Marley Geareducer 3600 User manual

Geareducer®model 3600 and 4000
INSTALLATION - OPERATION - MAINTENANCE
Z0493915_C ISSUED 06/2022 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT
user manual

2
fan hub installation
The following instructions detail the process for installing a fan
on a Marley Geareducer with a straight fan shaft using a split
taper bushing or a tapered fan shaft utilizing a bolted fan hub
retention plate.
Straight Fan Shaft with Split Taper Bushing
1. Remove the retention plate and hardware from the top of the
Geareducer shaft. Thoroughly clean the fan shaft, fan shaft
key, and the fan hub center bore to remove any debris and/or
protective coatings. After cleaning, apply a coat of anti-seize
compound to the top 7" (180mm) of the fan shaft.
2. Prior to hub installation, fully seat the key in the fan shaft
keyway. The key is a tight fit across the width and must never
be altered.
3. Raise the fan hub above the fan shaft for installation. Slowly
lower the hub onto the shaft with the keyways properly aligned.
Make certain the key does not slide down during installation.
Stake the key in the keyway with a center punch if necessary.
The fan shaft key should be approximately centered in the
engaged portion of the hub when engaged on the shaft. Verify
the center hub is fully seated by visual inspection.
4. Install the retention plate and hardware. Torque bolts to 70 ft·lbƒ
(95 N·m).
Tapered Fan Shaft
Warning – Correct key installation is imperative for proper and
safe operation
1. Remove the retention plate and hardware from the top of the
Geareducer shaft. Thoroughly clean the fan shaft, fan shaft key,
and the hub center bore to remove any debris and/or protective
coatings. After cleaning, apply a coat of anti-seize compound
to the top 7" (180mm) of the fan shaft.
2. Install the fan shaft key in the fan shaft keyway as shown in
Figure 2. The key is a tight fit across the width and must never
be altered.
3. Raise the hub assembly above the fan shaft for installation.
Slowly lower the assembly onto the shaft with the keyways
aligned. Make certain the key does not slide down during
installation.
After the hub assembly is installed the bottom end of the key
must extend through the bottom of the center hub, and the top
end of the key must be at least 5/8" (16mm) above the top of
the fan shaft. Do not force the key down once these criteria
are met.
4. Figure 1 illustrates proper retention plate and hardware instal-
lation. The retention plate is designed to allow clearance for
the fan shaft key, and when properly installed will not extend
over or interfere with the key in any way. Torque the retention
bolts to 70 ft·lbƒ(95 N·m) then turn up the locking strap corners
to prevent the bolts from loosening.
GEAREDUCER
FAN SHAFT
TAPERED SIDE
OF KEY
PREVIOUS
STYLE KEY
1
3
/ 8
"
1
3
/ 8
"
1
5
/ 8
"1
1
/ 2
"
1
1
/ 2
"1
1
/ 2
"
KEY
FAN HUB
LOCKING
STRAPS
RETENTION
PLATE
RETENTION
BOLTS
Figure 1 Retention Plate Assembly
Figure 2 Key Installation

