Geareducer® models 2200-2250-2400
Contents
1. MATCHED NUMBER TO BE COMPARED WITH THE SAMEO NUMBER ON THE RING GEAR EXAMPLE CO 43 PINION SETTING DISTANCE EXAMPLE 4 860 BACKLASH NORMAL AT WHICH THE GEARS WEREO LAPPED EXAMPLE 010 MATCHED NUMBER TO BE COMPARED WITH THE SAMEO NUMBER ON THE PINION GEAR EXAMPLE C0 43 THE PINION SETTING DISTANCE IS THE DISTANCEH THE END OF THE PINION SHOULD BE FROM THEH CENTERLINE OF THE RING GEAR SHAFT Figure 4 Gear Match Numbers and Setting Data field repair Pinion Cage Subassembly 1 2 8 9 10 Place O ring 506 on pinion shaft 101 Place oil slinger 301 on pinion shaft Press head bearing cone 311 on pinion shaft making sure oil slinger and bearing are against gear Press bearing cups 311 and 312 into pinion cage Lower pinion cage on pinion shaft until head bearing cone and cup mate Press tail bearing cone 312 on pinion shaft until it mates with its bearing cup Install locknuts and lockwasher 103 and 104 Tighten nuts on bearing cone until 5 to 15 inb 565 1695 mN m of bearing preload is obtained Bearing preload is the resistance in the bearings to shaft rotation measured in in lbf required to rotate the shaft at uniform velocity Preload is necessary to insure the stability ofthe gear engagement Crimp the lockwasher to hold the two nuts in place Install O ring 504 in groove Press oil seal 501 onto pinion shaft Position O r2. spxcooling spx com spxcooling com In the interest of technological progress all products are subject to design and or material change without notice ISSUED 6 2012 M99 1260E COPYRIGHT 2012 SPX Corporation
3. Pinion Cage 1 The X marked pinion and gear teeth should be clearly identi fied with chalk or other markings which can be seen from the inspection opening or the bottom of the case 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 4 883 Pinion setting distance of new gear 4 878 Difference 005 Remove 005 from shim gap Install shims 320 and pinion cage subassembly Note Care must be taken not to damage the pinion gear teeth by forcing them into the ring gear teeth field repair 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 tooth contact pattern and by the backlash With the X marked tooth on the pinion gear engaged between the two X marked teeth on the ring gear check the backlash with a dial indicator as shown in Figure 6 Lock the pinion shaft against rotation The amount of movement of the fan shaft mea sured at a distance equal to the outside radius of the ring gear is the backlash The backlash on the 6 50 1 gear set should be between 013 and 018 33 and 46mm The backlash on all other rat
4. 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 field repair Us be MN 502 BEARING RETAINER 201 GEAREDUCER BOTTOM CAP BEARING RETAINER CAP Figure 2 Exploded Cross Section 6 PINION CAGE 501 PINION CAGE CAP exci eee 504 312 104 320 505 Parts List 1 Complete Geareducer Assembly 8 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 3 45101 3 79t01 4 10to1 456to1 5 1101 550to1 6 12101 6501601 7 33 to 1 102 Ring gear attaching hardware 103 Locknuts 104 Lockwasher 200 Fan Shaft Set 201 Fan shaft 202 Ring gear hub key This is a special high strength ey It must be obtained from Marley 203 Fan key 210 Fan attaching hardware Cap screws and washers 301 Oil Slinger 310 Setof 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 Rings Set 502 Water slinger O ring 3 ID x 3 OD x A 503 Bearing retainer O ring 5 ID x 54 OD x 504 Pinion cage O ring 5
5. ID x 6 OD x 1 4 505 Pinion cage cap O ring 4 ID x 4 OD x 506 Oil slinger O ring 1 6 ID x 2 OD x 9e 501 Pinion Shaft Oil Seal 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 Always use new O rings and oil seal during a major overhaul Disassembly Part numbers and references refer to Figure 2 and 3 1 Remove drain plug and drain oil 2 Remove outer ring of bolts in pinion cage cap and remove pinion subassembly Note The thickness of the shim pack 320 is important in reset ting the gears The shim pack should either be saved or carefully measured with a micrometer If the gears are to be replaced record the pinion setting distance that is etched on the pinion gear 3 Remove water slinger 4 Turn case upside down and remove bearing retainer cap and shim pack 420 Note The thickness of this shim
6. SP USER MANUAL WHERE IDEAS MEET INDUSTRY Geareducer models 2200 2250 2400 OPERATION MAINTENANCE REPAIR M99 1260E ISSUED 6 2012 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT gt Marley operation and service Inspection Oil Level Check and Fill Figure 1 Service Fittings Protection Against Corrosion All Marley Geareducer units ship from the factory with a protective coating of epoxy enamel paint on all unmachined parts and with rust proofing oil and grease on machined surfaces Machined sur face coatings normally protect the Geareducer against atmospheric corrosion during storage periods for up to six months However if oil is added to the Geareducer the new oil will dissolve the rust proofing grease and require that the Geareducer be run once a week to keep a protective coating of oil on all interior machined surfaces Check Geareducer exterior yearly and touch up with epoxy paint if required If your Geareduceris equipped with an oil gauge and drain line coat any exposed threads at pipe joints to prevent corrosion Alignment 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 Vent Drain Plug Initia
