SPX Marley Geareducer 32.2 Series

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Summary

Corrosion and Dry Start-Up Protection

Status Definitions

Defines operational states: Pre-Commission, Operational, Idle, Seasonal Shutdown, Long-Term Storage/Downtime.

Pre-Commission Status

Unit's as-shipped condition with rust-proofing for up to 4 months.

Operational Status

State initiated by first motor-driven sequence for regular service.

Idle Status

Suspension in operational status, lasts up to two weeks, can be doubled by a run cycle.

Seasonal Shutdown Status

Extended idle condition, up to 4 months, requires additional maintenance.

Long-Term Storage or Downtime

Indefinite duration status requiring long-term preventive measures.

Run Cycle Procedure

Full speed operation for 30 mins to recoat internal components and expel moisture.

Initial Operation

Priming Procedure

Supplement lubricant prior to initial operation, 1-1.5 quarts, within 5 days.

Operation Warning

Operating outside specified oil levels can cause damage and safety concerns.

Service and Lubrication

Recommended Oil Filling Procedure

Step-by-step instructions for filling the Geareducer with oil via fill hole.

Alternate Oil Filling Procedure

Alternative method for filling using a three-way valve and stand pipe.

Geareducer Maintenance Schedule

Monthly and semi-annual maintenance tasks including oil level checks and oil changes.

Summary

Corrosion and Dry Start-Up Protection

Status Definitions

Defines operational states: Pre-Commission, Operational, Idle, Seasonal Shutdown, Long-Term Storage/Downtime.

Pre-Commission Status

Unit's as-shipped condition with rust-proofing for up to 4 months.

Operational Status

State initiated by first motor-driven sequence for regular service.

Idle Status

Suspension in operational status, lasts up to two weeks, can be doubled by a run cycle.

Seasonal Shutdown Status

Extended idle condition, up to 4 months, requires additional maintenance.

Long-Term Storage or Downtime

Indefinite duration status requiring long-term preventive measures.

Run Cycle Procedure

Full speed operation for 30 mins to recoat internal components and expel moisture.

Initial Operation

Priming Procedure

Supplement lubricant prior to initial operation, 1-1.5 quarts, within 5 days.

Operation Warning

Operating outside specified oil levels can cause damage and safety concerns.

Service and Lubrication

Recommended Oil Filling Procedure

Step-by-step instructions for filling the Geareducer with oil via fill hole.

Alternate Oil Filling Procedure

Alternative method for filling using a three-way valve and stand pipe.

Geareducer Maintenance Schedule

Monthly and semi-annual maintenance tasks including oil level checks and oil changes.

The document is a user manual for the Marley Geareducer® model 32.2, providing instructions for its installation, operation, and maintenance. The Geareducer is a mechanical device, likely a gearbox, used in cooling towers, designed to reduce the speed of a motor's output shaft to a lower speed suitable for driving a fan or other equipment.

Function Description:

The Marley Geareducer model 32.2 serves as a speed reducer, converting the high rotational speed of a motor into a lower, more appropriate speed for the driven equipment, such as a cooling tower fan. This mechanical reduction is achieved through a system of gears, specifically spiral bevel and helical gears, as illustrated in the manual's diagrams showing gear tooth patterns. The device is designed for continuous operation once commissioned and properly maintained.

Important Technical Specifications:

Model: Geareducer® model 32.2
Oil Capacity: The Series 32 Geareducers have an oil capacity of 9 gallons. An optional oil filter adds one additional gallon, and connecting oil gauge and drain lines require approximately one gallon of oil, bringing the total system capacity to around 11 gallons.
Lubricant Viscosity: The manual specifies different ISO viscosity grades for lubricants based on ambient air temperature at the Geareducer:
- Below 110°F (43°C): ISO 150
- Above 110°F (43°C) (Severe Duty/High Temperature): ISO 220
Material Protection: Internally, the Geareducer utilizes iron and steel materials, protected against corrosion by machine enamel on un-machined parts and rust-proofing oil and grease on machined surfaces during shipment.

Usage Features:

Operational Statuses: The manual defines several operational statuses to guide maintenance and storage:
- Pre-Commission: The as-shipped condition, protected internally, lasting up to 4 months (3 months for export). Requires specific steps if the cooling tower isn't ready for operation within this period.
- Operational: Initiated after the first motor-driven sequence, indicating regular service.
- Idle: A suspension in operational status for 2 to 4 weeks, extendable by performing a "Run Cycle."
- Seasonal Shutdown: An extended idle condition lasting up to 4 months, requiring additional preventive maintenance.
- Long-Term Storage or Downtime: Indefinite duration, requiring long-term preventive measures like an overflow reservoir system filled entirely with oil.
Run Cycle: Defined as full-speed operation for a minimum of 30 minutes. This helps recoat internal components with lubricant and expel moisture.
Priming: Before initial operation, supplemental lubricant (1 to 1.5 quarts) should be poured or pumped into the port above the interstage shaft while rotating the gear train by hand. This step should be performed within 5 days of initial operation.
Oil Level Monitoring: The Geareducer must be filled to the "Full" mark on the case and external sight glass. Operating at incorrect oil levels can cause damage.
Vent Line: The vent or vent line must be checked for blockage to prevent pinion shaft oil seal failure.
Alignment: The Geareducer must be installed level and properly aligned with the driveshaft and motor shaft, referencing the Driveshaft User Manual.

Maintenance Features:

Corrosion Protection: Regular checks for exterior corrosion and touch-ups with paint are recommended. Internal lubrication film is crucial for protecting working components.
Oil Changes: Semi-annually or every 3,000 hours of operation, the oil should be changed. The oil filter cartridge should also be replaced at every oil change.
Oil Level Checks: Monthly, the oil level should be checked at the sight glass after allowing 10 minutes for stabilization. If oil is added, a run cycle and recheck are necessary.
Water Condensation Drainage: During seasonal shutdown, water condensation should be drained monthly from the lowest point of the Geareducer and its oil system.
Internal Inspection: At each oil change, the inspection cover plate should be removed to check for cleanliness, sludge, and observe the contact pattern of the gear teeth. Incorrect patterns may indicate worn bearings, requiring replacement.
Fastener Checks: Monthly, all fasteners, including the oil plug, should be inspected and tightened.
Leak Checks: Monthly, oil leaks in the Geareducer and lube lines (if equipped) should be checked and repaired.
Driveshaft Inspection: Annually, driveshaft alignment, fasteners, and bushing/flex elements should be checked for wear.
Oil Filter Service: The manual provides detailed steps for replacing the oil filter cartridge, including draining oil, removing the old cartridge, cleaning, installing a new cartridge, and refilling.
Repair and Overhaul: Field repairs are possible, but major repairs may require a fully equipped machine shop. Instructions and parts manuals are available from Marley.
Lubricant Compatibility: Only Marley factory lubricants or those without specific additives (detergents or EP additives) that could reduce service life should be used. The responsibility for using non-Marley lubricants rests with the customer and supplier.