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user manual
Geareducer® model M1712 – M1712.5 – M1713
INSTALLATION - OPERATION - MAINTENANCE
Z1051231 ISSUED 04/2017
READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
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fan hub installation
RETENTION
RETENTION
BOLT
The following instructions detail the process for installing a fan
on a Marley Geareducer with a straight fan shaft using a split
taper bushing or a tapered fan shaft utilizing a bolted fan hub
retention plate.
1. Remove the retention plate and hardware from the top of the
Geareducer shaft. Thoroughly clean the fan shaft, fan shaft
key, and the fan hub center bore to remove any debris and/or
protective coatings. After cleaning, apply a coat of anti-seize
compound to the top 7" (180mm) of the fan shaft.
2. Prior to hub installation, fully seat the key in the fan shaft
keyway. The key is a tight fit across the width and must never
be altered.
3. Raise the fan hub above the fan shaft for installation. Slowly
lower the hub onto the shaft with the keyways properly aligned.
Make certain the key does not slide down during installation.
Stake the key in the keyway with a center punch if necessary.
The fan shaft key should be approximately centered in the
engaged portion of the hub when engaged on the shaft. Verify
the center hub is fully seated by visual inspection.
4. Figure 1 illustrates proper retention plate and hardware installation. The retention plate is designed to allow clearance for
the fan shaft key, and when properly installed will not extend
over or interfere with the key in any way. Torque the retention
bolts to 70 ft·lbƒ (95 N·m).
PLATE
Figure 1 Retention Plate Assembly
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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 lubricant 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 Bearing Cap to
expose port. Refer to Figure 3. If additional oil is being used, an
amount of 1 to 1.5 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 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 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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OIL LEVEL CHECK
OIL GAUGE
AND DRAIN LINE
VALVE
OIL GAUGE
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.
Figure 2 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.
OIL FILL PLUG
VENT LINE
INSPECTION
COVER
VIBRATION
ACCELEROMETER
MOUNTING
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.
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 the Geareducer for cleanliness of case and internal parts. If any sludge is present, flush the
inside of the 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. The oil capacity of
the M1712 is 17 gallons, the M1713 is 23 gallons. The oil level
gauge line requires approximately one additionalgallon of oil. Refer
to back cover for suggested lubricants.
VENT
OIL LEVEL
GAUGE
Figure 3 Service Fittings
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DRAIN PLUG
THREE-WAY
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operation and service
OIL LEVEL
OIL LEVEL
PLACARD
VENT
NOTICE
FULL
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
ADD
OIL
GAUGE
Figure 4 Oil Level Gauge Assembly
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 3 and 4. 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. If 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.
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 3.
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).
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.
Maintenance Service Monthly
Geareducer Drive:
Inspect and tighten all fasteners including oil plug
Check for and repair oil leaks
Check oil level
Change oil
Make sure vent is open
Check driveshaft or coupling alignment
Inspect and tighten driveshaft or coupling
fasteners
Check driveshaft or coupling bushing / flex
elements for unusual wear
Lube Lines (if equipped)
Check for oil leaks in hoses and fittings
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.
x x x
x R x
x R x
Semi-
annually
x x
R R
x x
Seasonal
Startup or
Annually
x
x
x
Maintenance of the Geareducer should be scheduled
as follows:
Monthly: Check oil level at least once a month using
the following 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 3 and 4.
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.
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GE
701
INSPECTION
parts list
WATER SLINGER
LABYRINTH RING
306
307
305
703
500
INTERSTAGE
BEARING CAP
704
500
204
206
COVER
AIR VENT
422
303
FAN SHAFT
301
304
302
201
421
202
412
603
GEAREDUCER
CASE COVER
5 – INTERSTAGE BEARING
RETAINER
101 – SPIRAL BEVEL
RING GEAR
106
201
INTERSTAGE SHAFT
411
203
205
602
Figure 5 Exploded Assembly
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GEAREDUCER
CASE
101 – PINION SHAFT AND GEAR
102
105
402
500
702
PINION CAGE
103
401
104
PINION CA
CAP
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parts list
1 Complete Geareducer Assembly
100 Spiral Bevel Gear Set
101 Set of matched spiral bevel gears including
integral pinion shaft with key
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)
200 Helical Gear Set
201 Set of matched helical gears including
interstage shaft and special key
202 Top interstage bearing retainer disc
203 Bottom interstage bearing retainer disc
204 Machine Bolts
205 Place bolts and washers
206 Washers
300 Fan Shaft Assembly
302 Key
303 Fan hub ring
304 Retainer ring
305 Fan hub retention plate
306 Retention cap screws
307 Lock washer
400 Pinion Shaft Bearing Set
401 Tail, tapered roller bearing
402 Head, tapered roller bearing
410 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
420 Fan Shaft Bearing Set
421 Lower tapered roller bearing
422 Upper tapered roller bearing
500 Shim set
501-502-503 Pinion shaft shims
504-505-506 Interstage shaft shims
507-508-509 Fan shaft shims
600 Gasket Set
602 Inspection cover gasket
603 Oil trough gasket
700 O-Rings Set.
701 Pinion Shaft Oil Seal
702 Pinion cage O-ring, 93⁄4" ID × 10″ OD × 1⁄8"
703 Water slinger O-ring
704 Interstage cap bolt O-ring
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
a one 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.
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Geareducer M1712 - M1712.5 – M1713
USER MANUAL
Suggested Lubricants
The list of lubricants is provided as reference only. These 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.
Manufacturer Product
SPX Cooling Technologies Inc. Mineral Turbine ISO 220
Chevron Regal R & O 220
Citgo Petroleum Corp. Pacemaker 220
ConocoPhillips Multipurpose R & O 220
ExxonMobil Corp. DTE Oil BB
ExxonMobil Corp. Teresstic 220
Lubrication Engineers Inc. Monolec 6405
Shell Morlina S3 GA 220
Synthetic Oil*
SPX Cooling Technologies Inc. Gearlube ISO 220
Chevron Clarity 220 Synthetic
Citgo Petroleum Corp. Citgear Synthetic HT 220
ConocoPhillips Syncon R & O 220
ExxonMobil Corp. SHC 630
Shell Morlina S4 B220
*Synthetic oil may be applicable for high temperature service
or extended oil live
SPX COOLING TECHNOLOGIES, I NC.
7401 WEST 129 STREET
OVERLAND PARK, KS 66213 USA
913 664 7400 | spxcooling@spx.com
spxcooling.com
Z1051231 | ISSUED 05/2017
COPYRIGHT © 2017 SPX CORPORATION
In the interest of technological progress, all products are subject to design
and/or material change without notice.
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