PREMIUM WORM SPEED REDUCERS

Installation and Maintenance

INSTALLATION AND ROUTINE MAINTENANCE

1.0 2.0 PREMIUM OVERVIEW GENERAL INFORMATION INTRODUCTION WARM UNITS PURPOSE OF THE MANUAL SAFETY INSTRUCTIONS WARNING SAFETY SYMBOLS GEAR UNIT IDENTIFICATION NAMEPLATE DETAILS HANDLING AND STORAGE UNPACKAGING SHIPPING WEIGHTS PROTECTION OF UNIT 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 INSTALLATION FOOT MOUNTED GEAR UNITS SHAFT MOUNTED GEAR UNITS MAINTENANCE DOS AND DONTS CONTACTS MARKINGS, BEARING END FLOATS, TIGHTENING TORQUE TEMP CHECK TROUBLESHOOTING TROUBLE SHOOTING CHART DISPOSAL OF GEAR UNITS/ PARTS

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4.0 5.0

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9.0 10.0

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 P Premium Transmission Ltd. 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 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 P P P P P P P P P Balke- Durr- Cooling Tower Manufacturer BHEL- Power plant manufacturer GMM Pfaudler- Germany Glass Lined vessel manufacturer GEA Cooling Towers Indian Space Research Organization-India (ISRO) Larson & Tubro Mc Neil- USA Tyre machinery Manufacturer Mesto Mineral- Material Handling National Thermal Power Corporation (NTPC) State Electricity boards (all over India.)

And many more.

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.

3.0

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.

4.0

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

WORM REDUCER

Premium Transmission Ltd. UNIT-I,CHINCHWAD, PUNE-411019. INDIA

Explanation of above symbols is detailed below1. 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

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, PUNE-411019. INDIA

1. 2. 3. 4. 5. 6. 8. 9. 10.

X-Special Instructions CE- Conformity Europina EX- ATEX certification symbol II- Group 2 2- Category 2 G- Gas environment 7.D- Dust environment C- Constructional safety for gearboxes. k- Components of the gearboxes partially or fully oil immersed. T4- Temp. class. Maximum surface temp. 135C

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. 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.

Chinchwad, Pune - 411019India

UNIT-I,CHINCHWAD, PUNE-411019. INDIA

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.

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. Loosen the foundation bolts 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

l l

Net Weights for Horizontal Units in kg (approx.) Unit Type H1 H2 H2SF H3 H3SF H4 H4SF B2 B2SF B3 B3SF B4 B4SF 140 150 235 235 290 290 295 295 270 270 300 300 305 305 160 190 265 265 310 310 320 320 285 285 310 310 320 320 180 240 300 300 330 330 345 345 305 305 330 330 345 345 200 300 360 360 380 380 * * 340 340 380 380 * * 225 395 470 470 490 490 * * 455 455 490 490 * * 250 495 590 590 630 630 * * 560 560 630 630 * * Units Size 280 315 680 810 810 850 850 * * 750 750 850 850 * * 915 1090 1090 1150 1150 * * 1000 1000 1150 1150 * * 355 1210 1445 1445 1525 1525 * * 1520 1520 1525 1525 * * 400 1650 1970 1970 2080 2080 * * 2050 2050 2080 2080 * * 450 2265 2690 2690 2840 2840 * * 2680 2680 2840 2840 * * 500 2970 3540 3540 3780 3780 3530 3530 3780 3780 560 4860 4860 5100 5100 5100 5100 630 6540 6540 6900 6900 6900 6900 -

*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 undercover 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.

