INSTRUCTION MANUAL .

ATOX MILL FOR RAW MEAL 70000056

34151 1.0
Atox 32.5; 35; 37.5; 40; 42.5 and 45

OPERATION AND MAINTENANCE

The text refers to the following instruction manuals etc.:

Atox mill. Safety 40471

Atox mill. Erection 34141
Atox mill. Hydraulic equipment 34171
Atox mill. Lubrication unit 33591
Atox mill. Wear measuring on grinding parts 34241
General safety regulation at sites of erection 32031
Separator RAR 33491
Rotary sluice 37581
Separately forwarded documentation for el. equipment

VIGERSLEV ALL 77 - 2500 VALBY - DENMARK 2040 AVENUE C - PA 18017-2188 BETHLEHEM USA CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA
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Contents: Page:

1. General information .................................................................................... 4

2. Construction and operation principle ........................................................... 6
2.1 Construction ............................................................................................................................6
2.1.1 Drive station ........................................................................................................................6
2.1.2 Grinding machinery .............................................................................................................6
2.2 Operating principle..................................................................................................................9
3. Erection ..................................................................................................... 10
4. Operation .................................................................................................. 11
4.1 General notes .........................................................................................................................11
4.2 Starting ..................................................................................................................................11
4.2.1 Starting conditions.............................................................................................................11
4.2.2 Start-up ..............................................................................................................................11
4.3 Shutdown...............................................................................................................................12
4.3.1 Shutdown of short duration (Max. 15 minutes) .................................................................12
4.3.2 Shutdown of long duration ................................................................................................12
4.4 Operation ...............................................................................................................................13
4.4.1 Cut-out...............................................................................................................................13
4.4.2 Vibration monitoring .........................................................................................................14
5. Maintenance .............................................................................................. 15
5.1 Preventive maintenance, survey ............................................................................................16
5.1.1 Lubrication ........................................................................................................................17
5.1.2 Clean-up ............................................................................................................................18
5.1.3 Inspection and adjustment .................................................................................................18
5.1.4 Checking of condition .......................................................................................................18
5.1.5 Replacement ......................................................................................................................20
5.2 Repairs ..................................................................................................................................22
5.2.1 Dismantling and mounting of rollers .................................................................................22
5.2.2 Adjustment of rollers on grinding table .............................................................................24
5.2.3 Replacement of wear segments on grinding table .............................................................27
5.2.4 Replacement of wear segments on grinding rollers ...........................................................29
5.2.5 Replacement of roller bearings and seals ..........................................................................30
5.2.6 Repair of tension rod system .............................................................................................33
5.2.7 Dismantling the gear unit ..................................................................................................37
5.2.8 Replacement of wear plates in feed chute .........................................................................39
5.2.9 Replacement of wear plates on scrapers ............................................................................39
6. Key to Appendices and Figures ................................................................. 40

Edited by: LPo Translated by: Pages:

Approved by: MGN code:
53
JaF B450
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Appendices:

Appendix I............................................................................................................................................ 44
Appendix II .......................................................................................................................................... 45
Appendix III ......................................................................................................................................... 46
Appendix IV ......................................................................................................................................... 47
Appendix V .......................................................................................................................................... 48
Appendix VI ......................................................................................................................................... 49
Appendix VII ....................................................................................................................................... 50
Appendix VIII ...................................................................................................................................... 51
Appendix IX ......................................................................................................................................... 52
Appendix X .......................................................................................................................................... 53
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NOTE !

The present instruction manual is concerned with the situations which,

according to the experience of FLS, are the most likely to occur. An
exhaustive enumeration of all conceivable situations which may occur
during the erection, operation and maintenance of the machine cannot be
provided.

Consequently, if a situation should arise, the occurrence of which is not

foreseen in the instruction manual, and which the operator is/or feels
unable to handle, we would recommend that FLS is contacted without
undue delay for advice on appropriate action.

1. General information

The Atox mill is a vertical mill specifically engineered for grinding

and drying of raw materials. See operating manual for the mill plant.

It is advisable to have the parts list and any related assembly

drawings close at hand as a source of reference when studying the
present instruction manual in order to enhance the overall level of
understanding.

MANDATORY REQUIREMENT!
ATOX mill to be used only for the aforementioned purpose.

MANDATORY REQUIREMENT!
Anyone assigned to work on the mill must be familiarised with the
relevant safety regulations and the specific requirements to be met.
This applies also to any person(s) not directly employed by the
plant, for example workers assigned to perform duties in the
proximity of mill or on the mill itself.
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READ SEPARATE SAFETY INSTRUCTIONS 40471

MANDATORY REQUIREMENT!
In connection with the normal use of mill, i.e. during operation and
when the special shutdown and safety precautions outlined in sub-
section 5.2 have not been taken, it is essential to ensure that no
inspection doors or covers are open and that all protective guards
are properly fitted.
NOTE!
Any removal of protective guards or covers will give direct access
to the rotary and moving parts!

NOTE!
- The temperature of mill housing and drive station will be very
high during operation. Temperatures as high as 300C may be
experienced on the lower part of the housing.
- The noise level of the mill and its auxiliary machinery may be so
high that, dependent on the duration of activities to be carried out
near the mill, it will be necessary to use appropriate protective
equipment.
- In case of operational irregularities, the intensity of the vibration
level of the mill may activate a safety system, causing the mill
system to be shut down. The vibrations may, even under normal
operation conditions, feel unpleasant to persons standing on the
foundation or mill platform, but do not pose any danger..
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2. Construction and operation principle

The ATOX mill essentially consists of a drive station, grinding

machinery, nozzle ring and an air separator. In regard to the
dynamic separator RAR, reference is made to separate FLS
instruction manual 33491. For gear unit, see separate instruction
manual.

2.1 Construction
See Appendix I.

2.1.1 Drive station

The drive station consists of motor, coupling and gear unit.
The torque of the motor is transmitted to the grinding table (03) of
the mill via the gear unit.
The gear unit (08) is a bevel gear unit. A segmental thrust bearing is
mounted in the gear unit to support the grinding table and grinding
rollers. The weight of the grinding machinery and the grinding force
are transmitted to the gearbox through this thrust bearing, and the
force is subsequently transmitted to the foundation of the mill.