7. e period of expo sure 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 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 If using turbine type mineral oil change oil see Changing Geareducer Oil for instructions Intermittent operation and extended periods of downtime can cause condensation of water in the oil Annually Check mechanical equipment anchor bolts drive shaft coupling bolts and coupling set screws Tighten as required Every 5 Years Change oil Geareducer was designed for 5 year oil change intervals Perform Monthly and Annual maintenance checks prescribed above To maintain five year change intervals use only Marley Gearlube 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 l
8. hs Winter or Summer Seasonal temperature changes may require one viscosity of oil for summer operation and another for winter operation Refer to the tables below for the seasonal selection information Severe Duty High Temperature Air Temperature at Geareducer Below 110 F 43 C Above 1 10 F 43 C ISO 150 ISO 220 Table 1 Synthetic oil 5 year oil change interval 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 operation and service Scheduled Maintenance Warning Make certain that mechanical equipment is inoper able 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 th
9. ing 505 and push cap with seal and sleeve in place on shaft Attach cap to pinion cage and slide sleeve from cap 1 Record the pinion setting distance that is etched on the pinion gear Installation of Fan Shaft 1 Press ring gear hub 8 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 90 ftlb 123 Nm Install upper fan shaft bearing 412 and bearing retainer without shims Turn the Geareducer case upside down and install the fan shaft assembly seating the upper fan shaft bearing cone into its cup Install the lower bearing cup 411 Install the bottom cover cap using sealer as indicated in Figure 5 and tighten cap screws to 25 ftlb 34 N m Use old shim pack or make up equivalent thickness shim pack 420 and install the bottom bearing retainer cap Do notinstall the O ring for the bottom bearing retainer at this time Tighten the cap screws to 25 ftlb 34 N m Turn the Geareducer right side up and rotate the fan shaft several turns in each direction to seat the bearing rollers With a dial indicator and using the Geareducer case as a reference measure and adjust the fan shaft bearings to 003 005 076 127mm endplay The endplay is adjusted by adding shims part 420 under the bearing retainer 1 8 DIA BEAD OF RTV SILICON GASKET SEALER Figure 5 Flange Seal of Bottom Bearing Cap Installation of
10. ios should be between 010 and 015 25 and 38mm With the X teeth engaged the backlash should be approximately in the middle of the allowable range Check the backlash at three other points around the ring gear to be sure the backlash is within the specified limits Adjust ring gear axially by removing or adding shims 420 at bottom bearing retainer TOP VIEW OF INDICATOR POINT OF MEASUREMENT OUTSIDE RADIUS OF GEAR DIAL INDICATOR COLLAR SET SCREW E Figure 6 Gear Backlash Measurement Note To maintain bearing adjustment corresponding shim 420 adjustment must be made at the bearing retainer Example Removing 003 shims at the bottom bearing retainer requires the addition of QOS shims at the top bearing retainer to maintain correct bearing adjustment Recheck the backlash to make sure it is within the proper limits With gears adjusted to the proper backlash blue Prussian blue in oil the pinion teeth By using a long handled brush or swab the pinion teeth can be reached through the inspection opening Drive the pinion by turning the fan shaft in both directions for several revolutions Observe the markings on both gears on both sides of the teeth Compare the markings with the contact pattern shown in Figure 7 If contact pattern is incorrect adjust the pinion position with shims between the pinion cage cap and Geareducer case When tooth contact is correct recheck backlash If neces
11. l Operation Check to be sure that the Geareducer is filled with oil and that there are no visible oil leaks If equipped with an external dipstick oil level gauge be sure the oil full mark corresponds with the full level at the Geareducer Note If this tower is equipped with a two speed motor allow a time delay of atleast 20 seconds when switching from high speed to low speed Allow a time delay of at least two minutes when changing direction of fan rotation Failure to provide these delays may significantly reduce equipment service life Lubricants Toinsure maximum performance and service life itis recommended Marley factory lubricants be used in all Marley Geareducers Marley lubricants can be purchased through your local Marley sales representative operation and service Iflubricants other than Marley factory lubricants are used they must notcontain 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 Note Geareducer is designed for 5 year oil change intervals To maintain five year change intervals use only Marley Gearlube Marley Gearlube must be inspected every six months to ensure the oil has not been contaminated If turbine type mineral oil is used the oil must be changed every six mont
