SPX Marley Geareducer 32.2 Series User manual

Geareducer® model 32.2
INSTALLATION - OPERATION - MAINTENANCE
Z0238997_B ISSUED 09/2016 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
user manual

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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 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 Bear-
ing Cap to expose port. Refer to Figure 1. If additional oil is be-
ing 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 rotat-
ing 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 Service and Lubrication 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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The Geareducer vent or vent line must be checked for blockage
to prevent failure of pinion shaft oil seal—clean when 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.
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.
Repair and Overhaul
Geareducers can be repaired in the field, however, major repairs
require the use of a fully equipped machine shop. If field repair or
overhaul is preferred, refer to Geareducer Parts Manual sheets for
parts required. Field repair instructions are available from Marley on
request. Contact the Marley sales office or Marley representative
in your area for information.
operation and service
Figure 1 Priming Interstage Shaft
Check all gasketed joints for oil seepage. Tighten cap screws 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 Service and Lubrication.
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
Detail B Helical Gear Tooth Pattern
operation and service

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Service and Lubrication
The horizontal part of the oil gauge and drain line must be level or
slightly lower at the sight glass than it is at the Geareducer. The oil
capacity of Series 32 Geareducers is 9 gallons. The oil capacity of
the optional oil filter is one additional gallon. Connecting oil gauge
and drain lines require approximately one gallon of oil. Refer to
Table I for suggested lubricants.
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 4. 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 turned clockwise,
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 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.
Regardless of the procedure used, the Geareducer must be
filled to the full mark on the Geareducer.
Maintenance of the Geareducer should be scheduled as follows:
MONTHLY: Check oil level at least once a week using the fol-
lowing procedure:
Stop the Geareducer. Allow ten minutes for oil level to stabilize
and check oil level at sight glass. If needed, add oil to Geareducer.
If oil is added, repeat steps 2 and 3 of recommended procedure
until stabilized oil level is at the proper height.
SEMI-ANNUALLY: Change oil at least every 6 month or 3,000
hours of operation. Refer to recommended oil fill procedure. The
oil filter cartridge should be replaced at every oil change.
Figure 2 Oil Gauge and Drain Line (Series 36 Geareducer is illustrated)
operation and service