtons of the gear unt/gear unt wth motor below;
● In clear and most-ars, the storage should not be made.
The gear unt/gear unts wth motor should not drectly be contacted to the ground.●
The place must be moveless where the both gear unt/gear unts wth motors are contacted. Otherwse there ●
could be damage durng the movement.
The gear unt should be got nto the secure to the fallng.●
The processed surfaces of the gear unts and both sold and hollow shafts must be lubrcated wth protectve ●
ol.
Gear unt/Gear unts wth motors must be n the place where there wll be no bg temperature dfferences ●
between and +40 .-5°C °C
Relatve humdty must be less than %60.●
Not drectly be exposed to sunlght and nfraded lght.●
Must be kept away from the abrasve materals whch causes corroson (drty weather, o zon, gases, solvents,●
acds, salts, radoactvty, etc.) n envronment.
The protectve ol SHELL ENSIS or smlar product should be used on the corrodble peces.●
If the gear unt s wthout ol, t must be filled wth lubrcaton ol.●
Gearboxes durng storage;
Provde protecton of unpanted and processed areas by lubrcant. In case of areas gettng
rusted, ATEX certficate wll be no longer vald.
EXPLOSION !
These processes should be made far away from explosve atmosphere.
If there s an unproper ol nsde of gearbox to operate, ths ol must be dscharged and be
cleaned.
EXPLOSION !
SECURITY MEASURES !
Precautons to be taken when returnng the gear unt to servce after storage:
The surfaces be output shafts and external must thoroughly cleaned of all rustproofing
product, contamnants and other mpurtes (use a standard commercal solvent).
Do ths outsde the area. must seal exploson hazard The solvent not touch the rngs as
ths may damage them, causng them to leak.
If the ol or protectve materal used durng storage s not compatble wth the synthetc ol
used durng the machne's operaton, the unt nteror of the must be thoroughly cleaned
before fillng wth the operatng ol.
The servce lfe of the bearng grease s reduced f the unt s stored for more than 1 year.
The bearng grease must be synthetc.

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GENERAL INFORMATION 1. UNIT
1.7.1 Long Term Storage Suggestons;
- The ncorrect and excessve long storage could cause the gearbox gettng defected.
- Please control not to exceed allowed storage perod before startng up the gearbox.
ATTENTION !
- PGR, recommends long-term storage opton for perods of more than 9 months holdng
and pausng tmes.
- By payng attenton both to the long-term storage opton and precautons whch lsted
below, the holdng of goods up to 2 years could be possble. Because of real efficency
of gearboxes dependng on local condtons wdely, these perods could be seen solely
gude values.
NOTE !
- In the long-term storage or durng the short-term storage, f the excessve temperature
dfferences occur, the ol n the gear unt must be changed before the operatng.
- In the fully ol filled gear unt, the ol level should be reduced accordng to the mountng
poston.
NOTE !
Long term storage suggestons;
● Mneral ol or synthetc ol accordng to mountng poston s filled of gettng avalable for operatng. Despte
ths, the ol level should be controlled before operatng.
The VCI Corroson protected tool are mxed nto the gear unt's ol.●
The carryng safety of the ventlaton plug must not be removed durng the storage. ●
The gear unt must be closed to the shape of unleaked.●

2.1
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PRODUCT DESCRIPTION2. UNIT
The nameplate specficatons regardng the maxmum surface temperature,
refer to readngs taken n normal ambent and nstallaton condtons.
Even mnmal varatons to sad condtons (e.g. smaller mountng cabnet)
may have a sgnficant effect on the unt s heat output.'
EXPLOSION !
2.2 Compatblty Declaraton
All gear unts or gearmotors (when suppled wth electrc motor) are desgned n complance wth the provsons
of applcable Essental Health and Safety Requrements, the Machnery Drectve EC and, f requested, " " 2006/42/
can be suppled wth a Manufacturer s Declaraton-Annex IIB as provded by sad Drectve.'