2.1.2 Grinding machinery

Appendices I - IV.
The grinding machinery consists of the grinding table (03), the
grinding rollers (01), the centre yoke (02) and the hydraulic
tensioning system.
The grinding table assembly (see Appendix II) features a circular
grinding track which consists of segments (21) manufactured from
wear-resistant white cast iron with a chromium alloy.
The segments (21) are fitted on the grinding table by means of a
number of retainer clamps (29) with through-going bolts to force the
segments down against the grinding table. Along the periphery of
the grinding table is fitted a dam ring (22) to retain the material to
be ground on the grinding track, thus forming a grinding bed of a
certain thickness.
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A segmented seal (28) and a sealing ring (27) are fitted at the point
where the grinding table extends through the partition of the mill
housing. Fitted to the lower part of the grinding table are scrapers
(20) which are used to divert any material and foreign objects -
dropping through the nozzle ring onto the bottom plate - to the
spillage outlet where extraction of such material takes place.
The three grinding rollers (01) (see Appendices III and IV) are
stationary in relation to the mill housing but rotatable about the
roller shafts (50), which are fixed to centre yoke (02). The rollers
rotate around the roller shaft in oil-lubricated roller bearings (43)
and (45).
The roller shaft is equipped with polished rings acting as journals
(42) and (55) for four shaft seals (61) and (69), the function of
which is partly to retain the oil charge of the roller and partly to
prevent ingress of dust into the roller. The shaft seals are fitted in
covers (54) and (57) on both sides of the rollers. The seals of the
rollers are also protected against dust infiltration by means of a
sealing air system; the air intake of the latter is equipped with a
filter.
From the wall of the mill housing the sealing air is directed to the
centre yoke (02) through a movable sealing air duct (98), see
Appendix VIII. From the centre yoke, the sealing air passes through
drillings in the centre yoke and roller shafts to the air seals of the
three rollers. These seals consist of rings (52)/(53) and (48)/(76),
which form chambers around the shaft seals. The air pressure in the
sealing air chambers is always higher than in the grinding
compartment, causing the clean sealing air to flow into the dusty
grinding compartment. This will prevent ingress of material into the
shaft seals, thereby eliminating the risk of damage to the seals.
In a parallel duct (104), the circulating oil system feed and drain
piping connect the rollers to the outside piping. For a full
description of the lubrication system, see instruction manual 33591.
The rollers are provided with wear segments (38) which are fixed by
means of retainer clamps (36) and (58) and through-going rod
screws (37). The hydraulic tensioning device consists of a
tensioning system and hydraulic equipment; a description of the
latter is given in separate instruction manual 34171.
The tensioning system consists of three tension rods (07) and three
torque arms (80). See Appendices I, VI and VII. The tension rods
and the torque arms are attached to the joint heads (75), which in
turn grip the end of the roller shafts. The tension rods are directly
connected to the piston rods in three hydraulic cylinders (06).
Through the tension rods the hydraulic cylinders deliver a pulling
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force, which, in conjunction with the weight of rollers, centre yoke

and tension rods, generates the necessary grinding force.
The hydraulic tensioning mechanism can also be used to lift the
rollers away from the grinding track.
The hydraulic cylinders are connected to nitrogen-charged pressure
accumulators (05), which act as grinding pressure springs.
The torque arms (80) retain the rollers in their positions during the
rotation of the grinding table. They are connected to the rollers
through the joint heads (75) and to the mill housing through rubber
buffer (85).
The nozzle ring consists of segments (33), attached with bolts to a
supporting ring (31) which is welded to a flange (30) in the mill
housing.
In conjunction with the grinding table, the nozzle ring segments
form radial air ducts which, in the vertical plane, form an angle of
45 to 60 (dependent on specific requirements) to the centreline of
the mill so that the airstream passing through is circulated. Guide
cone (32), which is mounted on the supporting ring (31), forces the
air to pass the grinding table.

Fig. 1
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The area of the nozzle ring can be adjusted by means of adjustment

plates (34) fastened to the vanes in the nozzle segments (33).
This adjustment depends on the nature and lump size of the material
and on other operational parameters as well, and, therefore, the
adjustment cannot be made prior to the commissioning of the mill.
The conveying air is led through the air spouts into the space
between the mill bottom plate and the lower side of the grinding
table, wherefrom the air is forced up through the ducts formed by
the nozzle ring and the grinding table.
The separator is installed above the mill housing, being connected to
the latter through an air-tight flanged joint. See instruction manual
for air separator.

2.2 Operating principle

Feeding of material to the mill is handled by a rotary sluice, which
feeds the material into the mill, while, simultaneously, the unit
functions as an air sluice. See separate instruction manual 37581.
From the rotary sluice the material drops down onto the grinding
table through the inlet chute and slides onto the grinding track
where it is subjected to grinding in response to the contact pressure
and seizure between the grinding rollers and grinding track, and,
eventually, the centrifugal force will cause the material to be thrust
beyond the outer edge of the grinding table.
The ground material is entrained in the hot airstream from the
nozzle ring ducts and carried up to the mill housing. The tailings are
returned to the grinding track for additional grinding, whereas the
fines are directed upstream to the separator. The material to be
ground passes through the guide vanes of the separator and
continues into the rotor of the separator. The guide vanes will
ensure that the material is evenly distributed across the entire height
of the rotor, while, simultaneously, it provides an effective pre-
separation of the grinding material by bringing into rotation the
mixture of air and grinding material.
During the passage of the fine fraction through the rotor and on
through the outlet, the coarse particles are thrown towards the guide
vanes on impact with the rotor blades, causing them to drop into the
cone under the rotor, wherefrom they are returned, through the reject
cone, to the grinding table for additional grinding.
The fineness of the finished product can be adjusted by varying the
speed of the rotor.
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Any adjustment of the guide vane positions must be carried out

during the commissioning period in order to optimise the operating
conditions. See instruction manual for the air separator.

MANDATORY REQUIREMENT!
Whenever an inspection of mill is to be conducted and in any
situation where protective guards and covers have been removed, it
is essential to ensure that precautionary measures have been taken to
prevent the mill from being started. Measures must be taken to
prevent the drive stations of the mill and separator from being
started, and similar precautions must be taken to prevent starting of
fans and dampers handling the airflow supply through the mill.

During start-up and in active operation, a certain amount of

material, i.e. the grinding bed, must be maintained between the
grinding rollers and grinding track to avoid direct contact
between the grinding rollers and the grinding track.

The grinding pressure, and hence the production rate of mill, can be
raised or lowered by increasing or decreasing the hydraulic pressure
in the cylinders. See also instruction manual for the entire mill
plant.

3. Erection

A description of the erection procedure is given in a separate FLS

erection manual 34141.
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4. Operation

4.1 General notes

In normal operation the mill is controlled/operated from the central
control panel. The mill and its auxiliary machines are started and
stopped from the control panel, either automatically or subject to the
supervision of an operator, interlocked sequentially with the other
operating units of the mill plant.
The preconditions for starting the mill are outlined below. Some of
the components may also be operated in local operating mode,
which is used for testing purposes and to make adjustments. The
mill can only be operated in entirely manual mode of operation in
exceptional circumstances.

4.2 Starting
It is a foregone conclusion that the erection of the mill has been
completed in accordance with the directions given in the erection
manual.

4.2.1 Starting conditions

A) Sealing air fan to be in operation.
B) Heat generator/fan for hot air to be in operation.
C) Temperature of airstream after mill to be at the rated
operational level.
D) Hydraulic pump station to be in operation.
E) Grinding rollers to be raised to uppermost position.
F) Lubrication system of mill gear unit to be in operation and
normality of the pressure, flow and temperature of the oil
must be ensured.
G) The roller lubrication system to be in operation and the
pressure, flow and temperature of the oil to be normal.

