Intall Maint Worm Gb

7/27/2019 Intall Maint Worm Gb

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Installation and Maintenance

PREMIUMWORM SPEED

REDUCERS


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1.0 PREMIUM OVERVIEW

2.0 GENERAL INFORMATION

PURPOSE OF THE MANUAL

3.0 SAFETY INSTRUCTIONS

WARNING

SAFETY SYMBOLS

4.0 GEAR UNIT IDENTIFICATION

NAMEPLATE DETAILS

5.0 HANDLING AND STORAGE

UNPACKAGING

SHIPPING WEIGHTS

PROTECTION OF UNIT

6.0 TECHNICAL INFORMATION

GREASE

THREAD LOCKS

CASKETING COMPOUND

BREATHERS

BEARINGS

OIL SEALS (REPLACING PROCEDURE)

PAINTS

NOISE LEVELS

VIBRATIONS

ELECTRICAL CONNECTIONS

ASSEMBLY / DISMANTLING (PARAMETERS)

SHAFT MOUNTED GEAR UNITS

CLEANING OF GEAR UNIT

OIL LEVELS & OIL CAPACITIES

7.0 INSTALLATION

FOOT MOUNTED GEAR UNITS

SHAFT MOUNTED GEAR UNITS

8.0 MAINTENANCE

DOS AND DONTS

CONTACTS MARKINGS, BEARING END FLOATS, TIGHTENING TORQUE

TEMP CHECK

9.0 TROUBLESHOOTING

TROUBLE SHOOTING CHART

10.0 DISPOSAL OF GEAR UNITS/ PARTS

INTRODUCTION WARM UNITS

INSTALLATION AND ROUTINE MAINTENANCEINSTALLATION AND ROUTINE MAINTENANCE

1


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DEAR CUSTOMER,

Thank you for choosing PREMIUM TRANSMISSION LTD. gear unit. We are a

part of B M Thapar group of companies in India and it includes companies like

P

P English Indian Clay etc.

Premium Overview:

Premium Transmission Limited, Unit l, Pune - 411019 earlier known as Greaves

Cotton Limited, Power Transmission, Unit l, Pune - 411019 erstwhile known as

Greaves Cotton & Co. Ltd. (Unit l) and formerly known as David Brown Greaves

Limited, was established in Jan. 1961 to manufacture the most comprehensive range ofworm reduction gears with the technical and financial collaboration of David Brown

Gear Industries UK, a world leader in worm gears and small helical gearboxes to giant

coal pulverizing gears. The works is situated at 147 km. From Mumbai and is well

equipped with modern machines, advance technology and skill manpower.

Today 45 years later, the company stands as an epitome of pioneering ventures diverse

in product range from Adaptable to heavy duty Worm Gears, small Helical Gearboxes to

Giant Coal Pulverizing Mill Gear Boxes for Thermal Power Stations. The product range

touches every conceivable segment of industries.

With the additions of R&D Centre, modernized machine tools, heat treatment facilities

and metrology, the companys product enjoy sustainable reputation for quality and

reliability, both in domestic as well as overseas market.

The companys aim is to achieve high growth rate with new collaboration, triggering

innovations and creating work ethos that inspires human achievements and

satisfaction, through harmonious convergence of knowledge, skills, efforts, new ideas

and excellence, all directed towards the Customer and his total satisfaction.

Some of the reputed clients of the company:

P Balke- Durr- Cooling Tower Manufacturer

P BHEL- Power plant manufacturer

P GMM Pfaudler- Germany Glass Lined vessel manufacturer

P GEA Cooling Towers

P Indian Space Research Organization-India (ISRO)

P Larson & Tubro

P Mc Neil- USA Tyre machinery Manufacturer

P Mesto Mineral- Material Handling

P National Thermal Power Corporation (NTPC)

P State Electricity boards (all over India.)

And many more.

Premium Transmission Ltd.

2

INSTALLATION AND ROUTINE MAINTENANCEPREMIUM OVERVIEW


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3

2.0 GENERAL INFORMATION

PURPOSE OF THE MANUAL:

The purpose of this manual is to provide the information about gear unit, its safe

transport, handling, installation, maintenance, repair and dismantling.

For rating of the gearboxes, selection of the gearboxes and other details Sales

Catalogues and individual product catalogue must be referred.

Apart from adhering to established engineering practices, the information given inthis manual must be read carefully and strictly followed.

Failure to the information provided or herein may result in risk to personal health

and safety, and may incur economical damages.

All the documents related to product must be stored by a person with the correct

authority and should be made available for consultation.

In case of loss or damage, replacement document must be requested directly from

Manufacturer, quoting the code of this manual No. .

The manual reflects the sate of art at the time of commercialization of the gear unit.The manual reserves the right to modify, supplement and improve the manual,

without the present publication being for that reason considered inadequate.

Particularly significant sections of the manual important specifications are

highlighted by symbols whose meaning is given below.

PREMIUM/WM/CA/107

INTRODUCTION WARM UNITS :

Premium Speed Reducers are of substantial construction, combining rogodity with

strength.

The worm is of high quality case-hardening steel, accurately generated, ground

and super-finished. The worm wheel comprises a phosphor bronze centrifugally

cast rim of substantial section welded to a rigid center, which is pressed and

keyed to the shaft.

Shafts are located on dual purpose bearings of ample capacity and having a

substantial margin on output shafts for accommodating overhung loads.

Lubrication is positive at all speeds, in either direction of rotation and apart from

an occasional oil check, no attention is denoting position of slow speed shaft

extension.


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3.0 SAFETY INSTRUCTIONS:

SAFETY SYMBOLS:

DANGER WARNING

This symbol indicates situation of serious danger that, if ignored, may

cause serious damage to health and safety of personnel.

CAUTION ATTENTION

This symbol indicates need to adopt specific precautions to avoid risks to

the health and safety of personnel and possible economical damage.

IMPORTANT

This symbol indicates important technical information.

WARNING

Warning :

Both foot and shaft mounted units are designed to operate in the horizontal

position. Reference must be made to Premium Transmission Limited with full details,

where units are required to operate in an inclined position.

Note : Torque arms must be secured to the chassis structure in a flexible mounting0as indicated within a maximum angle of 30 between the vertical plane and a

plane towards the gear unit output shaft as illustrated. See Installation details.

Warning :

ALL UNITS ARE DESPATCHED WITHOUT OIL OR GREASE & ANTI CORROSION

OIL. ON INSTALLING THE UNIT FILL IT WITH RECOMMENDED LUBRICANT TO

CORRECT LEVEL. SEE TECHNICAL INFORMATION. (TO PREVENT BURNING

AND FAST WEARING OUT OF THE LIPS OF OIL-SEALS DUE TO DRY RUNNING,

TILL OIL CIRCULATION DUE TO SPLASH LUBRICATION IS ESTABLISHED. A

FEW DROPS OF OIL MUST BE SQUIRTED ON THE LIPS OF OIL-SEALS TO WET

THEM PRIOR TO STARTING UP OF THE GEARBOX INITIALLY AS WELL AS AT

EVERY RESTART AFTER REST PERIODS IN EXCESS OF 24 HOURS).

Warning :The customer shall be responsible for the proper use articles supplied by the

company, particularly the rotating shafts between their driving and driven

members, and their guarding for safety and the company shall not be responsible

for any injury or damage sustained as a result of the improper use of the articles

supplied.

