User Manual 00-198C - SPX Cooling Technologies
Contents
1. Marley Geareducer Model 3600 and 4000 User Manual 00 198C SPX COOLING TECHNOLOGIES Operation and Service Instructions 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 run once a week to keep a protective coating of oil on all interior machined surfaces See Seasonal Shutdown section for information about nonoperat ing period maintenance Check Geareducer exterior yearly Touch up with paint as re quired Exposed pipe threads are coated to prevent corrosion Touch up coating as required 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 Service and Lubrication section for oil filling instructions Geareducers supplied with new towers include oil for the initial filling 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 full mark corresponds with the2. Full level in the Geareducer Check oil lines to be sure there are no leaks Geareducer vent or vent line must be open to prevent failure of pinion shaft oil seal clean when necessary 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 drive shaft and motor shaft Refer to the Driveshaft User Manual Seasonal Shutdown one week to three months At start of shutdown period operate Geareducer until oil is warm 120 F 50 C and change the oil See section on Service and Lubrication 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 Operate the Geareducer long enough to recoat all the interior surfaces with oil To put back into operation drain water condensation and check oil level Add oil if necessary For longer periods of shutdown see Marley Manual 92 1308 Downtime Instruction Manual 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 cleanli ness of case and internal parts If any sludge is present flush inside of Geareducer and connecting oil line Service and Lubrication The horizontal part of the oil line must be level or slightly lower at the oil level gauge than at the Geareducer Theoilcapacityof the
3. OIL LEVEL GAUGE Figure 2 Oil Level Gauge Assembly 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 A factory reconditioned Geareducer carries year warranty 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 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 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 recomme
4. 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 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 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 subassemblies into their respective bores Install dowel pins 20 to align bearing bores Fasten case cover to case with cap screws tightening to 75 ft lb 102 N m torque Position top interstage cap shims and install interstage bear ing cap with place bolts tightening to 85 90 10 116 122 N m torque Adjust shims to give proper backlash 007 009 normal 178 228mm between spiral bevel gears See Gear Setting Procedure page 14 Fan shaft bearing must be preloaded to 001 003 025 076mm in the following manner a 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 10 48 N m torque b Mount a dial indicator to measure axial movement of fan shaft Support indicato
5. Geareducer is 18 gallons The oil level gauge line requires approximately one gallon of additional oil Refer to Table 1 on page 5 for list of suggested lubricants 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 1 and 2 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 f 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 Operation and Service Instructions 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 1 1 Remove pipe plug Turn valve control stem clockwise to open drain 2 With Geareducer drained the three way valve turned clock wise 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 stabiliz
6. e 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 OIL LEVEL CHECK OIL GAUGE AND DRAIN LINE Figure 1 Service Fittings OIL FILL PLUG INSPECTION Maintenance of the Geareducer should be scheduled as fol lows Montly Check oil level at least once a month using the follow ing procedure Stop the fan drive Allow ten minutes for oil level to stabilize and check oil level at the gauge 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 months or 3 000 hours of operation Refer to recommended oil change procedure Check the oil level placard location each time the oil is changed The Full mark on the placard must be at the same elevation as the Full arrow on the side of the Geareducer case See Figures 1 and 2 Oil level gauge vent must be kept open Inspect at each oil change and clean when necessary Inspect internal parts and inside of Geareducer case at each oil change see section on inspection of internal parts OIL GAUGE VENT OIL LEVEL GAUGE DRAIN PLUG THREE WAY VALVE Operation and Service Instructions OIL LEVEL VENT PLACARD
