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PREMIUM

WORM SPEED
REDUCERS
Installation and Maintenance
INSTALLATION AND ROUTINE MAINTENANCE

1.0 PREMIUM OVERVIEW

2.0 GENERAL INFORMATION


INTRODUCTION WARM UNITS
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
DO’S AND DON’TS
CONTACTS MARKINGS, BEARING END FLOATS, TIGHTENING TORQUE
TEMP CHECK

9.0 TROUBLESHOOTING
TROUBLE SHOOTING CHART

10.0 DISPOSAL OF GEAR UNITS/ PARTS

1
INSTALLATION
PREMIUM OVERVIEW
AND ROUTINE MAINTENANCE

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 Premium Transmission Ltd.
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 of
worm 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 company’s product enjoy sustainable reputation for quality and
reliability, both in domestic as well as overseas market.
The company’s 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.

2
2.0 GENERAL INFORMATION

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.

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 in
this 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. PREMIUM/WM/CA/107.
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.

3
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 mounting
as indicated within a maximum angle of 300 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.

4
4.0 GEAR UNIT IDENTIFICATION

NAMEPLATE DETAILS :
Instructions in accordance with the requirements of ATEX 94/9/EC
The Gearbox is affixed with the nameplates as shown below
FOR CE MARKING FOR ATEX MARKING

India
Chinchwad, Pune - 411019

Explanation of above symbols is detailed below-


1. X-Special Instructions
WORM REDUCER 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
Premium Transmission Ltd.
UNIT-I,CHINCHWAD,
9. k- Components of the gearboxes partially or fully oil
PUNE-411019. INDIA
immersed
10. T4- Temp. class. Maximum surface temp. 135°C
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.
India
Chinchwad, Pune - 411019

Year of manufacturing.

WORM REDUCER

Premium Transmission Ltd.


UNIT-I,CHINCHWAD,

5
PUNE-411019. INDIA
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.
135°C

SPECIAL INSTRUCTIONS UNDER ‘X’


• Maximum Ambient operating Temperature + 5ºC to 50ºC
• 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.

SERVICE
Trained 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.

6
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.

WORM REDUCER

Premium Transmission Ltd.


UNIT-I,CHINCHWAD,
PUNE-411019. INDIA
Chinchwad, Pune - 411019India

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
5.0 HANDLING AND STORAGE

Procedure to unpack the gearbox from Packing:-

l 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.

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

8
Net Weights for Horizontal Units in kg (approx.)

Units Size
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 6540
H2SF 235 265 300 360 470 590 810 1090 1445 1970 2690 3540 4860 6540
H3 290 310 330 380 490 630 850 1150 1525 2080 2840 3780 5100 6900
H3SF 290 310 330 380 490 630 850 1150 1525 2080 2840 3780 5100 6900
H4 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 6900
B3SF 300 310 330 380 490 630 850 1150 1525 2080 2840 3780 5100 6900
B4 305 320 345 * * * * * * * * - - -
B4SF 305 320 345 * * * * * * * * - - -

*Refer to PREMIUM
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 without notice.

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 safe
temperature 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.

9
6.0 TECHNICAL INFORMATION
CLEANING FOR GEAR UNIT :
Adaptable double reduction units : Sizes 162 to 337

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
10 21 1st reduction wormwheel bearing housing
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 wheel
relative 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.

INCORRECT* CORRECT INCORRECT*


Move Wheel Contact marking clear on Move Wheel
entering side to provide oil
‘‘Lead in’’ when
running under load

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

11
Parameters
Type '0' Single Reduction Units : Sizes 1000 To 1400

NAMEPLATE DETAILS ESSENTIAL FOR 23 Oil seal for wheelshaft


CORRECT 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 joint
11 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

12
Type 'v' Single Reduction Units : Sizes 400 To 800

NAMEPLATE DETAILS ESSENTIAL FOR 23 Distance piece for wheelshaft


CORRECT 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 400
10 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
Note : Item 44 & 45 not shown

13
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 cover
6 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 wormshaft
17 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 key
28 Dipstick body 63 Output key
29 Dipstick body locknut Note : Item 1 to 47 are only for unit Sizes V1000 to V1400.
30 Fibre washer for drain plug Items 48 to 61 are only for unit Size V1700 Item 62 & 63 not shown.

