PREMIUM

WORM SPEED
REDUCERS
Installation and Maintenance

For Customer Assistance Call : Toll Free 1600-21-4563

General
The Premium Speed Reducer is a precision product
incorporating the very best in worm gear design. It is a self-
contained unit of simple rigid construction involving the
minimum number of moving parts and embodying a
lubrication system which ensures a positive supply of oil to
gears and bearings at all running speeds. With careful
Safety Instruction
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.
l 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
gar unit
Instructions related to Electrical connection:-
l The gear units are not supplied with electrical
connection. The prime mover like electric motor needs
experienced and trained personnel to connect it to the
power line.
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
installation Premium Speed Reducers will give complete
reliability in service and the only attention necessary is an
occasional oil level check.
This publication gives information on correct installation, thus
ensuring that the high initial efficiency is unimpaired in
operation.
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.
Instructions on handling noisy gear unit:-
l Feel the noise of the gear unit at regular intervals. In case the
noise level is abnormal (beyond 85 db) use ear mask, stop the
prime mover and check the alignments and conditions of
bearing after gear unit cools down to safe level.
Vibration limits:-
l Please check the vibration of the gear unit periodically. The
maximum vibration limit allowed for the worm and Helical
gear unit is 75 micron displacement.
Selection of the Gear unit:-
l Please check the selection procedure before finalizing the
model & size of the gear unit. In case of difficulty please get in
touch with our nearest office or distributor.
Checking foundation stability :-
l Please ensure, the foundation stability of the complete drive
system is checked once in 15 days for the first three months
and later on once in month to avoid misalignments and
leading to failure of the drive system.
Disposal of used Parts :-
l The fans & cowls made off polypropylene or Engineering
plastics is to be disposed off as per IS or International
standards.
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's
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.
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
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
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
Don'ts
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
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.
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.
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 working conditions.
Lining Up
Errors of alignment fall into the categories of
angularity (Fig. 1) and eccentricity (Fig. 2), or Fig. 1 Fig. 2
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 Fig. 3
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. 4

Changing Handing
When changing the handing of the slow speed shaft extension, applying a small braking pressure to the wheel, also by hand.
the shaft complete with wormwheel, bearings etc. should be
The correct marking should be slightly heavier on the "leaving
reversed as a unit. It should be appreciated that this has the
side" of the teeth, relative to the direction of rotation of the
effect of reversing the offset of the wheel relative to the
worm, so as to provide "lead in" for the lubricant and to avoid
worm. When changing the slow speed shaft handing of V type
concentration of pressure on the entering side as this would
units it should be noted that the position of the wheel relative
affect the smoothness of operation. This arrangement is
to the case must not be changed; it is necessary therefore to
shown in the diagrams. When the correct wheel setting has
press the wheel from the shaft. The position of the shaft in
been reached on the U type speed reducers, the oil scraper
relation to the wormwheel must be reversed. The end covers
clearance relative to the wormwheel should be set at 0.25
should be located in their respective positions. It is necessary
mm to 0.38 mm.
to check contact markings on the wormwheel teeth and if any
axial adjustment of the wormwheel is necessary, it can be If gearbox is dismantled for maintenance, while re-assembling
effected by means of the shims between end covers and care should be taken to gently scrape the joint faces and apply
bearing housing which should be moved from one side to the 'LOCTITE FLANGE SEALANT SUPERFAST 574, joint
other. It is essential that the top half of the gear case be compound on faces of cases and covers and catchers of all
replaced in its original position. 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 contact marking is checked by painting the worm with
the case joints.
red lead or Prussian Blue and rotating the worm by hand while