6.0

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

10

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

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* Move Wheel CORRECT Contact marking clear on entering side to provide oil Lead in when running under load INCORRECT* Move Wheel

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

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

NAMEPLATE DETAILS ESSENTIAL FOR CORRECT PARTS IDENTIFICATION 1 Upper half case 2 Lower half case 3 Cowl 4 Bolt for Cowl 5 Spring Washer for cowl 6 Fan 7 Locking screw for fan 8 Oil seal for wormshaft 9 Oil catcher for wormshaft 10 Bolt for wormshoft oil catcher 11 Shim for wormshaft oil catcher 12 Bearing for wormshoft 13 Wormshaft 14 End cover for wheelshaft 15 Bolt for wheelshaft covers 16 Shim for wheelshaft covers 17 Bearing for wheelshaft 18 Distance piece for wheelshaft 19 Wormwheel 20 Wheelshaft 21 Key for wheelshaft 22 Oil catcher for wheelshaft

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Oil seal for wheelshaft Drain plug Fibre washer for drain plug Dipstick Dipstick tube Dipstick body Dipstick body locknut Bolt for case joint Nut for case joint bolt Inspection plug Fibre washer for inspection plug Bolt for case joint Nut for case joint bolt Packing for case joint - not provided for size 1000 Eyebolt Screw for ventilator Ventilator Ventilator packing Nameplate Rivet for nameplate Input key Output key

Note : Item 43 & 44 not shown

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

NAMEPLATE DETAILS ESSENTIAL FOR CORRECT PARTS IDENTIFICATION 1 Case 2 Upper bearing housing for wheelshaft 3 Bolt for upper bearing housing 4 Lower bearing housing for wheelshaft 4A Shim for lower bearing housing 5 Bolt for lower bearing housing 6 Cowl 7 Bolt for cowl 8 Spring washer for cowl bolt 9 Fan 10 Locking screw for fan 11 Oil seal for wormshaft 12 Bolt for wormshaft oil catcher 13 Oil catcher for wormshaft - fan end 14 Shim for wormshaft oil catcher 15 Bearing for wormshaft 16 Oil flinger for wormshaft 17 Wormshaft 18 Oil catcher for wormshaft - shaft extension end 19 End cover for wheelshaft 20 Bolt for wheelshaft end cover 21 Shim for wheelshaft cover 22 Bearing for wheelshaft

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

Distance piece for wheelshaft Wormwheel Key for wheelshaft Wheelshaft Nilos ring for upper wheelshaft bearing Oil catcher for wheelshaft Oil seal for wheelshaft Bolt for wheelshaft oil catcher Ventilator packing Ventilator Screw for ventilator Eyebolt - not fitted to unit size 400 Dipstick - this item is oil level plug on Unit Size 400 Grease nipple for wheelshaft bearings Extension pipe for lower grease nipple Drain plug Nomeplate Rivet for nameplate Bolt for inspection cover Inspection cover Washer (For 700) Input key Output key
Note : Item 44 & 45 not shown

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

NAMEPLATE DETAILS ESSENTIAL FOR CORRECT PARTS IDENTIFICATION 1 Case 2 Upper bearing housing 2A Lower bearing housing 3 Cowl 4 Bolt for cowl 5 Spring washer for cowl bolt 6 Fan 7 Locking screw for fan 8 Oil seal for wormshaft 9 Bolt for wormshaft oil catcher 10 Oil catcher for wormshaft 11 Shim for wormshaft oil catcher 12 Bearing for wormshaft 13 Oil flinger for wormshaft 14 Wormshaft 15 Bolt for wheelshaft end covers 16 Oil seal for wheelshaft 17 Oil catcher for wheelshaft 18 Shim for wheelshaft 19 Bearing for wheelshaft 20 Nilos ring for upper wheelshaft bearing 21 Distance piece for wheelshaft 22 Wheelshaft 23 Key for wheelshaft 24 Wormwheel 25 End cover for wheelshoft 26 Dipstick 27 Dipstick tube 28 Dipstick body 29 Dipstick body locknut 30 Fibre washer for drain plug 14

31 32 33 34 35 36 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

Drain Plug Nomepldte Rivet for nameplate Grease nipple for wheelshoft Socket for extension piece Extension pipe for lower grease nipple Inspection cover Screw for inspection cover Bolt for bearing housings Screw for ventilator Ventilator Ventilator packing Grease lubricator for wheelshaft bearing Shim for lower bearing housing Eye bolt Oil seals for wormshoft End cover for wormshaft-fon end Shim for wormshaft oil catcher Circlip for wormshaft Bearing for wormshaft Oil flinger for wormshaft Wormshaft Distance piece Distance piece - small Locknut Screw for locknut Bearing for wormshaft Oil catcher for wormshaft Oil seals for wormshaft Input key Output key

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.

