PGR PH Series User manual

ATEX
ENMAINTENANCE AND OPERATION INSTRUCTIONS
PH / PB SERIES
Industral Type Gear Unts
GEAR UNIT WITH MOTORS / WITHOUT MOTORS
Certf cate No: KY3723/05/10-R15
1
Doc. No: PG.AG.KK.002_01
Publcaton DateRev. / : 06.2023 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.

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Important Warnngs
General Informaton
Correct Use
Safety Informaton
Qualfied Personnel
Specal Types of Hazards and Personal Protectve Equpment
Responsblty
Transportaton, Freghtage and Storage
Scope of Delvery
Freghtage
Connecton Ponts
Specal Condtons for Lubrcatng and Protectng the Reducer
Specal Condtons of Protecton of the Reducer
Transportaton
Transport of Gearboxes
Storage
Long Term Storage Suggestons
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.5
1.6
1.6.1
1.6.2
1.6.3
1.6.4
1.6.5
1.7
1.7.1
1.8
1.8.1
8 - 10
11
11
12
12
13 - 15
15
16 - 17
16
16 - 17
17
17
17
18 - 19
18 - 19
20
21
Output Shaft Versons
Housng
Reducer Equpment
Ol Supply to Reducer
Splashed Lubrcaton
Pressure Lubrcaton
Pump
Ol Flter
Bearng Arrangement of Shafts
Seals
Rotary Shaft Seals
Labyrnth Seal
Taconte Seals
Tacolab Seal
Backstop
Torque Lmter Backstop (Specal Verson)
Coolng
Fan
Cooler Col
Mounted Ol Supply System
Ol Supply System Mounted wth Ar-Ol Cooler
Ol Supply System Mounted wth Water-Ol Cooler
Pump
Ol Flter
External Ol Supply System
Couplngs
Shrnk Dsc
Heatng
Ol Level Indcator
3.1
3.2
3.2.1
3.3
3.3.1
3.3.2
3.3.2.1
3.3.2.2
3.4
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.6
3.7
3.8
3.8.1
3.8.2
3.8.3
3.8.3.1
3.8.3.2
3.8.3.3
3.8.3.4
3.8.4
3.9
3.10
3.11
3.12
27
27
28 - 29
29
29
30 - 31
31
31
31
31
31 - 32
32
32 - 34
34 - 35
35
36
37
37
38
39
39 - 40
40 - 41
41
41
42
42
42
42 - 44
44
Gear Unt Label
Compatblty Declaraton
Explanatons
Abbrevatons
2.1
2.2
2.3
2.4
22
22
23 - 25
26
PRODUCT DESCRIPTION
2. UNIT
GENERAL INFORMATION
1. UNIT
TECHNICAL INFORMATION AND ACCESSORIES
3. UNIT
CONTENTS

