INSTRUCTION .

OK Roller Mill 70001381

Erection manual

In the text, reference is made to the following instruction manuals etc.:

General safety regulations at erection site 32031

General Workshop Instruction Manual 520530

VIGERSLEV ALLÉ 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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Table of Contents: Page:

1 Grouting procedure for foundation parts 4

1.1 General sequence of work 4
1.2 Concrete preparation 5
1.3 Cementitious grout installation - anchor bolts 5
1.4 Cementitious grout installation 5
1.5 Equipment required for cementitious grout 10
1.6 Acceptable grout material 10
1.7 Non-shrink concrete material 10
2 Installing the mill bases 10
2.1 Adjusting the installation centering height. 11
3. Installing the gear frame 14
4. Pressure grouting with epoxy grout 16
4.1 Acceptable pressure grouting epoxy 16
4.2 Epoxy grout handling instructions 16
4.3 Paint 18
5. Installing the main gear 18
6. Assembling the bottom casing 19
7. Assembling the table assembly 19
8. Assembling the roller and pressure lever assembly 21
9. Swinging out the roller shaft boss assembly 27
10. Installing the spring box assembly 28
11. Connecting the hydraulic cylinder to the joint rod 28
12. Erecting the steel platform structure 30
13. Installing the mill housing 30
14. Assembling the nozzle ring 31
15. Assembling the ROKS separator 32
16. Installing the feed chute 33
17. Installing the hydraulic unit and piping in the field 34
18. Chemical washing procedure 38
19. Oil flushing procedure and pressure test 39
20. Preparations prior to roller swing-in 41
21. Swinging in the roller 42
22. Adjustment of roller stopper and grinding bed depth 44
22.1 Adjusting roller stopper 44
22.2 Confirm/Adjustment of setting values 45
23. Mounting the seals around roller shaft boss 45
24. Installing the main motor and coupling 46

Created by: DRS Sort code: 5B07 Translated by:

Approved by: DRS Approved date: 17 June 04 Pages 53
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ATTENTION!
The present instruction is concerned with the situations which, according to the
experience of F.L.Smidth, are the most likely to occur. An exhaustive
enumeration of all conceivable situations which may occur during the erection,
operation and maintenance of the equipment cannot be provided.

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

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

MANDATORY!
The directions outlined in instruction manual No. 32031 "General safety
regulations at erection site" must be strictly observed at the site of erection.
This instruction manual must be scrutinized by the client, the erection
contractor and FLS representatives before erection work is started.

MANDATORY!
The erection/maintenance activities described in the following sections must
only be carried out by skilled machine specialists or subject to the supervision
of such specialists.

MANDATORY!

The directions outlined in instruction manual No. 520530 "General Workshop

Instruction Manual" must be strictly observed at the site of erection.

This instruction manual [and in particular sections 4 Welding (requirements of)

and 5 Thread] must be scrutinized by the client, the erection contractor and
FLS representatives before erection work is started.
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1 Grouting procedure for foundation parts

The importance of establishing a good foundation for the mill cannot be over
stressed. Poor grouting will cause problems when the mill is operating. It is
strongly recommended that a representative from the grout manufacturer
be present so as to insure the grout is correctly mixed and poured. The
grouting procedure for the OK mill is a combination of cementitious and epoxy
grouts. The cementitious grout surrounds and fills the large areas in the
foundation. The epoxy grout fills the small voids between the cementitious
grout and the equipment. The epoxy also helps to seal the foundation,
preventing water and oil from damaging the foundation.

WARNING
Failures of machine components have occurred because of improper grout
specification. Voids that occur due to shrinkage of grout or incorrect
installation techniques of grout will not adequately support the machine.
The purpose of the grout is to insure that the machine and foundation
concrete mass act together as one mass in order to dampen vibrations. This
can only be achieved if there is intimate contact between the grout and the
machine; as well as intimate contact between the grout and the concrete.
Master Builders or other competent grout specialists must be hired to
supervise the installation including preparation of concrete; selection of grout
material, tools and equipment; mixing; placement; and curing.
If grout installation is not proper, repairs to the machine and to the grout will
be absolutely necessary and will be very expensive.