3
operation and service
Corrosion and Dry Start-Up Protection
Marley Geareducers utilize iron and steel materials, which if not
maintained correctly, may degrade. While some external corro-
sion is acceptable, an internal lubrication film must be main-
tained at all times to protect the working components against
corrosion and potential startup damage. The following informa-
tion describes methods of operation and preventive measures
to ensure suitability for long-term operation.
Status Definitions
Pre-Commission
Duration* = Up to 4 months after receipt.
*export shipment status duration is reduced by 1 month
This is the as-shipped condition, which contains a factory rust-
proofing coating on the interior of the unit as well as a grease
coating on the exposed shaft surfaces.
If the cooling tower is not ready for operation at the time of
status expiration, steps must be taken to place the Geareducer
into Long-Term Storage or Downtime status.
Operational
This stage is initiated upon the first motor driven sequence. The
Geareducer is now considered as being placed into regular
service and operation.
Idle
Duration = 2 to 4 weeks.
This stage is a suspension in operational status and lasts up
to two 2 weeks. The duration may be doubled by completing
a Run Cycle.
It is not recommended to extend the idle status more than once
in any given sequence.
A common application is during a temporary outage
Seasonal Shutdown
Duration = Up to 4 months after operational is suspended.
This stage may be considered an extended idle condition.
Requires additional preventive maintenance.
Long-Term Storage or Downtime
Duration = Indefinite.
Requires long-term preventive measures.
Run Cycle
Defined as full speed operation for a minimum of 30 minutes.
This recoats all internal components and surfaces with lubri-
cant and also helps to expel some moisture that may have
accumulated from daily ambient condition cycling.
As shipped, a Marley Geareducer is protected internally against
corrosion with machine enamel on un-machined parts and with
rust-proofing oil and grease on machined surfaces. These coatings
normally protect the Geareducer against corrosion for the duration
of the Pre-Commission phase. Adding normal lubricant to the
unit will dissolve the rust-proofing oil in the Geareducer sump.
Provided it is added via the filler-neck or pumped in through the
drain connection, this lubricant will not reduce the overall level
of protection however, if the unit is operated for any amount of
time, the Pre-Commission period is depleted and the unit is now
considered to be in Operational status.
Check the Geareducer exterior yearly. Touch up with paint as
required. Exposed pipe threads are coated to prevent corrosion.
Touch up coating as required.
Initial Operation
Priming
Due to lack of control over facility operational readiness, site
ambient conditions or storage practices, etc., it is recommended
to supplement lubricant prior to initial operation. The same fill
lubricant should be poured or pumped into the port above the
interstage shaft. Remove pipe plug in center of Interstage Bearing
Cap to expose port. Refer to Figure 3. If additional oil is being used,
an amount of 1 to 1 1/2 quarts should be used. If the lubricant
is being pumped from the sump bulk volume, at least 1 quart
should be transferred. In either case, this priming step should be
performed within 5 days of initial operation. If a delay occurs and
the 5 day duration is exceeded, repeat the process. In either case,
this priming step should be performed while rotating the gear train
by hand and within 5 days of initial operation.
Warning – Operating the Geareducer at an oil level other than
between the Add and Full levels may damage the unit and possibly
mating equipment. This could also escalate to a safety concern
for nearby personnel.
The Geareducer must be filled with oil to the Full oil level mark on
the Geareducer case before it is placed in operation. If the unit
is being taken out of Long-Term Storage or Downtime, the oil
should be drained down to the Full operating level. If drain-down
occurs within 5 days of the initial startup, the above priming se-
quence may be skipped. See Changing Geareducer Oil section
for oil filling instructions.
Geareducers supplied with new cooling towers include oil for the
initial filling and in some cases, will also ship with an additional
amount required to place the unit into Long-Term Storage or
Downtime status. Normally, oil is not furnished with Geareducers
supplied as a spare or on replacement orders. Before operating
the mechanical equipment, check to be sure the oil level is at the
Full mark at the Geareducer and that the external gauge placard
Full mark corresponds with the Full level in the Geareducer. Check
oil lines to be sure there are no leaks.