7. et 602 and pipe plugs 13 Field Repair Instructions Gear Setting Procedure Part numbers and references refer to Figures 3 and 13 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 the flange of the pinion cage Shims are placed under the top interstage bearing cap to adjust ring gear position The gear setting may require sev eral 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 13 The indicator can be in stalled 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 13 Gear Backlash Measurement 14 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
8. evel ring gear and spacer spacer used on 2 304 and 2 435 gear sets only from shaft 5 Pull upper bearings from top interstage retainer 5 Figure 6 Disassembly of Interstage Field Repair Instructions Figure 7 Disassembly of Fan Shaft MATCHED NUMBER TO BE COMPARED WITH THE SAME NUMBER ON THE RING GEAR EXAMPLE CO 43 gt 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 CO 43 THE PINION SETTING DISTANCE IS THE DISTANCE THE END OF THE PINION SHOULD BE FROM THE CENTERLINE OF THE RING GEAR SHAFT Figure 8 Gear Match Numbers and Setting Data 10 Disassembly of Fan Shaft Part numbers and references refer to Figures 3 and 7 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 ma
9. 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 can not be obtained as described in this manual the Geareducer should be returned to Marley in exchange for a factory recon ditioned unit Field Repair Instructions CORRECT PINION AND RING GEAR TOOTH CONTACT PATTERNS INCORRECT RING GEAR TOOTH CONTACT PATTERNS OUT OF POSITION CONTACT CAUSE PINION TOO CLOSE GEAR CENTER ORIGINAL REMEDY MOVE PINION OUT CONCAVE SIDE BREAK IN CONVEX SIDE OUT OF POSITION CONTACT 27777 CAUSE PINION TOO FAR FROM RINGGEAR GEAR CENTER CONVEX SIDE REMEDY MOVE PINION IN NCAVE SIDE ENTERING M xDIRECTION OF ROTATION Figure 14 Spiral Bevel Gear Tooth Pattern SP COOLING TECHNOLOGIES 7401 WEST 129 STREET OVERLAND PARK KANSAS 66213 UNITED STATES 913 664 7400 spxcooling spx com spxcooling com In the interest of technological progress all products are subject to design and or material change without notice 2008 SPX Cooling Technologies Inc Printed in USA Manual 00 198C
10. hers Fan Shaft Assembly 301 Fan shaft 302 Key 303 Fan hub retainer 304 Cap screw 305 Locking plates 306 Retainer ring 307 Key 400 410 420 500 600 700 701 Pinion Shaft Bearing Set 401 Tail tapered roller bearing 402 Head tapered roller bearing 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 Fan Shaft Bearing Set 421 Lower tapered roller bearing 422 Upper tapered roller bearing Shim set 501 502 503 Pinion shaft shims 504 505 506 Interstage shaft shims 507 508 509 Fan shaft shims Gasket Set 601 Pinion cage gasket 602 Inspection cover gasket 603 Oil trough gasket O Rings Set 702 Pinion cage O ring 9 4 ID x 10 OD x 703 Water slinger O ring 6 ID x 6 OD x 1 4 Pinion Shaft Oil Seal Field Repair Figure 4 Disassembly of Major Subassemblies General Geareducers can be repaired in the field however major re pairs 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 The
11. nded 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 Instructions Suggested Lubricants they must not contain any additives such as detergents or EP additives which are adversely affected by moisture and could The following list of lubricants Table 1 is provided as refer reduce the service life of the Geareducer Suitability of lubricants ence only These products have been recommended by their used other than those listed rests with the customer owner and respective manufacturers as acceptable for use in Marley spiral lubricant supplier 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 Manufacturer Product Amoco American Industrial Oil 220 Marathon Ashland Endurance R amp O Oil 220 BP Turbinol T 220 Century Renolin RO 220 Citgo Pacemaker 220 Exxon Teresstic 220 Lubrication Engineers Monolec 6406 Mobil Mobil DTE Oil 220 Mobil Mobil SHC630 Penzoil Pennzabell PB220 or RO220 Phillips 66 Magnus 220 Shell Turbo T 220 Sun Sunvis 9220 Texaco Regal Oil R amp O 220 Unocal east Unax RX220 Unocal west Turbine Oil 220 Valvoline Valvaline R amp O 220 Thi