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Ol Level Indcator System
Ol Temperature Indcator
Bearng Indcator
Bearng Control Usng Pt 100 Resstance Thermometer
Bearng Montorng wth Shock Impact Converter
Bearng Montorng wth Speed Sensor
Encoder
Auxlary Drve Reducer
Auxlary Drve Reducer Desgned as Mantenance Gear Reducer
Auxlary Drve Reducer Desgned as a Load Reducer
3.13
3.14
3.15
3.15.1
3.15.2
3.15.3
3.16
3.17
3.17.1
3.17.2
44
45
46
46
46
47
47
47 - 48
48 - 49
49 - 50
Assembly
Prerequstes of Assembly
General Assembly Instructons
Unpackng the Reducer
Installaton of Reducer
Foundaton
Descrpton of Assembly Work
Algnment
Reducer Mountng on Housng Foot
Installaton on Foundaton Housng
Installaton on Concrete Foundaton Usng Concrete Bolts or Foundaton Blocks
Mountng on Concrete Foundaton Usng Jont Bolts
Mountng the Reducer on the Connecton Platform
Mountng on Block Flange
Assembly of Reducer wth Block Flange
Torque Arm Assembly for Reducer Housng
Torque Arm Assembly
Hollow Shaft Coupled Reducer
Shaft Coupled Gearbox wth Hollow Shaft and Wedge Connecton
Preparaton
Assembly
Dsassembly
Hollow Shaft and Sldng Shaft Coupled Reducer Accordng to DIN 5480
Preparatons
Assembly
Dsassembly
Hollow Shaft and Concal Compresson Shaft Coupled Reducer
Assembly
Dsassembly
F Type Flange Shaft Reducer
Requrements
Installaton of Reducer
Couplngs
Connectng Components
Reducers wth Mounted Components
Makng Termnal Box Connectons for Pre-Wred Reducers
Connectng the Cooler Col
Connectng the Ar-Ol Cooler
Connectng the Water-Ol Cooler
Connectng the Heatng Element
Connectng the Pressure Indcator
Establshng a Separate Ol Supply System
Connectng the Ol Level Indcator System
4.1
4.1.1
4.1.2
4.2
4.3
4.3.1
4.3.2
4.3.2.1
4.3.3
4.3.3.1
4.3.3.2
4.3.3.3
4.3.3.4
4.3.4
4.3.4.1
4.3.5
4.3.5.1
4.4
4.4.1
4.4.1.1
4.4.1.2
4.4.1.3
4.4.2
4.4.2.1
4.4.2.2
4.4.2.3
4.4.3
4.4.3.1
4.4.3.2
4.5
4.5.1
4.5.2
4.6
4.7
4.7.1
4.7.2
4.7.3
4.7.4
4.7.5
4.7.6
4.7.7
4.7.8
4.7.9
51
51 - 52
53
54
54
54
55 - 56
56 - 57
57
57 - 58
58 - 59
60 - 61
61 - 62
63
64
64
64 - 65
65
65
65
66 - 67
67 - 69
70
70
70 - 72
72 - 74
74
74 - 76
76
76
76
77
77 - 78
78
78
78
79
79
79
80
80
80
80
ASSEMBLY
4. UNIT
TECHNICAL INFORMATION AND ACCESSORIES
3. UNIT
CONTENTS

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Connectng the Pt 100 Resstance Thermometer
Connectng the Temperature Indcator
Connecting the Bearing Monitoring System
Connectng the Encoder
Connectng the Motor Pump
Electrcal Connectons
Clampng Procedure
Bolts
Bolt Connecton Classes
Preload Forces and Tghtenng Torques
Temperature Stcker
Vsual Inspecton of the Temperature Stcker
Fnal Thngs to be Completed
4.7.10
4.7.11
4.7.12
4.7.13
4.7.14
4.7.15
4.8
4.8.1
4.8.2
4.8.3
4.9
4.9.1
4.10
81
81
81
81
81
82
82
82
83
83 - 84
85
85
86
ASSEMBLY
4. UNIT
Commssonng
Pre-Commssonng Measures
Locked Reducer
Auxlary Drve Reducer
Ol Level Indcator System
Cooler Col Reducers
Heated Reducer
Reducer wth Ol Supply System
Ol Fllng n Lock or Auxlary Drve Reducers
Precautons Durng Commssonng
Torque Lmter Locked Reducers
5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.2
5.2.1
87
87
87
88
88
88
89
89
89
90
90
6.1
6.1.1
6.2
Operatng
Operatng Data
Dsorders n Operaton
91
91
91
7.1
7.1.1
7.2
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
7.3.7
7.3.8
7.3.9
7.3.10
7.3.11
7.3.12
7.3.13
7.3.14
7.3.15
7.3.16
Servce
General Mantenance Informaton
Control and Perodc Mantenance
Mantenance and Servce Work
Checkng the Ol Temperature
Fllng the Lock wth Ol
Checkng the Outer Cage of the Torque-Lmtng Backstop
Fllng the Auxlary Drve Reducer's Mechancal Clutch wth Ol
Checkng Auxlary Drve Reducer
Cleanng the Fan and Reducer
Checkng the Cooler Col
Control of Shrnk Dsc
Cleanng the Straner Flter
Cleanng the Double Flter
Checkng Speed Indcator of Auxlary Drve Reducer
Measurng the Vbraton Levels of Bearngs
Measurng Temperature n Bearngs
Check all Fastenng Bolts are Tght
General Inspecton of Reducer
Fnal Thngs to be Completed
92
92
92 - 93
93
94
94
94 - 95
95
95
95
96
96
96
97
97
97
97
98
98
98
5. UNIT COMMISSIONING
6. UNIT OPERATING THE REDUCER
7. UNIT CONTROL AND MAINTENANCE
CONTENTS