4
operation and service
The Geareducer vent or vent line must be checked for blockage
to prevent failure of pinion shaft oil seal—clean when necessary.
Once each month drain any water condensation from the lowest
point of the Geareducer and its oil system. Check the oil level and
add oil if necessary. Perform a Run Cycle.
To put back into operation, drain water condensation from the
lowest point of the Geareducer and its oil system and check oil
level. Add oil if necessary.
Long-Term Storage or Downtime indefinite duration
If unit has been in an operational state, perform a Run Cycle
and drain the oil including volume in the oil line, if equipped. If in
storage, unit does not need to be operated.
Fabricate and install an overflow reservoir system and fill unit
entirely full of oil.
Maintenance Cycle If unit is stored outdoors, drain condensate
monthly and top off oil as necessary. If unit is stored indoors,
but not climate controlled, maintenance cycle may be extended
to 3 months. If stored in climate controlled space, cycle may be
extended to once per year.
See Marley User Manual Z0238848 “Cooling Tower Downtime
Instructions” and Marley Drawing Z0544916 “Marley Geareducer
Reservoir System” for further information.
Inspection Of Internal Parts
Remove the inspection cover plate from the side of the Geareducer
case at each oil change. Check inside of Geareducer for cleanliness
of case and internal parts. If any sludge is present, flush inside of
Geareducer and connecting oil line.
Figure 3 Priming Interstage Shaft
Check all gasketed joints for oil seepage. Tighten cap screws and
flange bolting if necessary.
TheGeareducer must be installedlevel and properlyaligned with the
driveshaft and motor shaft. Refer to the Driveshaft User Manual.
It is recommended to operate the Geareducer for no less than
30 minutes in any given run sequence. It is acceptable to ignore
this when “bumping” the motor for confirmation of the correct
direction of rotation.
Seasonal Shutdown up to 4 months
At start of shutdown period, perform a Run Cycle and change the
oil. See section on Changing Geareducer Oil.
Every 2 weeks check the oil level and perform a Run Cycle.
Changing Geareducer Oil
Drain the Geareducer oil by removing the drain plug. See
Figure 4 for location. If equipped with an external dipstick/oil
level gauge, remove the drain plug at that location, and drain the
entire system.
When using synthetic oil with extended service intervals remove a
sample for lab analysis and look for evidence of foreign material,
such as water, metal shavings or sludge. If you find unacceptable
condensation or sludge, flush the Geareducer with mineral oil
before refilling.
After inspection is complete, fill the Geareducer with 18.5 gallons
(70 liters) of oil. See Figure 4 for location. If the Geareducer is
equipped with an external dipstick/oil level gauge an additional 3
to 4 quarts of oil will be required. Be certain that the vent on the
Geareducer (and external dipstick/oil level gauge, if present) is
not plugged. Verify that the gauge/drain line is full and that there
aren't any leaks at the connections.

5
VENT LINE
OIL FILL PLUG
OIL LEVEL CHECK
INSPECTION
COVER
OIL GAUGE
AND DRAIN LINE
OIL LEVEL
GAUGE
DRAIN PLUG
THREE-WAY
VALVE
OIL GAUGE
VENT
Figure 4 Service Fittings
operation and service
VENT
OIL LEVEL
GAUGE
OIL LEVEL
PLACARD
FULL
ADD
OIL
NOTICE
CHECK OIL LEVEL TEN
MINUTES AFTER
FAN STOPS ROTATING
FILL AT GEAREDUCER
REFER TO SERVICE MANUAL
FOR OIL CHANGE AND
MAINTENANCE RECOMMENDATIONS
SPX COOLING TECHNOLOGIES
OVERLAND PARK, KS USA
92-110A
Figure 5 Oil Level Gauge Assembly
Fill the Geareducer and oil line system with oil, using one of the
following procedures:
Recommended procedure:
1. Install oil at the opening at the Geareducer inspection cover
until it reaches the level of the Full mark on the Geareducer
case and at the oil level gauge. See Figures 4 and 5. Install
plug.
2. Start the fan drive and run for one minute.
3. Stop the fan drive. Allow ten minutes for oil level to stabilize
and recheck oil level at the Geareducer.
4. If necessary, repeat steps 2 and 3 until stabilized oil level is at
the proper level.
5. Check gauge placard location. Full mark on the placard must
be at the same elevation as the Full mark at the Geareducer.
Alternate procedure:
The cooling tower has an external oil gauge and drain line equipped
with a three-way valve below the oil level gauge. See Figure 4.
1. Remove pipe plug. Turn valve control stem clockwise to open
drain.
2. With Geareducer drained, the three-way valve turned clockwise,
and the pipe plug removed, connect fill source (usually a hose
to a pump, to the three-way valve).
Pump oil through the hose. Check oil level occasionally by
turning the valve control stem counterclockwise and allowing
the oil level in the sight glass to stabilize.
Continue filling until full level mark is reached.
3. With the oil level at the full mark turn the valve control stem
counterclockwise to close the drain and open the valve to the
sight glass. Remove the oil filling line and reinstall pipe plug in
the three-way valve.

