Marley Geareducer
Marley Geareducer
Marley Geareducer
O P E R AT I O N - M A I N T E N A N C E – R E PA I R
Z0490769_A ISSUED 02/2017 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT
operation and service
Inspection
Drain Plug
All Marley Geareducer units ship from the factory with a protective Check to be sure that the Geareducer is filled with oil and that
coating of epoxy enamel paint on all unmachined parts and with there are no visible oil leaks. If equipped with an external dipstick/
rust-proofing oil and grease on machined surfaces. Machined sur- oil level gauge, be sure the oil full mark corresponds with the full
face coatings normally protect the Geareducer against atmospheric level at the Geareducer.
corrosion during storage periods for up to six months. However, if
Note—If this tower is equipped with a two-speed motor, allow a
oil is added to the Geareducer, the new oil will dissolve the rust-
time delay of at least 20 seconds when switching from high speed
proofing grease and require that the Geareducer be run once a
to low speed. Allow a time delay of at least two minutes when
week to keep a protective coating of oil on all interior machined
changing direction of fan rotation. Failure to provide these delays
surfaces.
may significantly reduce equipment service life.
Check Geareducer exterior yearly and touch up with epoxy paint if
Lubricants
required. If your Geareducer is equipped with an oil gauge and drain
line, coat any exposed threads at pipe joints to prevent corrosion. To insure maximum performance and service life, it is recommended
Marley factory lubricants be used in all Marley Geareducers.
Alignment
Marley lubricants can be purchased through your local Marley
In order to assure long service life, the Geareducer and motor must sales representative.
be level, and the drive shaft or coupling must be properly aligned.
Refer to the alignment instructions in the Driveshaft or Coupling
Manual shipped with the cooling tower. Copies are also available ➠
from your local Marley sales representative.
3
operation and service
If lubricants other than Marley factory lubricants are used, they must Seasonal temperature changes may require one viscosity of oil for
not contain any additives (such as detergents or EP additives) which summer operation and another for winter operation. Refer to the
are adversely affected by moisture and could reduce the service tables below for the seasonal selection information.
life of the Geareducer. The responsibility for use of lubricants other
than Marley factory lubricants rests with the customer/owner and
the lubricant supplier.
Geareducer Drive
Change oil R R
4
operation and service
Warning—Make certain that mechanical equipment is inoper- Check Geareducer exterior yearly and touch up with epoxy paint if
able during periods of maintenance—or during any situation of required. If your Geareducer is equipped with an oil gauge and drain
possible endangerment to personnel. If your electrical system line, coat any exposed threads at pipe joints to prevent corrosion.
contains a disconnect switch, lock it out until the period of expo-
Repair and Overhaul
sure to injury is over.
If your Geareducer ever needs replacement or repair, we recommend
Monthly—Check Geareducer oil level. Shut down the unit and
returning the unit to a Marley factory service center. Contact your
allow 5 minutes for the oil level to stabilize. Add oil if required,
Marley sales representative to discuss course of action. A factory
noting the addition in your maintenance log. If equipped with an
reconditioned Geareducer carries a one year warranty. The Order
external dipstick/oil level gauge, small quantities of oil can be
Number on your cooling tower will be required if the Geareducer is
added at that location.
shipped back to the factory for repair. Obtain a “Customer Return
Semi-annually—Check that all the assembly bolts and cap screws Material” tag from the Marley sales representative in you area. To
are tight, that oil plugs and pipe connections are in place and free find your Marley sales representative call 913 664 7400 or check
from leaks, and that the vent on the Geareducer (and external the internet at spxcooling.com.
dipstick/oil level gauge, if present) is clear—a clogged vent can
Major repairs require the use of a fully equipped machine shop.
lead to oil leaks. If using turbine-type mineral oil, change oil—see
If you decide to repair or overhaul your Geareducer, refer to the
Changing Geareducer Oil for instructions. Intermittent operation
Field Repair Section and Geareducer Parts List.
and extended periods of downtime can cause condensation of
water in the oil.