Gear Unt Label
The type plate must be firmly attached to the gear unt and must not be subjected to permanent solng. P lease
contact the PGR servce department f the type plate s llegble or damaged.
Exploson hazard: Falure to comply may cause severe, or even fatal njures.
It must be checked and ensured that the gear unt type, all techncal data and the ATEX
labellng conform to the plannng of the plant or the machne.
EXPLOSION !
Fgure 2: Gearbox Nameplate and Explanaton
Allowed Range for Surroundng Temperature
Seral Number
Output Torque (Nm)
Output Speed (rpm)
Axal Loads (kN)
Overhung Loads (kN)
Ol Brand Type
Quantty of Ol
Rated Motor Power
Engne (motor) Rpm
Engne (motor) Axal Force
Engne (motor) Radal Force
Type
Reducton Rato
Mountng Postons
Year Of Constructon
Shaft Dameter Would Be Wrtten
Servce Interval (h)
Instructons For Custom Manufacturng
L
kN
n1
EN 80079 - 36: 2016
EN 80079 - 37: 2016
II 2G Ex h IIC T4 Gb
II 2D Ex h IIIC T120°C Db
Ol
M2
n2
FA2
FR2
Nm
P.T.
-1
mn
FA1
FR1
kN
Qty
kW
İ
M.P.
-1
mn
kN
kN
Ta
IR2
MI
S
h
TypeType
S.NoS.No
°C°C
mmmm
Tel : [phone] - 16 (pbx)
Fax: [phone]
www.pgr.com.tr
Tel : [phone] - 16 (pbx)
Fax: [phone]
www.pgr.com.tr
Gearboxes that are sutable to 2014 /34 /EU nstructon; have ATEX label " "
whch s at the standard of EN ISO 80079-36:2016, EN ISO 80079-37:2016
and also proper to stated contents. An example s gven below:
EXPLOSION !
1. Group (Always II, quarres are not ncluded)
2. Category (for gas 2G-3G, for powder 2D-3D)
3. If firng protectve type (c) s put
4. Implementng explosve group (IIC, IIB)
5. Temperature Class (for gas T1-T3 or T4) or maxmum surface heat (for example for
powder 125 °C) or specfic maxmum surface heat, look at prvate documents. (TX)
6. Temperature measurement durng access to a plant. (X)
Markng accordng to ATEX (EN ISO 80079-36:2016, EN ISO 80079-37:2016):

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PRODUCT DESCRIPTION 2. UNIT
2.3 Explanatons
Table 3: Product Descrpton
Catalog : PCS
Page : 455 - 469
-
112 M / 4 BRE
: Reducton rato
ges
Catalog : PCS
Page : 21 - 446
95.40
Catalog : PCS
Page : 5
Other pole
combnatons
on request.
Number
of Poles
4
2 - 12
Motor
Accessores
71
80
90
100
112
132
160
180
PAM
PCS
S3 M1
AKUPLE PAM + Mt MOTOR
S1
S3
Engine
Working Class
M1
M3
M5
M6
Mountng
Poston
BRE
EF
EN
TF
TW
HR
ATEX
10
Housng
Sze
1
3
5
10
20
25
40
50
60
Housng
Sze
71 M
80 M
90 L
100 L
112 M
132 M
160 M/L
180 M
-
Type: Crane Gear Unts (PCS)

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3.1 Prerequstes of Assembly
Prerequstes of assembly:
Take nto the consderaton whch lsted below;
● The nformatons placed on gear unt wth motor n accordance wth current network voltage.
● There could be no damage n the gear unt.
● At standard gear unts; the ambent temperature should be fitted temperature values gven n the ''Lubrcant''
part.
ASSEMBLY INSTRUCTIONS;
PREPARATION, INSTALLATION
3. UNIT
Exploson hazard: Falure to comply may cause severe, or even fatal njures.