1.1 General sequence of work

1. Preparation of concrete and equipment.

2. Installation of equipment and anchor bolts.
3. Alignment of mill bases.
4. Cementitious grout for mill base anchor bolts.
5. Time delay for grout cure.
6. Partial tensioning of mill base anchor bolts.
7. Weld mill base joint blocks and check alignment as welding progresses.
8. Align gear frame.
9. Cementitious grout for gear frame anchor bolts. Pour up to bottom of bottom
flange of gear frame.
10. Time delay for grout cure.
11. Tension gear frame anchor bolts to 100%.
12. Complete cementitious grout for gear frame and mill bases.
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13. Time delay for grout cure.

14. Epoxy grout.
15. Time delay for grout cure.
16. Tension mill base anchor bolts to 100%.
17. Paint the grout and concrete.

1.2 Concrete preparation

Independent of the grouting method used, the base concrete should be poured
with a rough surface and water cured. Before placing the mill base frame in
place, all lattice and weak concrete must be removed. If the base concrete was
cast smooth, bush, hammer or chip the surface to leave a sound, clean rough
surface. (A continuously rough surface will develop the full shear strength of the
concrete under the grout). During the installation of the frame, care must be
taken to avoid oil and grease spillage.

The concrete surface must be recleaned and saturated with water for 24 hours
just prior of placing grout. Remove free water from the concrete just before
starting the grout placement.

1.3 Cementitious grout installation - anchor bolts

The anchor bolts are grouted into pockets in the concrete. Place the mill bases,
gear frame and anchor bolts in. Cover the anchor bolt top portion, only as
indicated on the installation drawings, with duct tape or tubular urethane foam to
prevent the anchor bolt from bonding to the cementitious grout or epoxy. The
duct tape or tubular urethane foam, properly installed on the anchor bolt, will
allow the anchor bolt to stretch when tensioned.

After mill bases and gear frame are aligned and levelled in close proximity to the
final position, then use cementitious grout to grout the mill base anchor bolts into
the pockets. Do not grout the gear frame bolts at this time. The top of the anchor
bolt must be extended a certain distance above the top of the steel member
being bolted down. This distance is specified on the drawings.

Allow at least 7 days for the grout to cure before tensioning the mill base anchor
bolts.

1.4 Cementitious grout installation

There are two methods for grouting the mill, which are acceptable. A “two stage”
and a “three-stage” method which are explained as follows:
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Method A - Two stage (see sketch)

Step 1
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Mix enough grout in a ready-mix truck to flood the bottom flange to a depth of
approximately 150mm for the mill bases only. Note that the gear frame should
only be grouted to the bottom of the bottom flange. Most grout materials will
require the ready-mix truck to be in a pouring position when loaded, or moved
there during mixing. Do not wait for completion of mixing to maneuver truck.
The consistency should be fluid, for a flow cone CRD-C 79 time of 20-25
seconds.

The mixing procedure for the grout must follow manufacturer’s instructions. In the
case of Embeco 636 grout, iced mixing water is placed into truck first then dry
grout pre-batched in a bucket or hopper is charged into the truck in a maximum
of five (5) minutes. Mixing time is for three (3) to five (5) minutes.

Agitation straps should be used to level the grout as it is poured, and to remove
air from under the flanges.

The grout must be cured by ponding with water for a minimum of two (2)
days or until it is time to proceed with Step 2 of grouting. (Ponding with
water will dissipate the heat of hydration.)

Step 2

The curing water should be removed. Using mortar mixers, mix the grout
with 6 to 10mm clean, round gravel to a plastic consistency (6" to 8"
slump). In the case of Embeco 636 Grout this would be a mixture ratio of
12 kg. gravel per 25 kg. of grout.

This mixture should be mechanically pumped until the grout flows outward
from under the top plate of the bedplate for gear. It is extremely important
that no voids exist under or around the flanges. The outer edge of grout
will have to be troweled with a slope from bottom corner of the top plate to
the top of the concrete. The inner area of the gear frame should be filled
with grout to within 1 mm of the top of the plate.

For the mill bases, the grout should be mechanically pumped until the
grout is level with the top of concrete. In each mill base, there is a drain
hole. The grout around the hole must be sloped to allow for drainage of oil
and water.