4.2.2 Start-up
The starting conditions mentioned in sub-section 4.2.1 must be met.

NOTE!
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The heat generator/fan for hot air must be started at early stage to
give the inner surface of the mill the necessary time to attain the
proper operating temperature prior to start-up.
The sealing air fan must be in operation before exhaust gases are
drawn through the mill.
When the hydraulic pump station is started, the rollers are raised to
their uppermost position, and the top limit switches of the cylinders
will indicate that the rollers are in raised position, allowing the
start-up procedure to be continued.
A) Start the mill motor, and allow the grinding table to rotate.
B) Start feeding at a low rate, and lower the rollers onto the
grinding table, with application of a low grinding pressure.
See also the process instruction.
C) Having generated the necessary grinding bed, the feed and
grinding pressure must be uprated to the target level.

4.3 Shutdown
4.3.1 Shutdown of short duration (Max. 15 minutes)
A) Stop the feed.
B) Stop the mill motor. The grinding rollers are automatically
lifted away from the grinding bed. The hydraulic pump
station, the roller lubrication station and the pump station of
mill gear unit must be maintained in operation. The sealing
air fan must remain in operation.

4.3.2 Shutdown of long duration

A) Reduce the feed rate to a minimum.
B) Stop feeding.
C) Stop the mill motor.
The grinding rollers are automatically lifted when the mill
motor is stopped.
D) Stop heat generator, if incorporated.
E) Stop the fan for hot air.
F) Stop the hydraulic pump station. The rollers will immediately
be lowered, bringing them to rest on the bed of grinding
material.
G) Stop the pump station of the gear unit when the oil
temperature permits this to be done. In case of low
 70000056 // 3415148 13

temperatures, it may be advantageous to keep the pump

station in operation since it will take quite some time to heat
up the oil.
H) Stop the roller lubrication station when the oil temperature
permits this to be done. In case of low temperatures, it may
also be advantageous to keep this pump station in operation.
I) Stop the sealing air fan after the mill has been stopped for a
period of approximately two hours.

4.4 Operation
In normal operation the mill is controlled from the control panel of
the mill plant. The mill is stopped and started in interlock sequence
with the other operating units at mill plant.

4.4.1 Cut-out
The mill motor may be cut out automatically during operation in
response to any of the following events:
Mill:
Absence of sealing air, fan stopped, pressure low or temperature
high.
Air temperature after the mill is too high/low.
Vibration level is too high.
Hydraulic equipment:
Oil level in oil tank for hydraulic oil is too low.
Oil pressure is too low.
Oil temperature in oil tank is too high.
Gear unit:
Oil level in tank is too low.
Inadequate oil flow to gear unit.
Oil pressure to gear unit is too low.
Oil temperature in gear unit is too high.
Roller lubrication:
Oil level in tank is too low.
Inadequate oil flow to rollers.
Oil pressure to rollers is too low/high.
Oil temperature from rollers is too high.
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After an automatic cut-out of the mill motor, it is essential to

determine and eliminate the underlying condition before the mill is
put back in operation.
See also separate manuals for gear unit, roller lubrication and
hydraulic equipment.

4.4.2 Vibration monitoring

A vibration monitor is mounted on the base flange of the gear unit.
If the vibration level reaches the pre-set MAX 1-level, an alarm is
tripped to alert the operator. If the vibration level rises to the higher
MAX 2-level, likewise pre-set, an alarm signal will be released and
the mill motor (mill plant) is automatically stopped.
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5. Maintenance

Day-to-day inspections
For every 8 hours of operation the personnel responsible for the
maintenance of mill should inspect the mill and the separator as
indicated below:

Listen for abnormal noise from mill and separator.

Look for any material spillage around the gear unit.
Check the seals around the tension rods.
Check the functionality of scraper (20); is the amount of material
in the vibration conveyor normal?
Check the hydraulic pump unit and lubrication units. Look, listen
and check for irregularities of any kind

Check the oil level in the tanks. Oil loss, if any, must be duly
reported. When refilling is necessary, the quality of the input oil
must always correspond to that of the oil in the tank. Check the oil
filters. Reporting is needed if the indicator shows any signs of filter
clogging. However, indication of this condition is usually reported
back to the control room.
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5.1 Preventive maintenance, survey

.1 Lubrication
.2 Cleaning
.3 Inspection and adjustment
.4 Checking of condition
.5 Replacement (incl. lubricants)
.6 Performance test

Pos. Text 1 2 3 4 5 6
00 ATOX mill S M
01 Grinding roller T M
21 Wear segment * M T
20 Scraper M
38 Grinding roller segment M T
61 Shaft seal 4AT
69 Shaft seal 4AT
74 Tensioning rod seal M
81 Spherical plain bearing T
85 Rubber buffer M
Hydraulic equipment T
Sealing air fan, filter S 4AT
* for grinding track

D = per 8-hour operation A number in front of the letter

indicates the frequency of
S = weekly
procedure.
M = monthly
A = yearly
For example, 2M = twice a
T = see text in instruction month.
manual
 70000056 // 3415148 17

5.1.1 Lubrication
Oil products corresponding to the symbols applied by FLS for
lubricants are listed in the FLS Key to Lubricants 36501 forwarded
on a separate basis. (Use only where applicable).

5.1.1.1 Lubrication of grinding rollers (01)

See special instruction manual for roller lubrication.

5.1.1.2 Lubrication of seal rings (61) and (69) for grinding roller
A special grease is used for lubrication of the seals of the rollers,
viz.:
Klberlub BE 41-1501
Unless a specific, written agreement to the contrary exists between
the client and FLS, it is essential to avoid usage of any other grease
grade for lubricating the seals.

Filling of grease must be done as follows:

1. Dismantle the closing screws (60) and (64) and fit grease nipples
instead of the screws.
2. The lubrication of the seals must be duly recorded so that
excessive lubrication is avoided. Normally, lubrication should
not take place more than 4-6 times a year, and the specified
grease quantity must not be exceeded. For the ATOX 32.5 - 45
mill; the grease quantity is 110 cm 3 on the outside and 180 cm 3
on the inside. Charge one-third of the grease quantity, turn the
roller approximately one-third of a full revolution, then add
another third of the grease quantity, turn the roller again and
charge the remaining grease quantity. Both sides of the roller
must be charged with grease.
Where new seals are used, the initial grease quantity must be
three times higher than the normal rate.
Remember! Excessive greasing will cause the sealing air
chambers to be blocked by grease, and the seals will be
irreparably damaged by infiltrating material.
Mount the guard plate (63) over the closing screws and plugs.
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5.1.1.3 Spherical plain bearings (81) and (82)

Do not lubricate the spherical plain bearings (82) of the torque
arms.
The spherical plain bearing (81) in the joint heads does not require
frequent lubrication but grease should be added under the bearing
cover once a year. A grease charge has been provided during the
erection procedure, and this grease charge must be renewed as
necessary.
Grease quality: Klberlub BE41-1501.

5.1.2 Clean-up
ATOX mill (00)
General cleaning on and around the machine.
Hydraulic equipment (110)
Clean the oil tank in connection with every oil change. For oil
change, see sub-section 5.1.5.