Care must be taken that drve elements attached to the gear unt, such as clutches, pulleys
etc. and drve motors are also ATEX-complant.
EXPLOSION !
The bearngs, gear wheels, shafts and housng may be damaged by ncorrect fittng.
● Observe the assembly nstructons.
● The push-on gear unt must be fitted onto the shaft usng a sutable puller, whch wll not
exert damagng axal forces on the gear unt. In partcular, do not ht the gear unt wth a
hammer.
EXPLOSION !
In applcatons where an ncorrect rotatonal drecton may result n damage or potental rsk, the correct
rotatonal drecton of the output shaft s to be establshed by test runnng the drve when uncoupled and
guaranteeng such for subsequent operaton.
Gears wth ntegrated return stops are marked wth arrows on the drve/drven sdes. The arrows pont n the
rotaton drecton of the gear unt. When connectng the motor and durng motor control, t must be ensured
that the gear unt can only operate n the drecton of rotaton.
For gear unts wth an ntegrated back stop, swtchng the drve motor to the blocked drecton
of rotaton, .e. ncorrect drecton of rotaton, may result n damage to the gear unt.
Take care that the drecton of rotaton of ar unt s correct the ge when connectng the motor
and the motor control unt.
NOTE !
EXPLOSION !
Before access to a plant, those belows should be controlled and be secured:
● Durng assembly of gearbox, whatever any exploson danger such as due to lubrcant,
acd, gas and steam radaton, could not be happened and there should not be pow der
accumulaton at gearbox more than 5 mm.
● Durng operatng process, gearbox should be put n a well-vented room and not to be
exposed n an effect of substantally heat radaton from outsde.
● Durng operatng process, the temperature of coolng ar should not exceed 40°C.
● Controllng of lubrcant and both dschargng plugs and valves must be easly accessble.
● Several other devces belong to gearbox, seperately from ther own functons should
have an ATEX Certficate. (Protectve electrcal workng substance aganst exploson)
● The settng of gearboxes whch have hollow shafts (even f there may be a frcton
preventer connecton or may not) should be made properly accordng to an nstructons
at ths hand gude.
● After set up process s completed, cleanng of gearbox would be requred.
● Please be sure that all parts expandng and shftng wth help of machne operator or all
operatng devces whch prevent unwanted contacts between gearbox gaskets, would be
operatveness.

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ASSEMBLY INSTRUCTIONS;
PREPARATION, INSTALLATION 3. UNIT
Please note that for geared motors (gear unts wth attached electrc motors) the electrc motor has ts own
type plate and separate ATEX desgnaton. The motor labellng must also comply wth data for the plannng of
the plant or the machne.
The lowest exploson protecton level on the gear unt and the motor labellng apples for the geared
motor unt.
If the electrc motor s drven wth a frequency nverter, the motor requres ATEX approval for nverter operaton.
If the motor s operated wth an nverter, sgnficant dfferences between the nomnal speeds on the type plates
of the motor and the gearbox are normal and permssble. For operaton of the motor wth the mans supply,
dfferences of the nomnal speeds on the motor and the gear unt of up to ± 60 rpm are permssble.
Exploson hazard: Falure to comply may cause severe or even fatal njures.
● The gear unt may only be operated n the stated verson.
● The permssble verson s stated on the type plate (IM…). If an X s present n the field IM,
the specal documentaton, whose number s n field S, must be observed. (Secton 4.1
" " page 27-28) or the specal documentaton, shows the Control and Perodc Mantenance
configuraton of the ndvdual types of gear unts.
● It must be checked and ensured that the configuraton as stated on the type plate comples
wth the nstallaton orentaton and that the nstallaton orentaton does not change durng
operaton.
Please heed the Operatng Instructons for the motor, n partcular wth regard to the
chosen verson.
EXPLOSION !