Shaft Mounted Gears Type 'OD' Single Reduction Units : Sizes 400 To 1400

NAMEPLATE DETAILS ESSENTIAL FOR CORRECT PARTS IDENTIFICATION 1 1 st reduction case 2 Upper half 2nd reduction case 3 Lower half 2nd reduction case 4 Oil catcher for 1st reduction wormshaft 4A Oil catcher for 1st reduction wormshaft (unit sizes 800 to 1400) 5 Bolt for oil catcher 6 Shim for 1st reduction wormshaft oil catcher 7 End cover for 1st reduction wormshaft (unit sizes 400 to 700) 8 Oil seal for 1st reduction wormshaft 8A Oil seal for 1st reduction wormshaft (unit sizes 800 to 1400) 9 Bearing for 1 st reduction wormshaft 10 1st reduction wormshaft 11 Fan (unit sizes 800 to 1400) 12 Locking screw for fan (unit sizes 800 to 1400) 13 Cowl (unit sizes 800 to 1400) 14 Bolt for cowl (unit sizes 800 to 1400) 15 Spring washer for cowl bolt (unit sizes 800 to 1400) 16 Drain plug for 1st reduction case 17 Breather plug for 1st reduction case 20 1 st reduction wormwheel bearing housing 21 Shim for 1st reduction wormwheel bearing housing 22 Bearing for 1st reduction wormwheel

23 24 26 25 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

Expanding plug for 1st reduction wormwheel 1 st reduction wormwheel Nut for stud Stud for 1st reduction case Shim for 1st reduction wormwheel Oil seal for 2nd reduction wormshaft Bearing for 2nd reduction wormshaft 2nd reduction wormshaft Key for 2nd reduction wormshaft Shim for 2nd reduction wormshaft end cover End cover for 2nd reduction wormshaft Bolt for 2nd reduction wormshaft end cover Oil seal for 2nd reduction wheelshaft Oil catcher for 2nd reduction wheelshaft Shim for 2nd reduction wheelshaft covers Bearing for 2nd reduction wheelshaft Distance piece for 2nd reduction wheelshaft 2nd reduction wheelshaft Key for 2nd reduction wheelshaft 2nd reduction wormwheel End cover for 2nd reduction wheelshaft Drain plug for 2nd reduction case Stud for 2nd reduction case join Nut for Stud 2nd reduction case Screw for ventilator

48 49 50 51 52 53 54 55 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87

Ventilator for 2nd reduction case Ventilator packing Oil scraper Eyebolt (unit sizes 700 and 800) Bolt for 2nd reduction case joint Dipstick (unit size 400 is fitted with oil level plug) wormshaft Nameplate Rivet for nameplate Upper half, 2nd reduction case Lower half, 2nd reduction case Packing for cose joint - not provided for size 1000 Bolt for case joint Nut for case joint bolt Bolt for case joint Nut for case joint bo Fibre washer for inspection plug Inspection plug Dipstick Dipstick tube Dipstick bod Locknut for dipstick body Drain plug Fibre washer for drain plug Eyebolt Screw for ventilator Ventilator Packing for Ventilator Oil scraper Nameplate Rivet for nameplate Key retaining plate Bolt Grease Nipple Nilos Ring (not shown in above sketch) Input key 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