12. ook 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 10 quarts 9 5 liters of oil See Figure 1 for location If the Geareducer is equipped with an external dipstick oil level gauge an additional 2 to 3 quarts 1 9 to 2 8 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 Protection Against Corrosion Check Geareducer exterior yearly and touch up with epoxy paint if required If your Geareducer is equipped with an oil gauge and drain line coat any exposed threads at pipe joints to prevent corrosion Repair and Overhaul IfyourGeareducer ever needs replacementor repair we recommend returning the unit to a Marley factory service center Contact your Marley sales representative to discuss course of action A factory reconditioned Geareducer carries a one year warranty The 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
13. pack is important in the back lash setting of the gears The shim pack should either be saved or carefully measured with a micrometer 5 Remove bottom cap and fan shaft assembly 6 Turn Geareducer case right side up and remove bearing retainer and shim pack 420 Note The thickness of this shim pack is important in setting the fan shaft bearing endplay This pack should be saved or carefully measured with a micrometer 7 Remove bearing cups 411 and 412 from the bottom cap and Geareducer case using a soft metal punch or mallet Pinion Cage Disassembly 1 Remove pinion cage cap from pinion cage 2 Remove O rings 504 and 505 3 Remove locknuts and lockwasher 103 and 104 then press pinion shaft 101 out of pinion cage This will free tail bear ing cone 312 A hydraulic press or jack is recommended for removing or assembling press fit parts 4 Press oil slinger O rings 301 and 506 and head bearing cone 311 from the pinion shaft Bearings must not be exposed to dirt dust or moisture 5 Press bearing cups 311 and 312 out of pinion cage Fan Shaft Disassembly 1 Remove ring gear 101 from the ring gear hub 8 2 Press ring gear hub 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
14. 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 Do not remove new bearings from packaging until ready to use Clean all bearings new or used Do not spin dry bearings Take each bearing set and roll the cup on the cone to note any roughness Replace bearing if necessary If bearings cannot be installed immediately after cleaning lubricate and cover to protect against dust moisture etc If press is not available to install bearing cones they can be heated as long as the temperature does not exceed 275 300 F 135 149 If the bearings get hotter than this they will begin to draw and soften Bearings can be heated with infrared lamps or with oil baths If an oil bath is used the bearing should be sup ported an inch or so above the pan to prevent local overheating FAN HUBO RETENTION HARDWARE FAN SHAFT BEARING RETAINER O RING AIR VENT WATER SLINGER GEAREDUCER CASE PINION GEAR RING GEAR HUB hy OIL SEAL PINION SHAFT PINION CAGEO RING GEAR CAP O RING PINION CAGE DRAIN PLUG BOTTOM COVER CAP BOTTOM BEARING O RING OIL SLINGER RETAINER CAP Figure 3 Cross Section
15. sary adjust ring gear to obtain proper backlash and recheck contact pattern Proper contact is more important of the two On a used set of gears it may be necessary to set the gears with slightly greater backlash in order to obtain proper tooth contact Should a condi tion be encountered where correct contact cannot be obtained contact your local Marley sales representative for information on factory repair service Final Assembly 1 Remove bottom bearing retainer cap and install the O ring 503 Reinstall the bottom bearing retainer cap and tighten the cap screws to 25 ftlb 34 Nm Install O ring 502 in water slinger Install water slinger on fan shaft 8 Replace air vent and all pipe plugs a 0o N Fill with lubricant selected from Table 4 11 Geareducer S PX user manul WHERE IDEAS MEET INDUSTRY Correct Pinion and Ring Gear Tooth Contact Patterns Incorrect Ring Gear Tooth Contact Patterns OUT OF POSITION CONTACT Cause Pinion too close t 7 gear center ORIGINAL Remedy Move pinion out PATTERN AFTER CONVEX SIDE CONCAVE SIDE BREAK IN OUT OF POSITION CONTACT Cause Pinion too far fro RING GEAR E gear center Remedy Move pinion in CONVEX SIDE CONCAVE SIDE ENTERING LEAVING DIRECTION OF ROTATION Figure 7 Tooth Contact Pattern Correct and Incorrect SPX COOLING TECHNOLOGIES INC 7400 W 129 STREET OVERLAND PARK KANSAS 65213 USA P 913 664 7400 F 913 664 7439
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