Attention is hereby drawn to the danger of using naked lights in proximity to

openings in gearboxes and gear units supplied by the company, and the company

shall not be liable for any claim for injury or damage arising from any action in

contravention of this warning.


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4.0 GEAR UNIT IDENTIFICATION

EQUIPMENT IDENTIFICATION

The gear unit bears the following nameplate. The nameplate bears all references and

important safety instructions. The gear unit's identifying code is explained in the Sales

Catalogue.

If the gear unit is supplied with other systems as Forced Lubrication System etc. all

information regarding this is supplied in the FLS manual.

Nameplate for CE and ATEX- specified gear units:

Order No.

Product type.

Serial No.

Ratio.

Max. Torque.

Year of manufacturing.

NAMEPLATE DETAILS :

Instructions in accordance with the requirements of ATEX 94/9/EC

The Gearbox is affixed with the nameplates as shown below

FOR ATEX MARKINGFOR CE MARKING

Explanation of above symbols is detailed below-1. X-Special Instructions2. CE- Conformity Europina3. EX- ATEX certification symbol4. II- Group 25. 2- Category 26. G- Gas environment7. D- Dust environment8. C- Constructional safety for gearboxes9. k- Components of the gearboxes partially or fully oil

immersed10. T4- Temp. class. Maximum surface temp. 135C

5

IndiaChinchwad, Pune - 411019


UNIT-I,CHINCHWAD,

PUNE-411019. INDIA

WORM REDUCER



UNIT-I,CHINCHWAD,

PUNE-411019. INDIA

WORM REDUCER


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SPECIAL INSTRUCTIONS UNDER X Maximum Ambient operating Temperature + 5C to 50C Type of bearings used in Helical gearboxes are Taper Roller and Double row

Spherical Roller bearings of reputed make. Type of bearings used in worm Gearboxes are Taper Roller and Angular contact

bearings of reputed make.

Sealant used Loctite Make Medium Blue 243 Thread locker and 574 Flange sealant. Lubricant used ISO VG 320 Grade oil for makes refer IOM PREMIUM/WM/CA/ 107

and PREMIUM/HG/CA/203 Grease to be used is multipurpose grease or wheel bearing grease of any reputed

make. Type of Paint used is Air drying Blue Hammertone paint manufactured by Asian Paint

India. External earthing to be provided by the end user. Whenever the gearboxes are to be installed in Angular position the same shall be

referred back to PREMIUM for suitable advice. Instruction given for operation, installation and routine maintenance for CE products

should also be followed.

INSTALLATION Ensure no metallic shocks, impacts are made to the gearboxes. All the operating and safety instructions should be thoroughly followed. Installation must be carried out at ambient temperature. All other electrical equipments shall meet the appropriate ATEX category and type of

atmosphere. The precautions during welding operations etc. shall be taken as per the

requirements.

MAINTENANCE Periodic cleaning of dust deposits on gearbox surface as well as in the gap of moving

part shall be ensured. Persons carrying out maintenance shall be qualified to work in potentially hazardous

area appropriate to the category of equipment in use. Equipment manufacturer/end user shall use all the tooling required for the

maintenance appropriate to the working area. All original spare parts must be used during maintenance.

SERVICETrained and qualified person shall carry out service job.

Readability of the nameplate

The nameplate and the information given must be readable at all times and regularly cleaned.

Incase of nameplate wear and / or damaged so as to affect its readability or that of even one of

the items information thereon, the end user must request a new nameplate from the

Manufacturer, quoting the information given in this manual, and replace the old one.

1. X-Special Instructions

2. CE- Conformity Europina

3. EX- ATEX certification symbol

4. II- Group 2

5. 2- Category 2

6. G- Gas environment 7.D- Dust environment

8. C- Constructional safety for gearboxes.

9. k- Components of the gearboxes partially or

fully oil immersed.

10. T4- Temp. class. Maximum surface temp.

135C

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MARKING

The Gearbox is supplied with a Nameplate fixed on the Casing. This Nameplate provides

details like Sr. No., Size, Type, Ratio, Handing/Position, Year of manufacture, Speed,

Torque, Address of the Manufacturer and the CE marking.

The nameplates are shown below.

Apart from the instructions in Installation and Maintenance manuals nos.

PREMIUM/WM/CA/107 & PREMIUM/HG/CA/203, please note the following.

The gearboxes dispatched from PREMIUM are generally with shaft extensions and keys.

The machine manufacturer or the end user must use the required equipment with CE

mark as appropriate for safe working.

Whenever Gearboxes are sent with motor mounting adaptors the machine manufacturer

or end user to fix the CE marked motor with appropriate type of CE marked couplings and

the instructions of the coupling manufacturer for alignment must be followed. All other

equipments should also have CE marking.

The machine manufacturer or end user to provide 1to 2.5-meter space around the gearbox

depending upon size of the gearbox for maintenance. For long time storage gearbox must

be filled with oil so that it touches the bearing roller height at maximum height of bearing

in the gearbox. The input shaft of the gearbox to be rotated few times once in 15 days.

7


Premium Transmission Ltd.UNIT-I,CHINCHWAD,

PUNE-411019. INDIA

WORM REDUCER


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5.0 HANDLING AND STORAGE

Procedure to unpack the gearbox from Packing:-

l

l Loosen the foundation bolts

l Use suitable size wire rope/ sling and lifting lugs on the gear unit to lift the gear unit.

Please see that the ends of the rope or sling are placed at equal distance from the hook

to avoid imbalance or tilting of the gear unit during lifting. Not adhering to this

instruction may lead to falling of the gear unit and may cause injury to the work men

apart from damages to the gear unit

Remove nails, using nail pullers and then lift the top plank using a suitable material

handling tool. The workman is advised to wear hand gloves.


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The machine manufacturer or end user to provide 1 to 2.5 meter space around the

gearbox depending upon size of the gearbox for maintenance. For long time storage

gearbox must be filled with oil so that it touches the bearing roller height at maximum

height of bearing in the gearbox. The input shaft of the gearboxes to be rotated few times

once in 15 days.

Instructions on handling hot gear units:-

l Feel the temperature of the gear unit at regular interval. In case of abnormal raise in

temperature please measure it using industrial thermometer. In case the temperatures

exceeds 95 Deg C, switch of the prime mover and allow the gear unit to cool down to a safetemperature for handling and the open the breather.

Protection of Unit:

l All units prior to despatch are test run with a rust preventive oil giving adequate protection

to internal parts for a period of six months covering normal transport inland and overseas

and covered storage. When the unit is installed the rust preventive dissolves in the first fill

of lubricant without harmful effect. Shaft extensions and hollow output shafts are

protected with a rust inhibitor which is proof against sea water and suitable for under-

cover storage upto 12 months.

Notes: 1. Where gear units are to operate in abnormal conditions, or where they are to stand

for long periods without running, e.g. in plant installation, Premium Transmission Limited

must be notified so that suitable protective arrangements can be made.

2. Gear units which are commissioned and then left standing for an extended period should

be operated, loaded or unloaded for a short time every two weeks to circulate the lubricant to

protect surfaces. If this is not possible the unit should be protected from corrosion.

*Refer to PREMIUMAs improvements in design are continually being made, this specification is not to be regarded as binding in detail anddimensions are subject to alteration without notice.