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field repair
210
WATER SLINGER
502
BEARING RETAINER
420
203 201
GEAREDUCER
412 CASE
AIR VENT
506
102
202
101
411
BOTTOM CAP
BEARING RETAINER
CAP
6
Parts List
7
field repair
Geareducers can be repaired in the field—however, major repairs 1. Remove pinion cage cap* from pinion cage.
require the use of a fully equipped machine shop. When field repair
2. Remove O-rings* (504 and 505).
or replacement of parts is necessary, the following procedure is
recommended for the disassembly and assembly of the unit. If any 3. Remove locknuts and lockwasher (103 and 104) then press
O-ring, oil seal or gasket is to be reused, care should be taken pinion shaft (101) out of pinion cage. This will free tail bear-
not to damage it during disassembly. Parts which contain O-rings ing cone (312). A hydraulic press or jack is recommended for
or seals should not be jerked or twisted past a shoulder or edge. removing or assembling press fit parts.
These parts are marked with an asterisk (*) in the description
4. Press oil slinger*, O-rings* (301 and 506), and head bearing
below. O-rings, oil seal and gaskets should be carefully inspected
cone (311) from the pinion shaft. Bearings must not be exposed
for damage before being reinstalled. Always use new O-rings and
to dirt, dust or moisture.
oil seal during a major overhaul.
5. Press bearing cups (311 and 312) out of pinion cage.
Disassembly
Fan Shaft Disassembly
Part numbers and references—refer to Figure 2 and 3.
1. Remove ring gear (101) from the ring gear hub (8).
1. Remove drain plug and drain oil.
2. Press ring gear hub and lower bearing cone (411) off of the
2. Remove outer ring of bolts in pinion cage cap and remove
fan shaft (201).
pinion subassembly*.
3. Remove lower fan shaft key (202).
Note—The thickness of the shim pack (320) is important in reset-
ting the gears. The shim pack should either be saved or carefully 4. Press the top bearing cone (412) off of the shaft.
measured with a micrometer. If the gears are to be replaced, record
the pinion setting distance that is etched on the pinion gear.
Assembly
3. Remove water slinger*.
Before assembling a new pinion gear in the pinion cage, check
4. Turn case upside down and remove bearing retainer cap* and
match numbers on pinion gear and spiral bevel ring gear to be
shim pack (420).
certain that they are a matched set. Gears are lapped in matched
Note—The thickness of this shim pack is important in the back- sets at the factory and should not be separated. Numbers are
lash setting of the gears. The shim pack should either be saved etched on both the pinion and ring gear as illustrated in Figure 4.
or carefully measured with a micrometer.
All parts that are to be reused should be thoroughly cleaned before
5. Remove bottom cap and fan shaft assembly. being reinstalled. Do not remove new bearings from packaging
until ready to use. Clean all bearings (new or used). Do not spin
6. Turn Geareducer case right side up and remove bearing retainer
dry bearings. Take each bearing set and roll the cup on the cone
and shim pack (420).
to note any roughness. Replace bearing if necessary. If bearings
Note—The thickness of this shim pack is important in setting the cannot be installed immediately after cleaning, lubricate and cover
fan shaft bearing endplay. This pack should be saved or carefully to protect against dust, moisture, etc.
measured with a micrometer.
If a press is not available to install bearing cones, they can be
7. Remove bearing cups (411 and 412) from the bottom cap and heated as long as the temperature does not exceed 275°-300°F
Geareducer case using a soft metal punch or mallet. (135°-149°C). If the bearings get hotter than this, they will begin
to draw and soften. Bearings can be heated with infrared lamps
or with oil baths. If an oil bath is used, the bearing should be sup-
ported an inch or so above the pan to prevent local overheating.
8
FAN HUB
RETENTION HARDWARE
FAN SHAFT
BEARING RETAINER
O-RING
WATER SLINGER
AIR VENT
GEAREDUCER CASE
O-RING
PINION GEAR
PINION SHAFT
PINION CAGE
RING GEAR CAP
O RING
PINION CAGE
DRAIN PLUG
9
field repair
6. Press tail bearing cone (312) on pinion shaft until it mates with
its bearing cup.
1/8" DIA. BEAD
7. Install locknuts and lockwasher (103 and 104). Tighten nuts on
OF RTV SILICON
bearing cone until 5 to 15 in·lbƒ (565-1695 mN·m) of bearing
GASKET SEALER
preload is obtained. Bearing preload is the resistance in the
bearings to shaft rotation measured in in·lbƒ required to rotate
the shaft at uniform velocity. Preload is necessary to insure the
stability of the gear engagement. Crimp the lockwasher to hold
the two nuts in place.
