SPX Marley Geareducer 34.4 Series

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Summary

Operation and Maintenance

Protection Against Corrosion

Details internal and external corrosion protection methods for the Geareducer.

Initial Operation

Steps for initial setup, oil level checks, and alignment before operation.

Seasonal Shutdown

Procedures for protecting the unit during short-term shutdowns.

Inspection Of Internal Parts

Guidance on checking internal cleanliness and looking for sludge during maintenance.

Service and Lubrication

Instructions for filling oil, checking oil capacity, and gauge verification.

Suggested Lubricants

Lists recommended lubricants for the Marley Geareducer.

Parts List

3400 Series Parts List

Exploded view and list of components for the 3400 series Geareducer.

34.4 Series Parts List

Exploded view and list of components for the 34.4 series Geareducer.

Field Repair

General Field Repair Information

Overview of field repair capabilities and general advice for Geareducer maintenance.

Disassembly of Major Subassemblies

Steps for disassembling major subassemblies of the Geareducer unit.

Disassembly of Pinion Cage

Detailed steps for disassembling the pinion cage assembly.

Disassembly of Interstage

Detailed steps for disassembling the interstage components.

Disassembly of Fan Shaft

Steps for disassembling the fan shaft assembly.

Geareducer Assembly Procedures

Procedures for assembling the Geareducer, including gear matching.

Interstage Assembly

Detailed steps for assembling the interstage components.

Fan Shaft Assembly

Steps for assembling the fan shaft and related components.

Final Assembly

Final steps for assembling the 3400 and 34.4 series Geareducers.

Gear Setting Procedure

Instructions for setting gear backlash and tooth contact.

Spiral Bevel Gear Tooth Pattern

Illustrations of correct and incorrect spiral bevel gear tooth contact patterns.

Summary

Operation and Maintenance

Protection Against Corrosion

Details internal and external corrosion protection methods for the Geareducer.

Initial Operation

Steps for initial setup, oil level checks, and alignment before operation.

Seasonal Shutdown

Procedures for protecting the unit during short-term shutdowns.

Inspection Of Internal Parts

Guidance on checking internal cleanliness and looking for sludge during maintenance.

Service and Lubrication

Instructions for filling oil, checking oil capacity, and gauge verification.

Suggested Lubricants

Lists recommended lubricants for the Marley Geareducer.

Parts List

3400 Series Parts List

Exploded view and list of components for the 3400 series Geareducer.

34.4 Series Parts List

Exploded view and list of components for the 34.4 series Geareducer.

Field Repair

General Field Repair Information

Overview of field repair capabilities and general advice for Geareducer maintenance.

Disassembly of Major Subassemblies

Steps for disassembling major subassemblies of the Geareducer unit.

Disassembly of Pinion Cage

Detailed steps for disassembling the pinion cage assembly.

Disassembly of Interstage

Detailed steps for disassembling the interstage components.

Disassembly of Fan Shaft

Steps for disassembling the fan shaft assembly.

Geareducer Assembly Procedures

Procedures for assembling the Geareducer, including gear matching.

Interstage Assembly

Detailed steps for assembling the interstage components.

Fan Shaft Assembly

Steps for assembling the fan shaft and related components.

Final Assembly

Final steps for assembling the 3400 and 34.4 series Geareducers.

Gear Setting Procedure

Instructions for setting gear backlash and tooth contact.

Spiral Bevel Gear Tooth Pattern

Illustrations of correct and incorrect spiral bevel gear tooth contact patterns.

The document describes the Marley 34.4 - 3400 Series Geareducer, a mechanical device primarily used in cooling tower applications. This user manual provides comprehensive instructions for its installation, operation, and maintenance, emphasizing proper care to ensure long life and smooth operation.

Function Description

The Geareducer is a type of gearbox designed to reduce the speed of a motor's output shaft to a lower speed suitable for driving a fan in a cooling tower. It utilizes a combination of spiral bevel and helical gears to achieve the desired speed reduction. The manual details two main series: the 3400 Series and the 34.4 Series, with exploded views and parts lists for both, indicating slight differences in components like the lower fan shaft cap. The core function involves transmitting power efficiently while reducing rotational speed, which is crucial for the optimal performance of cooling tower fans.