Unit Type 140 160 180 200 225 250 280 315 355 400 450 500 560 630

H1 150 190 240 300 395 495 680 915 1210 1650 2265 2970 - -H2 235 265 300 360 470 590 810 1090 1445 1970 2690 3540 4860 6540H2SF 235 265 300 360 470 590 810 1090 1445 1970 2690 3540 4860 6540H3 290 310 330 380 490 630 850 1150 1525 2080 2840 3780 5100 6900H3SF 290 310 330 380 490 630 850 1150 1525 2080 2840 3780 5100 6900H4 295 320 345 * * * * * * * * - - -H4SF 295 320 345 * * * * * * * * - - -B2 270 285 305 340 455 560 750 1000 1520 2050 2680 3530 - -B2SF 270 285 305 340 455 560 750 1000 1520 2050 2680 3530 - -B3 300 310 330 380 490 630 850 1150 1525 2080 2840 3780 5100 6900B3SF 300 310 330 380 490 630 850 1150 1525 2080 2840 3780 5100 6900B4 305 320 345 * * * * * * * * - - -B4SF 305 320 345 * * * * * * * * - - -

Net Weights for Horizontal Units in kg (approx.)

Units Size


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6.0 TECHNICAL INFORMATION

NAMEPLATE DETAILS ESSENTIAL FOR CORRECT PARTS IDENTIFICATION

1 1st reduction case 22 Bearing for 1st reduction wormwheel

2 2nd reduction case 23 Distance piece for 1st reduction wormwheel

3 Oil seal for 1 st reduction wormshaft 24 Circlip for 1 st reduction wormwheel

4 Bolt for 1 st reduction wormshaft covers 25 End cover for 1 st reduction wormwheel

5 Oil catcher for 1st reduction wormshaft 26 Bolt for 1st reduction wormwheel end cover

6 Shim for 1st reduction wormshaft covers 27 Oil seal for 2nd reduction wheelshaft

7 Bearing for 1st reduction wormshaft 28 Oil catcher for 2nd reduction wheelshaft

8 1st reduction wormshaft 29 Shim for 2nd reduction wheelshaft covers

9 End cover for 1st reduction wormshaft 30 Nilos'ring

10 Plug for 1st reduction case 31 Bearing for 2nd reduction wheelshaft

10A Breather for 1st reduction case 32 2nd reduction wheelshaft

11 Bolt for 2nd reduction case 33 Key for 2nd reduction wheelshaft

12 Bolt for 2nd reduction wormshoft end cover 34 2nd reduction wormwheel

12A Copper washer for 2nd reduction 35 2nd reduction wheelshaft end cover

wheelshaft covers on size 162 only 36 Plug for 2nd reduction case

13 End cover for 2nd reduction wormshaft 36A Breather

14 Shim for 2nd reduction wormshaft end cover 37 Nomeplate

15 Bearing for 2nd reduction wormshaft 38 Rivet for nameplate

16 2nd reduction wormshaft 40 No. 1 foot

17 Key for 2nd reduction wormshaft 41 Bolt for No. 1 foot

18 Oil seal for 2nd reduction wormshaft 42 No. 2 foot

19 1st reduction worm wheel 43 Bolt for No. 2 foot

20 Shim for 1st reduction wormwheel 44 Input key

bearing housing 45 Output key

21 1st reduction wormwheel bearing housing

CLEANING FOR GEAR UNIT :

Adaptable double reduction units : Sizes 162 to 337


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INCORRECT*Move Wheel

CORRECTContact marking clear on

entering side to provide oilLead in when

running under load

INCORRECT*Move Wheel

*Incorrect wheel assembly will lead to premature wearing of worm wheel

Changing Handing

When changing the handing of the slow speed shaft extension, the shaft complete with

wormwheel, bearings etc. should be reversed as a unit. It should be appreciated that this

has the effect of reversing the offset of the wheel relative to the worm. When changing the

slow speed shaft handing of V type units it should be noted that the position of the wheelrelative to the case must not be changed; it is necessary therefore to press the wheel from

the shaft. The position of the shaft in relation to the wormwheel must be reversed. The

end covers should be located in their respective positions. It is necessary to check contact

markings on the wormwheel teeth and if any axial adjustment of the wormwheel is

necessary, it can be effected by means of the shims between end covers and bearing

housing which should be moved from one side to the other. It is essential that the top half

of the gear case be replaced in its original position.

The contact marking is checked by painting the worm with red lead or Prussian Blue and

rotating the worm by hand while applying a small braking pressure to the wheel, also by

hand.

The correct marking should be slightly heavier on the "leaving side" of the teeth, relative

to the direction of rotation of the worm, so as to provide "lead in" for the lubricant and to

avoid concentration of pressure on the entering side as this would affect the smoothness

of operation. This arrangement is shown in the diagrams. When the correct wheel setting

has been reached on the U type speed reducers, the oil scraper clearance relative to the

wormwheel should be set at 0.25 mm to 0.38 mm.

If gearbox is dismantled for maintenance, while re-assembling care should be taken to

gently scrape the joint faces and apply 'LOCTITE FLANGE SEALANT SUPERFAST 574,

joint compound on faces of cases and covers and catchers of all type of units. But for sizes

U/O1000 and above paper packings of size supplied by Premium to be used between two

halves of the case joints.


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Parameters

Type '0' Single Reduction Units : Sizes 1000 To 1400

NAMEPLATE DETAILS ESSENTIAL FOR 23 Oil seal for wheelshaftCORRECT PARTS IDENTIFICATION 24 Drain plug

1 Upper half case 25 Fibre washer for drain plug

2 Lower half case 26 Dipstick

3 Cowl 27 Dipstick tube

4 Bolt for Cowl 28 Dipstick body

5 Spring Washer for cowl 29 Dipstick body locknut

6 Fan 30 Bolt for case joint

7 Locking screw for fan 31 Nut for case joint bolt

8 Oil seal for wormshaft 32 Inspection plug

9 Oil catcher for wormshaft 33 Fibre washer for inspection plug

10 Bolt for wormshoft oil catcher 34 Bolt for case joint11 Shim for wormshaft oil catcher 35 Nut for case joint bolt

12 Bearing for wormshoft 36 Packing for case joint - not provided for

13 Wormshaft size 1000

14 End cover for wheelshaft 37 Eyebolt

15 Bolt for wheelshaft covers 38 Screw for ventilator

16 Shim for wheelshaft covers 39 Ventilator

17 Bearing for wheelshaft 40 Ventilator packing

18 Distance piece for wheelshaft 41 Nameplate

19 Wormwheel 42 Rivet for nameplate

20 Wheelshaft 43 Input key

21 Key for wheelshaft 44 Output key

22 Oil catcher for wheelshaft

Note : Item 43 & 44 not shown


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NAMEPLATE DETAILS ESSENTIAL FOR 23 Distance piece for wheelshaftCORRECT PARTS IDENTIFICATION 24 Wormwheel

