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Worm Maintenence Manual
Worm Maintenence Manual
WORM SPEED
REDUCERS
Installation and Maintenance
INSTALLATION AND ROUTINE MAINTENANCE
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
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
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.
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
Order No.
Product type.
Serial No.
Ratio.
Max. Torque.
India
Chinchwad, Pune - 411019
Year of manufacturing.
WORM REDUCER
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
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.
WORM REDUCER
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
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 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.
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
11
Parameters
Type '0' Single Reduction Units : Sizes 1000 To 1400
12
Type 'v' Single Reduction Units : Sizes 400 To 800
13
Type 'v' Single Reduction Units : Sizes 1000 To 1700
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
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
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
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
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
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
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
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.
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
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
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.
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.
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.
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
E
HØ
FØ
30
8.0 MAINTENANCE
B B
B
L
G
L
D D
D
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
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
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 « « « « « « «
Joint Leakage « « « « «
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
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
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