6
Maintenance Service Monthly Semi-
annually
Seasonal
Startup or
Annually
Geareducer Drive:
Inspect and tighten all fasteners including oil plug x x
Check for and repair oil leaks x x x
Check oil level x R x
Change oil R R
Make sure vent is open x x
Check driveshaft or coupling alignment x
Inspect and tighten driveshaft or coupling
fasteners x
Check driveshaft or coupling bushing / flex
elements for unusual wear x
Lube Lines (if equipped)
Check for oil leaks in hoses and fittings x R x
R– Refer to instructions within this manual
Note: It is recommended at least weekly, that the general operation and condition be observed. Pay particular
attention to any changes in sound or vibration that may signify a need for closer inspection.
Warning—Make certain that mechanical equipment is inoperable
during periods of maintenance—or during any situation of possible
endangerment to personnel. If your electrical system contains
a disconnect switch, lock it out until the period of exposure to
injury is over.
Monthly—Check Geareducer oil level. Shut down the unit and
allow 5 minutes for the oil level to stabilize. Add oil if required,
noting the addition in your maintenance log. If equipped with an
external dipstick/oil level gauge, small quantities of oil can be
added at that location.
Semi-annually—If using turbine-type mineral oil, change oil—see
Changing Geareducer Oil for instructions. Check that all the
assembly bolts and cap screws are tight, that oil plugs and pipe
connections are in place and free from leaks, and that the vent on
the Geareducer (and external dipstick/oil level gauge, if present) is
clear—a clogged vent can lead to oil leaks. Intermittent operation
and extended periods of downtime can cause condensation of
water in the oil. If using synthetic Marley Gearlube, the oil condition
must be inspected every six months—see Changing Geareducer
Oil for maximizing service life.
Annually—Check mechanical equipment anchor bolts, drive shaft
coupling bolts, and coupling set screws. Tighten as required. Check
Geareducer exterioryearly and touch up with epoxy paintif required.
Coat all exposed threads at pipe joints to prevent corrosion.
Every 5 Years—If using synthetic Marley Gearlube, change oil.
To maintain five-year change intervals, use only synthetic Marley
Gearlube. It is recommended to monitor the oil condition every
six months throughout the five-year period per the instructions in
Changing Geareducer Oil.
scheduled maintenance

7
repair and lubricants
Table 1
Repair and Overhaul
If your Geareducer ever needs replacement or repair, SPX Cooling
Technologies recommends returning the unit to a Marley factory
service center. Contact your Marley sales representative to discuss
a course of action. The Marley Order Number on your cooling
tower will be required if the Geareducer is shipped back to the
factory for repair. Obtain a “Customer Return Material” tag from
the Marley sales representative in you area. To find your Marley
sales representative call 913 664 7400 or check the internet at
spxcooling.com.
Major repairs require the use of a fully equipped machine shop.
If you decide to repair or overhaul your Geareducer, refer to the
Field Repair Section and Geareducer Parts List.
Manufacturer Product
SPX Cooling Tech, LLC Mineral Turbine ISO 220
Chevron Regal R & O 220
Citgo Petroleum Corp. Pacemaker 220
ConocoPhillips Multipurpose R & O 220
ExxonMobil Corp. DTE Oil BB
ExxonMobil Corp. Teresstic 220
Lubrication Engineers Inc. Monolec 6405
Shell Morlina S3 GA 220
Synthetic Oil*
SPX Cooling Tech, LLC Gearlube ISO 220
Chevron Clarity 220 Synthetic
Citgo Petroleum Corp. Citgear Synthetic HT 220
ConocoPhillips Syncon R & O 220
ExxonMobil Corp. SHC 630
Shell Morlina S4 B220
*Synthetic oil may be applicable for high temperature service
or extended oil life
Suggested Lubricants
The following list of lubricants in Table 1 is provided as reference
only. These products have been recommended by their respective
manufacturers as acceptable for use in a Marley spiral bevel and/
or helical Geareducer for cooling tower applications. This list is
not an attempt to include all the lubricants that may be satisfac-
tory. If lubricants other than those listed are used they must not
contain any additives—such as detergents or EP additives—which
are adversely affected by moisture and could reduce the service
life of the Geareducer. Suitability of lubricants used other than
those listed rests with the customer/owner and lubricant supplier.