NAMEPLATE DETAILS ESSENTIAL FOR CORRECT PARTS IDENTIFICATION 1 1 st reduction case 2 2nd reduction case 3 Oil catcher for 1 st reduction wormshaft 3A Oil catcher for 1st reduction wormshaft (unit sizes 800 to 1400) 4 Bolt for 1 st reduction wormwheel 5 Shim for 1st reduction wormshaft oil catcher 6 End cover for 1 st reduction wormshaft (unit sizes 400 to 700) 7 Oil seal for 1 st reduction wormshaft 7A Oil seal for 1st reduction wormshaft (unit sizes 800 to 1400) 8 Bearing for 1st reduction wormshaft 9 1st reduction wormshaft 10 Fan (unit sizes 800 to 1400) 11 Locking screw for fan (unit size800 to 1400) 12 Cowl (unit sizes 800 to 1400) 13 Bolt for cowl (unit sizes 800 to 1400) 14 Spring washer for cowl bolt (unit sizes 800 to 1400) 15 1 st reduction wormwheel bearing housing 16 Shim for 1 st reduction wormwheel bearing housing 17 Bearing for 1 st reduction wormwheel 18 Expanding plug for 1st reduction wormwheel

1 st reduction wormwheel Shim for 1 st reduction wormwheel 21 Oil seal for 1st reduction 22 Bearing for 2nd reduction 23 Oil flinger 24 2nd reduction wormshaft 25 Key for 2nd reduction 26 Shim for 2nd reduction end Cover 27 End cover for 2nd reduction wormshaft 28 Bolt for 2nd reduction end cover 29 Oil seal for 2nd reduction wheelshaft 30 2nd reduction wheelshaft oil catcher 31 Grease nipple for 2nd reduction wheelshaft bearing 32 Shim for 2nd reduction wheelshaft 33 Bearing for 2nd reduction wheelshaft 34 Nilos Ring for 2nd reduction wheelshaft bearing 35 Distance piece for 2nd reduction wheelshaft 36 2nd reduction wheelshaft 37 Key for 2nd reduction wormwheel 38 2nd reduction wormwheel 39 End cover for 2nd reduction wheelshaft 40 Lower b'earing housing for 2nd reduction wheelshaft 40A Shim for lower bearing housing 41 Bolt for 2nd reduction lower bearing housing 42 Upper bearing housing for 2nd reduction wheelshaft 43 Bolt for 2nd reduction upper

19 20

bearing housing Eye bolt Stud for 1 st reduction case Nut for 1 st reduction case Drain plug for 1st reduction case Breather plug Screw for ventilator Ventilator Ventilator packing Dipstick Dipstick tube Dipstick body Locknut for dipstick body Inspection cover Bolt for inspection cover Extension pipe for lower nipple Socket for lower grease nipple Drain plug for 2nd reduction case 58 A Fibre washer for drain plug 59 Nameplate 60 Rivet for nameplate 61 Key retaining plate 62 Bolt 63 Washer (For 700) 64 Input key 65 Out key 44 45 46 47 48 51 52 53 54 54 A 54 B 54 C 55 56 57 57A 58 Refer page 10 for the following additional ports for VD 1700: Circlip (51), Additional wormshaft bearing (52), Distance piece (55), Distance piece (56), lockout (57), Screw for Locknut (58), Bearing for wormshaft (59). Not shown in above sketch.

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.

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

311 312 313 314 315 316 317 318 319 320

Lower bearing housing Oil seal housing Lower bearing Oil seal Shim for oil seal housing Bolt for oil seal housing Output shaft Upper bearing Distance piece 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

351 352 353 354 355 356 357 358 359 360 361 362

Motor plate Hinge pin for motor plate Bolt for motor plate Eye bolt Bolt for eye bolt Nut for eye bolt Washer for eye bolt Support bracke Bolt for support bracket Cover plate Lubricator extension 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

401 402 403 404 405 406 407 408 409 410 411 411A 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427

Plug Oil seal for wheelshaft Bolt for wheelshaft covers Grease nipple Oil seal housing Bearing for wheelshaft-top Bearing for wheelshaft - bottom Upper bearing housing Eye bolt Wheelshaft Oil filler/drain connection Oil level plug (NOT SHOWN) Case Wormwheel Key for wormwheel Inspection cover Bolt for inspection cover Ball retainer Ball Ball seat Spring Pin Plunger Distance piece Lower bearing housing Shim End cover for wheelshaft Swash plate