14
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 nameplate
wormshaft (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 body
12 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.

15
Type 'VD' Double Reduction Units : Sizes 400 To 1700

NAMEPLATE DETAILS ESSENTIAL 19 1 st reduction wormwheel bearing housing


FOR CORRECT PARTS 20 Shim for 1 st reduction 44 Eye bolt
IDENTIFICATION wormwheel 45 Stud for 1 st reduction case
1 1 st reduction case 21 Oil seal for 1st reduction 46 Nut for 1 st reduction case
2 2nd reduction case 22 Bearing for 2nd reduction 47 Drain plug for 1st reduction case
3 Oil catcher for 1 st reduction 23 Oil flinger 48 Breather plug
wormshaft 24 2nd reduction wormshaft 51 Screw for ventilator
3A 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 packing
1400) Cover 54 Dipstick
4 Bolt for 1 st reduction 27 End cover for 2nd reduction 54 A Dipstick tube
wormwheel wormshaft 54 B Dipstick body
5 Shim for 1st reduction 28 Bolt for 2nd reduction end cover
wormshaft oil catcher 54 C Locknut for dipstick body
29 Oil seal for 2nd reduction 55 Inspection cover
6 End cover for 1 st reduction wheelshaft
wormshaft (unit sizes 400 to 56 Bolt for inspection cover
30 2nd reduction wheelshaft oil 57 Extension pipe for lower nipple
700) catcher
7 Oil seal for 1 st reduction 57A Socket for lower grease nipple
31 Grease nipple for 2nd reduction
wormshaft 58 Drain plug for 2nd reduction
wheelshaft bearing
7A Oil seal for 1st reduction case
32 Shim for 2nd reduction
wormshaft (unit sizes 800 to 58 A Fibre washer for drain plug
wheelshaft
1400) 59 Nameplate
33 Bearing for 2nd reduction
8 Bearing for 1st reduction wheelshaft 60 Rivet for nameplate
wormshaft 61 Key retaining plate
34 Nilos Ring for 2nd reduction
9 1st reduction wormshaft wheelshaft bearing 62 Bolt
10 Fan (unit sizes 800 to 1400) 35 Distance piece for 2nd reduction 63 Washer (For 700)
11 Locking screw for fan (unit wheelshaft 64 Input key
size800 to 1400) 36 2nd reduction wheelshaft 65 Out key
12 Cowl (unit sizes 800 to 1400) 37 Key for 2nd reduction
13 Bolt for cowl (unit sizes 800 to wormwheel Refer page 10 for the following
1400) 38 2nd reduction wormwheel additional ports for VD 1700: Circlip
14 Spring washer for cowl bolt (unit 39 End cover for 2nd reduction (51), Additional wormshaft bearing
sizes 800 to 1400) wheelshaft (52), Distance piece (55), Distance
15 1 st reduction wormwheel 40 Lower b'earing housing for 2nd piece (56), lockout (57), Screw for
bearing housing reduction wheelshaft Locknut (58), Bearing for wormshaft
16 Shim for 1 st reduction (59). Not shown in above sketch.
40A Shim for lower bearing housing
wormwheel bearing housing
41 Bolt for 2nd reduction lower
17 Bearing for 1 st reduction bearing housing
wormwheel
42 Upper bearing housing for 2nd
18 Expanding plug for 1st reduction reduction wheelshaft
wormwheel
43 Bolt for 2nd reduction upper

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.

16
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.