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CONTENTS
Product Dsposal
Dsposal
Possble Errors
Possble Malfunctons and ther Remedes
Troubleshootng
8.1
8.1.1
8.2
8.2.1
8.2.1.1
TROUBLESHOOTING
8. UNIT
Spare Parts
Requred Informaton for Orderng Spare Parts
10.1
10.1.1
SPARE PART
10. UNIT
11.1
11.2
11.3
11.4
11.5
Ambent Temperature
Product Types
Weghts
Ol Quanttes
Measurng Surface Sound Pressure Level
11. UNIT TECHNICAL DESCRIPTIONS
Authorzed Servce
9.1
AUTHORIZED SERVICE
9. UNIT
Contact Informaton
13.1
CONTACT INFORMATION
13. UNIT
12. UNIT WARRANTY
12.1
12.2
99
99
100
100
100 - 104
106
106
107
108
109 - 110
110 - 112
113 - 116
105
119
117
118
Declaraton of Conformty
ATEX Document

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17
18 - 19
18
18
19
19
19
22
27
28
28
28
29
29
30
31
32
32
32
33
34
35
36
37
38
39
39
40
41
43
44
45
46
46
47
48
49
55
56
57
58
59
60
60
62
63
64
Lst of llustratons
Fgure 1 : Cross and Sde Pull on Eyebolts
Fgure 24
: Aqueous Ol Coolng System Mounted on PB Type Reducer
Fgure 25
: Heatng System n PH / PB Type Reducers
Fgure 26
: Ol Level Montorng System n PH / PB Type Reducers
Fgure 27 : Ol Temperature Montorng System n PH / PB Type Reducers
Fgure 28 : Bearng Montorng Usng a Pt 100 Resstance Thermometer
Fgure 29
: Montorng Usng Shock Pulses Transducer
Fgure 30 : Encoder
Fgure 2 : Transport of Gearboxes
Fgure 2- a : Poston of Addtonal Lftng Ponts for Reducers of Type PH / PB
Fgure 2 - b: Postons of Addtonal Lftng Ponts for Geared Motor Reducers of Type PH
Fgure 2 - c: Postons of Addtonal Lftng Ponts for Geared Motor Reducers of Type PB
Fgure 2 - d: Poston of Addtonal Lftng Ponts for Reducers wth Torque Arm, Type PB
Fgure 2 - e: Poston of Addtonal Lftng Ponts for Auxlary Drve Reducers of Type PB / PH
Fgure 3 : Gearbox Nameplate and Explanaton
Fgure 4 : Output Shaft Versons
Fgure 5 : PH - H ≤ 12 Type Reducer Equpment
Fgure 6 : PH - H ≥ 13 Type Reducer Equpment
Fgure 7 : PB - H ≥ 13 Type Reducer Equpment
Fgure 8 : PB3 - H ≤ 12 Type Reducer Equpment
Fgure 9
: PB3 - H ≥ 12 Type Reducer Equpment
Fgure 10 : Ol Supply System n PH Type Reducers
Fgure 11 : Ol Supply System n PB Type Reducers
Fgure 12 : Rotary Shaft Seal
Fgure 13 : Labyrnth Seal
Fgure 14 : Taconte Seal
Fgure 15 : Taconte Seal Types
Fgure 16 : Tacolab Seal
Fgure 17 : Backstop
Fgure 18
: Torque Lmter Backstop
Fgure 19 : Fan
Fgure 20 : Cooler Col Connecton
Fgure 21 : Ar Ol Coolng System Mounted on PH Type Reducer
Fgure 22 : Ar Ol Coolng System Mounted on PB Type Reducer
Fgure 23
: Aqueous Ol Coolng System Mounted on PH Type Reducer
Fgure 31 : Basc Desgn of Man and Auxlary Reducers
Fgure 32 : Reducer Desgn (Connectng Auxlary Drve Reducer)
Fgure 33 : Gap Sze n Grease Labyrnth
Fgure 34
: Algnment Surfaces for Reducers up to Frame Sze 12
Fgure 35 : Algnment Surfaces for Reducers wth Frame Sze 13 and Above
Fgure 36 : Concrete Bolt
Fgure 37 : Base Block
Fgure 38 : Installng Anchor Bolt
Fgure 39 : Clampng Anchor Bolt
Fgure 40 : Torque Support for Reducer
Fgure 41
: Block Flange Reducer
Fgure 42 : Torque Arm for Reducer Housng
CONTENTS