INCORRECT*
Move Wheel

CORRECT INCORRECT*
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
Axial Floats Lubrication
After assembling it is essential that shaft end The Premium Speed Reducer lubrication system is self contained
floats be correctly set. The following axial floats positive and automatic at all speeds of operation and in either
for wormshaft and wheelshaft are direction of rotation. Adaptable units are provided with breather,
recommended. However it is better to maintain oil level and drain plugs and it must be ensured that these are
axial float at lower recommended value. They correctly positioned as shown on the accompanying diagram.
should be checked preferably using a dial Other units incorporate a dipstick for oil level checking, an oil filler-
indicator gauge mounted on a magnetic base. 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
Size Wormshaft Wheelshaft
to ensure that the correct oil level is not exceeded as over filling
(mm) (mm)
causes oil churning, resulting in overheating and leakage.
112 0.025/0.075 0.025/0.050
162 0.025/0.075 0.025/0.050 Extreme Pressure (E.P.) Lubricants
200 0.025/0.075 0.025/0.050
Extreme Pressure (E.P.) lubricants or cylinder oils with sulphur
237 0.025/0.075 0.025/0.050
phosphorus additives are not acceptable and should not be used in
287 0.025/0.075 0.025/0.050 worm gearing.
337 0.025/0.075 0.025/0.050
400 0.050/0.100 0.025/0.050 Use only
500 0.050/0.100 0.025/0.050 CAUTION
Vertical gearboxes have PREMIUM
600 0.050/0.100 0.025/0.050 dry well arrangement on TRAXOL
the output line. Please fill
700 0.050/0.100 0.025/0.075 oil in between marks 'L' - G32
and 'H' of dipstick. Excess
800 0.050/0.100 0.025/0.075 oil filled beyond level 'H'
may lead to leakage of oil
1000 0.050/0.100 0.025/0.075 through output seal.
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

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

B
B
B
L

Position B Position C
L
L
Position A D
D
D
B

B
B

D
Position D Position E
L
L D L
Position F
D
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

Using Plain Mineral Oil Using Oils Containing Additives

Temp. °C Adaptables Other Units Temp. °C Adaptables Other Units
75 or less 2500 hr. or 6 months 5000 hr. or 12 months 75 or less 2500 hr. or 6 months 5000 hr. or 12 months
80 2000 hr. or 6 months 3500 hr. or 6 months 80 1500 hr. or 6 months 3000 hr. or 6 months
85 1500 hr. or 3 months 2500 hr. or 6 months 85 1000 hr. or 3 months 2000 hr. or 6 months
90 1000 hr. or 3 months 1000 hr. or 3 months 90 750 hr. or 3 months 750 hr. or 3 months

--- whichever is the shorter period --- 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

Dipstick as fitted on units

size 1000 and above
L

D D L

Primary Units on type UD and VD Units

Sizes 400 -1700 and on types OD Sizes 400 - 1400
B
B - Breather/Filler plug
L - Oil level Plug/dipstick
D - Drain plug
G - Grease lubricator

D
L
D
L
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.

Chinchwad, Pune - 411019India

WORM REDUCER

Premium Transmission Ltd.

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
motor with appropriate type of couplings and the instructions
of the coupling manufacturer for alignment must be followed.
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 to bearing roller height at
maximum height of bearing in the gearbox and the input shaft
to be rotated few times once in 15 days.
Instructions In accordance with the requirements of ATEX 94/9/EC
The Gearbox is affixed with the nameplates as shown below
FOR CE MARKING
India
Chinchwad, Pune - 411019
WORM REDUCER
Premium Transmission Ltd.
UNIT-I,CHINCHWAD,
PUNE-411019. INDIA
SPECIAL INSTRUCTIONS UNDER ‘X’
l Maximum Ambient operating Temperature + 5ºC to 50ºC
l Type of bearings used Taper Roller and Double row
Spherical Roller bearings for helical gearboxes of reputed
Make.
l Type of bearings used Taper Roller and Angle contact
bearings for Worm gearboxes of reputed Make.
l Sealant used Loctite Make Medium Blue 243 Thread
locker and 574 Flange sealant.
l Lubricant used ISO VG 320 Grade oil for makes refer IOM
PREMIUM/WM/CA/ 107 and PREMIUM/HG/CA/203
l Grease multipurpose grease or wheel bearing grease of
any reputed Make.
l Type of Paint used Air drying Blue Hammertone paint
Asian Paint India.
l External earthing to be provided by the end user.
l Gearboxes are dispatched with shaft extensions. The
equipments manufacturer or end user should take
appropriate care during installation, maintenance and
service.
l Instruction given for operation, installation and routine
maintenance for CE products should also be followed.
FOR ATEX MARKING
Explanation of above symbols is detailed below-
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
l Ensure no metallic shocks, impacts are made to the
gearboxes.
l All the operating and safety instructions should be
thoroughly followed.
l Installation must be carried out at ambient temperature.
l All other electrical equipments shall meet the appropriate
ATEX category and type of atmosphere.
l The precautions during welding operations etc. shall
be taken as per the requirements.
MAINTENANCE
l Periodic cleaning of dust deposits on gearbox surface
as well as in the gap of moving part shall be ensured.
l Persons carrying out maintenance shall be qualified
to work in potentially hazards area appropriate to
the category of equipment in use.
l Equipment manufacturer/end user shall use all the
tooling required for the maintenance appropriate to
the working area.
l All original spare parts must be used during maintenance.
SERVICE
Trained and qualified person shall carry out service job.
 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