428 Fibre washer for plug 429 Plug 430 Bolt for swash plate 430A Washer 431 Bolt for bearing housing 432 Bolt for cowl 433 Spring washer 434 Cowl 435 Locking screw for fan 436 Fan 437 Oil catcher for wormshaft 438 Bearing for wormshaft 439 Oil flinger for wormshaft 440 Wormshaft 441 Ventilator connection 442 Shim for wormshaft covers 442A Shim for wheelshaftcover 443 Oil catcher for wormshaft 444 Oil seal for wormshaft 445 Name plate 446 Rivet for name plate 447 Oil strainer (1000 To 1400) 448 Brand nameplate (400 to 700) 449 Washer for 700 450 Key - wheelshaft 451 Key - wormshoft
NAMEPLATE DETAILS ESSENTIAL FOR CORRECT PARTS IDENTIFICATION

19

Premium cooling tower units

401 402 403 404 405 406 407 408 409 410 411 411A 412 413 414 415 416 420 422 423 424 425

Plug Oil seal for wheelshoft Bolt for wheelshaft covers Grease nipple Oil seal housing Bearing for wheelshaft - top Bearing for wheelshaft - bottom Upper bearing housing Eye bolt Wheelshaft Oil filler/drain connection Oil level plug (NOT SHOWN) Case Wormwheel Key for wormwheel Inspection cover Bolt for inspection cover Spring Plunger Distance piece Lower bearing housing Shim

20

Type CT

426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 442A 443 444 445

End cover for wheelshaft Swash plate Fibre washer for plug Plug Bolt for swash plate Bolt for bearing housing Bolt for cowl Spring washer Cowl Locking screw for fan Fan Oil catcher for wormshaft Bearing for wormshaft Oil flinger for wormshaft Wormshaft Ventilator connection Shim for wormshaft covers Shim for wheelshaft cover Oil catcher for wormshaft Oil seal for wormshaft Name plate

446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465

Rivet for name plate Oil strainer Pump housing Gasket - pump cover Set screw - pump cover Plunger body Shim - plunger body Cap screw - plunger body Ball Spring Pipe assembly ,for pump Circlip - wormshaft Distance piece Bearing for wormshaft Bearing for wormshaft Lock nut Screw for lock nut Distance piece Key - wheelshaft Key - wormshaft

21

Premium gearboxes with special features

101 102 103 104 105 106 107 108 109 110 111

Output shaft of high tensile steel Output shaft extended on both sides-standard material Output shaft extended on both sides-high tensile steel Wider bearing on output shaft Narrow distance piece for use with item 104 Roller holdback sub-assembly - for Sizes 400 upwards Housing for roller holdback sub-assembly Key for holdback sub-assembly Circlip for holdback sub-assembly Dustproof ventilator-tor Sizes 400 upwards 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 800 and not shown in above sketch. Parts shown above are substitute/additional parts for the with sleeves sleeve bearing feature. All other parts are common to standard unit of respective size. 201 Case 202 Bearing housing with white metal/bronze sleeve-driving end 203 Bearing housing with white metal/bronze sleeve-closed end

204 205 206 207 208 209 210 211 212 213

Oil Seal housing Duplex bearing End cover Input shaft with sleeves Wormwheel Locknut Lockwasher Bolt for oil seal housing Bolt for end cover Spacer

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' and 'H' of dipstick. Excess oil filled beyond level 'H' may lead to leakage of oil through output seal.

