ALUMINUM WORM GEAR SPEED REDUCER INSTRUCTION MANUAL

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ALUMINUM WORM GEAR SPEED REDUCER

INSTRUCTION MANUAL

Introduction The Aluminum Worm Gear Speed Reducer is a new product combining the advanced technology of our cast iron speed reducers with a new aluminum body.It is ideal for applications requiring a reduced output speed, increased torque or change in drive direction.

USE AND SAFETY GURANTEE• Do not exceed the maximum input horsepower rating.• This speed reducer is shipped with oil and it does not need to be filled before it is used.• During installation make sure not to damage the oil seals on the input or output shaft.• Make sure the input and output shaft are the correct rotation before turning on the electric motor.

This will prevent damaging the speed reducer or any of the other components.• Install safety covers over any open rotating shafts to prevent injuries from occurring.

Features• Aluminum heat sinking designed housing with epoxy coating• Lightweight and rust resistant• The compact design requires less mounting space• Completely sealed against dust, dirt and other contaminates• High torque output with low noise and reduced vibration

Specifications

ALUMINUM WORM GEAR SPEED REDUCER

INSTRUCTION MANUAL

Item No.: 8607384 & 8607392

SKU No.

8607384

8607392

Model No.

NRV-40-100-1

NRV-50-60-1

Ratio

100:1

60:1

Max. Input HP

Max. Torque Output (in-lb)

Max. Input Shaft Side Load (lbs)

Hollow Output Shaft Dia. (in.)

Max. Input Shaft Speed (RPM)

Efficiency

Max. Input HP

Max. Torque Output (in-lb)

Max. Input Shaft Side Load (lbs)

Hollow Output Shaft Dia. (in.)

Max. Input Shaft Speed (RPM)

Efficiency

1/4 HP

460

79

3/4

1,800

75%

1/2 HP

513

110

1

1,800

75%

Specifications

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ALUMINUM WORM GEAR SPEED REDUCER

INSTRUCTION MANUAL

ALUMINUM WORM GEAR SPEED REDUCER

INSTRUCTION MANUAL

SKU No.

8607384

8607392

MODEL No.

NRV-40-100-1

NRV-50-60-1

RATIO

100:1

60:1

A

6.50

7.54

B

4.53

5.17

C

1.18

1.57

D

4.78

5.67

E

0.84

1.12

F

2.36

2.76

G

3.07

3.62

H

2.76

3.15

SKU No.

8607384

8607392

MODEL No.

NRV-40-100-1

NRV-50-60-1

RATIO

100:1

60:1

INPUT SHAFT(DIA.) I

1/2

5/8

HOLLOW OUTPUT SHAFT(DIA.) J

3/4

1

K

3/16

1/4

Installation Dimensions(Inch)

Exploded Parts View

Part No.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

Parts Name

Housing

Hex Head Cap Screw

Input Shaft Cap

Input Shaft Bearing

O-ring

Oil Drain Plug

Steel Plug

Hex Head Cap Screw

Output Bearing Carrier Cap

O-ring

Output Hollow Shaft Seal

Output Hollow Shaft Bearing

Ring Gear

Output Hollow Shaft

Input Shaft Cap

Input Shaft Oil Seal

Input Shaft Key

Worm Gear Input Shaft

Parts Quantity

1

6

1

2

2

1

1

8

1

1

2

2

1

1

1

1

1

1

4 2

111

89

10 11 12

12 13

6

14

3 5 47

16

18

5

17

15

A

FG

B

E

H

C

J

K

I

D

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ALUMINUM WORM GEAR SPEED REDUCER

INSTRUCTION MANUAL

Read these instructions thoroughly before installing or operating the gearbox.

GENERAL INSTALLATION INSTRUCTIONS• Leave the protective shaft sleeves in place for safe handling of the gearbox during installation.• This speed reducer is tested and filled with synthetic oil prior to shipment (Refer to the Lubrication

and Maintenance section for more information.)• Align all shafts accurately, since improper alignment can result in premature failure.• For hollow-bore output gearboxes – Use anti-seize compound when inserting the load shaft into

the Hollow Output Shaft. It is preferable to size the load shaft with sufficient length to allow complete insertion through the Hollow Output Shaft of the gearbox. This allows equal support of the load shaft by both of the output shaft bearings, and permits the use of the output shaft set screws to lock the two shafts together on both sides of the gearbox. At minimum, the load shaft should be inserted at least half way into the hollow output shaft, and secured with the setscrews on the insertion end of the gearbox.

• Mount the gearbox to a rigid foundation, and use the maximum possible bolt size. Periodically inspect the mounting bolts. (Refer to the Lubrication and Maintenance section for allowable mounting orientations.)

• Mount auxiliary drive components such as sprockets, gears and pulleys on the gearbox shafts as close to the housing as possible in order to minimize the effects of side loading. Avoid force fits that might damage bearings or gears.