Gearboxes are ether dspatched wthout motor or motors by ATEX are assembled to a gearbox after gettng
suppled from electrcal motor manufacturer. Electrc connecton belongs to end user.
ealzed convenent to the ambent At specal applcatons the configuraton of gear unt/gear unt wth motor are r
condtons. Output shafts, processed surfaces, corroson preventve materal on the sold shaft /hallow shaft,
jerks etc. must be cleaned.
-solvent must be used. e bearng houses and sealng Extensve usage The solvent should not be contacted to th
components.
sealng components must be protected to the wearng In the abrasve ambent condtons, both output shaft,
Connecton flanges must be attached to the hollow shaft/sold shaft accordng to DIN 332.
ere the wrong drecton of rotaton could caused to damages and dangers, before the mountng,
The stuatons wh
the test work should mplemented to the gear
unt so the rght drecton of rotaton could be determned and
must got nto the secure for the next operatng.
In the one-way locked gear unts, nbs are placed at the entry and ext sde of the gear unt. The ends of the
nbs shows the drecton of rotaton of the gear unt. Durng the motor connecton and motor-operatng wth the
help of magnetc field, the gear unt must be operated just at the drecton of rotaton.
DANGER !
In the one -way locked gear unts, the gear unt must be operated at the drecton of lock
rotaton, otherwse the damage could be occured.
Around the mountng poston, there must be sured that there are not any materals fused to metal, lubrcatng
tool or elastomers whch causes corroson or wll not be emerged.
The Gear unt must not be mounted n the ambent condtons lsted below:
- Explosve atmosphere, hgh corrosve and / or ols, acds, gases, steams, radaton,
- Places drectly contacted to the food.
DANGER !

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ASSEMBLY INSTRUCTIONS;
PREPARATION, INSTALLATION
3. UNIT
In case of below actons that were taken, the ATEX Certficate wll be nvald.
● Dfferent usng other than label values based on the gearbox.
● Use n more dangerous area (explosve envronment) other than stated level at the
label of gearbox.
● Use of gearbox n the area whose equpment class s I. (quarres under dangerous
orgnated by fire-damp).
● Use of gearbox at dffrent forces apart from gotten one.
● Changng of assembly poston.
EXPLOSION !
Maxmum surface temperature states gotten measurements n normal setup and usage
condtons.
If the usage condtons of gearbox are dfferent from those, surface temperature could
up to hgher values.
In that case ol crculatng coolng unt must be used.
EXPLOSION !
The lftng eyebolts screwed to gear unt must be used n gear unt mountng.
● Mountng of gear unt/gear unt wth motor to the machne and selecton of mountng place are crucal.
● The convenent connecton ponts must be determned for gear unt type. ( oot mounted or Flange mounted)F
● Ventlaton plug must be opened after the carryng process.
● The connecton tools whch attached durng the mountng to the machne must be tghtened convenent to
the torc gven at the table.
● Because of the voltage, for to avod t ransferrng addtonal forces to the gear unt, both the gear unt and
drven machne shaft must be algned.
● There should not be any weldng process on the gear unt. In the weldng processes, the gear u ust not nt m
be used as a bracket. Otherwse bearng and gear part could damaged.
3.2 Gear Unt Mountng
Exploson hazard: Falure to comply may cause severe, or even fatal njures.
No explosve atmosphere must be present when nstallng the gear unt. ●
The coolng ar suppled to the gear unt/geared motor must be wthn the permssble ●
temperature range stated on the type plate.
In case of drect sunlght fallng onto the gear unt, the coolng ar suppled to the gear ●
unt/geared motor must be at least 10°C below the hghest permssble temperature of
the ambent temperature range Tu, whch s stated on the type plate.
EXPLOSION !
Danger of Burns:
The surfaces of gear unts or geared motors may become hot durng or shortly after
operaton.
Hot surfaces whch can be touched drectly must be protected wth a contact guard.
DANGER !
Damage to the gear unt due to overheatng.
DANGER !
Check that there is no radial or axial run-out of the coupling element between
the PAM and the output shaft.
ATTENTION !