1 Case 25 Key for wheelshaft

2 Upper bearing housing for wheelshaft 26 Wheelshaft

3 Bolt for upper bearing housing 27 Nilos ring for upper wheelshaft bearing

4 Lower bearing housing for wheelshaft 28 Oil catcher for wheelshaft

4A Shim for lower bearing housing 29 Oil seal for wheelshaft

5 Bolt for lower bearing housing 30 Bolt for wheelshaft oil catcher

6 Cowl 31 Ventilator packing

7 Bolt for cowl 32 Ventilator

8 Spring washer for cowl bolt 33 Screw for ventilator

9 Fan 34 Eyebolt - not fitted to unit size 40010 Locking screw for fan 35 Dipstick - this item is oil level plug on Unit

11 Oil seal for wormshaft Size 400

12 Bolt for wormshaft oil catcher 36 Grease nipple for wheelshaft bearings

13 Oil catcher for wormshaft - fan end 37 Extension pipe for lower grease nipple

14 Shim for wormshaft oil catcher 38 Drain plug

15 Bearing for wormshaft 39 Nomeplate

16 Oil flinger for wormshaft 40 Rivet for nameplate

17 Wormshaft 41 Bolt for inspection cover

18 Oil catcher for wormshaft - shaft extension 42 Inspection cover

end 43 Washer (For 700)

19 End cover for wheelshaft 44 Input key

20 Bolt for wheelshaft end cover 45 Output key

21 Shim for wheelshaft cover

22 Bearing for wheelshaft

Type 'v' Single Reduction Units : Sizes 400 To 800

Note : Item 44 & 45 not shown


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Type 'v' Single Reduction Units : Sizes 1000 To 1700

NAMEPLATE DETAILS ESSENTIAL FOR 31 Drain Plug

CORRECT PARTS IDENTIFICATION 32 Nomepldte

1 Case 33 Rivet for nameplate

2 Upper bearing housing 34 Grease nipple for wheelshoft

2A Lower bearing housing 35 Socket for extension piece

3 Cowl 36 Extension pipe for lower grease nipple

4 Bolt for cowl 39 Inspection cover

5 Spring washer for cowl bolt 40 Screw for inspection cover6 Fan 41 Bolt for bearing housings

7 Locking screw for fan 42 Screw for ventilator

8 Oil seal for wormshaft 43 Ventilator

9 Bolt for wormshaft oil catcher 44 Ventilator packing

10 Oil catcher for wormshaft 45 Grease lubricator for wheelshaft bearing

11 Shim for wormshaft oil catcher 46 Shim for lower bearing housing

12 Bearing for wormshaft 47 Eye bolt

13 Oil flinger for wormshaft 48 Oil seals for wormshoft

14 Wormshaft 49 End cover for wormshaft-fon end

15 Bolt for wheelshaft end covers 50 Shim for wormshaft oil catcher

16 Oil seal for wheelshaft 51 Circlip for wormshaft17 Oil catcher for wheelshaft 52 Bearing for wormshaft

18 Shim for wheelshaft 53 Oil flinger for wormshaft

19 Bearing for wheelshaft 54 Wormshaft

20 Nilos ring for upper wheelshaft bearing 55 Distance piece

21 Distance piece for wheelshaft 56 Distance piece - small

22 Wheelshaft 57 Locknut

23 Key for wheelshaft 58 Screw for locknut

24 Wormwheel 59 Bearing for wormshaft

25 End cover for wheelshoft 60 Oil catcher for wormshaft

26 Dipstick 61 Oil seals for wormshaft

27 Dipstick tube 62 Input key28 Dipstick body 63 Output key

29 Dipstick body locknut

30 Fibre washer for drain plug

Note : Item 1 to 47 are only for unit Sizes V1000 to V1400.

Items 48 to 61 are only for unit Size V1700 Item 62 & 63 not shown.


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Shaft Mounted Gears

Type 'OD' Single Reduction Units : Sizes 400 To 1400

NAMEPLATE DETAILS ESSENTIAL 23 Expanding plug for 1st reduction 48 Ventilator for 2nd reduction case

FOR CORRECT PARTS wormwheel 49 Ventilator packing

IDENTIFICATION 24 1 st reduction wormwheel 50 Oil scraper

1 1 st reduction case 26 Nut for stud 51 Eyebolt (unit sizes 700 and 800)

2 Upper half 2nd reduction case 25 Stud for 1st reduction case 52 Bolt for 2nd reduction case joint

3 Lower half 2nd reduction case 27 Shim for 1st reduction 53 Dipstick (unit size 400 is fitted

4 Oil catcher for 1st reduction wormwheel with oil level plug) wormshaft

wormshaft 28 Oil seal for 2nd reduction 54 Nameplate

4A Oil catcher for 1st reduction wormshaft 55 Rivet for nameplatewormshaft (unit sizes 800 to 1400) 29 Bearing for 2nd reduction 60 Upper half, 2nd reduction case

5 Bolt for oil catcher wormshaft 61 Lower half, 2nd reduction case

6 Shim for 1st reduction 30 2nd reduction wormshaft 62 Packing for cose joint - not

wormshaft oil catcher 31 Key for 2nd reduction wormshaft provided for size 1000

7 End cover for 1st reduction 32 Shim for 2nd reduction 63 Bolt for case joint

wormshaft (unit sizes 400 to 700) wormshaft end cover 64 Nut for case joint bolt

8 Oil seal for 1st reduction 33 End cover for 2nd reduction 65 Bolt for case joint

wormshaft wormshaft 66 Nut for case joint bo

8A Oil seal for 1st reduction 34 Bolt for 2nd reduction 67 Fibre washer for inspection plug

wormshaft (unit sizes 800 to 1400) wormshaft end cover 68 Inspection plug

9 Bearing for 1 st reduction 35 Oil seal for 2nd reduction 69 Dipstick

wormshaft wheelshaft 70 Dipstick tube

10 1st reduction wormshaft 36 Oil catcher for 2nd reduction 71 Dipstick bod

11 Fan (unit sizes 800 to 1400) wheelshaft 72 Locknut for dipstick body12 Locking screw for fan (unit sizes 37 Shim for 2nd reduction 73 Drain plug

800 to 1400) wheelshaft covers 74 Fibre washer for drain plug

13 Cowl (unit sizes 800 to 1400) 38 Bearing for 2nd reduction 75 Eyebolt

14 Bolt for cowl (unit sizes 800 to wheelshaft 76 Screw for ventilator

1400) 39 Distance piece for 2nd reduction 77 Ventilator

15 Spring washer for cowl bolt (unit wheelshaft 78 Packing for Ventilator

sizes 800 to 1400) 40 2nd reduction wheelshaft 79 Oil scraper

16 Drain plug for 1st reduction case 41 Key for 2nd reduction 80 Nameplate

17 Breather plug for 1st reduction wheelshaft 81 Rivet for nameplate

case 42 2nd reduction wormwheel 82 Key retaining plate

20 1 st reduction wormwheel 43 End cover for 2nd reduction 83 Bolt

bearing housing wheelshaft 84 Grease Nipple

21 Shim for 1st reduction 44 Drain plug for 2nd reduction case 85 Nilos Ring (not shown in above

wormwheel bearing housing 45 Stud for 2nd reduction case join sketch)22 Bearing for 1st reduction 46 Nut for Stud 2nd reduction case 86 Input key

wormwheel 47 Screw for ventilator 87 Output key

Note: Item 23 is only for unit sizes OD 400 to OD 800, Item 82 & 83 are only for unit sizes OD 1000 to OD 1400. Item 85 to 87 not shown.

The 2nd reduction case of unit sizes 1000 to 1400 are of a design different to that of sizes 400 to 800. Items 60 to 81 replace Items 2, 3, 44 & 55.