5.1.3 Inspection and adjustment

5.1.3.1 Hydraulic equipment (110)
Check the pre-charging pressure of the accumulators. See separate
instruction manual 34171.

5.1.4 Checking of condition

ATOX mill (00)
Check the positioning of the grinding rollers on the grinding track.
Make any necessary adjustments. (See sub-section 5.2.3).
Check that the rubber buffers remain intact, and that there is no
build-up of material in the buffer housing. Inspect the centre yoke
(02), nozzle ring (32) and (33), the walls of the mill housing and
other internal fittings for wear and material cakings. Identification
of any incipient wear at an early stage is of paramount importance
since severe wear on the joint heads of the grinding rollers, covers,
and particularly wear exposure of the sealing air pipe, will lead to
bearing failure unless corrective action is taken.
Localised wear of the mill housing may occur. This is due to
unpredictable airstreams and material concentrations. Wear plates
may be fitted locally to minimise wear exposure, or local hardfacing
to be added.
 70000056 // 3415148 19

Check the suspension and seals of the tension rods. An internal

inspection of the sealing air line must be carried out.
Check that the nuts of the stay bolts for the wear segments for
grinding table and grinding rollers and for the flanged joint between
roller shafts and the centre yoke are tightened to the specified pre-
tension force/tightening torque. See assembly drawing.
Check that the protective caps are fitted in correct manner.

Check the tightening rate of the bolts during the initial start-up and
following repairs, and after 8 hours of operation and then again for
every 24 hours of operation until the specified tightening torque or
force remains constant.

Retighten all bolts and screws on the grinding table, centre yoke,
grinding rollers and tensioning system to the specified torque level.
See assembly drawings.
Measure the wear rates on the wear segments on grinding table and
check the grinding rollers for wear using the supplied templates.
Ascertained wear rates to be recorded.

Before the mill is put into operation:

Use the provided templates to measure the segments for the grinding
table and the grinding rollers to determine their condition when the
mill is put into operation. Subsequent measurements of wear rates
must be taken at intervals of approximately 1000 hours of operation.
Data such as recorded values, number of service hours, throughput
in tonnes, etc. must be entered (see separate instruction manual
34241) in the inspection form and the completed form must be sent
to FLS. In case of irregular wear, it will be possible to extend the
service life of the grinding roller segments by inverting the
segments.
Grinding rollers (01)
Normally, the condition of the grinding roller bearings must be
checked once a year in connection with the replacement of grinding
parts or when the mill is stopped for other reasons. The condition of
the bearings is checked by manually rotating the raised rollers to
check that they can be turned quite easily.
Check the rollers for leaks, particularly at the flanged joints.
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Scrapers (20)
Check the fastening of the scrapers and their height above the
partition. The scrapers must skirt across the partition without any
physical contact between the units.
Check other internal fittings below the grinding table for wear and
check their fastening.

Hydraulic equipment
An oil sample must be extracted from the tank at regular intervals of
six months and a laboratory analysis must be obtained to determine:
a. Purity of the oil
b. Viscosity of the oil
c. Acid rating of the oil
d. The water content of the oil
e. Anti-foaming characteristics of oil

The oil must be replaced if the viscosity of oil has been changed by
more than 15 per cent since the oil was initially charged.

Also, an oil change is necessary if the acid value exceeds 1.5 mg

KOH/g or if the water content is more than 0.05 weight percentage.

Hydraulic cylinders (06)

Check that the piston and piston rod seals are tight. See instruction
manual for hydraulic equipment.
Sealing air fan
Replace the filter on a monthly basis or more frequently if deemed
to be necessary. Check whether the area around the point of suction
is dust-free.

5.1.5 Replacement
5.1.5.1 Hydraulic equipment
Replacement of hydraulic oil
Oil to be replaced on the basis of extracted oil samples, see sub-
section 5.1.4.
 70000056 // 3415148 21

In a hostile operating environment, involving high temperatures and

substantial dust loading in the air, more frequent replacements of the
oil may be necessary, for example for every 1000 hours of operation
Maximum cleanliness must be exercised when replacing the oil. Use
a plastic scraper to remove sediments from the tank. Avoid use of
cotton waste or rags.
Clean the suction strainer and the flow filter of filter pump.
Replace the air filter cartridge.
Replace the cartridge in flow filter.
Clean the oil drums very carefully around the bung holes before the
screw plugs are removed.
Filling of oil is done using the filter pump as described in the
instruction manual for hydraulic equipment.
Oil quality:
Always ensure that the hydraulic oil used is of a high quality,
corresponding to the following symbols in the FLS Key to
Lubricants 36501.
Limit values for temperature Oil grade
of the oil during operation

34 C - 71 C FLS 7025
42 C - 81 C FLS 7026

Oil quantity
When the plant is out of operation, the oil level in the tank may be
substantially higher than is the case during active operation. The oil
quantity indicated on the rating plate of the tank indicates the
volume in the tank. The total oil quantity will be somewhat higher.
Oil filters
Replace the filter elements if indicators or differential pressure
gauges indicate obstruction of the filter elements.
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5.2 Repairs
Safety precautions when working inside the mill:
Always ensure that the main motor is locked in the MCC prior to
initiation of any activities or inspection work inside the mill. In
connection with any repair work inside the mill with raised rollers,
the rollers must be locked in the raised position. This is done by
placing the two-part supports (120), included in the supply, around
the cylinder piston rods between the flange and cylinder head. The
rollers are then lowered until they come to rest mechanically on the
supports. See appendix X. Having done this, the oil pumps can be
stopped and locked, and clearance to work inside the mill housing
can be given.
Because of the very high temperatures in the mill, it is essential to
ensure that adequate precautions be taken to eliminate the risk of
injuries to operating personnel.
When the grinding table is to be turned manually, it will be
necessary to remove the protective guard around the flexible
coupling between the main motor and the gear unit. To allow this to
be done, the main motor must be locked in the MCC and remain
locked out until the entire mill assembly operation has been
completed and the mill has been closed. Each staff member should
have his own private padlock to ensure effective lockout.

5.2.1 Dismantling and mounting of rollers

See Appendices I, III, IV, VI and IX.

5.2.1.1 Dismantling
Tools for dismantling the grinding rollers and 3 supports (110) for
supporting the centre yoke (02) are included in the mill supply. The
grinding rollers can be dismantled as follows:
A) Raise the rollers to their uppermost position by means of the
hydraulic cylinders.
B) Dismantle the mill housing door. The door can be lifted away
after opening. Lifting eyes are integrated in the door. Dependent
on the separator size, it can be necessary to remove part of the
separator platform.
C) Dismantle the oil hoses and their protective pipe (104) from the
centre yoke and the protecting box (92). Carefully plug the holes
in the centre yoke, lubrication bracket and oil hoses to avoid
contamination.
 70000056 // 3415148 23

D) Dismantle the sealing air pipe (98).