The grout should be covered with wet rags or burlap until troweled
smooth.
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Method B - Three stage (see sketch)

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Step 1

Mix grout to full fluid consistency and pump grout under the flange until it
rises 25 to 50mm above the flange. This is 20-25 seconds, flow cone
CRD-C 79, fluid consistency.

This can be cured by ponding with water. Another way to cure is to cover
all exposed shoulders with wet rags early. The interior grout will cure
adequately if all openings to grout are closed to prevent air circulation.

Step 2

This stage can be filled with a non-shrink grout, non-shrink concrete or

expansive cement concrete. The intent of using a concrete is to decrease
the cost of materials being used.

Non-shrink concrete can not be used in contact with horizontal surfaces.

This concrete will lose partial contact because of bleeding.

If a non-shrink grout is used for this stage, it should be mixed with pea
gravel to a flowable consistency and poured rapidly. This should be
poured to within 75 mm of the bottom of the gear frame or top of concrete
foundation. A vibrator must not be used to encourage flow. Rodding is
permissible but should not be necessary.

If a non-shrink concrete or expansive cement concrete is used it should be

mixed to a 6 to 8 inch slump and placed through a tremi. It should be filled
to within 150 mm of the top of the gear frame or top of concrete
foundation. A vibrator should be used to encourage flow.

This stage pour should be left rough so as to establish a good contact with
the final grouting. It should be water cured by ponding.

Step 3

The base concrete or grout must be presaturated with water for several
hours. The grout should be mixed with pea gravel to a plastic consistency.
The grout must be pumped to eliminate the possibility of entrained air
bubbles remaining in the grout.

It is extremely important that no voids exist under the top plate of the gear
frame.
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The grout around the drain hole must be sloped to allow for drainage of oil
and water.

The grout must be covered with wet rags or burlap until troweled smooth.

1.5 Equipment required for cementitious grout

The equipment required for this work will be at least a moderate capacity grout
pump capable of handling pea gravel mix at a rate of 1.7 to 3.4 m3 per hour, two
large mortar mixers 0.15 m3 or larger and a ready mix truck.

1.6 Acceptable grout material

1. Masterflow 928 grout

2. Embeco 636 Grout
3. Masterflow 713 Grout
4. Sauereisen No. F-100

Note: Other grout material may be acceptable, but should be reviewed to insure
it will provide correct non-shrink and 28-day strength characteristics.
Compressive strength per ASTM C-109 must be around 7,000 psi, fluid
consistency.
1.7 Non-shrink concrete material

1. 16-18 kg. of Embeco (catalyzed) aggregate mixed with 45 kg. of Portland

cement in a conventional concrete mix.

2. Mix expansive cement (type K) in a concrete mix.

Note: This material must only be used for the 3 stage procedure for Step
2. This is intended only to be a filler material.

2 Installing the mill bases

(Section 02.02)
1. Install the No.1 mill base.
2. Position anchor bolts etc. into pockets before setting of mill base.
3. Dress the connecting surface of the joint blocks prior to lifting the mill base.
4. When lifting the mill base, use padding material for protection of the bearing cap.
5. Lift the mill base by using the bearing cap portion as shown in the following figure.
6. Install the No.1 mill base at the desired position.
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7. Place mill base on hydraulic jacks while grouting support pads. See assembly
drawing. The guideline of pad hardening time is approximately 36 hours.
Center deviation tolerance, within ± 1 mm

2.1 Adjusting the installation center height.

Adjust the installation center height. Perform the adjustment by using the jack
bolts attached to the mill base.

1. Measure the anchor bolt for projection.

Tolerance: ±2 mm

2. Check the upper surface of foundation for height and lower surface of mill
base in accordance with the bench marks on the mill bases.
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3. Determine the correct dimensional difference between the upper surface of

the foundation and the bearing block center line.

4. Grout anchor bolts and allow curing.

5. Perform the centering of mill base

a) Make sure that the centerline has been marked off on the mill
base main unit.
b) Adjust the positioning for points “1” - “4” shown in the following
figure, in accordance with the mark-off line described in the last
paragraph.
Mark-off line deviation is within 1 mm.
c) Tighten the No. 1 mill base mounting bolt temporarily. (Anchor bolts)
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6. Installing the No. 2-No. 4 mill bases

a) The installation procedure for the No.2-No.4 mill bases is the

same as that for the No.1 mill base.
b) Rough centering should be performed at this stage.
c) Assemble the scaffolding at the circumference of mill base to
ensure safety and protection.

