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
www.pgr.com.tr < 01
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

www.pgr.com.tr
02 >
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

www.pgr.com.tr < 03
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

www.pgr.com.tr
04 >
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

www.pgr.com.tr < 05
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.

www.pgr.com.tr
06 >
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

www.pgr.com.tr < 07
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 !

www.pgr.com.tr
08 >
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