• Check and record gear backlash at installation and again at regular intervals. This should be done by measuring the degrees of rotary movement of the output shaft (rotating alternately clockwise and counterclockwise) while holding the input shaft stationary. The gearbox should be replaced when the backlash exceeds four times the measurement taken at installation.

• Initial operating temperatures may be higher than normal during the break-in period of the gear set.For maximum life, DO NOT ALLOW THE SPEED REDUCER TO OPERATE CONTINUOUSLY ABOVE 225°F at the gear case. In the event of overheating, check for overloads or high ambient temperatures. Keep shafts and vent plugs clean to prevent foreign particles from entering seals or gear housing.

Preparing the AreaClean the work area until it is free of debris and dust before disassembling the Reducer. Contaminates can adhere to oil coating the parts and may damage the mechanism. Have a clean container ready to place the parts during the disassembly process.Tools Required• 6mm Allen Wrench• Torque WrenchWhen this manual refers to a part name, please refer to the Exploded Parts View on Page 2.

Removal and Installation of the Ring Gear Output Hollow Shaft AssemblyRemoval:To remove the Ring Gear Output Hollow Shaft Assembly you need to remove the Worm Gear Input Shaft Assembly first.

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ALUMINUM WORM GEAR SPEED REDUCER

INSTRUCTION MANUAL

1. Remove the Oil Drain Plug (#6) to completely drain the oil.2. Remove the Hex Head Cap Screws (#8) from the Output Bearing Carrier Cap (#9)3. CAREFULLY slide the Front Output Bearing Carrier Cap (#9) off of the Output Hollow Shaft (#14)4. The Ring Gear Output Hollow Shaft Assembly ((#13, #14, #12)) can now be removed from the

Housing (#1)Note: Be careful not to nick or scratch the ring gear or output Hollow shaftReplacing the Ring Gear:1. Place the Ring Gear Output Hollow Shaft Assembly into a press and remove the rear Output Bearing (#12) and Ring Gear (#13) from the Output Hollow Shaft (#14)2. Press on the new Ring Gear (#13) and then the rear Output Shaft Bearing (#12)**Make sure the Output Hollow Shaft Assembly is tight with no spaces between the componentsInstallation:To install the Ring Gear Output Hollow Shaft Assembly into the housing you need to install the Worm Gear Input Shaft Assembly at the same time so they can be meshed together.1. Install the Ring Gear Output Hollow Shaft Assembly into the Housing (#1)2. Slide the Output Bearing Carrier (#9) over Output Hollow Shaft (#14) and bolt it to the housing with the Hex Head Cap Screws (#8) and torque them to 225 in. lbs.

Removal and Installation of the Worm Gear Input Shaft AssemblyRemoval:1. Remove the Hex Head Cap Screws (#2) from the Input Shaft Cap (#15)2. CAREFULLY remove the Input Shaft Cap (#3) and the Input Shaft Cap (#15)3. Remove the Worm Gear Input Shaft Assembly (#18) by gently tapping it on one end of the shaft

with a rubber mallet until it comes out the other side of the housingNote: The Worm Gear Input Shaft Assembly (#18) can not be switched to the other side

Installation1. Place the Worm Gear Input Shaft Assembly (#4,18,) back in the Housing (#1) in its original

configuration2. Install the O-ring (#5) on each side of the Housing (#1)3. Slide the Input Shaft Cap over Input Shaft (#18) and bolt it to the housing with the Hex Head Cap

Screws (#2) and torque them to 225 in. lbs.

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ALUMINUM WORM GEAR SPEED REDUCER

INSTRUCTION MANUAL

CAUTION-Worm Gear Speed Reducers are Not To Be Considered a Fail Safe Or Self-Locking Devices. If These Features Are Required, A Properly Sized Independent Holding Device Should Be Utilized.

-Depending Upon Gear Geometry and Operating Conditions, Worm Gear Speed Reducers May OrMay Not Back Drive. Special Consideration Should Be Given To High Inertia Loads ConnectedTo The Reducer Output Shaft.

-Reducers Driven By Brake Motors Must Be Sized To Accommodate Motor Driving and Brake andInertia Loads To Prevent The Braking Torque Or Inertia Loads From Exceeding The Motor Rating.

2. Lubrication and Maintenance2.1 LubricationThis speed reducer is shipped with oil and it is not necessary to fill it before use.2.2 Oil ChangesThe Speed Reducer is shipped to you filled with synthetic lubricant which should be changed every 6,000 hours of operation or every 2 years, which ever comes first. It is very important to use the proper lubricant type. It is also very important to keep the oil free from oxidation and contamination by water or debris. 1. Remove the oil Drain Plug (#6) to completely drain out the oil. 2. Replace the Drain Plug (#6) and remove the Steel Plug (#7). Refill with 10.14 oz. of recom-

mended gear oil.3. Install the Steel Plug (#7) and torque to 195 in. lbs.