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Fgure 55: Temperature Stcker
65
67
68
68
69
70
71
73
73
75
77
78
85
94
108
Lst of llustratons
Fgure 43: Hollow Shaft, Keyway Reducers
Fgure 44: Ball Screw Assembly Process
Fgure 45: Dsmantlng by usng a Puller
Fgure 46: Dsassembly Usng Hydraulc Pullng Equpment
Fgure 47: Keyway, Hollow Shaft
Fgure 48: Preparation for a Hollow Shaft Gear Unit with a Flat Hole on one Side and a Spline on the Other Side
Fgure 49: Pre-Assembled Bushng Sleeve Assembly
Fgure 50: Dsmantlng by usng a Puller
Fgure 51: Dsassembly Usng Hydraulc Pullng Equpment
Fgure 52: Preparaton for Hollow Shaft, Concal Compresson Reducers
Fgure 53: Couplng Assembly
Fgure 54: Algnment Process wth Flexble Couplng
Fgure 56: Torque Lmt Backstop
Fgure 57: Product Types
CONTENTS

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Tablo 1 : Safety Alerts and Informaton Sgns
Tablo 2 : Symbols and Marks
Tablo 3 : General Warnngs
Tablo 4 : Product Descrpton (PH)
Tablo 5 : Product Descrpton (PB)
Tablo 6 : Product Descrpton (PB-PKD)
Tablo 7 : Abbrevatons
Tablo 8 : Taconte Seal Models
Tablo 9 : Water Flow Rates n the Col
Tablo 10 : Specfic Heat Output Table
Tablo 11 : Motor Selecton for Reducer Base
Tablo 12 : Motor Selecton for Foundaton Support
Tablo 13 : Gude Dmensons on Shaft Surface of Hollow Shaft Reducer
Tablo 14 : Maxmum Forcng Pressures
Tablo 15 : Tghtenng Torques of Flange Connectons
Tablo 16 : Informaton on Tghtenng the Connectng Bolts
Tablo 17 : Preload Forces and Tghtenng Torques
Tablo 18 : Operatng Data
Tablo 19 : Servce and Mantenance Operatons
Tablo 20 : Dsposal Table
Tablo 21 : Troubleshootng
Tablo 22 : Authorzed Servce
Tablo 23 : Weghts
Tablo 23 - 1a: Weghts
Tablo 23 - 1b: Weghts
Tablo 23 - 2a: For Auxlary Drven Reducers (Falure Mantenance Work)
Tablo 23 - 2b: For Auxlary Drven Reducers (Falure Mantenance Work)
Tablo 23 - 3a: For Auxlary Drven Reducers (Workng Under Load)
Tablo 23 - 3b: For Auxlary Drven Reducers (Workng Under Load)
Tablo 24 : Ol Quanttes
Tablo 24 - 1a
:Output Seal Ol Quanttes
Tablo 24 - 1b: Output Seal Ol Quanttes
Tablo 24 - 1c: Output Seal Ol Quanttes
Tablo 24 - 2 : Labyrnth Seal Ol Quanttes
Tablo 24 - 3a: Ol Quanttes for Intermedate Flange
Tablo 24 - 3b: Ol Quanttes for Intermedate Flange
Tablo 24 - 4a: Immerson Lubrcaton
Tablo 24 - 4b: Immerson Lubrcaton
Tablo 24 - 5a: Pressure Lubrcaton
Tablo 24 - 5b: Pressure Lubrcaton
Tablo 25 : Measurement Surface Sound Pressure Level
Tablo 25 - 1 : Measurng Surface Sound Pressure Level for Fan Cooled Concal Helcal Reducer LpA, dB [A]
Tablo 25 - 2 : Measurng Surface Sound Pressure Level LpA, dB [A] for Fanless Concal Helcal Reducer
Tablo 25 - 3 : Sound pressure level for fan cooled Helical Gearbox LpA, dB [A]
Tablo 25 - 4 : Sound pressure level for Fanless Helical Gearbox LpA, dB [A]
8
9
10
23
24
25
26
33 - 34
38
43
62
65
69
69
77
83
83 - 84
91
92 - 93
99
100 - 104
105
109 - 110
109
109
109
110
110
110
110 - 112
110
111
111
111
111
111
112
112
112
112
113 - 116
113
114
115
116
Lst of tables
CONTENTS