Use only PREMIUM TRAXOL - G32

RECOMMENDED LUBRICANTS
MANUFACTURER Henkel Corp./Emery Group Mobil Oil Corporation MANUFACTURER Bharat Petroleum Tide Water Castrol Chemoleums Gulf Oil IOCL Hindustan Petroleum BRAND NAME - SYNTHETICS OIL Emery - 2843 Synthetic Lubricant Mobil SHC634 Synthetic Lubricant BRAND NAME - MINERAL OIL Cabol 320 Avalon 320 Alpha ZN 320 Erato 320 Gulf Harmony AWC 320 Servosystem 320 Enklo 320

24

Oil capacity and shipping specification Size of unit 112 Net Weight (kg.) Gross Weight (kg.) Volume Packed (cu.m.) Oil Required at 1st filling (lit.) A supply of oil is not included in any unit Approximate Shipping Specification and Oil Capacities Size Net Weight (kg.) Gross Weight (kg.) Volume Packed (cu.m.) Packed (cu.m) wheelshaft down Oil Required at 1st filling (lit.) 400 77 90 .12 .11 4.0 500 109 125 .17 .15 5.7 600 145 163 .21 .19 6.3 700 200 226 .28 .25 10.2 800 254 286 .44 .39 12.5 1000 1200 1400 1700 465 580 1.0 .9 22.7 690 830 1.4 1.3 37.4 970 1750 1250 2100 1.9 1.75 68.5 2.8 2.6 105 5 5 0.004 0.14 162 7 8 0.007 0.28 200 13 14 0.013 0.28 237 20 21 0.022 0.57 287 31 34 0.034 0.85 337 49 50 0.048 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 Net Weight (kg.) Gross Weight (kg.) Volume Packed (cu.m.) Oil Required at 1st filling (lit.) 400 68 79 .08 3.0 500 95 109 .12 4.3 600 125 140 .15 6.3 700 172 191 .21 9.1 800 218 244 .27 11.4 1000 1200 1400 1700 350 395 .48 15.9 540 635 .76 22.7 864 1340 928 1440 1.1 36.4 1.7 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 SIZE A Types U, O, V SIZE U O V 400 3.0 2.3 4.0 500 4.3 2.8 5.7 600 6.3 4.0 6.3 700 9.1 5.7 10.2 800 11.4 9.1 12.5 1000 17.5 11.0 22.7 1200 23.0 15.0 37.4 1400 37.0 24.0 68.5 1700 45.0 -105 112 0.1 SINGLE REDUCTION UNITS 162 0.3 200 0.3 237 0.6 287 0.9 337 1.4

25

Types AD SIZE AUD AOD AVD Secondary Unit UNIT Primary Unit

DOUBLE REDUCTION UNITS 162 0.1 0.3 200 0.1 0.3 237 0.3 0.6 287 0.3 0.9 337 0.3 1.4

Types UD, OD, VD SIZE UD OD VD UNIT Primary Unit Secondary Unit Primary Unit Secondary Unit Primary Unit Secondary Unit 400 0.6 3.0 0.6 2.3 0.6 4.0 500 0.6 4.3 0.6 2.8 0.6 5.7 600 1.1 6.3 1.1 4.0 1.1 6.3 700 1.7 9.1 1.7 5.7 1.7 10.2 800 2.8 11.4 2.8 9.1 2.8 12.5 1000 4.0 17.5 4.0 11.0 4.0 22.7 1200 5.7 23.0 5.7 15.0 5.7 37.4 1400 9.1 37.0 9.1 24.0 9.1 68.5 1700 11.4 45.0 -11.4 105

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 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 closecoupled, 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. 1 2 3 4 5 6 Bolt size in mm M 16 M 20 M 24 M 27 M 30 M 36 * * * * * * Torque in NM 80 160 270 400 540 920

* THESE ARE BOLTS OF 4.6 GRADES Sr. No. 1 2 3 4 5 6 Bolt size in mm M 10 M 12 M 16 M 20 M 22 M 24 ** ** ** ** ** ** Torque in NM 40 70 180 350 470 580