NAMEPLATE DETAILS ESSENTIAL FOR CORRECT PARTS IDENTIFICATION

Hinged Motor Plates For Stirrer Units : Sizes 400 To 1700

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

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/

17
Type CT sizes 400 to 1400

18
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 Washer
405 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 connection
415 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 - wheelshaft
426 End cover for wheelshaft 451 Key - wormshoft
427 Swash plate
NAMEPLATE DETAILS ESSENTIAL FOR CORRECT PARTS IDENTIFICATION

19
Premium cooling tower units

401 Plug
402 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

20
Type CT

426 End cover for wheelshaft 446 Rivet for name plate
427 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

21
Premium gearboxes with special features

101 Output shaft of high tensile steel


102 Output shaft extended on both sides-standard material
103 Output shaft extended on both sides-high tensile steel
104 Wider bearing on output shaft
105 Narrow distance piece for use with item 104
106 Roller holdback sub-assembly - for Sizes 400 upwards
107 Housing for roller holdback sub-assembly
108 Key for holdback sub-assembly
109 Circlip for holdback sub-assembly
110 Dustproof ventilator-tor Sizes 400 upwards
111 Wormshaft extended on both sides.

Parts shown above are substitute/additional parts for the


required feature All other parts are common to standard
unit of respective size and type.

NAMEPLATE DETAILS ESSENTIAL FOR CORRECT PARTS IDENTIFICATION

22
Premium lift units (Sleeve bearings on input shaft) : Type SLA
Sizes 500 to 1200

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 Locknut
210 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/bronze
sleeve-closed end

Premium standard duty stirrer units : Type STR


Sizes 400 to 1700

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.

23
OIL LEVELS
Lubrication
The 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.

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.

Caution
Vertical gearboxes have dry well
arrangement on the output line.
Please fill oil in between marks 'L'
Use only
and 'H' of dipstick. Excess oil filled PREMIUM
beyond level 'H' may lead to TRAXOL - G32
leakage of oil through output seal.

RECOMMENDED LUBRICANTS
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

24
Oil capacity and shipping specification
Size of unit
112 162 200 237 287 337
Net Weight (kg.) 5 7 13 20 31 49
Gross 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


Approximate Shipping Specification and Oil Capacities
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

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.
Approximate Shipping Specification and Oil Capacities
Size 400 500 600 700 800 1000 1200 1400 1700
Net Weight (kg.) 68 95 125 172 218 350 540 864 1340
Gross 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

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)


Adaptable Units SINGLE REDUCTION UNITS
SIZE 112 162 200 237 287 337
A 0.1 0.3 0.3 0.6 0.9 1.4

Types U, O, V
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

25
Types AD DOUBLE REDUCTION UNITS
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 UD, OD, VD


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 11.4
Secondary Unit 4.0 5.7 6.3 10.2 12.5 22.7 37.4 68.5 105

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

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:

26
Paints
Types of Pint used Air drying Blue Hammertone paint Asian Paint India. Acolite
Hammertone finish (air drying)

Noise Levels
Feel 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.

Fig. 1 Fig. 2

Fig. 3

Fig. 4 27
7.0 INSTALLATION

FOOT MOUNTED GEAR UNITS :

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.

Allowance For Bearing Clearance


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 of
experience.

Effect of Temperature
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 30°C 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

28
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 :


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

Torque arms must be secured to the chassis structure in a flexible mounting, as indicated,
within a maximum angle of 300 between the vertical plane and a plane towards the gear unit
output 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 position
or where torque arm mounting positions exceed the 300
maximum 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, long
travel and cross travel) boggie drives and selected high inertia load roller table drives, it is
recommended that shaft mounted units should be fitted with shock absorbing Torque Arms.
Consult Premium with specific
application details.

29
THE TORQUE ARM MUST BE FLEXIBLY MOUNTED TO
THE CHASSIS STRUCTURE

EACH PAIR OF DISC SRINGS


TO BE COMPRESSED
X MM ON ASSEMBLY

E

30
8.0 MAINTENANCE

(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 :

B B
B
L
G
L

D D
D

Type U 400-1700 Type O 400-1400 Type V 400-1700

31
Using Oils Containing Additives
Temp.0C 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
85 1000 hr. or 3 months 2000 hr. or 6 months
90 750 hr. or 3 months 750 hr. or 3 months
--- whichever is the shorter period