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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.
WARNING !
General usage nformaton
If proper precautions are not taken that indicates serious personal
injury may occur.
GENERAL INFORMATION1. UNIT

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1.) Unscrew the ol control stck,
2.) Check the ol level,
3.) Renstall f approprate.
These symbols ndcate that there s an ol dpstck, t must be screwed tghtly.
Table 2: Symbols and Marks
Vent plug
Dran plug
Ol level
Ol fill pont
Ol level plug
Lubrcaton pont
Ol control stck
Use grease
Earthng connecton pont
Vbraton ndcator connecton
pont
Eye bolt
Eye bolt
Do not dsassemble
Correcton surface, (horzontal)
Correcton surface, (vertcal)
For ol level control wth ol control stck;
GENERAL INFORMATION 1. 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
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Table 3: General Warnngs
GENERAL INFORMATION1. UNIT

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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.
Correct Use
1.3
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 !
Fallng rsk!
Possble rsk of serous njury from fallng.
When the reducer s not runnng, you can walk or stand on the reducer only for mantenance
and repar work. Do not step on or stand on shaft ends, protecton covers, assembled
components or ppes.
DANGER !
1.2
GENERAL INFORMATION 1. UNIT
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 !

1. 4
Qualfied Personnel
The product / system descrbed n ths document may only be operated by authorzed personnel for a specfic
task n accordance wth the relevant warnngs and, n partcular, warnng notces and safety nstructons.
Qualfied personnel are people who, based on ther tranng and experence, can dentfy rsks and avod
potental hazards when workng wth these products /systems.
1. .14
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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.
Safety Informaton
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 !
GENERAL INFORMATION1. UNIT

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Fallng rsk!
Standng or walkng on the gear unt durng operaton creates a rsk of fallng.
Walk or stop on the gear unt only f the gear unt s not workng for mantenance and repar
work on the gear unt and ts assembled components. Do not walk or stand on shaft ends,
protecton covers, mounted components or ppes.
WARNING !
Danger to lfe due to rotatng or movng parts!
There s a danger that rotatng or movng parts could catch you or pull you n.
Take safety precautons aganst contact and/or movng parts.
WARNING !
Hazards durng operaton;
The reducer may be damaged.
If ncomprehensble changes are notced durng operaton, stop the reducer mmedately. Such changes may
nclude unusual reducer nose or a sgnficant ncrease n operatng temperature.
1. .24 Specal Types of Hazards and Personal Protectve Equpment
Before startng to work on the reducer, fulfill the followng condtons:
· Make sure that the ol pressure lnes are not pressurzed.
Work on the reducer only when the system s statonary and not workng.·
Dsconnect electrcal systems from the power source.·
Protectve equpment;
When usng the reducer, wear the followng personal protectve equpment:
· Safety shoes,
Overalls,·
Helmet,·
Protectve gloves,·
Protecton glasses.·
Rsk of eye njury!
Small foregn partcles such as sand or dust can enter the protecton plate of the rotatng parts
and be thrown back from there.
Wear safety glasses.
DANGER !
Electrc shock!
Movng parts can cause electrc shock.
Before startng the electrcal nstallaton work, make sure that the entre faclty s deenergzed.
DANGER !
GENERAL INFORMATION 1. UNIT