* 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

G E H

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 G G L

B L

D Type U 400-1700 Type O 400-1400

D D Type V 400-1700

31

Using Oils Containing Additives

Temp.0C 75 or less 80 85 90 Adaptables 2500 hr. or 6 months 1500 hr. or 6 months 1000 hr. or 3 months 750 hr. or 3 months Other Units 5000 hr. or 12 months 3000 hr. or 6 months 2000 hr. or 6 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 Sizes 162-337 Primary Units on type UD and VD Units Sizes 400 -1700 and on types OD Sizes 400 - 1400
B

D L D

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 112 162 200 237 287 337 400 500 600 700 800 1000 1200 1400 1700

Wormshaft (mm) 0.025/0.075 0.025/0.075 0.025/0.075 0.025/0.075 0.025/0.075 0.025/0.075 0.050/0.100 0.050/0.100 0.050/0.100 0.050/0.100 0.050/0.100 0.050/0.100 0.075/0.125 0.075/0.125 0.075/0.125

Wheelshaft (mm) 0.025/0.050 0.025/0.050 0.025/0.050 0.025/0.050 0.025/0.050 0.025/0.050 0.025/0.050 0.025/0.050 0.025/0.050 0.025/0.075 0.025/0.075 0.025/0.075 0.050/0.100 0.050/0.100 0.050/0.100

33

Do's
Use recommended grade of oil Fill oil up to Dipstick marking only Breather should be clean. Check it's condition periodically Align gearbox correctly with Motor as per manual instructions Check oil level periodically, top up the level If necessary Change oil in gearbox periodically Change oil seals during overhauling While fitting oil seals, clean shaft diameter & catcher face and then fit oil seal with proper oil seal adapter Use oil seals as per specifications provided by Premium only Keep end float as recommended Ensure correct contact & backlash while assembling after dismantling or overhauling the gearbox While assembling gearbox after dismantling / overhauling, ensure the oil channels / holes provided for lubrication are cleaned properly Apply few drops of oil on oil seal lip while starting to wet it prior to starting, if gearbox is idle for long time While assembly, use bevel gears & pinions in pairs only In case the gear unit is stored beyond three months, please rotate the gear box input shaft few times by hand.

Don'ts
Do not use any other oil Do not fill excess or less oil Do not keep breather in choked condition Do not run gearbox without ensuring alignment Do not run gearbox without checking oil level Do not run gearbox without changing oil for long time- Refer manual Do not use same oil seals again & Again Do not fit oil seal on unclean & Damaged oil seal diameter, also don't Hammer the oil seal Do not use any local make oil seals Do not keep excess or less end float Do not run gearbox without ensuring correct contact & backlash After dismantling / overhauling, do not assemble gearbox leaving oil channels, holes, in clogged condition Failure to adhere to this instruction may lead to oil seal failure due to dry running of the oil seal lip Do not interchange bevel gears & pinions Failure to perform this operation may result in reduced bearing life

Recommended Maintenance Schedule For Gearboxes Sr. No. Area of Maintenance 1 Breathers Frequency Weekly Work to be done Clean the Breathers to avoid clogging. Keep one set of breathers duly cleaned as stand by for easy replacement. On the Grease points wherever provided. Check oil level as per dispstick or oil level indicator glass, top up if required. Ensure foundation bolts are properly tightening.

2 3

Greasing Surfaces of the Gear unit

Weekly As Needed

Foundation bolts

Fortnightly

Other points of maintenance to be followed as per the instructions given in IOM

34

9.0
SYMPTOM

TROUBLE SHOOTING CHART

TYPICAL CAUSES

Lubricant Unsuitable Insufficient

Oilseal Lip Overfilling

Clogging of Breather

Play Excess Less

Improper Contact

Backlash More

Environmental Dust

Alignment Overload

Operational Vibration High Speed

Hardened

Damaged

Less

Heat

Chemical

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 : 9122-25262622, 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. Jamshedpur : Flat No. 61 A, First Floor, Rajendranagar Colony, Sakchi, Jamshedpur 831001, Jharkhand. Mobile : (0) 9771844408. Rourkela : A/72, Sector - 13, 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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