7) Installing the joint blocks

a) Clean and dress the joint surfaces and remove any paint close
to welding area.
b) Assemble the joint blocks between mill bases. Allow for weld
contraction (2-4 mm diagonally) Check that horizontal alignment is
within 1 mm.
c) Weld the roots on joint blocks to mill bases using preferably 8
welders to minimize distortion, starting with the top weld. Start
intermittent welding from the outside inwards. Root material ~
AWS E7016-1. Check distortion regularly, too high a heat input
will result in high distortions.
d) Finish welding from the top; (AWS E7018-1) avoiding too much
heat input.
e) Gouge root weld from the bottom and weld first seam with AWS
E7016-1. Finish weld from the bottom.
f) Weld vertical joint following same procedure.

8. When the mill base has been welded, make sure that the mark-off line
of the mill bases are aligned with the main foundation lines. The target
deviation tolerance is within 1 mm.

9. If the mark-off line is not consistent, loosen the mill base anchor bolts
in order to adjust the centering.

10. Perform the final level centering of the mill base.

a) Set a linear scale on the machined surface at the upper part of

mill base (Bearing blocks).
Height tolerance is within ± 0.5 mm.
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b) After executing centering adjustment on other mill bases in the c)

Adjust the height by using the jacks and adjustment screws located
at the lower side of the mill base.
The axial level is within 0.10 mm/m.

10. Allow at least 7 days cure time, then tension the mill base anchor bolts to
100% of specified value with the supplied hydraulic tool.

11. Finish grout in mill bases.

3. Installing the gear frame

(Assembly 01.01)
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1. Chip the concrete surface on which the lower side of the gear frame
is located, and clean the area completely. The surface shall be clean,
dry and free from oil and other contaminants.
See grouting procedure.
2. Align gear frame with the center mark of the foundation.
3. Degrease and clean all steel parts to be embedded in grout.
4. Adjust the height by using the jack bolts attached to the gear frame
and fix the frame temporarily by using the anchor bolts.
- Temporary centering allowance
- Within ± 0,5 mm
5. Execute the final centering adjustment of gear frame by using a
straight edge and a level.

In hot climates, pay attention to the following.

Shade the foundation from sunlight for at least 24 hours before final
alignment, to avoid thermal deformation of gear frame.
- Horizontal allowance
- Within ± 0,02 mm/m
- Within 0,2 mm (Whole surface)
Performing this work at night may also reduce the effects of sunlight.
6. Align slide rails and frame for motor. Weld to gear frame and tighten
anchor bolts.

7. Protect the threads and nut outside surfaces with duct tape or tubular
urethane foam.

Grout the gear frame anchor bolts up to bottom of the bottom flange of
gear frame. Do not let the grout come up and over the bottom flange
since access will be required later to tension the anchor bolts.

Allow at least seven (7) days for grout to cure before tensioning the gear
plate anchor bolts. Tension bolts to 100% of recommended value with the
supplied hydraulic tool.

8. Complete cementitious grout for gear base plate and mill bases.
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4. Pressure grouting with epoxy grout

The cementitious grout is required to have a seven day minimum cure time
before the equipment must be pressure grouted with epoxy.

Pressure grouting with epoxy is done by pumping epoxy compound with pressure
into cracks and voids in the cementitious grout. The epoxy fills the small voids
and cracks in the cementitious grout around the equipment.

A specialist in epoxy pressure grouting is required to direct the installation.

Epoxy pressure grouting requires special equipment and handling. Also epoxy is
sensitive to temperature and can harden almost immediately if proper
precautions are not taken.

4.1 Acceptable pressure grouting epoxy

Master Builders Ceilcote 647R Injection Epoxy

Master Builders Ceilcote 648 Epoxy Mortar Grout without the Aggregate

4.2 Epoxy grout handling instructions

ATTENTION!
Use supplier’s specifications, installation instructions, safety instructions, and
warnings.

• Epoxy grout must be stored in a cool place at a temperature around 20°C for
at least one day before using. The temperature of the epoxy must be checked
before usage.

• Epoxy and hardener must be mixed at least 3 minutes using a powered

mixer. Powered mixer must be run at low speed to avoid entraining air in the
epoxy. Only mix the amount of epoxy that can be used in about five minutes.

