The provided manual describes the Marley Geareducer models 3600 and 4000, which are mechanical speed reducers primarily used in cooling tower applications. The manual covers installation, operation, and maintenance procedures for these units.
Function Description:
The Marley Geareducer is designed to reduce the speed of a motor's output shaft to a lower speed suitable for driving a fan, typically in a cooling tower. It utilizes a combination of spiral bevel and helical gears to achieve the desired speed reduction. The manual details the assembly and disassembly of various components, including the pinion shaft, interstage shaft, and fan shaft, which are critical for its operation. Proper gear setting, including backlash adjustment and tooth contact pattern, is emphasized to ensure long life and smooth operation. The Geareducer is designed to operate with specific lubricants, and the manual provides a list of recommended mineral and synthetic oils.
Important Technical Specifications:
The Geareducer models 3600 and 4000 offer various gear ratios for both spiral bevel and helical gear sets.
- Spiral Bevel Gear Set (100): Available ratios include 2.304 to 1, 2.435 to 1, 2.762 to 1, 3.158 to 1, 3.167 to 1, and 3.944 to 1.
- Helical Gear Set (200): Available ratios include 4.18 to 1, 4.70 to 1, and 5.00 to 1.
- Bearing Preload: Pinion shaft bearing preload should be 10 to 18 in·lbf (1130-2034 mN·m) resistance to rotation.
- Backlash: Normal backlash between spiral bevel gears should be 0.007-0.009 inches (0.178-0.228 mm).
- Fan Shaft Bearing Preload: The fan shaft bearing must be preloaded to 0.001-0.003 inches (0.025-0.076 mm).
- Lubricant Capacity: The Geareducer requires 18.5 gallons (70 liters) of oil. If equipped with an external dipstick/oil level gauge, an additional 3 to 4 quarts of oil will be needed.
- Torque Specifications:
- Retention plate bolts (fan hub installation): 70 ft·lbf (95 N·m).
- Pinion cage cap bolts (23): 55 in·lbf (75 N·m).
- Interstage retainer bolts (203): 55 ft·lbf (75 N·m).
- Interstage disc place bolts (202): 150 ft·lbf (204 N·m).
- Case cover cap screws and eye bolts: 75 ft·lbf (102 N·m).
- Interstage bearing cap place bolts: 85-90 ft·lbf (116-122 N·m).
- Labyrinth ring cap screws (for fan shaft lip seal cases): 35 ft·lbf (48 N·m).
Usage Features:
The Geareducer is designed for integration into cooling tower systems, requiring proper installation and alignment with the driveshaft and motor shaft. The manual provides detailed instructions for installing the fan hub on both straight and tapered fan shafts, emphasizing the correct seating of keys and torque application for retention bolts.
- Fan Hub Installation: Specific procedures are outlined for straight fan shafts with split taper bushings and tapered fan shafts, including cleaning, anti-seize compound application, key seating, and torqueing of retention plate hardware.
- Oil Filling and Level Checks: The manual describes recommended and alternate procedures for filling the Geareducer with oil, including starting and stopping the fan drive to stabilize oil levels. It highlights the importance of checking the oil level gauge and ensuring the vent is not plugged.
- Gear Match Numbers and Setting Data: For assembly, it is crucial to match the numbers etched on the pinion and ring gears, as they are factory-lapped sets. Pinion setting distance and backlash are critical parameters that must be adhered to for optimal performance.
- Tooth Contact Pattern: The manual provides illustrations and guidance on achieving the correct tooth contact pattern using Prussian Blue, and troubleshooting "out-of-position contact" issues by adjusting pinion and ring gear positions.
Maintenance Features:
The manual outlines a comprehensive maintenance schedule to ensure the longevity and reliable operation of the Geareducer.
- Status Definitions:
- Pre-Commission: Up to 4 months after receipt, requiring an export shipment status reduction by 1 month if protective coating is applied.
- Operational: Initial stage of operation, requiring a Run Cycle and checking for oil leaks.
- Idle: 2 to 4 weeks, requiring a Run Cycle.
- Seasonal Shutdown: Up to 4 months, requiring a Run Cycle and oil change at the start, and bi-weekly oil level checks and Run Cycles.
- Long-Term Storage or Downtime: Indefinite duration, requiring a Run Cycle and oil drain if operational, or filling the unit entirely with oil and installing an overflow reservoir system if in storage.
- Scheduled Maintenance Intervals:
- Monthly: Check Geareducer oil level, check for and repair oil leaks, make sure vent is open, and check lube lines for leaks.
- Semi-annually: Change oil (if using turbine-type mineral oil), inspect and tighten all fasteners, check for and repair oil leaks, make sure vent is open, and check lube lines for leaks.
- Annually: Inspect and tighten all fasteners, check for and repair oil leaks, change oil (if using turbine-type mineral oil), make sure vent is open, check driveshaft or coupling alignment, inspect and tighten driveshaft or coupling fasteners, check driveshaft or coupling bushing/flex elements for unusual wear, and check lube lines for leaks. Also, check mechanical equipment anchor bolts, driveshaft coupling bolts, and coupling set screws, and touch up exterior paint.
- Every 5 Years: Change oil (if using synthetic Marley Gearlube), with oil condition monitoring every six months.
- Inspection of Internal Parts: During oil changes, the inspection cover plate should be removed to check for cleanliness of the case and internal parts, flushing with mineral oil if sludge is present.
- Changing Geareducer Oil: Instructions for draining old oil, inspecting for foreign material, and refilling with new oil are provided.
- Repair and Overhaul: SPX Cooling Technologies recommends returning units to a Marley factory service center for major repairs. However, field repair procedures are detailed for disassembly and assembly of major subassemblies, emphasizing careful handling of O-rings, oil seals, and gaskets. New O-rings and oil seals are recommended for every major overhaul.
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