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 without notice. Oil level has to be maintained as per dipstick level marking.

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
 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

DOMESTIC ADDRESSES

Manufacturing Units : Unit-I : Old Mumbai - Pune Road, Chinchwad, Pune - 411 019, India. Tel. : 91-20- 66314100 Fax : 91-20- 27450287,
27472384. Unit-II : Falta Industrial Growth Centre, Sector-III, Falta, 24 Parganas (South), West Bengal 743504, India. Tel.: 91-3174-222231 / 32 / 33 / 37,
Fax : 91-31749 222234. Unit-III : G-56 / 57, MIDC Industrial Area, Chilkalthana, Aurangabad - 431 210, India. Tel.: 91-240-2485521, 2485856, 2485056,
Fax : 91-240-2485756. Unit-IV : 31-P, MIDC Industrial Area, Chilkalthana, Aurangabad - 431 210, India. Tel.: 91-240-2482858, 2471298, Fax : 91-240-
2482857.

Regional Offices : Mumbai : Corporate Park II, 4th Floor, Sion, Trombay Road, Chembur, Mumbai - 400071, India. Tel.: 91-22-25264750, 25264763,
Fax : 91-22-25262622, 25264800. New Delhi : Express Building Annexe, 9-10, Bahadhur Shah Zafar Marg, New Delhi - 110 002, India. Tel. : 91-11-
23730554 (8 Lines), Fax : 91-11-23359782 / 23357739. Kolkata : Thapar House, 25, Brabourne Road, Kolkata - 700 001, India. Tel.: 91-33-22424316,
22423780, 22423805, 22424317 / 20 / 21, 22438815, 22420817, Fax : 91-33-22424325. Chennai : "Wavoo Mansion", 7th Floor, New No. 48 (Old No. 39)
Rajaji Salai, Chennai - 600 001, India. Tel.: 91-44-25255200, 91-44-25224557. Nagpur : Plot No 15, State Bank Colony, Ujjwal Nagar, Somalwada,
Wardha Road, Nagpur - 25. Mobile : (0) 9425009827

Branch Offices : Ahmedabad : ‘Jaldarshan' Ashram Road, Navrangpura, Ahmedabad - 380 009, India. Tel.: 91-79-26580428 / 0518 / 1856 / 1857 /
1861, Fax : 91-79-26587783. Bangalore : 16/3, Ali Asker Road, Off Cunningham Road, Bangalore - 560 052, India. Tel.: 91-80-22262062, Fax : 91-80-
22253472. Hyderabad : 6-2-47, A, C. Guards, 1st Floor, Hyderabad - 500 004, India. Tel.: 91-40-23314025, 23316446, 23390544, Fax : 91-40-
23318557. Kochi : 39/5567, M. G. Road, Emakulam, Kochi - 682 015, India. Tel.: 91-484-2359661, 2359372, 2359190, Fax : 91 484-2359589.

Representative Offices : Lucknow : G-901, 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 :
www.pratisaad.com 11/06

(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. Vishakhapattnam : Flat No. 101, Yadu Residency, Rednum Garden,
Ramnagar, Vishakhapattnam-530002, Mobile : (0) 9866167594.