8
parts list
Figure 6 Exploded Assembly
304
305
303
101- PINION SHAFT AND GEAR
402
102
105
501-503
702
701*
701*
411
103
INSPECTION
COVER
421
201
306
307
302
706*
705*
GEAREDUCER
CASE
PINION CAGE
PINION CAGE
CAP
201-INTERSTAGE SHAFT
106
108
101- PINION SHAFT AND GEAR
5-INTERSTAGE BEARING
RETAINER
WATER SLINGER
LABYRINTH RING
INTERSTAGE
BEARING CAP
AIR VENT
301-FAN SHAFT
PLUG
504-506
703
704
206
202
412
GEAREDUCER
CASE COVER
20-DOWEL PIN
507-509
422
203
205
204 PINION ASSEMBLY
LIP SEAL
23
23
603
602
PRE-2013 STANDARD

9
parts list
1 Complete Geareducer Assembly
100 Spiral Bevel Gear Set
101 Set of matched spiral bevel gears including
integral pinion shaft with key
Gear ratios as follows:
2.304 to 1 2.435 to 1 2.762 to 1
3.158 to 1 3.167 to 1 3.944 to 1
102 Oil slinger
103 Locknuts
104 Lockwasher
105 Pinion shaft key
106 Interstage shaft key
108 Ring gear spacer (2.304 and 2.435 gear
sets only)
200 Helical Gear Set
201 Set of matched helical gears including
interstage shaft and special key
Gear ratios as follows:
4.18 to 1 4.70 to 1 5.00 to 1
202 Top interstage bearing retainer disc
203 Bottom interstage bearing retainer disc
204 Place bolts and washers
205 Place bolts and washers
206 Place bolts and washers
300 Fan Shaft Assembly
301 Fan shaft
302 Key
303 Fan hub retainer
304 Cap screw
305 Locking plates
306 Retainer ring
307 Key
400 Pinion Shaft Bearing Set
401 Tail, tapered roller bearing
402 Head, tapered roller bearing
410 Interstage Bearing Set
411 Lower, double row, tapered roller bearing.
Matched assembly with cone spacer
412 Upper, double row, tapered roller bearing.
Matched assembly with cup spacer
420 Fan Shaft Bearing Set
421 Lower tapered roller bearing
422 Upper tapered roller bearing
500 Shim set
501-502-503 Pinion shaft shims
504-505-506 Interstage shaft shims
507-508-509 Fan shaft shims
600 Gasket Set
602 Inspection cover gasket
603 Oil trough gasket
700 O-Rings Set.
702 Pinion cage O-ring, 93⁄4" ID x 10"OD x 1⁄8"
703 Water slinger O-ring, 61⁄2" ID x 63⁄4" OD x 1⁄8"
704 Interstage cap bolt O-rings, 1⁄2" ID x 5⁄8" OD x 1⁄16"
701* Pinion shaft oil seal
705* Water slinger seal wear sleeve
706* Fan shaft seal
*Geareducers prior to 2013 utilize a lip type oil seal.
Current geareducer models utilize an Inpro/Seal®
bearing isolator.
*Geareducers prior to 2013 do not utilize a water slinger
wear sleeve and fan shaft seal items (705) and (706).

10
field repair
General
Geareducers can be repaired in the field—however, major repairs
require the use of a fully equipped machine shop. When field repair
or replacement of parts is necessary, the following procedure is
recommended for the disassembly and assembly of the unit. If any
O-ring, oil seal or gasket is to be reused, care should be taken
not to damage it during disassembly. Parts which contain O-rings
or seals should not be jerked or twisted past a shoulder or edge.
These parts are marked with an asterisk (*) in the description
below. O-rings, oil seal and gaskets should be carefully inspected
for damage before being reinstalled. SPX recommends that new
O-rings and oil seal be installed during every major overhaul.
Disassembly of Major Subassemblies
Part numbers and references—refer to Figures 6 and 7.
1. Drain oil.
2. Remove interstage bearing cap.
3. Pull water slinger off fan shaft.*
4. Lift off Geareducer case cover.
5. Pull interstage shaft and fan shaft subassemblies out of
Geareducer case simultaneously.
6. Remove pinion cage subassembly.*
Figure 7 Disassembly of Major Subassemblies
2
3*
4
5
5
5
6*