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Type 'VD' Double Reduction Units : Sizes 400 To 1700

Note: Item 18 is only for unit sizes VD 400to VD 800, Item 61 & 62 are only for sizes VD 1000 to VD 1700.

Parts 2, 40 to 44, 51 to 60 applicable for Unit sizes 1000 to 1700 are shown on right portion of the sketch. Item 64 & 65 not shown.

NAMEPLATE DETAILS ESSENTIAL 19 1 st reduction wormwheel bearing housingFOR CORRECT PARTS 20 Shim for 1 st reduction 44 Eye boltIDENTIFICATION wormwheel 45 Stud for 1 st reduction case1 1 st reduction case 21 Oil seal for 1st reduction 46 Nut for 1 st reduction case2 2nd reduction case 22 Bearing for 2nd reduction 47 Drain plug for 1st reduction case3 Oil catcher for 1 st reduction 23 Oil flinger 48 Breather plug

wormshaft 24 2nd reduction wormshaft 51 Screw for ventilator3A Oil catcher for 1st reduction 25 Key for 2nd reduction 52 Ventilator

wormshaft (unit sizes 800 to 26 Shim for 2nd reduction end 53 Ventilator packing1400) Cover 54 Dipstick

4 Bolt for 1 st reduction 27 End cover for 2nd reduction 54 A Dipstick tube

wormwheel wormshaft 54 B Dipstick body5 Shim for 1st reduction 28 Bolt for 2nd reduction end cover 54 C Locknut for dipstick bodywormshaft oil catcher29 Oil seal for 2nd reduction 55 Inspection cover6 End cover for 1 st reduction wheelshaft 56 Bolt for inspection coverwormshaft (unit sizes 400 to30 2nd reduction wheelshaft oil 57 Extension pipe for lower nipple700) catcher

57A Socket for lower grease nipple7 Oil seal for 1 st reduction 31 Grease nipple for 2nd reduction58 Drain plug for 2nd reductionwormshaft

wheelshaft bearingcase7A Oil seal for 1st reduction

32 Shim for 2nd reduction58 A Fibre washer for drain plugwormshaft (unit sizes 800 to wheelshaft

1400) 59 Nameplate33 Bearing for 2nd reduction

8 Bearing for 1st reduction 60 Rivet for nameplatewheelshaftwormshaft 61 Key retaining plate34 Nilos Ring for 2nd reduction

9 1st reduction wormshaft 62 Boltwheelshaft bearing10 Fan (unit sizes 800 to 1400) 63 Washer (For 700)35 Distance piece for 2nd reduction11 Locking screw for fan (unit 64 Input keywheelshaft

size800 to 1400) 65 Out key36 2nd reduction wheelshaft12 Cowl (unit sizes 800 to 1400) 37 Key for 2nd reduction13 Bolt for cowl (unit sizes 800 to Refer page 10 for the followingwormwheel

1400) additional ports for VD 1700: Circlip38 2nd reduction wormwheel14 Spring washer for cowl bolt (unit (51), Additional wormshaft bearing39 End cover for 2nd reduction

sizes 800 to 1400) (52), Distance piece (55), Distancewheelshaft15 1 st reduction wormwheel piece (56), lockout (57), Screw for

40 Lower b'earing housing for 2ndbearing housing Locknut (58), Bearing for wormshaftreduction wheelshaft

(59). Not shown in above sketch.16 Shim for 1 st reduction 40A Shim for lower bearing housingwormwheel bearing housing

41 Bolt for 2nd reduction lower17 Bearing for 1 st reduction bearing housing

wormwheel42 Upper bearing housing for 2nd

18 Expanding plug for 1st reductionreduction wheelshaft

wormwheel43 Bolt for 2nd reduction upper


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Premium Heavy Duty Stirrer Units : Type Hds - Sizes 400 To 1700

311 Lower bearing housing

312 Oil seal housing

313 Lower bearing

314 Oil seal

315 Shim for oil seal housing

316 Bolt for oil seal housing

317 Output shaft

318 Upper bearing

319 Distance piece

320 Nilos ring

Parts shown above are substitute/

additional parts. All other parts

are common to standard V type

unit of respective size.

351 Motor plate

352 Hinge pin for motor plate

353 Bolt for motor plate

354 Eye bolt

355 Bolt for eye bolt

356 Nut for eye bolt

357 Washer for eye bolt

358 Support bracke

359 Bolt for support bracket

360 Cover plate

361 Lubricator extension

362 Oilfiller

Hinged Motor Plates For Stirrer Units : Sizes 400 To 1700


Case and cowl of sizes 400-800 and upper bearing housing of Sizes 1000-1700 are modified for lifting motor plate.

Quote item Numbers 371, 372, 373 for these modified components respectively/


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18

Type CT sizes 400 to 1400


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19

Type CT sizes 400 to 1400

401 Plug 428 Fibre washer for plug

402 Oil seal for wheelshaft 429 Plug

403 Bolt for wheelshaft covers 430 Bolt for swash plate

404 Grease nipple 430A Washer405 Oil seal housing 431 Bolt for bearing housing

406 Bearing for wheelshaft-top 432 Bolt for cowl

407 Bearing for wheelshaft - bottom 433 Spring washer

408 Upper bearing housing 434 Cowl

409 Eye bolt 435 Locking screw for fan

410 Wheelshaft 436 Fan

411 Oil filler/drain connection 437 Oil catcher for wormshaft

411A Oil level plug (NOT SHOWN) 438 Bearing for wormshaft

412 Case 439 Oil flinger for wormshaft

413 Wormwheel 440 Wormshaft

414 Key for wormwheel 441 Ventilator connection415 Inspection cover 442 Shim for wormshaft covers

416 Bolt for inspection cover 442A Shim for wheelshaftcover

417 Ball retainer 443 Oil catcher for wormshaft

418 Ball 444 Oil seal for wormshaft

419 Ball seat 445 Name plate

420 Spring 446 Rivet for name plate

421 Pin 447 Oil strainer (1000 To 1400)

422 Plunger 448 Brand nameplate

423 Distance piece (400 to 700)

424 Lower bearing housing 449 Washer for 700

425 Shim 450 Key - wheelshaft426 End cover for wheelshaft 451 Key - wormshoft

427 Swash plate



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Premium cooling tower units

401 Plug402 Oil seal for wheelshoft

403 Bolt for wheelshaft covers

404 Grease nipple

405 Oil seal housing

406 Bearing for wheelshaft - top

407 Bearing for wheelshaft - bottom

408 Upper bearing housing

409 Eye bolt

410 Wheelshaft

411 Oil filler/drain connection

411A Oil level plug (NOT SHOWN)