• The container of mixed epoxy must be placed in an ice bath to extend the
working life.

• If the epoxy gets hot, then the epoxy must be discarded and replaced with a
freshly mixed batch.

• Large quantities of thinner are required to clean out the pumps and hoses. If
the epoxy gets too hot then the pump and hoses will have to be immediately
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cleaned with paint thinner to avoid the epoxy hardening in the equipment.

• Personnel handling the epoxy must wear gloves, goggles and protective
clothing.

• Mix and handle the epoxy in a well-ventilated area. Avoid excess breathing of
epoxy vapours. In enclosed areas or areas of poor ventilation an approved air
mask must be used.

Epoxy pressure grouting

Step 1

Pressure grout the gear frame. The bottom flange should be injected first
and then the top flange, alternating between top and bottom flanges and
working around the piece.

During the pressure grouting, the fittings adjacent to and surrounding the
area being pressure grouted must be opened to allow air, epoxy, etc. to
bleed out from around the equipment. Be careful not to over-pressurize
the epoxy.

Continue the pressure grouting until all fittings have been alternately used
as pressure (supply) and bleed points.

Repeat the above procedure, for each mill base.

Step 2

Clean up excess grout, and water from the top of mill pad. Clean out any
epoxy from the threaded holes for the gear bolts.

Cut all tubes and grind them flush with the grout or top of plate.

Step 3

Apply a thin coat of epoxy to the top of grout inside the mill base. Apply at
the joint of the mill base steel and the grout to provide a seal at the joint.
Similarly, apply a coat of epoxy at the outside perimeter of the mill base
approximately 100 mm wide.

Cure time will depend on the ambient temperature of the foundation. Measure
the temperature of the foundation in the early morning before the radiant heat
from the sun warms up the foundation. Foundation temperature of 24 °C and
above will require a minimum of 24 hours curing time. Foundation temperature of
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16 °C will require a minimum of 60 hours curing time. Cured epoxy will be a solid
glasslike structure. Epoxy that is still pliable like putty or plastic is not completely
cured. Check that the epoxy is cured before tensioning the anchor bolts.

4.3 Paint

Even though the sealing compound such as Masterseal does reduce absorption
of oil spills, all grout and concrete around the mill and inside the mill base must
be painted with oil resistant epoxy paint.

5. Installing the main gear

(Section 12.01)
For specific information on main gear box, see separate instruction.

1. Check and mark off the mill base installation centerlines prior to mounting
the main gear.

2. Items to examine prior to installing the main gear.

a) Selection of lifting device.
b) Investigation of lifting capacity.
c) Confirmation of ground subsidence under crane and outrigger
location.
d) Investigation of lifting equipment (Wire, shackle, chain hoist, etc.).
e) Investigation of lifting device installation area.

3) Installation of main gear.

a) Dress the lower surface of the main gear.
b) Apply a thin coat of oil to upper surface of gear frame.
c) Install the main gear on the gear frame.
d) When moving the gear for fine adjustment, perform centering,
while pushing with the jacking screws.
e) Since each gear mounting bolt needs to be tightened to a specified
value, refer to the instruction manual for the hydraulic tool.
f) Align the gear centerlines with orthogonal mark-off line.
g) Tighten each gear mounting bolt.
h) The target tolerance for gear installation level is within 0.02 mm/m.
See manual by main gear manufacturer.
i) Drill and ream the positioning taper holes.
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6. Assembling the bottom casing

(Section 02.04)

1. Assemble and finish weld the bottom casing, without the ducts.

2. Assemble the seal ring castings around the reducer top.

3. Lift the bottom casing, in the horizontal position, to mount it on the mill
base.

4. Roughly center the bottom casing and seal castings. Perform the final
centering after mounting the Table.

5. Fix the bottom casing to the joint blocks by tack welding.

6. Attach the ducts to the bottom casing by welding in accordance with

the assembly and layout drawings.

7. Assembling the table assembly

(Section 03.01)
1. Dress and clean the table-mounting surface.

2. Preparation of table lifting tools.

Prepare the large-capacity chain hoist and tensioning tolls for
tightening.
Before lifting in the table, mount scrapers.

