Marley 2700-3000 Series User manual

2700 -3000 Series Geareducer®
INSTALLATION - OPERATION - MAINTENANCE
user manual
uk_Z0529732_A ISSUED 06/2017 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.

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.
maintenance schedule

3
operation and service
INITIAL PROTECTION AGAINST CORROSION
As shipped, a Marley Geareducer is protected internally against
corrosion with machine enamel on unmachined parts and with
rust-proofing oil and grease on machined surfaces. These coatings
normally protect the Geareducer against atmospheric corrosion for
storage periods up to six months. However, if oil is added to the
Geareducer, it will dissolve the rust-proofing grease and oil, requiring
the Geareducer to be operated once a week to keep a protective
coating of oil on all interior machined surfaces.
Check Geareducer exterior. If exterior finish has been damaged dur-
ing shipment or installation, touch up with epoxy paint as required. If
Geareducer is equipped with a remotedipstick/oil levelgauge and/or
drainline, coatany exposedthreads atpipe jointsto preventcorrosion.
INITIAL OPERATION
The Geareducer must be filled with oil to the full oil level mark on
the Geareducer case before it is placed in operation. See Changing
Geareducer Oil section for oil filling instructions.
Geareducers supplied with new towers include oil for the initial fill-
ing. Oil is not furnished with Geareducers supplied as spares 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 (if equipped) full mark corre-
sponds with the “Full” level in the Geareducer. Check any oil lines
to be sure there are no leaks.
Be certain that the vent on the Geareducer (and external dipstick/
oil level gauge, if present) is not plugged.
In order to assure long service life, the Geareducer and motor must
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.
Note—If the tower is equipped with a two-speed motor, allow a time
delay of at least 20 seconds when switching from high speed to
low speed. Allow a time delay of at least two minutes when chang-
ing direction of fan rotation. Failure to provide these delays may
significantly reduce equipment service life.
Figure 1 – Service Fittings
➠
VENT
VENT
DRAIN
PLUG
OIL LEVEL
CHECK AND FILL

4
operation and service
SCHEDULED MAINTENANCE
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 dis-
connect 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
additionin yourmaintenance log.Ifequipped withan 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 opera-
tion and extended periods of downtime can cause condensation of
water in the oil. If using 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 exterior yearly and touch up with epoxy paint if required.
Coat all exposed threads at pipe joints to prevent corrosion.
Every 5 Years—If using Marley synthetic Gearlube, change oil.
To maintain five-year change intervals, use only 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.
LUBRICANTS
To insure maximum performance and service life, it is recommended
Marley factory lubricants be used in all Marley Geareducers. Marley
lubricants can be purchased through your local Marley sales rep-
resentative.
If lubricants other than Marley factory lubricants 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. The responsibility for use of lubricants other
than Marley factory lubricants rests with the customer/owner and
the lubricant supplier.
Seasonal temperature changes may require one viscosity of oil for
summer operation and another for winter operation. Refer to Table
1for the seasonal selection information.
Winter or Summer Severe Duty/High Temperature
Air Temperature at Geareducer
Below 43°C Above 43°C
ISO 150 ISO 220
Table 1

5
CHANGING GEAREDUCER OIL
Drain the Geareducer oil by removing the drain plug. See Figure
1 for location. If equipped with an external dipstick/oil level gauge,
remove the drain plug at that location, and drain the entire system.
To maximize service life of the Geareducer, remove a sample from the
drained oil and look for evidence of foreign material, such as water,
metal shavings or sludge, or send the oil sample to an oil analysis
lab for inspection. If you find unacceptable condensation or sludge,
flush the Geareducer with mineral oil before refilling.
After inspection is complete, fill the Geareducer with 53 liters of
oil. See Figure 1 for location. If the Geareducer is equipped with
an external dipstick/oil level gauge an additional 3 to 4 liters 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.
Alternate procedure:
If the cooling tower has an external oil gauge and drain line equipped
with a three-way valve below the oil level gauge. See Figure 2.
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).
operation and service
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.
REPAIR AND OVERHAUL
The Model 2700 and 3000 Geareducer is assembled using special-
ized tools and fixtures. Bearings and gear sets are unique and not
available from other sources. Geareducers can be repaired in the
field — however, major repairs require the use of a fully equipped
machine shop. Refer to the Field Repair section of this manual for
further instructions.
If your Geareducer ever needs replacement or repair, Marley recom-
mends returning the unit to a Marley factory service center. Contact
your Marley sales representative todiscuss course of action. Afactory
reconditioned Geareducer carries a one year warranty. The Marley
Order Number on yourcooling tower willbe required ifthe 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 check the internet at
spxcooling.com/sales.
OIL LEVEL CHECK
OIL GAUGE
AND DRAIN LINE
OIL GAUGE
VENT
OIL LEVEL
GAUGE
DRAIN PLUG
THREE-WAY
VALVE
Figure 2 – Service Fittings