412 Case

413 Wormwheel

414 Key for wormwheel

415 Inspection cover

416 Bolt for inspection cover

420 Spring

422 Plunger

423 Distance piece

424 Lower bearing housing

425 Shim


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21

Type CT

426 End cover for wheelshaft 446 Rivet for name plate427 Swash plate 447 Oil strainer

428 Fibre washer for plug 448 Pump housing

429 Plug 449 Gasket - pump cover

430 Bolt for swash plate 450 Set screw - pump cover

431 Bolt for bearing housing 451 Plunger body

432 Bolt for cowl 452 Shim - plunger body

433 Spring washer 453 Cap screw - plunger body

434 Cowl 454 Ball

435 Locking screw for fan 455 Spring

436 Fan 456 Pipe assembly ,for pump

437 Oil catcher for wormshaft 457 Circlip - wormshaft

438 Bearing for wormshaft 458 Distance piece

439 Oil flinger for wormshaft 459 Bearing for wormshaft

440 Wormshaft 460 Bearing for wormshaft

441 Ventilator connection 461 Lock nut

442 Shim for wormshaft covers 462 Screw for lock nut

442A Shim for wheelshaft cover 463 Distance piece

443 Oil catcher for wormshaft 464 Key - wheelshaft

444 Oil seal for wormshaft 465 Key - wormshaft

445 Name plate


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23

Note : Item 21 3 is only for unit sizes 700 and 204 Oil Seal housing

800 and not shown in above sketch. 205 Duplex bearing

Parts shown above are substitute/additional 206 End cover

parts for the with sleeves sleeve bearing 207 Input shaft with sleeves

feature. All other parts are common to 208 Wormwheel

standard unit of respective size. 209 Locknut210 Lockwasher

201 Case 211 Bolt for oil seal housing

202 Bearing housing with white metal/bronze 212 Bolt for end cover

sleeve-driving end 213 Spacer

203 Bearing housing with white metal/bronzesleeve-closed end

Premium lift units (Sleeve bearings on input shaft) : Type SLA

Sizes 500 to 1200

301 Output shaft

302 Roller bearing

303 Distance piece

304 Nilos ring

See page 1 7 for motor plate parts.

Parts shown above are

substitute/additional parts. All

other parts are common to

standard V type unit of respective

size.

Premium standard duty stirrer units : Type STR

Sizes 400 to 1700


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Premium Speed Reducer units are supplied without oil and must be filled Premium Traxol

lubricant to the correct level. It is important to ensure that the correct oil level is not

exceeded as over filling causes oil churning, resulting in overheating and leakage.

Extreme Pressure (E.P.) Lubricants

Extreme Pressure (E.P.) lubricants or cylinder oils with sulphur phosphorus additives are

not acceptable and should not be used in worm gearing.

Use only

PREMIUM

TRAXOL - G32

Caution

Vertical gearboxes have dry well

arrangement on the output line.

Please fill oil in between marks 'L'

and 'H' of dipstick. Excess oil filled

beyond level 'H' may lead toleakage of oil through output seal.

MANUFACTURER BRAND NAME - SYNTHETICS OIL

Henkel Corp./Emery Group Emery - 2843 Synthetic Lubricant

Mobil Oil Corporation Mobil SHC634 Synthetic Lubricant

MANUFACTURER BRAND NAME - MINERAL OIL

Bharat Petroleum Cabol 320

Tide Water Avalon 320

Castrol Alpha ZN 320

Chemoleums Erato 320

Gulf Oil Gulf Harmony AWC 320

IOCL Servosystem 320

Hindustan Petroleum Enklo 320

RECOMMENDED LUBRICANTS

LubricationThe Premium Speed Reducer lubrication system is self contained positive and automatic at

all speeds of operation and in either direction of rotation. Adaptable units are provided

with breather, oil level and drain plugs and it must be ensured that these are correctly

positioned as shown on the accompanying diagram. Other units incorporate a dipstick for

oil level checking, an oil filler-cum-ventilatorand drain plugs. Their locations are shown

on the following page.

OIL LEVELS


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Oil capacity and shipping specification

Size of unit

112 162 200 237 287 337

Net Weight (kg.) 5 7 13 20 31 49Gross Weight (kg.) 5 8 14 21 34 50

Volume Packed (cu.m.) 0.004 0.007 0.013 0.022 0.034 0.048

Oil Required at 1st filling (lit.) 0.14 0.28 0.28 0.57 0.85 1.42

A supply of oil is not included in any unit

Size 400 500 600 700 800 1000 1200 1400 1700

Net Weight (kg.) 77 109 145 200 254 465 690 970 1750

Gross Weight (kg.) 90 125 163 226 286 580 830 1250 2100

Volume Packed (cu.m.) .12 .17 .21 .28 .44 1.0 1.4 1.9 2.8

Packed (cu.m) wheelshaft down .11 .15 .19 .25 .39 .9 1.3 1.75 2.6

Oil Required at 1st filling (lit.) 4.0 5.7 6.3 10.2 12.5 22.7 37.4 68.5 105

Size 400 500 600 700 800 1000 1200 1400 1700

Net Weight (kg.) 68 95 125 172 218 350 540 864 1340Gross Weight (kg.) 79 109 140 191 244 395 635 928 1440

Volume Packed (cu.m.) .08 .12 .15 .21 .27 .48 .76 1.1 1.7

Oil Required at 1st filling (lit.) 3.0 4.3 6.3 9.1 11.4 15.9 22.7 36.4 45

Approximate Shipping Specification and Oil Capacities

Approximate Shipping Specification and Oil Capacities

As improvements in design are continually being made, this specification in not regarded

as binding in detail, and dimensions are subject to alteration without notice.

As improvements in design are continually being made, this specification in not regarded

as binding in detail, and dimensions are subject to alteration without notice.

OIL CAPACITIES FOR FIRST FILLING (in litres)

SIZE 112 162 200 237 287 337

A 0.1 0.3 0.3 0.6 0.9 1.4

Adaptable Units SINGLE REDUCTION UNITS

SIZE 400 500 600 700 800 1000 1200 1400 1700

U 3.0 4.3 6.3 9.1 11.4 17.5 23.0 37.0 45.0

O 2.3 2.8 4.0 5.7 9.1 11.0 15.0 24.0 --

V 4.0 5.7 6.3 10.2 12.5 22.7 37.4 68.5 105

Types U, O, V


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Grease :

Grease multipurpose grease or wheel bearing grease of any reputed Make.

Thread Locks :

Sealant used Loctite Make Medium Blue 243 Thread locker or equivalents can be used.

Casking Compound :

574 Flange sealant or equivalent can be used

Breathers :

Breathers are provided on the gearbox. Please see that these are not clogged or choked up.

Regular clearing of the breathers must be carried out.

Bearings :

Type of bearings used Taper Roller and Double row Spherical Roller bearings for helical

gearbox of reputed make.

Oil Seals:

SIZE UNIT 162 200 237 287 337

AUD Primary Unit 0.1 0.1 0.3 0.3 0.3

AOD

AVD Secondary Unit 0.3 0.3 0.6 0.9 1.4

Types AD DOUBLE REDUCTION UNITS

Types UD, OD, VD

The above oil quantities are approximate as improvements in design are continually being made.

This specification is not to be regarded as binding in detail and dimensions are subject to alteration

SIZE UNIT 400 500 600 700 800 1000 1200 1400 1700

UD Primary Unit 0.6 0.6 1.1 1.7 2.8 4.0 5.7 9.1 11.4

Secondary Unit 3.0 4.3 6.3 9.1 11.4 17.5 23.0 37.0 45.0

OD Primary Unit 0.6 0.6 1.1 1.7 2.8 4.0 5.7 9.1 --

Secondary Unit 2.3 2.8 4.0 5.7 9.1 11.0 15.0 24.0 -

VD Primary Unit 0.6 0.6 1.1 1.7 2.8 4.0 5.7 9.1 11.4Secondary Unit 4.0 5.7 6.3 10.2 12.5 22.7 37.4 68.5 105


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Fig. 3

Fig. 4

Fig. 1 Fig. 2

Paints

Types of Pint used Air drying Blue Hammertone paint Asian Paint India. Acolite

Hammertone finish (air drying)

Noise LevelsFeel the noise of the gear unit at regular internals. In caseof notice level is abnormal

(beyond 85db) use ear mask, stop the prime mover and check the alignments and

conditions of bearing after gear unit cools down to safe level.