Note : Figures quoted in the table are for oil temperatures when the unit
has attained normal running temperature when operating under load.
These figures are based on normal running but where conditions are
particularly severe it may be necessary to change the oil more frequently.
Consult the lubricant supplier regarding presence of E.P. additives in the
grades supplied by them.
Primary Units on type AUD, AOD, AVD Units Primary Units on type UD and VD Units
Sizes 162-337 Sizes 400 -1700 and on types OD Sizes 400 - 1400
B

D D
D
L L
D
L

Dipstick as fitted on units


size 1000 and above
B - Breather/Filler plug
L - Oil level Plug/dipstick
D - Drain plug
G - Grease lubricator

Axial Floats
After assembling it is essential that shaft end floats be correctly set. The
following 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 mounted
on a magnetic base.

32
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

33
Do's Don'ts

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 condition
periodically
Align gearbox correctly with Motor as per Do not run gearbox without ensuring alignment
manual instructions
Check oil level periodically, top up the level Do not run gearbox without checking oil level
If necessary
Change oil in gearbox periodically Do not run gearbox without changing
oil 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 Hammer
oil seal adapter the oil seal
Use oil seals as per specifications provided by Do not use any local make oil seals
Premium 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 correct
assembling after dismantling or overhauling contact & backlash
the gearbox
While assembling gearbox after dismantling / After dismantling / overhauling, do not assemble
overhauling, ensure the oil channels / holes gearbox leaving oil channels, holes, in clogged
provided for lubrication are cleaned properly condition
Apply few drops of oil on oil seal lip while Failure to adhere to this instruction may lead
starting to wet it prior to starting, if gearbox is to oil seal failure due to dry running of
idle for long time the oil seal lip
While assembly, use bevel gears & pinions in Do not interchange bevel gears & pinions
pairs only
In case the gear unit is stored beyond three Failure to perform this operation may result
months, please rotate the gear box input shaft in reduced bearing life
few times by hand.

Recommended Maintenance Schedule For Gearboxes

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


1 Breathers Weekly Clean the Breathers to avoid
clogging. Keep one set of breathers
duly cleaned as stand by for easy
replacement.
2 Greasing Weekly On the Grease points wherever
provided.
3 Surfaces of the Gear unit As Needed Check oil level as per dispstick or
oil level indicator glass, top up if
required.
4 Foundation bolts Fortnightly Ensure foundation bolts are
properly tightening.

Other points of maintenance to be followed as per the instructions


given in IOM

34
9.0 TROUBLE SHOOTING CHART
TYPICAL CAUSES
SYMPTOM Lubricant Oilseal Lip Clogging of Play Improper Backlash Environmental Operational
Alignment
Unsuitable Insufficient Overfilling Hardened Damaged Breather Excess Less Contact More Less Dust Heat Chemical Overload Vibration High 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 periodically l Check alignment of Input and Output shaft
l Ventilator to be kept clean

35
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.

36
Premium Transmission Limited
Head 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
PREMIUM/WM/CA/107

: 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.
Jamshedpur : Flat No. 61 A, First Floor, Rajendranagar Colony, Sakchi, Jamshedpur 831001, Jharkhand. Mobile : (0) 9771844408. Rourkela : A/72, Sector - 13,
pratisaad.com 08/02

Rourkela - 769009. Orissa. Mobile : (0) 9437122066. Jaipur : B-1A, Vivekanand Colony, Naya Kheda Near Ambabari, Jaipur - 302012, Rajasthan. Mobile : (0)
9887720845. Coimbatore : Door no. 55, Rangsamy Layout, Pellamedu, Coimbatore - 641004. Mobile : (0) 9894295769. Baroda : B 24, Deep Darshan 1 Society,
Ataladra, Padra Road, Baroda, Gujarat. Mobile : (0) 9375122012. Raipur : A-10, Shubham Vihar, Behind Anmol Super Market, New Puraina, Mahavir Nagar,
Raipur - 492 001 Chhatisgarh, Mobile : (0) 9826903132. Indore : C-6, Shreevardhan Complex, 4, RNT Marg., Indore - 452001. Ph : 0731-2510943. Mobile : (0)
9302690943

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