6
Figure 3
parts list
210
502
BEARING
RETAINER
203
202
101
301
420
104
105
103
311503312501
PINION
CAGE
PINION
CAGE
CAP
320
DOWEL PIN
420
412
201
102
101
008
VENT
WATER
SLINGER
GEAREDUCER
CASE
204
411
BOTTOM CAP
CASE COVER
DOWEL PIN

7
1Complete Geareducer Assembly
008 Ring Gear Hub
100 Spiral Bevel Gear Set
101 Set of matched spiral bevel gears, including integral pinion shaft with key
Gear ratios as follows:
Model 2700
5.77 to 1 7.71 to 1 8.66 to 1
Model 3000
5.06 to 1 5.44 to 1 6.14 to 1 6.85 to 1
7.91 to 1 8.80 to 1 9.60 to 1
102 Ring gear attaching hardware
103 Lock nut
104 Tongue Washer
105 Lockwasher
200 Fan Shaft Set
201 Fan Shaft
202 Ring gear hub key
203 Fan key
204 Ring spacer—Model 2700 Geareducer only
210 Fan attaching hardware
Cap screws and washers
301 Oil Slinger
310 Set of Two Pinion Shaft Bearings
311 Head, tapered roller bearing
312 Tail, tapered roller bearing
320 Pinion Cage Shims
410 Fan Shaft Bearing Set
411 Lower tapered roller bearing
412 Upper tapered roller bearing
420 Fan Shaft Shims
500 O-Ring Set
502 Water slinger O-ring
503 Pinion cage O-ring
501 Pinion Shaft Oil Seal
PARTS LIST
parts list

8
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. Marley recommends that new O-rings and oil seal
be installed during a major overhaul.
DISASSEMBLY
Part numbers and references—refer to Figure 3.
1. Drain oil.
2. Remove outer ring of bolts in pinion cage and remove pinion
subassembly*.
Note—The thickness of the shim pack (320) is important in resetting
the gears. The shim pack shouldeither be savedor carefully measured
with a micrometer. If the gears are to be replaced, record the pinion
setting distance that is etched on the pinion gear. See Figure 4.
3. Remove water slinger*.
4. Remove bearing retainer and shim pack (420) from top of case.
Note—The thickness of this shim pack is important in
the endplay and backlash setting of the gears. The shim
pack should either be saved or carefully measured with a
micrometer.
Figure 4 – 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.

9
5. Drive dowel pins down into case.
6. Remove bolts and case cover and lift fan shaft assembly out
of the case.
7. Turn case over and remove bottom cap and shim pack (420).
Note—The thickness of this shim pack is important in setting the
fan shaft bearing endplay and backlash. This pack should be saved
or carefully measured with a micrometer.
8. Remove bearing cups (411 and 412) from the Geareducer
case and cover.
PINION CAGE DISASSEMBLY
1. Remove pinion cage cap* from pinion cage.
2. Remove O-ring* (503).
3. Remove locknut, lockwasher and tongue washer (103, 105 and
104) then press pinion shaft (101) out of pinion cage. This will
free tail bearing cone (312).
4. Press oil slinger (301) and head bearing cone (311) from the
pinion shaft.
5. Press bearing cups (311 and 312) out of pinion cage.
FAN SHAFT DISASSEMBLY
1. Remove ring gear (101) from the ring gear hub
(008).
2. Press ring gear hub, ring spacer (204—Model 2700 only) and
lower bearing cone (411) off of the fan shaft (201).
3. Remove lower fan shaft key (202).
4. Press the top bearing cone (412) off of the shaft.
ASSEMBLY
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 4.
All parts that are to be reused should be thoroughly cleaned before
being reinstalled. Replace bearings if necessary.
PINION CAGE SUBASSEMBLY
1. Place oil slinger (301) on pinion shaft.
2. Press head bearing cone (311) on pinion shaft making sure oil
slinger and bearing are against gear.
3. Press bearing cups (311 and 312) into pinion cage.
4. Lower pinion cage on pinion shaft, until head bearing cone and
cup mate.
5. Press tail bearing cone (312) on pinion shaft until it mates with
its bearing cup.
6. Install locknut, lockwasher and tongue washer (103, 105 and
104). Tighten nuts on bearing cone until 8 to 12 in·lbƒ (904-
1356 mN·m) of bearing 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. Bend
tab(s) on lockwasher to secure locknut in place.
7. Install O-ring (503) in groove on pinion cage.
8. Press oil seal onto pinion shaft.
9. Tighten pinion cage cap screws to 45 ft·lbƒ (61 N·m).
10. Record the pinion setting distance that is etched on the pinion
gear. See Figure 4.
INSTALLATION OF FAN SHAFT
1. Press ring gear hub (008), ring spacer (204—Model 2700 only)
and the upper and lower bearing cones (411 and 412) on the
fan shaft (201). Install ring gear (101) on ring gear hub and
tighten cap screws to 75 ft·lbƒ (102 N·m) for Model 2700 or
150 ft·lbƒ (203 N·m) for Model 3000.
2 Install the bottom cap using old shim pack or make up equivalent
thickness shim pack (420).
3. Press lower fan shaft bearing cup (411) in bore.
4. Install fan shaft assembly in case.
5. Press upper fan shaft bearing cup (412) in cover. Apply a bead
of sealant to the cover flange inboard of the bolt holes. Install
cover on case. Install dowel pins in cover and drive flush with
top of cover.
6. Install cap screws and tighten to 45 ft·lbƒ (61 N·m).
7. Install bearing retainer using old shim pack (420) or equivalent
thickness and tighten cap screws to 45 ft·lbƒ (61 N·m).
field repair
➠