Vibrations

Please check the vibration of the gear unit periodically. The maximum vibration limit

allowed for helical gear unit is 75-micron displacement.

Electrical Connections

The gear units are not supplied with electrical connection. The prime mover like electrical

motor needs experienced and trained personnel to connect it to the power line.

Assembly / Dismantling

Lining Up

Errors of alignment fall into the categories of angularity (Fig. 1) and eccentricity (Fig. 2),

or combinations of both. Angularity error should be corrected first by using feeler gauges

(Fig. 3) and arriving at a constant gap measured every 90 of rotation, rotating both

halves simultaneously. Eccentricity error can be corrected by using a straight edge (Fig. 4)

if both couplings have the same outside diameter. If not a straight edge should be used in

conjunction with a feeler gauge equal to half the difference in diameters. Here also

checking should be done every 90 while rotating both halves simultaneously.


30/40

Where a Premium Speed Reducer with shafts mounted on ball or roller bearings, is

coupled to a prime mover or a driven machine with plain bearings, an allowance for "lift"

should be made to accommodate the probable change in centre height when running, due

to thickness of the oil film and upward reaction (if any) under load.

No hard and fast rule can be given as to the exact amount of correction to allow and this,

dependent upon so many factors peculiar to individual cases, is largely a matter ofexperience.

Allowance For Bearing Clearance

Any change in temperature will alter the height of a shaft above its foundations. If there is

much difference between the temperature of a gear casing and that of the driven machine,

or prime mover, the resulting difference in level may be appreciable. The coefficient of

linear expansion of cast iron is 0.000011 mm per mm per C; hence with a centre height

of 500mm above the bedplate and difference in temperature of 30C between the gear

casing and the machine, the error of alignment, if correct when cold, will be 0.165mm.

Such conditions may, particularly in the case of large units and those which are close-coupled, impose very severe loads on the bearings. If this is so, it is recommended that an

allowance be made so that the alignment will be more nearly correct under normal

Effect of Temperature

7.0 INSTALLATION

It is preferable, although not essential, to mount the gear unit and prime mover on a

common bedplate. Any foundation used should be rigid so as to minimise the effect of

fluctuating or heavy loads. When lowering a bedplate on to its foundation flat steel

packings should be used, placed on either side and as close as possible to each foundation

bolt. Packings should also be placed in such a position that support is given in the plane of

the coupling faces. Care must be taken so as not to spring the bedplate when the final

bolting down is carried out after the unit and prime mover have been lined up, as strains

may be set up in the gear casing and errors of alignment in shafts and gears may be

introduced. It is advisable to check the alignment after bolting down, even when a gear

unit and motor have been assembled and lined up on a bedplate.

After installation and lining up has taken place, the two opposite feet should be drilled,

reamed and dowels fitted.

FOOT MOUNTED GEAR UNITS :

28


31/40

Tightening Torques For Gearbox Casing, Covers, Bearing housings etc.

Sr. No. Bolt size in mm Torque in NM

1 M 16 * 80

2 M 20 * 160

3 M 24 * 270

4 M 27 * 400

5 M 30 * 540

6 M 36 * 920

* THESE ARE BOLTS OF 4.6 GRADES

Sr. No. Bolt size in mm Torque in NM

1 M 10 ** 40

2 M 12 ** 70

3 M 16 ** 180

4 M 20 ** 350

5 M 22 ** 470

6 M 24 ** 580

* THESE ARE BOLTS OF 8.8 GRADES

SHAFT MOUNTED GEAR UNIT :

29

Torque arms are available for double and triple reduction shaft mounted units with parallelor right angle shafts, type H2S, H3S, B2S and B3S. They are supplied as optional extras andare secured to gear cases as shown below.

Torque arms must be secured to the chassis structure in a flexible mounting, as indicated,0

within a maximum angle of 30 between the vertical plane and a plane towards the gear unitoutput shaft as illustrated.

Shaft mounted units are designed to operate in the horizontal position. Reference must be

made to Premium with full details, where units are required to operate in an inclined position0or where torque arm mounting positions exceed the 30maximum angle of inclination to the vertical plane.

Shaft mounted units for High Inertia Drive

When used on Traverse drives with high inertia driven loads, e.g. crane drives (slewing, longtravel and cross travel) boggie drives and selected high inertia load roller table drives, it isrecommended that shaft mounted units should be fitted with shock absorbing Torque Arms.Consult Premium with specificapplication details.


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30

THE TORQUE ARM MUST BE FLEXIBLY MOUNTED TOTHE CHASSIS STRUCTURE

EACH PAIR OF DISC SRINGS

TO BE COMPRESSED

X MM ON ASSEMBLY

G

E

D

H

F


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31

8.0 MAINTENANCE

Type O 400-1400Type U 400-1700

L

B

D

B

D

L

Type V 400-1700

D

G

G

B

L

(1) WEEKLY INSPECTION(a) Check the oil level by means of the dipstick or oil level plug and if necessary, top up

with the recommended grade of lubricant.

(b) Ensure that breathers are cleaned regularly. Care must be taken not to paint over the

breathers, otherwise pressure will build up, resulting in oil leakage.

(c) On units having grease lubricated bearings, add two shots of grease from a grease

gun, or where screw-in type lubricators are fitted, screw in the lubricator two turns

and refill when necessary with the recommended grease.

(2) OIL CHANGES

Regular oil changes are essential to ensure that the unit gives long and trouble-free

service. The frequency at which the oil should be changed is determined by the following

factors :

(a) Oil temperature-unit operating under load

(b) Type of oil-plain or containing additives

(c) Environment-humidity, dust etc.

(d) Operating conditions-shock loading etc.

At elevated temperatures the effective life of the oil is very much reduced. This is most

pronounced with oil containing fatty and E.P. additives. To prevent unit damage through

lubricant breakdown, the oil should be renewed as shown in the following tables :


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32

Axial Floats

After assembling it is essential that shaft end floats be correctly set. Thefollowing axial floats for wormshaft and wheelshaft are recommended.However it is better to maintain axial float at lower recommended value.They should be checked preferably using a dial indicator gauge mountedon a magnetic base.

Using Oils Containing Additives0

Temp. C Adaptables Other Units

75 or less 2500 hr. or 6 months 5000 hr. or 12 months

80 1500 hr. or 6 months 3000 hr. or 6 months



--- whichever is the shorter period

Note : Figures quoted in the table are for oil temperatures when the unithas attained normal running temperature when operating under load.These figures are based on normal running but where conditions areparticularly severe it may be necessary to change the oil more frequently.

Consult the lubricant supplier regarding presence of E.P. additives in thegrades supplied by them.