E) Place the 3 supports (110) under the centre yoke (02), and fasten
them on the centre yoke with the associated yoke and stay bolts.
The supports need to be pulled into the mill across the grinding
table by means of chain blocks attached to the nozzle ring vanes
or table dam ring.
F) Dismantle the torque rod from the joint head.
G) Dismantle the connection between roller shaft (50) and joint
head (75). During dismantling, a hydraulic equipment for
expansion of the adapter bushing (86) must be used. The joint
head can be supported up against the mill housing wall.
H) Start the pumping station of gear unit (high-pressure as well as
low-pressure pumps) and turn the grinding table until the
grinding roller is positioned correctly.

NOTE!
The grinding table must NEVER be turned unless the pump
station for the gear unit is in operation!

I) Mount crane girder (111) and hoisting gear in the mill. Attach
the hoisting yoke (112) to the roller and tension of the tackle.
J) Dismantle the roller shaft from the centre yoke.
K) Using the lifting gear, the roller can now be withdrawn from the
mill.

5.2.1.2 Mounting
Mounting sequence to be reversed in relation to that mentioned in
sub-section 5.2.1.1.
The roller shaft is bolted to the centre yoke as indicated in Appendix
III.
Before the rollers are remounted, the joint faces between the roller
shaft and centre yoke must be cleaned very carefully, and they must
be clean and degreased.
Place the O-rings (51) for sealing air and lubrication channels in the
grooves on the flange of the roller shaft, see Appendix III. O-rings
must be greased. Used O-rings must never be re-used.
Place the roller shaft so that its flange is made to rest on the recess
on the centre yoke. On contact between the two faces lateral
displacement of the parts must not occur since this would cause
24 70000056 // 3415148

destruction of the O-rings (51), entailing failure in the supply of oil

and sealing air, with attendant risk of severe damage to shaft seals
and bearings. Flanges to be tightened up to the correct bolt force
with the hydraulic tightening tools.
Stay bolts to be re-tightened to the correct force after 8 hours
and again after 24 hours of operation until the force remains
constant.
Place the protective caps on the nuts.
Remove crane girder and hoisting gear.
Mount joint heads on the roller shafts.
Mount pipes and hoses for the sealing air and lubrication system.
Mount the mill housing door.
After the grinding rollers have been reinstalled on the grinding table
and connected to the tension rods, it must be checked that an air gap
of approximately 0.5 mm exists between two sealing air rings (48)
and (76).

5.2.2 Adjustment of rollers on grinding table

It is a precondition for adjusting the position of the rollers on the
grinding table that the hydraulic pumping station as well as the
pumping station of the gear unit are in active operation so that it
will be possible to turn the grinding table and to raise and lower the
rollers.
The position of the rollers is adjusted by means of shims (84), which
are inserted between the buffers (85) and the bracket (83).
The position of the rollers is checked by lowering the rollers onto
the grinding table - without application of grinding pressure
allowing the table to be turned slightly. The table can be turned
manually by turning the coupling between the gear unit and motor
when the gear unit pumping station is in operation. It may be quite
difficult to move the grinding table when the rollers are placed on
the table, but the very fact that the torque arms have been aligned
will make it less likely that a renewed alignment will have to be
made following the initial start-up.

NOTE!
The grinding table must NEVER be turned unless the pump
station for the gear unit is in operation!
 70000056 // 3415148 25

The purpose of the roller adjustment procedure is to ensure that the

segments of the grinding track are centered relatively to the
segments of the rollers.
See Figs. 2 and 3.

The shims (84) will affect the position of the rollers on the grinding
table in the following way:
Insertion of a shim with the thickness t under the buffer at roller No.
1 will cause roller No. 2 to be moved t/ 3 inwards in direction of
the centre of the mill, and roller No. 3 will be moved away from the
centre to the same extent.
However, in case shims of identical thickness t are inserted (or
removed), this will not affect the centering, but the position of the
pull rods in the seals will be altered to the extent of distance t.

In order to determine the immediate position of the rollers on the

grinding table, the distances S must be measured at all three rollers
(see Fig. 3).

To obtain centering of the rollers, it is essential to ensure

modification of the shims at two locations, for example at No. 1 and
No. 2. This will give the following thicknesses: (- indicates need to
remove shims):

t1 = -(2 x S2 - S1 - S3)/ 3 (+ t offset )

t2 = +(2 x S1 - S2 - S3)/ 3 (+ t offset )
t3 = 0 (+ t offset )

If it is not possible to remove shims at No. 1, it will suffice to add

an identical thickness toffset for all three buffers. Following the
centering of rollers, the position of the pull rods must be adjusted as
described above. With reasonable care and some desk calculations it
will be possible to make the entire adjustment in one single
operation.

On completion of adjustment procedure, the S-dimensions should

not deviate by more than 5 mm relative to one another.
26 70000056 // 3415148

When adjustment check is made, check that the tension rods are
more or less vertical and that the wear bushing (73) is more or less
centered in the duct without any risk of physical contact.

Fig. 2

Fig. 3
 70000056 // 3415148 27

If the rollers are retained in the same position after start-up, this
means that the adjustment made is correct; otherwise the adjustment
procedure must be repeated.

No adjustment will probably be needed if the torque rods have only

been loosened at the joint heads. If necessary, new shims must be
fabricated in the required thickness, using the shims supplied as
templates.

5.2.3 Replacement of wear segments on grinding table

Dismantling
A) Dismantle dam ring (22) and (23) and, if necessary, the
supporting ring (24). This may lead to improved accessibility,
and this operation would need to be carried out anyway since
new segments will always necessitate a readjustment of the dam
ring.
B) Dismantle the retainer clamps (29). The nuts are accessible
through the inspection port in the mill housing. Run a steel bar
through the holes (18) in the grinding table and use a jack to
detach the wear segments from the grinding table.
C) Raise the rollers to their uppermost position (see sub-section 5.2
in regard to safety precautions) and turn the grinding table so
that the segment to be dismantled is placed right in the middle
between the two rollers at the large doors.
D) Push the segment outwards in direction of the edge of grinding
table and lift it out of the mill by means of the provided lifting
gear and small mobile crane with a long telescopic arm.
Grinding parts
The fact that the grinding parts of the mill, i.e. the wear segments
for the grinding track and grinding rollers, are manufactured from
cast steel with a chromium alloy means that great caution must be
exercised when handling such components.
The segments are extremely wear-resistant with a high degree of
hardness, but with low toughness characteristics.
Grinding of the castings to be done only in exceptional
circumstances, subject to prior agreement with FLS.
It is essential to avoid any operations involving welding and flame
cutting (hardfacing of worn segments can be carried out, and is
normally safe, but is done on own risk). The brittleness of the
parts is such that the parts may break if handled improperly.
Extreme care is needed in connection with all transportation and
28 70000056 // 3415148

erection procedures. Rough handling of the parts involves

significant risk of breakage.