11
field repair
Disassembly of Pinion Cage
Part numbers and references—refer to Figures 6 and 8.
1. Remove pinion cage cap and oil seal (701).
2. Remove locknuts (103) and washer (104) from pinion shaft.
3. Press pinion shaft with head bearing cone (402) out of pinion
cage. This will free cone of tail bearing (401).
4. Remove bearing cups from pinion cage.
5. If bearing cone on head of pinion shaft is to be replaced, it
will be necessary to press off oil slinger (102) and bearing
cone at the same time.
Disassembly of Interstage
Part numbers and references—refer to Figures 6 and 9.
1. Remove top and bottom interstage bearing discs (202 and
203).
2. Pull bottom bearing (411), two cones with spacer and one
cup from shaft.
3. Push shaft out of upper bearing (412) and retainer.
4. Remove spiral bevel ring gear from shaft.
5. Pull upper bearings from top interstage retainer (5).
Figure 8 Disassembly of Pinion Cage
1
2
3
4
4
5
Figure 9 Disassembly of Interstage
1
1
2
3
4
5

12
field repair
Figure 11 Gear Match Numbers and Setting Data
MATCHED NUMBER TO BE COMPARED WITH THE SAME
NUMBER ON THE RING GEAR. (EXAMPLE CO-43)
PINION SETTING DISTANCE. (EXAMPLE 4.860)
BACKLASH (NORMAL) AT WHICH THE GEARS WERE
LAPPED. (EXAMPLE .010)
MATCHED NUMBER TO BE COMPARED WITH THE SAME
NUMBER ON THE PINION GEAR. (EXAMPLE C0-43)
THE PINION SETTING DISTANCE IS THE DISTANCE
THE END OF THE PINION SHOULD BE FROM THE
CENTERLINE OF THE RING GEAR SHAFT.
Figure 10 Disassembly of Fan Shaft
Disassembly of Fan Shaft
Part numbers and references—refer to Figures 6 and 10.
1. Press helical ring gear (201), lower fan shaft spacer (40) and
lower cone (421) from shaft. Remove key spacer ring.
2. Remove upper bearing cone (422).
3. Remove upper fan shaft bearing cup (422) from case cover
(not illustrated).
4. Remove lower fan shaft bearing cup (421) from case (not
illustrated).
Assembly of Geareducer
Gear Match Numbers and Setting Data
Before assembling a new pinion gear in the pinion cage check
match numbers on pinion gear and spiral bevel ring gear to be
certain that they are a matched set. Gears are lapped in matched
sets at the factory and should not be separated. Numbers are
etched on both the pinion and ring gear as illustrated in Figure 11.
Pinion Cage Assembly
Part numbers and references—refer to Figures 6 and 12 .
1. Press oil slinger (102) onto pinion shaft.
2. Install pinion head bearing cone (402) on pinion shaft.
3. Press pinion head bearing cup (402) into pinion cage.
4. Press pinion tail bearing cup (401) into pinion cage.
5. Lower pinion cage over pinion shaft until head bearing cone
(402) mates with cup.
6. Press tail bearing cone (401) onto pinion shaft.
a. Lock with lock nuts (103) and lockwasher (104) to provide
bearing preload of 10 to 18 in·lbƒ(1130-2034 mN·m)
resistance to rotation of pinion shaft.
b. Crimp ears of lockwasher (104) to locknuts after obtaining
prober preload.
7. For Inpro/Seals (701) press the stator into the pinion cage
cap.
For conventional lip seals (701) install the lip seal in the
pinion cage cap.
8. Apply a bead of RTV sealer on the face of the pinion cage
interface with the pinion cage cap, encircling all the holes.
Fasten the pinion cage cap to the pinion cage. Tighten bolts
(23) to 55 in·lbƒ (75 N·m) torque. For Inpro/Seal complete
the rotor installation per the instructions included with the
seal.
1
2

13
field repair
Figure 12 Pinion Cage Assembly
Figure 13 Interstage Assembly
9
5
2
1
5
Interstage Assembly
Part numbers and references—refer to Figures 6 and 13.
1. Install key (106) and spiral bevel ring gear on interstage shaft.
2. Press top cone of bottom interstage bearing (411) onto
interstage shaft.
3. Install double cup and spacer of bottom interstage bearing
(411).
4. Press bottom cone into place.
5. Install retainer (203) with bolts. Tighten to 55 ft·lbƒ (75 N·m)
torque.
6. Press lower cup of upper interstage bearing into
retainer (5).
7. Lower retainer (5) over interstage shaft.
8. Press upper bearing cones (412) onto shaft.
9. Press upper cup (412) and spacer into retainer (5).
10. Install disc (202) with place bolts. Tighten to 150 ft·lbƒ
(204 N·m) torque.
3
4
7
6
8
10
1
2
35
4
6
8
6B
7