Primary Units on type AUD, AOD, AVD UnitsSizes 162-337

L

D D

Primary Units on type UD and VD UnitsSizes 400 -1700 and on types OD Sizes 400 - 1400

B

D

L

LD

Dipstick as fitted on unitssize 1000 and above

B - Breather/Filler plugL - Oil level Plug/dipstickD - Drain plugG - Grease lubricator

L


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Size Wormshaft Wheelshaft(mm) (mm)

112 0.025/0.075 0.025/0.050

162 0.025/0.075 0.025/0.050

200 0.025/0.075 0.025/0.050

237 0.025/0.075 0.025/0.050

287 0.025/0.075 0.025/0.050

337 0.025/0.075 0.025/0.050

400 0.050/0.100 0.025/0.050

500 0.050/0.100 0.025/0.050

600 0.050/0.100 0.025/0.050

700 0.050/0.100 0.025/0.075

800 0.050/0.100 0.025/0.075

1000 0.050/0.100 0.025/0.075

1200 0.075/0.125 0.050/0.100

1400 0.075/0.125 0.050/0.100

1700 0.075/0.125 0.050/0.100


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Do's Don'ts

Sr. No. Area of Maintenance Frequency Work to be done

1 Breathers Weekly Clean the Breathers to avoidclogging. Keep one set of breathersduly cleaned as stand by for easyreplacement.

2 Greasing Weekly On the Grease points whereverprovided.

3 Surfaces of the Gear unit As Needed Check oil level as per dispstick oroil level indicator glass, top up ifrequired.

4 Foundation bolts Fortnightly Ensure foundation bolts areproperly tightening.

Recommended Maintenance Schedule For Gearboxes

Other points of maintenance to be followed as per the instructions

given in IOM

Use recommended grade of oil Do not use any other oil

Fill oil up to Dipstick marking only Do not fill excess or less oil

Breather should be clean. Check it's condition Do not keep breather in choked conditionperiodically

Align gearbox correctly with Motor as per Do not run gearbox without ensuring alignmentmanual instructions

Check oil level periodically, top up the level Do not run gearbox without checking oil levelIf necessary

Change oil in gearbox periodically Do not run gearbox without changingoil for long time- Refer manual

Change oil seals during overhauling Do not use same oil seals again & Again

While fitting oil seals, clean shaft diameter Do not fit oil seal on unclean & Damaged

& catcher face and then fit oil seal with proper oil seal diameter, also don't Hammeroil seal adapter the oil seal

Use oil seals as per specifications provided by Do not use any local make oil sealsPremium only

Keep end float as recommended Do not keep excess or less end float

Ensure correct contact & backlash while Do not run gearbox without ensuring correctassembling after dismantling or overhauling contact & backlashthe gearbox

While assembling gearbox after dismantling / After dismantling / overhauling, do not assembleoverhauling, ensure the oil channels / holes gearbox leaving oil channels, holes, in cloggedprovided for lubrication are cleaned properly condition

Apply few drops of oil on oil seal lip while Failure to adhere to this instruction may leadstarting to wet it prior to starting, if gearbox is to oil seal failure due to dry running ofidle for long time the oil seal lip

While assembly, use bevel gears & pinions in Do not interchange bevel gears & pinionspairs only

In case the gear unit is stored beyond three Failure to perform this operation may resultmonths, please rotate the gear box input shaft in reduced bearing lifefew times by hand.


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9.0 TROUBLE SHOOTING CHART

TYPICAL CAUSES

SYMPTOM Lubricant Oilseal Lip Clogging of Play Improper Backlash Environmental OperationalAlignment

Unsui table Insuf fi cien t Ove rf il ling Hardened Damaged B reathe r Excess Less Con tact More Less Dust Hea t Chemica l Ove rload V ibra tion H igh Speed Low Speed

Oilseal Leakage

Noise

Over Heating

Bearing Failure

Wormwheel Worn Out

Joint Leakage

Oil Oozing out through Ventilator

Oil Leakage through Output Oilseal (V Type)

Special points to be observed : l Use of correct grade of oil l Fill oil to the correct level l Change oil periodicallyl Check alignment of Input and Output shaft

l Ventilator to be kept clean


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36

10.0 DISPOSAL OF GEAR UNITS/ PARTS

Disposal of used Parts :-l The fans & cowls made off polypropylene or Engineering plastics is to be dis posed off

as per IS or International standards.


39/40


40/40

PREMIUM/WM/CA/107

Premium Transmission LimitedHead Office : Premium House, Mumbai-Pune Road, Chinchwad, Pune - 411019, India.

Tel. : (91-20) 27488886 / 27488947, Fax : (91-20) 27450287 / 27472384

Website : www.premiumtransmission.com

Manufacturing Units :Unit-I : Old Mumbai - Pune Road, Chinchwad, Pune - 411 019, India. Tel. : 91-20- 66314100 Fax : 91-20- 27450287, 27472384.Unit-II : Falta Industrial Growth Centre, Sector-III, Falta, 24 Parganas (South), West Bengal 743504, India. Tel.: 91-3174-222231 / 32 / 33 / 37, Fax : 91-31749

222234. Unit-III : G-56 / 57, MIDC Industrial Area, Chilkalthana, Aurangabad - 431 210, India. Tel.: 91-240-2485521, 2485856, 2485056, Fax : 91-240-2485756.

Unit-IV : 31-P, MIDC Industrial Area, Chilkalthana, Aurangabad - 431 210, India. Tel.: 91-240-2482858, 2471298, Fax : 91-240-2482857.

Regional Offices :Mumbai : Corporate Park II, 4th Floor, Sion, Trombay Road, Chembur, Mumbai - 400071, India. Tel.: 91-22-25264750, 25264763, Fax : 91-22-25262622, 25264800. New Delhi : Express Building Annexe, 9-10, Bahadhur Shah Zafar Marg, New Delhi - 110 002, India. Tel. : 91-11-23730554 (8 Lines),

Fax : 91-11-23359782 / 23357739. Kolkata : Thapar House, 25, Brabourne Road, Kolkata - 700 001, India. Tel.: 91-33-22424316, 22423780, 22423805,

22424317 / 20 / 21, 22438815, 22420817, Fax : 91-33-22424325. Chennai : "Wavoo Mansion", 7th Floor, New No. 48 (Old No. 39) Rajaji Salai, Chennai - 600

001, India. Tel.: 91-44-25255200, 91-44-25224557. Nagpur : Plot No 15, State Bank Colony, Ujjwal Nagar, Somalwada, Wardha Road, Nagpur - 25. Mobile : (0)

9425009827

Branch Offices : Ahmedabad : Jaldarshan' Ashram Road, Navrangpura, Ahmedabad - 380 009, India. Tel.: 91-79-26580428 / 0518 / 1856 / 1857 / 1861, Fax :

91-79-26587783. Bangalore : 16/3, Ali Asker Road, Off Cunningham Road, Bangalore - 560 052, India. Tel.: 91-80-22262062, Fax : 91-80-22253472. Hyderabad

: 6-2-47, A, C. Guards, 1st Floor, Hyderabad - 500 004, India. Tel.: 91-40-23314025, 23316446, 23390544, Fax : 91-40-23318557. Kochi : 39/5567, M. G. Road,

Emakulam, Kochi - 682 015, India. Tel.: 91-484-2359661, 2359372, 2359190, Fax : 91 484-2359589.

Representative Offices : Lucknow : G-701, Halwasiya Utsav Enclave, Opposite HAL, Faizabad Road, Lucknow - 226 016, India. Tel.: 91-522-4001344, Mobile

: (0) 9793581144. Mohali : House No. 33, 1st Floor, Phase - XI, Sas Nagar (Mohali), Punjab - 160 062, Tel.: 91-172-2230633, Mobile : (0) 9814640863.

Documents

Intall Maint Worm Gb