10
field repair
8. Measure fan shaft end play with a dial indicator on a surface
normal to the plane of rotation. Lift shaft axially and rotate slowly
until all axial movement stops. Zero the dial indicator. Lower
shaft (zero lifting load) and rotate shaft until axial movement
stops. End play will be read directly from the dial indicator.
Adjust the fan shaft bearings to .003 -.005" (.076-.127mm)
end play. The end play is adjusted by adding or removing shims
(420) under the bearing retainer.
Installation of Pinion Cage
1. Find the difference between the pinion setting distance of
the old gear and the new pinion gear and adjust the old shim
pack (320) or make a new shim pack to compensate for the
different setting distances.
Example:
Pinion setting distance of old gear 6.505"
Pinion setting distance of new gear 6.500"
Difference .005"
Remove .005 from shim pack.
2. Install pinion cage subassembly into case and tighten cap
screws to 102 N·m.
3. Engage pinion gear tooth with “X” marked on end between ring
gear teeth marked with “Xs”. Care must be taken not to damage
the pinion gear teeth by forcing them into the ring gear teeth.
GEAR SETTING PROCEDURE
The proper mounting of the gear set is essential to obtain long life
and smooth operation of the gears. The pinion and ring gears were
positioned approximately in the preceding steps. The correct gear
position is determined by the gear backlash.
1. Based on the backlash etched on the gearset, find theequivalent
backlash setting in Table 2, Column 2.
2. With the “X” marked tooth on the pinion gear engaged be-
tween the two “X” marked teeth on the ring gear, check the
backlash with a dial indicator as shown in Figure 5. Lock the
pinion shaft against rotation. The amount of movement of the
fan shaft, measured at a distance equal to the outside radius
of the ring gear is the backlash. Obtain backlash setting by
adjusting ring gear axially by removing or adding shims (420)
at bottom bearing cap.
Note—To maintain the previous fan shaft bearing endplay adjust-
ment, a corresponding shim (420) adjustment must be made at the
bearing retainer.
Example: Removing .003 shims at the bottom bearing cap requires
the addition of .003 shims at the bearing retainer to maintain correct
bearing adjustment.
Recheck the backlash to make sure it is within the proper limits.
3. After the equivalent backlash setting has been obtained with the
marked teeth in mesh, check the backlash at two other points
on the ring gear (points approximately 120° apart). See Table
2, Column 3 for tolerances.
FINAL ASSEMBLY
1. Remove bottom cap and apply a bead of sealant to the bot-
tom cap flange inboard of the bolt holes. Reinstall the bottom
bearing cap and tighten the cap screws to 75 ft·lbƒ (102 N·m).
2. Install O-ring (502) in water slinger.
3. Install water slinger on fan shaft (201).
4. Replace air vent and all pipe plugs.
5. Fill with lubricant selected from Table 1.
COLLAR
SET SCREW
TOP VIEW
OF INDICATOR
POINT OF MEASUREMENT
OUTSIDE RADIUS OF GEAR
DIAL INDICATOR
Figure 5 – Gear Backlash Measurement

11
field repair
Table 2
Backlash Etched on Gears Set the Gears to Backlash
.008 .010 .003 / .008
.009 .0115 .003 / .008
.010 .013 .003 / .008
.011 .014 .004 / .010
.012 .015 .004 / .010
.013 .017 .004 / .010
.014 .0185 .004 / .010

uk_Z0529732_A (uk_02-128C) | ISSUED 06/2017
COPYRIGHT © 2017 SPX CORPORATION
In the interest of technological progress, all products are subject to design
and/or material change without notice.
SPX COOLING TECHNOLOGIES UK LTD
3 KNIGHTSBRIDGE PARK
WORCESTER WR4 9FA UK
44 1905 750 270 | [e-mail]
spxcooling.com
Geareducer
USER MANUAL