12. on both sides of the teeth The contact pattern should be as shown in Figure 14 If correct tooth contact pattern is not obtained on first attempt refer to Figure 14 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 14 and choose the required remedy When propertooth contact has been obtained recheckthe back lash at marked teeth If it is within the desired range 007 009 178 228 check backlash with dial indicator at two ad ditional points 120 apart with inspection cover removed and as shown in Figure 13 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 9 an amount proportional to the number of teeth in the respective members For example on 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
13. r 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 Lift ing force should be 800 Ib 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 Field Repair Instructions Figure 12 Final Assembly e The difference in dial indicator readings steps c and 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 008 152 203 in shim thickness f Tighten labyrinth ring cap screws to 35 ft lb 48 N m torque g Fill grooves of labyrinth ring and water slinger with lithium base grease of NLGI No 2 consistency h Install water slinger and its O ring 703 on fan shaft Install inspection cover gask
14. s synthetic product may be applicable for high temperature service or extended oil life Table 1 Parts List 304 305 303 WATER SLINGER 703 LABYRINTH RING 500 AIR VENT FAN SHAFT 301 gt 307 306 201 40 421 INSPECTION COVER 602 GEAREDUCER CASE Figure 3 Exploded Assembly 204 INTERSTAGE BEARING CAP 206 500 202 412 603 20 DOWEL GEAREDUCER CASE COVER 5 INTERSTAGE BEARING RETAINER 101 SPIRAL BEVEL RING GEAR 108 106 201 INTERSTAGE SHAFT 411 203 205 101 PINION SHAFT AND GEAR 102 208 e 702 PINION CAGE 401 104 PINION CAGE 402 Parts List 100 200 300 Complete Geareducer Assembly 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 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 was
15. se 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 3 and 4 1 Drain oil Remove interstage bearing cap Pull water slinger off fan shaft 2 3 4 Lift off Geareducer case cover 5 Pull interstage shaft and fan shaft subassemblies out of Geareducer case simultaneously 6 Remove pinion cage subassembly Field Repair Disassembly of Pinion Cage Part numbers and references refer to Figures 3 and 5 1 Remove pinion cage and rotating portion of 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 3 and 6 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 b
16. tage bearing 411 onto interstage shaft Install double cup and spacer of bottom interstage bearing 411 Press bottom cone into place Install retainer 203 with bolts Tighten to 55 10 75 torque Press lower cup of upper interstage bearing into retainer 5 Lower retainer 5 over interstage shaft Press upper bearing cones 412 onto shaft Press upper cup 412 and spacer into retainer 5 Install disc 202 with place bolts Tighten to 150 10 204 N m torque 11 Field Repair Instructions Figure 11 Fan Shaft Assembly Fan Shaft Assembly Part numbers and references refer to Figures and 11 1 Install the key spacer ring Install key and press helical gear 201 on fan shaft Press lower bearing spacer 40 on fan shaft Press bottom bearing cone 421 onto fan shaft Press upper bearing cone 422 on fan shaft cO ON case not illustrated 6 Install upper fan shaft bearing cup 422 into Geareducer case cover not illustrated Final Assembly Part numbers and references refer to Figure 12 1 Install O ring 702 onto pinion cage subassembly 2 Boltpinion 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 8 Tighten to 75 ft lb 102 N m torque 12 Install lower fan shaft bearing cup 421 into Geareducer Lower fan shaft and interstage shaft subassemblies
17. tched 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 8 Pinion Cage Assembly Part numbers and references refer to Figures 3 and 9 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 pro vide bearing preload of 10 to 18 in lb 1130 2034 mN m resistance to rotation of pinion shaft b Crimp ears of lockwasher 104 to locknuts after obtaining prober preload 7T Slide oil seal 701 onto pinion shaft 8 Assemble pinion cage cap to pinion cage with gasket or RTV 601 Tighten bolts 23 to 55 ft lb 75 N m torque Field Repair Instructions ed CP 1 Figure 10 Interstage Assembly eres CPR 10 Interstage Assembly Part numbers and references refer to Figures and 10 Install spiral bevel ring gear spacer spacer used on 2 304 and 2 435 gear sets only against top of helical pinion Install key 106 and spiral bevel ring gear on interstage shaft Press top cone of bottom inters
Download Pdf Manuals
Related Search