Note: If you fill the speed reducer with a synthetic lubricant, please use the original steel plug (see fig.1).If you fill the speed reducer with a mineral lubricant, please use the supplied plastic air vent for air bleeding (see fig.2).

1. Remove the Steel Plug (#7).2. Replace with the supplied plastic air vent and torque to 195 in. lbs.

ALUMINUM WORM GEAR SPEED REDUCER

INSTRUCTION MANUAL

Installation1.1 Motor and Speed ReducerRV series speed reducers are shipped with oil so they do not need to be filled before use.

1.2 Motor WiringTo Power SupplyConnection of the electric motor to the power supply should be made by a qualified electrician. Thecurrent rating of the motor will be identified on the motor plate, and the correct sizing of the wire tomeet electrical regulations is essential.

1.3 Mounting The Speed ReducerTo mount the speed reducer feet to the equipment use 3/8" UNC bolts (Minimum ISO grade 8.8) and torque them to 750 in-lbs. It can either be free standing by foot mounting, or if required, mounted on a standard base-plate with a foot mounted motor correctly aligneda) Align the Speed ReducerNote: It is important to insure when aligning the speed reducer on the base-plate that all machined mounting points are supported over their full area.During the final assembly insure the unit or base-plate are not distorted. This will cause strain on the gear case resulting in the possible misalignment of the shafts and gearing.b) Install safety guards in accordance with local regulationsc) Check the motor wiring diagram for the correct direction of rotation. This is important when a

load holding device has been added.

original steel plug supplied plastic air vent

fig.1 fig.2

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ALUMINUM WORM GEAR SPEED REDUCER

INSTRUCTION MANUAL

Problem (s)

Overheating

Vibration

Noise

Oil Leakage

Tooth surface of the worm gear sets abrades quickly

Possible Cause (s)

1.Improper alignment between the prime mover, speed reducer or operating device2.Overloading3.Excessive friction of the output shaft oil seal4.The gear oil is over or under filled5.The oil is very contaminated or of inferior quality

1. The prime mover, speed reducer or the operating device is not mounted properly2. The tooth surface of the worm gear set is worn-out or damaged3. A bearing is worn-out

1. A bearing is damaged or worn2. The worm gear set is not meshing properly3. The oil level is low 4. Contamination inside the gear housing

1. The oil seal lip is worn-out2. The shaft is worn in the area of the oil seal3. The oil level is to high4. The oil drain plug is loose

1. Overloading2. The oil does not conform to the recommended standards3. The oil level is low4. The oil is contaminated and needs replaced5. Overheating while running

Suggested Solution (s)

1. Adjust installation position to make all components align2. Adjust load or replace with a suitable type of speed reducer3.Lubricate the output shaft oil seal4.Adjust to the proper oil level using oil sight glass5.Change the oil and replace with the recommended type

1. Isolate the loose bolts and tighten2.Replace the worm gear set3.Replace the bearing

1. Replace the bearing2. Mend the tooth surface or replace the worm gear set3. Adjust to the proper oil level using oil sight glass4.Drain out the dirty oil and replace with the recommended type

1.Replace the oil seal2.Replace input or output shaft3. Adjust to the proper oil level using oil sight glass4.Remove the oils drain plug, coat with sealant and reinstall

1.Adjust load or replace with a suitable type of speed reducer2.Replace with approved oil3. Adjust to the proper oil level using oil sight glass4.Change the oil and replace with the recommended type 5. Adopt preventative measure to make the ambient temperature lower

Size:145x210mm REV 04/07/15 2.09.05.30.569

ALUMINUM WORM GEAR SPEED REDUCER

INSTRUCTION MANUAL

2.4 Lubricant Capacity and Mounting Orientation

TroubleshootingContact Princess Auto Ltd. for a solution if the speed reducer does not function properly or parts are missing. If unable to do so, have a qualified technician service the device.

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Aluminum Speed Reducer Lubricant Capacities

This speed reducer has been filled with oil and tested. You do not need to add oil before it is used.

Speed Reducer Mounting OrientationSpeed Reducer Mounting Orientation

8607384 Approx Capacity(fl oz)

8607392 Approx Capacity(fl oz) 5.07

2.70

A B C D E

A

AmbientTemperature

-30℃ to 5℃(-22 ℉ to 41℉)

5℃ to 25℃(41 ℉ to 77℉)

25℃ to 40℃(77 ℉ to 104℉)

40℃ to 65℃(104 ℉ to 149℉)

Load

Normal

Heavy-duty

Normal

Heavy-duty

Normal

Heavy-duty

Normal

Heavy-duty

Oil Viscosity (ISO)

VG-100

VG-150

VG-220

VG-320

VG-320

VG-460

VG-460

VG-680

Oil Viscosity (SAE Gear Oil)

85

90

90

140

140

140

140

250

B C D E F

Speed Reducer Mounting Orientation

Horizontal Input Shaft Vertical Input Shaft

- Oil filling hole