Marley Geareducer 32.2 User manual

Geareducer® model 32.2
INSTALLATION - OPERATION - MAINTENANCE
uk_Z0238997_D ISSUED 11/2022 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
user manual

2
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 corrosion
is acceptable, an internal lubrication film must be maintained at all
times to protect the working components against corrosion and
potential startup damage. The following information describes
methods of operation and preventive measures to ensure suit-
ability 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 toplace 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 andgrease on machined surfaces. These coatings
normally protect the Geareduceragainst 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 1. If additional oil is being
used, an amount of 1 to 1 1/2 liters should be used. If the lubri-
cant is being pumped from the sump bulk volume, at least 1 liter
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 sequence 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.

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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 inspectioncover plate fromthe side ofthe Geareducer
case at each oil change. Check inside of Geareducer for cleanli-
ness of case and internal parts. If any sludge is present, flush
inside of Geareducer and connecting oil system.
Also at this time, observe the contact pattern of the gear teeth
to see if they appear as illustrated in Detail A and B. If incorrect
gear tooth pattern should occur, refer to Marley Field Repair
Manual for Series 32.2 Geareducer.
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.
Check all gasketed joints for oil seepage. Tighten cap screws
Figure 1 Priming Interstage Shaft
and flange bolting if necessary.
The Geareducer must be installed level and properly aligned
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.
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.

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Detail A Spiral Bevel Gear Tooth Pattern
operation and service
INCORRECT PATTERN
CHECK TOP INTERSTAGE
BEARING AND BOTTOM FAN
SHAFT BEARING. IF ONE OR
BOTH ARE WORN, REPLACE
CORRECT PATTERN
AFTER BREAK IN
DIRECTION OF ROTATION
RING GEAR
PINION
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
Detail B Helical Gear Tooth Pattern

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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
Changing Geareducer Oil
Drain the Geareducer oil by removing the drain plug. See
Figure 2 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 re-
move 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.
The horizontal part of the oil line must be level or slightly lower
at the oil level gauge than at the Geareducer. The oil capacity
of the 32.2 Series Geareducer is 34 litres.
The oil level gauge line requires approximately one additional
gallon of oil. Refer to back cover for suggested lubricants. If
the Geareducer is equipped with an external dipstick/oil level
gauge an additional 3 to 4 litres 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.
Fill the Geareducer and gauge and drain line system with oil,
using one of the following procedures:
Recommended procedure:
1. Pour oil through fill hole in Geareducer inspection cover until
it reaches height of “full” mark in the Geareducer case and
at the slight glass. See Figures 2 and 3. Reinstall pipe plug
in the fill hole.
2. Start fan drive. Run for one minute.
3. Stop the Geareducer. Allow ten minutes for oil level to stabilize
and recheck oil level at Geareducer.
4. If necessary, repeat steps 2 and 3 until stabilized oil level is
at the proper height.
5. Check placard location. “Full” mark on placard must be at same
elevation as “full” mark on Geareducer.
Alternate procedure:
If the cooling tower has an external oil gauge and drain line
equipped with three-way valve below sight glass the following
alternate procedure may be used:
1. Remove pipe plug. Turn valve control stem clockwise to open
drain. Collect used oil in an appropriate container.
2. With Geareducer drained, the three-way valve turnedclockwise,
and the pipe plug removed, connect fill source, either a street
ell and stand pipe of sufficient length to extend above top of
the sight glass or a hose to a pump, to the three-way valve.
Pour oil through a funnel and stand pipe, or pump oil through
the hose. Check oil level occasionally by turning thevalve 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.
operation and service
VENT LINE
OIL FILL PLUG
OIL LEVEL CHECK
INSPECTION
COVER
OIL GAUGE
AND DRAIN LINE
DRAIN PLUG
OIL LEVEL
GAUGE
DRAIN PLUG
THREE-WAY
VALVE
OIL GAUGE
VENT
Figure 3 Sight glass gauge assembly
Figure 2 Oil Gauge and Drain Line (a Series 36 Geareducer is illustrated)

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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 alignment x
Inspect and tighten driveshaft fasteners x
Check driveshaft 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.
scheduled maindtenance
Warning—Make certain that mechanical equipment is inoperable
during periods of maintenance—or duringany 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 opera-
tion 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 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 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.

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Table 1 Oil Viscosity
Winter or Summer Severe Duty/High Temperature
Air Temperature at Geareducer
Below 43°C Above 43°C
ISO 150 ISO 220
scheduled maindtenance
Repair and Overhaul
If your Geareducer ever needs replacement or repair, SPX Cool-
ing 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 44 1905 750 270 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.
Suggested Lubricants
Table 1 provides viscosity for seasonal and severity of duty
applications. Refer to Marley SB-20 for a list of lubricants for
consideration. Those 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 satisfactory. 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.
Geareducer Lubricants SB-20 is available for download at
spxcooling.com.

uk_Z0238997_D | ISSUED 11/2022
© 2016-2022 SPX TECH, LLC | ALL RIGHTS RESERVED
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, WAINWRIGHT ROAD
WORCESTER WR4 9FA UK
44 1905 750 270 | [e-mail]
spxcooling.com
Geareducer 32.2
USER MANUAL