Installation
Clean the grinding table.
Mount the internal bolts for fixation of the wear segment from the
interior of the grinding table.
Lift the grinding segments onto the grinding track and pull them,
one at a time, towards the inner edge on the grinding table, and
insert distance irons (25). Insert shims between distance irons and
grinding table if there is clearance.
If the contact between the segments and the inner edge of the
grinding table has to be improved, this can be done by grinding the
segments; however, this must only be done if specifically agreed
with FLS.
It must be strongly emphasised that the process of grinding must not
under any circumstances involve heating of the segments.
Mount the retainer clamps (29), internally as well as externally, as
shown on the assembly drawing. Next, mount the dam ring. If the
dam ring has been dismantled or if a new unit is to be fitted, the
assembly procedure will be as follows:
Fit the sections (24), (23) and (22) of the dam ring on the grinding
table. Always ensure that the sections are laid in bonds. Variations
in the thickness of the supplied sections will occur, and, therefore,
the height can be adjusted within a range of 10 mm. Mount the
fixing screws as shown on the assembly drawing. Always ensure
that the correct grade of bolts is used.

NOTE!
Always remember to retighten the bolts used to retain the
grinding segments and the dam ring after a period of 8 hours
and then again for every 24 hours of operation, applying the
correct torque level until the torque remains constant.
For tightening torques, see assembly drawing.
 70000056 // 3415148 29

5.2.4 Replacement of wear segments on grinding rollers

When replacing wear segments, it is advisable to replace the rod
screws as well as retainer clamps if they show any signs of wear.
5.2.4.1 Dismantling
A) Turn the roller so that the segment to be dismantled is facing
upwards.
The roller must be locked to prevent it from turning.
B) Mount lifting rail on separator inner cone and place trolley on
rail, see instruction manual 33491.
C) Dismantle the retainer clamps (36) and (58) and attach the
lifting gear at hand to the wear segment.
D) Lift away the segment.
5.2.4.2 Mounting of wear segments on grinding rollers
Use the screw (59) to fit the retainer clamps (58) on the roller hub.
Check that the pin (65) between the segments is undamaged, replace
if necessary.
Smear the conical faces of the retainer clamp with a grease
containing a molybdenum disulphide additive.
Use the available lifting gear to position one wear segment on the
cylindrical face of the roller so that the line of symmetry of the
retainer piece coincides with the centreline of the segment.
Check that the segment lies true against the cylindrical contact face
of the roller.
If this is not the case, the underlying cause must be identified and
remedied. Grinding on segments must not take place unless
sanctioned by FLS.
Screw two rod screws (37) into the retainer piece at the wear
segment. The end of the screws must be flush with the surface of the
retainer piece.
Place a retainer clamp (36) on the two rod screws. Smear the conical
face of the retainer clamp and the thread of the rod screws with a
grease containing a molybdenum disulphide additive.
Fit nuts on the screws and tighten the nuts, while easing the clamp
slightly, with the hydraulic tool, applying a force at 50 per cent of
the specified level.
Mount all the wear segments on the three rollers in similar manner.
The segments must be evenly distributed over the circumference of
the roller hub.
30 70000056 // 3415148

Tighten the rod screw nuts one more time, this time applying the
full tightening force level, and check, simultaneously, that the
segments lie true against the roller hub.
Fit the protective caps for the nuts after full tightening of the bolts.
Retighten the rod screws to the correct tightening force level
after 8 hours and again after every 24 hours of operation until
the tightening force remains constant.

5.2.5 Replacement of roller bearings and seals

See Appendices III, IV and V.

5.2.5.1 Dismantling
1) Dismantle the roller with roller shaft from the centre yoke as
described in sub-section 5.2.1.
Plug up the sealing air and lubrication holes in the centre yoke
and roller shaft to avoid contamination.
2) Place the roller with the roller shaft vertically positioned with
the flange against the ground.
Dismantle the sealing air ring and bearing cover (57) with the
sealing rings (69) and retainer ring (47).
The covers are equipped with threaded holes for dismantling
screws.
3) Mount the hydraulic nut for removing the tapered sleeve (46).
Mount the retainer plate loosely by use of 3 bolts ensuring an air
gap of approx. 20 mm between the hydraulic nut and retainer
plate. Purpose of the retainer plate, when dismantling, is to limit
the travel of the withdrawal sleeve when it suddenly comes
loose, i.e. as a safety device for personnel and equipment.
Mount equipment provided for pressurising the sleeve. Apply
pressure on it. See separate instructions for hydraulic nut.
4) Release the tapered sleeve by slowly increasing the pressure for
the hydraulic nut. Maintain the pressure on the sleeve injection
oil until it is released. Pressure up to 800 bar is typical.
5) With caution, hook up the roller hub in a crane. The roller hub
must be horizontally positioned to maximum practicable extent.
Lift the roller hub very cautiously. The roller shaft must stand
firmly but must not be fixed to the floor.
6) Then dismantle sealing air ring (53) and cover (54) with the
sealing rings (61).
 70000056 // 3415148 31

7) Dismantle the spherical roller bearing (45), the distance ring (44)
and the cylindrical roller bearing (43).
The roller hub is provided with channels for hydraulic
dismantling of the outer races of the bearings.
8) Dismantle the distance ring (44) and the inner race of the roller
bearing (43) from the roller shaft.

5.2.5.2 Assembly of bearings, roller shaft and hub

1) Preparation of hub
Check that the level of cleanliness of the hub interior is satisfactory.
Where possible, the bearings should be mounted in the hub by
raising the temperature of the hub to a level, which is 120 higher
than the ambient temperature and the temperature of the bearings.
If heating is not feasible, the following alternative method may be
applied:
The spherical roller bearing (45) and cylindrical roller bearing (43)
must be cooled in a mixture of dry ice and alcohol.
The temperature must not be reduced to a level below minus 50C.
The temperature of the hub must be close to plus 20C.
When using this mounting procedure it is very important to ensure
removal of the condensation arising in connection with the
equalisation of temperatures. Subsequent to such action, a rust-
inhibiting oil must be applied thoroughly to the bearings to
eliminate any risk of rusting.
Mount the bearing (43) so that it just allows the cover (54) to touch
the outer race of the bearing. Mount the cover (54).
Position the hub (39) so that it will be possible to insert the distance
ring (44) and roller bearing (45) in the hub. The distance ring and
the outer race of the bearing must be bottomed COMPLETELY on
the hub, i.e. the distance ring must touch the outer race of bearing
(43) and bearing (45) must touch distance ring (44). See Appendix
III.
After the temperature has been equalised, remove cover (54)
Smear the outer ring on the shaft seals (61) with special grease,
Klber NOSOL UTA 4 or a similar grade, and place the shaft seals
in the bearing cover (54).
Do not forget the distance ring between the seals.
Mount the inner sealing air ring (53) on the bearing cover (54).
Refit the cover (54).
32 70000056 // 3415148