Important Technical Specifications

The Geareducer features specific gear ratios for its spiral bevel and helical gear sets. For the Spiral Bevel Gear Set (100), the available gear ratios are:

2.76 to 1
2.375 to 1
2.476 to 1

For the Helical Gear Set (200), the available gear ratios are:

4.182 to 1
4.70 to 1

The oil capacity of the Geareducer is 18.5 gallons, with an additional approximately one gallon required for the oil level gauge line. Bearing preload for the pinion shaft is specified at 10 to 18 in-lbf (1130-2034 mN·m) resistance to rotation. Backlash between spiral bevel gears should be .007-.009" (0.178-0.228mm) normal to the ring gear tooth. Fan shaft bearing preload is .001-.003" (0.025-0.076mm). Torque specifications for various bolts are provided:

Pinion cage cap bolts (23): 55 ft·lbf (75 N·m)
Retainer disc (203) bolts: 55 ft·lbf (75 N·m)
Disc (202) place bolts: 150 ft·lbf (204 N·m)
Case cover cap screws: 75 ft·lbf (102 N·m) for 3400 Series, 45 ft·lbf (61 N·m) for 34.4 Series
Interstage bearing cap place bolts: 85-90 ft·lbf (116-122 N·m) for 3400 Series, 90 ft·lbf (122 N·m) for 34.4 Series
Bottom cap screws: 80 ft·lbf (109 N·m)

The manual also highlights the importance of matching gear sets, as gears are lapped at the factory and should not be separated. Match numbers are etched on both the pinion and ring gear.

Usage Features

The Geareducer is designed for continuous operation in cooling tower environments. Key usage features include:

Initial Operation: Requires filling with oil to the full mark before starting. For new towers, oil is included; for spares, it must be supplied. Proper alignment with the driveshaft and motor shaft is crucial. The vent or vent line must be open to prevent oil seal failure.
Seasonal Shutdown (1 week to 3 months): Before shutdown, operate the Geareducer until oil reaches 120°F (50°C), then change the oil. Monthly, drain water condensation, check oil level, and operate briefly to recoat internal surfaces.
Longer Shutdowns: Refer to Marley Manual 92-1308 "Downtime Instruction Manual."
Lubrication: The manual provides a list of suggested lubricants (Table 1) from various manufacturers, emphasizing the use of oils without detergents or EP additives that could be adversely affected by moisture.
Oil Level Monitoring: Equipped with an external oil gauge and drain line, allowing for easy oil level checks and filling. The "Full" mark on the placard must align with the "Full" mark on the Geareducer case.
Inspection Cover: A removable inspection cover plate allows for visual inspection of internal parts and cleanliness during oil changes.

Maintenance Features

Regular maintenance is critical for the Geareducer's longevity and performance. The manual outlines a detailed maintenance schedule:

Monthly:
- Check oil level and add if necessary.
- Inspect and tighten all fasteners, including oil plugs.
- Check for and repair oil leaks.
- Ensure the vent is open.
Semi-Annually (or every 6 months/3,000 hours of operation):
- Change oil.
- Inspect internal parts and case cleanliness through the inspection cover.
- Clean the oil level gauge vent.
Seasonal Startup or Annually:
- Check driveshaft or coupling alignment.
- Inspect and tighten driveshaft or coupling fasteners.
- Check driveshaft or coupling bushing/flex elements for unusual wear.
- Check for oil leaks in hoses and fittings (if lube lines are equipped).
Oil Filling Procedures: Two methods are described: a recommended procedure involving filling through the inspection cover, running the fan drive briefly, and rechecking; and an alternate procedure for cooling towers with an external oil gauge and three-way valve, allowing filling via a hose.
Corrosion Protection: As shipped, internal parts are protected with machine enamel and rust-proofing oil/grease. If oil is added, weekly operation is required to maintain the protective coating. Exterior paint touch-ups are recommended yearly.
Field Repair and Overhaul: While major repairs require a fully equipped machine shop, the manual provides detailed disassembly and assembly procedures for major subassemblies (pinion cage, interstage, fan shaft). It strongly recommends replacing O-rings and oil seals during every major overhaul.
Gear Setting Procedure: Critical for long life and smooth operation, this involves adjusting pinion cage position with shims to achieve the correct pinion setting distance and adjusting ring gear position with shims to achieve proper backlash and tooth contact pattern. The manual provides illustrations for correct and incorrect tooth contact patterns and remedies.
Troubleshooting: If correct contact cannot be obtained, the Geareducer should be returned to Marley for exchange with a factory reconditioned unit.

The manual emphasizes the importance of reading and understanding its contents prior to operating or servicing the product to ensure safe and effective use.