Chemcals;
Injures can contnue when chemcals are used.
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Surface temperature;
The surface temperatures of the reducer can be very extreme dependng on the operatng condtons.
Rsk of chemcal burns due to chemcals!
There s a rsk of chemcal burns when workng wth aggressve cleanng agents.
Follow the manufacturer's nstructons on how to use cleanng agents and solvents.
Use sutable protectve equpment (gloves, safety glasses). Please use bnders to
mmedately clean up all splt solvents.
EXPLOSION !
Rsk of njury due to chemcally aggressve operatng materals!
There s a rsk of eye and hand njury when workng wth chemcally aggressve
operatng materals. Please follow the safety nstructons n the data sheets of the ol
used. Use sutable protectve equpment (gloves, safety glasses). Use an ol-bndng
agent to clean up splled ol mmedately.
EXPLOSION !
Rsk of burns!
Rsk of serous burns from hot surfaces (> 55 °C). Wear sutable protectve gloves and
protectve clothng.
DANGER !
Rsk of Scaldng!
There s a rsk of serous njury of hot workng envronment durng the replacements of
the parts on the gearbox. Wear protectve gloves,goggles and clothng.
DANGER !
Danger due to low temperatures!
Rsk of serous njury (<0 °C) from frost (pan, numbness, frostbte) on cold surfaces.
Wear sutable protectve gloves and protectve clothng.
DANGER !
GENERAL INFORMATION1. UNIT

1.5 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.
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Exploson hazard;
An exploson may occur n an explosve atmosphere.
Danger of exploson by gnton of a potentally explosve atmosphere!
Danger to lfe due to possble explosve atmosphere gntng whle the reducer s operatng.
Do not use the reducer n explosve atmospheres.
EXPLOSION !
Lfe-threatenng rsk due to the movable system!
Death or serous njury wll occur.
Before dong any work, always turn off the reducer and any ol supply system (whether
separate or attached to the reducer). Secure the drve aganst accdental startng as
follows:
* Turn off the operatng swtch (turn the system off).
* Remove the fuses from the power supply.
* Attach a warnng to the start swtch that clearly ndcates that the reducer s workng.
Make sure the entre unt s unloaded so there s no danger once you start removng
components.
EXPLOSION !
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 !
GENERAL INFORMATION 1. UNIT

Transportaton, Freghtage and Storage
Scope of Delvery;
The scope of delvery s lsted n the shppng documents. Immedately after recevng the reducer, check that t
has been delvered completely. Immedately report damaged and / or mssng parts to Customer Servce
(Page 119).
1.6
1.6.1
1.6.2
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Serous njury wth defectve product!
Serous njures can occur. If there s vsble damage to the reducer, you should not put
t nto operaton.
PATLAMA !
Fallng load!
There s a rsk of fatal njury from fallng f the load s not securely attached to the lftng
equpment. Never stand or st under suspended loads. Do not exceed the load lmts of
the lftng equpment.
DANGER !
Freghtage;
The reducer s delvered fully assembled. Addtonal parts such as concal clamps, couplngs, ol coolers, ppng
and valves can be packaged separately as requred.
To avod damage to the reducer whle transportng the reducer, follow the nstructons below:
· Always use sutable equpment to transport the reducer,
· Transport the reducer wthout ol fillng and leave t n the transported packagng.
Dependng on the order specficatons, the reducer can be shpped filled wth ol. Take nto account the extra
weght (lter x 10 N) and move the reducer to ts final mountng poston,
· Do not use wrong connecton ponts.
Threaded holes n shaft end surfaces cannot be used for attachment of lftng equpment,
· Do not use the ppng system to move or carry the reducer.
· Make sure that the lftng equpment s properly desgned to support the weght of the reducer.
Connectng the reducer
To carry the reducer, attach the suspenson straps to the marked attachment ponts made for ths purpose only.
Please note the followng when attachng or rasng, lowerng or movng the slngs to the load:
· Do not exceed the specfied load lmts,
· If you are usng a load suspenson devce wth several load hooks, make sure that the load s evenly
dstrbuted between them,
· Note the eccentrc center of gravty,
· Make sure the lftng equpment s securely attached,
· Reduce your speed whle carryng the load,
· Do not allow the load to swng and do not te the load to objects or structures nsde the buldng,
· Loads should not hang from the end of the load hook,
· Products should always be placed on a flat, non-dsplacement and stable base.
GENERAL INFORMATION1. UNIT
Rsk of crushng!
There s a rsk of beng crushed by a part to be dsmantled because the lft reducer and
load suspenson devce are not sutable for holdng the part.
Please follow the load dstrbuton nformaton on the packagng durng lftng.
When the product s n a rased poston, move t slowly and carefully to avod njury to
persons or damage to the reducer.
PATLAMA !