NOTE!
If the roller bearings are provided with oil drillings and if the outer
race is equipped with drilled channels for lubrication, these must be
closed to allow dismantling of bearings to be done by means of
hydraulic equipment at a subsequent point in time.
2) Preparation of roller shaft
Clean the sealing air ducts and oil drillings very carefully by means
of clean and dry compressed air. Place the roller shaft in vertical
position, standing on its flange.
Apply a corrosion-inhibiting grease, for example NeverSeez, at
locations where the bearings and rings are to be fitted. Mount
sealing air ring (52) on the roller shaft.
Mount wear ring (42) on the roller shaft. Mounting is done by
heating the parts to a level which is 120C above the ambient
temperature, subsequently lowering the parts onto the roller shaft.
Mount inner race of bearing (43) and distance ring (44) on the roller
shaft. The fit applied on the inner race is a shrink fit; slight heating
(50C - 100C) of the inner race is necessary prior to mounting.
3) Mounting of hub on roller shaft
Mounting is done by cautiously lowering the hub with the inserted
bearings and ring down onto the vertically positioned roller shaft.
Grease must be applied between the two seals in the cover (54). Use
only Klberlub BE41-1501.
The hub with bearings must be able to slide smoothly down over the
roller shaft until the roller bearing (45) lands on the recess on the
roller shaft.
Check that the roller shaft is centered in the spherical roller bearing.
Apply a thin layer of special grease, Klber Altemp Q NB 50, to the
tapered sleeve (46), internally as well as externally.
Then insert the tapered sleeve between the roller shaft and the inner
race of the bearing so that the parts lie true against one another. The
slit in the sleeve must be lying in the horizontal plane of the roller
shaft. Attach the hydraulic nut (70) to the sleeve thread (see
appendix V) so that the full thread of the nut is active. The piston of
the nut must face away from the bearing (45). Mount the retainer
plate (71) onto the roller shaft (50) keeping the holes in the plate
positioned at the oil connection drillings in the sleeve. Tighten the
screws to make the retainer plate touch the hydraulic nut.
 70000056 // 3415148 33

Then place the roller so that the roller shaft is horizontally

positioned. Apply pressure to the tapered sleeve, when possible, and
at the same time apply pressure to the hydraulic nut. Check the
clearance in the bearing (45) by means of feeler gauges and turn the
roller shaft from time to time while raising the pressure on the nut,
and stop the operation when the bearing clearance is 30-75 m.
Relieve the sleeve of the hydraulic pressure.
Again check the clearance. If the clearance exceeds the specified
tolerance range, repeat the fitting operation on shaft until the
clearance is maintained within the range 30-75 m.
Dismount the hydraulic equipment, and fit retainer ring (47). If
some of the parts have been exchanged, this ring may need
machining.

4) Mounting of outermost covers

Special grease, Klber NOSOL UTA 4 or a similar grade must be
applied to the outer ring on the shaft seals (69) and the shaft seals
must be mounted in the bearing cover (57). For orientation of the
seals, see assembly drawing.
Do not forget the distance ring between the seals.
Mount sealing air ring (48) on the bearing cover (57).
Apply grease between the two seals. Use only Klberlub BE41-
1501.
Then lower the entire bearing cover (57) very carefully down over
the vertically positioned roller shaft. Tighten all screws to the
specified torque level.
If a roller is not put into service immediately, its interior must be
protected for a very short time with the oil used in the lubrication
system or with special conservation oil for longer period.
When reinstalled, refer to roller lubrication instructions 33591 for
procedures.

5.2.6 Repair of tension rod system

See Appendices VI and VII.

5.2.6.1 Dismantling
Relax the tension rod seal (74) and wear sleeve (73) and pull the
latter down over the tension rod, thereby gaining access to the
assembly joint between tension rod (07) and joint head (75).
34 70000056 // 3415148

Disassemble the flanged joint between joint head (75) and tension
rod (07).
Dismantle the torque rod (80) at the eye in the joint head (75).
Then dismantle the joint head (75) from the roller shaft of the roller
by means of the hydraulic pump and dismantling tools and pull the
joint head out of the mill using the lifting gear.
Dismantle the tension rod seal (74) and wear sleeve (73).
If dismantling of piston rod (78) and tension rod (07) is necessary,
the position of the cylinder must be secured by means of supports.

5.2.6.2 Reinstallation of tensioning system

See Appendices VI and VII.

If spherical plain bearings, joint heads or adapter bushings need

to be replaced, it may be necessary to readjust, or replace, the
tapered sleeve (86). See erection manual for further details.

1) Spherical plain bearings

Normally, the spherical plain bearings are mounted in the eyes of
the hydraulic cylinders. The spherical plain bearings must not be
mounted in the joint heads (75) until the tapered sleeve (86) has
been thrust into the inner race of the bearings. Make sure that the
end of the tapered sleeve (86), which has the smallest diameter, is
flush with the bearing. It should be noted that the tapered sleeve
may require adaptation. See aforementioned notes.
Unpacking of the individual spherical plain bearings should not take
place until mounting is about to begin. It is essential to avoid use of
cleaning liquids for cleaning the spherical plain bearings; instead
use a clean cotton cloth to wipe off the bearings.
The outer race of the bearing features a dividing slot, and, at stage
of mounting, this slot must be offset through 90 in relation to the
load direction.
The fit between bearing and joint head is tight. It is necessary to
heat the joint head with a lazy flame to approximate 80C above
ambient temperature before mounting the bearing.
In the joint head, the "open" end of the inner race must face the
roller shaft.
 70000056 // 3415148 35

2) Hydraulic cylinders.
If the hydraulic cylinders have been dismantled or if new cylinders
are to be mounted, proceed as follows:
Mount the pin and cylinder in the brackets.
Do not forget the distance rings!
Support the cylinders so that they are positioned in reasonably
correct positions.

3) Mounting of joint heads on the roller shafts of rollers

Mount sealing air ring (76) on the joint head (75).
Check that the air gap between the sealing air ring (76) and sealing
air ring (48) is close to 0.5 mm.
Clean the conical surface on the roller shaft (50) and the inner face
of the adapter sleeve very carefully. Apply Klber ALTEMP Q NB
50.
Push the joint head over the roller shaft (50).
Mount the locking plate (56) on the shaft end, and tighten it lightly.
The plate may be a tool provided with a hole for the oil injection
tube, which must be replaced by the permanent plate after forcing-
in. See assembly drawing.
Pump hydraulic oil in through the shaft end for expansion of the
inner race of the spherical plain bearing, and, at the same time,
tighten screws of the locking plate until the plate lies true against
the end of the roller shaft. Then, while maintaining the hydraulic
pressure on the shaft end, tighten all screws to the specified torque
level. The oil pressure must be maintained right up to the point
where all screws have been tightened, subsequently removing the
hoses. If the plate is a tool only, use the permanent plate to replace
it.

4) Mounting of tension rods

Following the finishmounting of the joint heads, and with the
rollers placed on the grinding table, the tension rods (07) must be
lifted through the hatches at each head and fitted to the joint heads
by means of the retainer rings (77) and stay bolts.
Clean the contact faces.
Use the supplied hydraulic bolt tensioner to tighten the stay bolts.
36 70000056 // 3415148

1. Clean the bolt and nut. Check that the nuts of the bolt can be
turned by hand. If the nut is provided with a stamped mark, the
mark must face away from the contact face.
2. Use the tool to tighten the nuts lightly in crosswise sequence.
3. The tightening force stipulated on the assembly drawing must be
strictly observed.
4. The bolts of the flanged joint must be tightened crosswise and in
three stages to eliminate risk of the flanges being distorted.