8. Install O-ring (504) in groove. Figure 5 Flange Seal of Bottom Bearing Cap
9. Press oil seal (501) onto pinion shaft.
10. Position O-ring (505) and push cap—with seal and sleeve—in
place on shaft. Attach cap to pinion cage and slide sleeve Installation of Pinion Cage
from cap. 1. The "X" marked pinion and gear teeth should be clearly identi-
11.Record the pinion setting distance that is etched on the pinion fied with chalk or other markings which can be seen from the
gear. inspection opening or the bottom of the case.
3. Turn the Geareducer case upside down and install the fan Difference .005
shaft assembly seating the upper fan shaft bearing cone into
Remove .005 from shim gap.
its cup. Install the lower bearing cup (411).
3. Install shims (320) and pinion cage subassembly.
4. Install the bottom cover cap using sealer as indicated in Figure
5 and tighten cap screws to 25 ft·lbƒ (34 N·m). Use old shim
pack or make up equivalent thickness shim pack (420) and
Note—Care must be taken not to damage the pinion gear teeth
install the bottom bearing retainer cap. Do not install the O-ring
by forcing them into the ring gear teeth.
for the bottom bearing retainer at this time. Tighten the cap
screws to 25 ft·lbƒ (34 N·m).
10
field repair
The proper mounting of the gear set is essential to obtain long Note—To maintain bearing adjustment corresponding shim (420)
life and smooth operation of the gears. The pinion and ring gears adjustment must be made at the bearing retainer.
were positioned approximately in the preceding steps. The correct Example: Removing .003" shims at the bottom bearing retainer
gear position is determined by the gear tooth contact pattern and requires the addition of .003" shims at the top bearing retainer to
by the backlash. maintain correct bearing adjustment.
With the "X" marked tooth on the pinion gear engaged between Recheck the backlash to make sure it is within the proper limits.
the two "X" marked teeth on the ring gear, check the backlash
with a dial indicator as shown in Figure 6. Lock the pinion shaft With gears adjusted to the proper backlash, blue (Prussian blue in
against rotation. The amount of movement of the fan shaft, mea- oil) the pinion teeth. By using a long handled brush or swab, the
sured at a distance equal to the outside radius of the ring gear pinion teeth can be reached through the inspection opening. Drive
is the backlash. The backlash on the 6.50/1 gear set should be the pinion by turning the fan shaft in both directions for several
between .013 and .018" (.33 and .46mm). The backlash on all revolutions. Observe the markings on both gears on both sides of
other ratios should be between .010 and .015" (.25 and .38mm). the teeth. Compare the markings with the contact pattern shown
With the "X" teeth engaged, the backlash should be approximately in Figure 7.
in the middle of the allowable range. Check the backlash at three If contact pattern is incorrect, adjust the pinion position with shims
other points around the ring gear to be sure the backlash is within between the pinion cage cap and Geareducer case.
the specified limits. Adjust ring gear axially by removing or adding
shims (420) at bottom bearing retainer. When tooth contact is correct, recheck backlash. If necessary,
adjust ring gear to obtain proper backlash and recheck contact
pattern. Proper contact is more important of the two. On a used set
of gears, it may be necessary to set the gears with slightly greater
backlash in order to obtain proper tooth contact. Should a condi-
tion be encountered where correct contact cannot be obtained,
contact your local Marley sales representative for information on
TOP VIEW
OF INDICATOR factory repair service.
POINT OF MEASUREMENT
COLLAR OUTSIDE RADIUS OF GEAR
SET SCREW DIAL INDICATOR Final Assembly
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Geareducer
U S E R M A N UA L
Correct Pinion and Ring Gear Tooth Contact Patterns Incorrect Ring Gear Tooth Contact Patterns
*
Cause: Pinion too close to
ORIGINAL
* gear center.
Remedy: Move pinion out.
PATTERN
AFTER CONVEX SIDE CONCAVE SIDE
BREAK IN
*
OUT-OF POSITION CONTACT
Cause: Pinion too far from
RING GEAR gear center.
Remedy: Move pinion in.
CONVEX SIDE CONCAVE SIDE
ENTERING LEAVING
* DIRECTION OF ROTATION