14
Figure 14 Fan Shaft Assembly
1
2
Fan Shaft Assembly
Part numbers and references—refer to Figures 6 and 14.
1. Install the key spacer ring. Install helical gear key and press
helical gear (201) on fan shaft.
2. Press lower bearing spacer (40) on fan shaft.
3. Press bottom bearing cone (421) onto fan shaft.
4. Press upper bearing cone (422) on fan shaft
5. Install lower fan shaft bearing cup (421) into Geareducer
case (not illustrated).
Final Assembly
Part numbers and references—refer to Figure 15.
1. Install O-ring (702) onto pinion cage subassembly.
2. Bolt pinion cage subassembly to case using proper number
of shims to give indicated pinion setting distance which is
etched on front face of pinion gear. See Figure 11. Tighten
to 75 ft·lbƒ (102 N·m) torque.
3
43. Lower fan shaft and interstage shaft subassemblies into case
simultaneously. Engage marked spiral bevel ring gear teeth
with marked spiral bevel pinion tooth. The gear and pinion
are match-marked when lapped and must be assembled the
same way. The ring gear has the end of two teeth marked “X”
and the pinion has one tooth so marked— the gears should
be engaged with the X-marked pinion tooth between those
marked on the ring gear. Match mark location can be checked
through the inspection opening.
4. Apply a coat of Permatex®Form-a-Gasket No. 2 to surface of
Geareducer case which mates with case cover. Lower case
cover subassembly onto case, piloting both shaft subassem-
blies into their respective bores.
5. Install dowelpins (20) to align bearing bores. Fastencase cover
to case with cap screws and eye bolts tightening to 75 ft·lbƒ
(102 N·m) torque.
6. Position top interstage cap shims and install interstage bear-
ing cap with place bolts tightening to 85-90 ft·lbƒ (116-122
N·m) torque.
7. Install upper fan shaft bearing cup (422) into Geareducer
case cover (not illustrated).
8. Adjust shims to give proper backlash—.007–.009" normal
(.178–.228mm)—between spiral bevel gears. See Gear Set-
ting Procedure, page 15.
9. Fan shaft bearing must be preloaded to .001–.003" (.025–
.076mm) in the following manner:
a. For cases that have the fan shaft lip seal, press the new
lip seal into the labyrinth ring. Install labyrinth ring in case-
cover initially with a quantity of shims between cover and
labyrinth ring to insure that axial bearing end play exists.
Tighten labyrinth ring cap screws to 35 ft·lbƒ (48 N·m)
torque.
b. Mount a dial indicator to measure axial movement of fan
shaft. Support indicator stand on the cover or interstage
cap adjacent to fan shaft and position indicator to read
on machined top surface of fan shaft
c. Rotate the fan shaft slowly in one direction until all down-
ward movement stops. Rotation is necessary to align the
bearing rollers and seat roller ends on cone lip. Record
the dial indicator reading or zero the indicator.
d. Move shaft in the opposite axial direction by attaching to
the shaft with a swivel joint and hoist and lifting on shaft.
Lifting force should be 800 lb (363 kg) to sufficiently
overcome the weight of the fan shaft assembly. Rotate
the shaft slowly in one direction until all axial movement
stops. Record the dial indicator reading.
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Figure 15 Final Assembly
4
6
5
4
3
3
3
2
1
9
9
10
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e. The difference in dial indicator readings (steps c and d) is
the initial fan shaft bearing end play. In order to achieve
the prescribed preload of .001" to .003" (.025–.076mm)
remove an amount of shims from between the case and
labyrinth ring equal to the measured end play plus .001"
to .003" . For example if the measured end play is .005"
(.127mm), remove a total of .006" to .008" (.152–.203mm)
in shim thickness.
f. Tighten labyrinth ring cap screws to 35 ft·lbƒ (48 N·m)
torque.
g. Fill grooves of labyrinth ring and water slinger with lithium-
base grease of NLGI No. 2 consistency.
h. For cases that have the fan shaft lip seal, press the new
wear sleeve into the water slinger. Install water slinger and
its O-ring (703) on fan shaft.
10. Install inspection cover, gasket (602) and then fasten with
the screws provided. Install the pipe plugs.
11. Install oil trough covers and gaskets (603).
12. Install fan shaft key and retention hardware.
11
12