If welding is to be performed in proximity of the parts of the

tensioning system, it is very important to ensure that adequate
precautions are taken to avoid infliction of undercuts on the parts. A
high-alloy material, which has been subjected to heat treatment, is
used in the tensioning system, and any undercuts caused by welding
will act as major stress raisers which may eventually cause ruptures
in the system.
Caution is also needed in connection with the handling and
transportation of the tension rods.
Place the wear bushing (73) on the tension rod and mount it in
accordance with the directions given on the assembly drawing.
Pull the flanges on the tension rod (07) and the piston rod (78) of
the cylinder close together. If operational, the hydraulic system can
be used.
Place the retainer rings (77) and the stay bolts in the flanges;
tightening to be done as described in item 4 above.
Mount the tension rod seal as indicated on the assembly drawing.
Connect the torque rods (80) to the eye in the joint heads (75) and to
the buffers (85).
Refit the shims (84) removed in connection with the dismantling
operation.
If centering of the rollers is deemed to be inadequate, the rollers
must be adjusted as outlined in sub-section 5.2.2
Fit the wear protection features (79) for the torque rods (80).
 70000056 // 3415148 37

5.2.7 Dismantling the gear unit

Dismantling the gear unit is not a normally occuring event; it is
foreseen to be a rare occurrence, and, therefore, the special tools
needed for dismantling are not included in the overall mill supply.

Fig. 5

The procedure is as follows:

1. Lift the grinding rollers, and lock them in the upper position.
2. Remove the 3 covers in the bottom plate. Prior to doing so, clean
the surrounding area inside the mill. If the scrapers interfere with
the holes, remove as necessary.
3. Check the grouted-in rails outside the mill for possible obstacles
and scars, and repair as necessary.
4. Enter the interior of the grinding table and remove nuts and stud
screws. Contamination of threads etc. must be avoided.
5. Remove the platform above the coupling and remove the main
motor (09).
6. Dismount electrical connections and oil connections from the
gear unit. Remember to plug the oil connections.
7. Arrange suitable columns as shown. Use 3 jacks, be sure only to
use jacks that are equipped with lock nuts to keep them in raised
position. Support column loosely at holes in bottom plate. Make
38 70000056 // 3415148

a good supporting at the table, and make sure that tilting of

column will not occur.
8. Lift table evenly approximately 60 mm, to ensure that the gap
between table and gear is larger than 10 mm.
9. Remove gear fixing bolts with hydraulic bolt tensioner tool.
Remove tapered pins with pulling tool.
10. Provide a number of 10mm round bars, length as the gearbox
width.
11. Jack up gearbox with jacks at the 4 jacking points. Take care not
to interfere with the grinding table flange.
12. Put in the bars underneath the gear bottom flange. Lower the
gear.
13. Use a suitable pulling equipment to haul out the gearbox, moving
bars from the back to the front as they are released.

Before hauling out the gear, ensure that adequate attachment points
on the foundation and mill housing are available for the pulling
equipment.

Refitting is done in sequence opposite that described above; a

certain amount of grease must be applied to the bedplate surface.
When the precise position has been found, remove the bars, put in
the tapered pins when the holes are aligned, and ease the gear into
position until the ultimate fitting of pin is ensured.

It is essential to avoid dangerous situations during this

operation; the components are heavy, and only skilled personnel
should be involved in the operation.
 70000056 // 3415148 39

5.2.8 Replacement of wear plates in feed chute

The feed material sliding into the mill may entail wear exposure of
the wear plates in the feed chute.
Prior to replacing the wear plates, it is necessary to dismount and
remove the rotary sluice.
Now the wear plates can be lifted out one by one starting with the
uppermost plate.
Remounting is done in reversed order.

5.2.9 Replacement of wear plates on scrapers

The wear plates on the scrapers are exposed to wear.
If the monthly checking of condition shows sign of wear on the
scrapers or other parts located below the grinding table, parts need
to be exchanged.
When changing parts below the grinding table, it is necessary to
build scaffolding to get a proper accessway to the door in the lower
part of the mill housing.
40 70000056 // 3415148

6. Key to Appendices and Figures

Appendix I
01 Grinding roller
02 Centre yoke
03 Grinding table
04 Mill housing
05 Pressure accumulator
06 Hydraulic cylinder
07 Tension rod
08 Gear unit
09 Motor

Appendix II
18 Hole for detaching segments
19 Central cover
20 Scraper
21 Wear segment, grinding table
22 Dam ring top section
23 Intermediate segments
24 Supporting ring
25 Distance iron
26 Pin for wear segment
27 Sealing ring
28 Labyrinth seal
29 Retainer clamp

Fig. I
30 Flange
31 Supporting ring
32 Guide cone
33 Nozzle segment
34 Adjustment plates
 70000056 // 3415148 41

Appendices III and IV

35 Grub screw
36 Retainer iron
37 Rod screw
38 Wear segment, grinding roller
39 Roller hub
40 Protective cap
41 Stay bolt for centre yoke
42 Wear ring
43 Roller bearing
44 Distance ring
45 Roller bearing
46 Tapered sleeve
47 Retainer ring
48 Sealing air ring
50 Roller shaft
51 O-rings
52 Sealing air ring
53 Sealing air ring
54 Bearing cover
55 Wear ring
56 Locking plate
57 Bearing cover
58 Retainer iron
59 Screw
60 Closing screw
61 Shaft seal
62 O-ring
63 Guard plate
64 Closing screw
65 Pin
66 O-ring
67 Closing screw
68 Guard plate
69 Shaft seal
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Appendix V
45 Roller bearing
46 Tapered sleeve
55 Wear ring
70 Hydraulic nut
71 Auxiliary tools
72 Hydraulic tools

Appendix VI
07 Tension rod
73 Wear sleeve
74 Tension rod seal
75 Joint head
76 Sealing air ring
77 Retainer ring
78 Piston rod
81 Spherical plain bearing
86 Tapered sleeve

Appendix VII
75 Joint head
79 Wear protection
80 Torque rod
81 Spherical plain bearing
82 Spherical plain bearing
83 Bracket
84 Shim
85 Buffer
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Appendix VIII
92 Protecting box
93 Locking ring
94 Retainer piece
95 Connecting piece
96 Bushing
97 Spherical plain bearing
98 Sealing air pipe
99 Wear bushing
100 Spherical ring
101 Locking ring
102 Bushing
103 Spherical plain bearing
104 Protective pipe
105 Wear bushing
106 Spherical ring
107 Locking ring
108 Locking ring
109 Locking plate

Appendix IX
01 Grinding roller
110 Support for centre yoke
111 Crane girder
112 Lifting yoke
113 Trolley

Appendix X
06 Cylinder
07 Tension rod
120 Two-part support
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Appendix I
 70000056 // 3415148 45

Appendix II
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Appendix III
 70000056 // 3415148 47

Appendix IV
48 70000056 // 3415148

Appendix V
 70000056 // 3415148 49

Appendix VI
50 70000056 // 3415148

Appendix VII
 70000056 // 3415148 51

Appendix VIII
52 70000056 // 3415148

Appendix IX
 70000056 // 3415148 53

Appendix X

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