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Packagng
The reducer s delvered fully assembled. Addtonal equpment s also packaged separately as needed.
The reducer can be packaged n varous ways, dependng on ts sze and shppng method.
Please observe the symbols appled on the packagng.
1. .46
Specal Condtons for Lubrcatng and Protectng the Reducer;
Re-greasng the Bearngs
- Grease-lubrcated rotatng ball bearng:
The reducer can be suppled wth bearngs lubrcated wth grease. Grease-lubrcated bearngs are filled wth
grease pror to shpment. For nformaton on ol quanttes and relubrcaton ntervals, please refer to the labels
at the relubrcaton ponts.
1. .6 5
Specal Condtons of Protecton of the Reducer;
Internal Protecton by Ol Fllng
Ol fillng should not be used as a means of protectng reducers usng grease-lubrcated bearngs.
1.6.3 Connecton Ponts;
Lftng eye bolts
Lftng eyebolts are attached to the reducer to ad handlng durng fabrcaton and assembly.
When the lftng equpment s attached to strap loop,the rope transport drecton must not exceed 45°.
Belt rng
Screw holes of the transport eyebolts are provded on the reducer to assst n carryng durng manufacturng
and assembly.
When the lftng equpment s attached to the belt rngs, the scssor pull must not exceed 45°.
Eye bolts
It s generally recommended to use belt rngs nstead of eyebolts.
When usng eyebolts, please note that ther load - bearng capacty may be reduced f they are alternately
connected to dfferent components that need to be moved.
It s forbdden to load the eyebolts by pullng them sdeways n the opposte drecton to the hole drecton.
Locaton of connecton ponts
Drve unts wth addtonal components (reducer motor, couplng, etc.) mounted on the reducer may requre an
extra connecton pont due to the dsplacement n the centre of gravty caused by the mounted components.
Further nformaton, a detaled drawng of the reducer and the poston of the reducer can be found n the
techncal drawng n the reducer documentaton.
A Permssble dagonal pull n the drecton of the rng surface (maxmum angle of 45°).
B Inadmssble sde pull towards the opposte drecton of the rng surface.
r
BA
r
Fgure 1: Cross and Sde Pull on Eyebolts
GENERAL INFORMATION 1. UNIT

PH... PB...
PH / PB
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If addtonal unts such as the electrc motor, clutch are connected to the reducer, an addtonal connecton
pont may be requred due to the change n the centre of gravty.
Fgure 2 - b: Postons of addtonal lftng ponts for geared motor reducers of type PH
Fgure 2 - a: Poston of addtonal lftng ponts for reducers of type PH / PB
The load wll not be lfted n an nclned poston f fastened wth eyebolts.
NOTE !
Transportaton
Transport of Gearboxes;
1.7
1.7.1
Fgure 2: Transport of Gearboxes
GENERAL INFORMATION1. UNIT