16
Gear Setting Procedure
Part numbers and references—refer to Figures 6 and 16.
The proper mounting of the gear set is essential to obtain long
life and smooth operation of the gears. The pinion cage position
adjustment is obtained by shims under theflange of the pinion cage.
Shims are placed under the top interstage bearing cap to adjust
ring gear position. The gear setting may require several attempts
before obtaining the proper backlash and tooth contact pattern.
The gear and pinion are match-marked when lapped and must be
assembled the same way. The ring gear has the end of two teeth
marked "X" and the pinion has one tooth so marked—the gears
should be engaged with the X-marked pinion tooth between those
marked on the ring gear. Match marks can be checked through
the inspection opening.
With the marked teeth of the gear engaged, check backlash with
dial indicator—see Figure 16. The indicator can be installed through
the inspection cover opening. Change shims under top interstage
bearing cap until backlash is between .007–.009" (.178–.228mm)
normal to ring gear tooth.
POINT OF NORMAL
BACKLASH MEASUREMENT
Figure 16 Gear Backlash Measurement
With gears adjusted for proper backlash, blue (Prussian Blue in
oil) the gear teeth. Drive the pinion by turning ring gear in both
directions for several revolutions. Observe the contact pattern on
both gears on both sides of the teeth. The contact pattern should
be as shown in Figure 17.
If correct tooth contact pattern is not obtained on first attempt,
refer to Figure 17—these illustrations show the two cases of
“out-of- position contact” in the extreme. One of the remedies
indicated will correct the out-of-position contact—compare the
tooth contact pattern with the illustrations in Figure 17 and choose
the required remedy.
When proper tooth contact has been obtained, recheck the back-
lash at marked teeth. If it is within the desired range—.007–.009"
(.178–.228mm), check backlash with dial indicator at two additional
points 120° apart (with inspection cover removed), and as shown
in Figure 16. All backlash readings must be within the specified
range. If backlash is not within the limits, adjust ring gear height
with shims until it is, checking again as described.
The tooth contact pattern should again be checked to determine
if adjusting the backlash has produced any shift. If it has shifted,
move the pinion in the opposite direction the gear was moved
with respect to the cone center. If the gear mounting distance
is reduced, increase pinion setting distance, and vice versa, (see
Figure 12) an amount proportional to the number of teeth in the
respective members. For example: on a 10 to 1 gear set, if the
ring gear was moved .010" (.25mm), the pinion should be moved
0.001" (.025mm). This would be necessary only if the contact
pattern had visually shifted due to movement of the ring gear
while adjusting backlash.
When setting a used set of gears, follow the method outlined
above. However, depending upon the amount of wear, it may be
necessary to set the gears up with slightly greater backlash in
order to obtain proper contact. Proper tooth contact pattern is
the most important factor for correct installation.
Should a condition be encountered where correct contact cannot
be obtained as described in this manual, the Geareducer should
be returned to Marley in exchange for a factory reconditioned unit.
DIRECTION OF ROTATION
RING GEAR
ORIGINAL
PATTERN
AFTER
BREAK IN
**
*
*
CONVEX SIDE
ENTERING CONCAVE SIDE
LEAVING
CONCAVE SIDE
CONVEX SIDE
OUT OF POSITION CONTACT
CAUSE: PINION TOO CLOSE TO
GEAR CENTER.
REMEDY: MOVE PINION OUT.
OUT OF POSITION CONTACT
CAUSE: PINION TOO FAR FROM
GEAR CENTER.
REMEDY: MOVE PINION IN.
CORRECT PINION AND RING GEAR TOOTH CONTACT PATTERNS INCORRECT RING GEAR TOOTH CONTACT PATTERNS
Figure 17 Spiral Bevel Gear Tooth Pattern
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Z0493915_C | ISSUED 6/2022
COPYRIGHT © 2022 SPX TECHNOLOGIES
In the interest of technological progress, all products are subject to design
and/or material change without notice.
Inpro/Seal®is a registered trademark of Inpro/Seal LLC
Geareducer 3600 - 4000
USER MANUAL
SPX COOLING TECH, LLC
7401 WEST 129 STREET
OVERLAND PARK, KS 66213 USA
913 664 7400 | [email protected]
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