3. Attach the lifting tool to the table assembly, and lift it horizontally.
Accurate lifting will ease assembly.

4. Assemble the table to the main gear.

5. Tighten the table fixing bolts according to assembly drawing

specifications.

6. Mount the table segments according to assembly drawing assuring full

contact between segment and table.

This could also be done outside the mill before erecting the table on
the gearbox. Verify lifting capabilities prior to using this method.
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a) Start with placing one table track (segment) on the table.

b) Tighten the clamping bolts from left to right (seen from the inside)
to half the specified value. Then fully tighten bolts assuring that
the segments stay in contact with the table. Check with feeler
gauge.
c) Mount next track against the first and clamp as in b)
d) Mount all tracks and adjust thickness of table track spacer. Weld
in spacer. See procedure for machining spacer on Grinding Table
Assembly III drawing.

7. Center the bottom casing.

a) Mount Table seal castings. Bottom casing may require lifting to

position castings.
b) Perform the final centering of the bottom casing in accordance with
the lower side of the Table and outer circumference of the
machined surface.
c) Take measurements at 8 points on the circumference by using a
linear steel scale or inside callipers.
Tolerance for dimension “A” is ± 5 mm.
d) Perform final welding of the bottom casing together with inlet ducts.
e) Mount remaining table seal components.
f) Cast Densit lining according to the specific Densit instruction.
g) Install bottom casing liners.
h) Adjust scraper blade height per drawing.
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8. Assembling the roller and pressure lever assembly

(Sections 04.01 & 05.01)

8.1 Separate roller and swing lever delivery.

1. Preliminary preparation items

a) Investigation of crane selection and layout.
b) Preparation of pressure lever assembly lifting tools. Prepare the
shackle, wire and chain hoist.
c) Perform the following preparations.
-Dress the mill base bearing
-Dress the fulcrum shaft sliding part
-Dress the spring box mounting surface
-Keep the spring box separate from the swing lever.
-Withdraw the roller stopper
-Clean the joint rod Screw
-Lower the hydraulic cylinder rod to avoid interference.

2. Assemble the bearing bush to the fulcrum shaft of the pressure lever
assembly.

3. Lift the pressure lever assembly in accordance with the figure, to

assemble it in the mill base.
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4. Insert the pressure lever assembly, while adjusting the lower end angle
of swing lever using a chain hoist.

5. Attach the accessories to the pressure lever assembly.

a) Attach the bearing cap. Confirm the match mark.

b) Drive in the positioning parallel pin to the bearing cap. Apply the
seizure-preventing agent.
c) After fitting the bearing cap, make sure that the grease hole is
clear.
d) Assemble the spacer (A) and thrust retainer (B) to the mill base
assembly.
e) Attach the thrust plate (C) to the nut (D).
f) Adjust the clearance in thrust direction, referring to the
assembly drawing.

Measure the clearance at lower part “T”, and make adjustment by using the
Shim (E).

g) After re-confirming the clearance adjustment, lock the bolt.

h) Attach the end cover for the fulcrum shaft.
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6.
a) Pull out the two locking pins and conical sleeves between roller
shaft boss and swing lever.
b) Swing out the roller shaft boss to a vertical position as described
below in paragraph 9.
c) Mount silicone seal temporarily on roller.
d) Lift up the roller including conical sleeve and insert into roller shaft
boss. Split conical sleeve will not stay on shaft with out rigging.
e) Mount conical sleeve and clamp plate from the bottom and tighten
bolts to specified torque.
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8.2 Roller and swing lever assembly delivered assembled

Roller and swing lever assembly are normally delivered separately,

but in case they come assembled this is the procedure.

1. Preliminary preparation items

a) Investigation of crane selection and layout.
b) Preparation of roller and pressure lever assembly lifting tools.
Prepare the shackle, wire and chain hoist.
c) Perform the following preparations.
-Dress the mill base bearing
-Dress the fulcrum shaft sliding part
-Dress the spring box mounting surface
-Keep the spring box separate from the swing lever.
-Withdraw the roller stopper
-Clean the joint rod Screw
-Lower the hydraulic cylinder rod to avoid interference.

2. Assemble the bearing bush to the fulcrum shaft of the pressure lever
assembly.

3. Lift the roller and pressure lever assembly in accordance with the
figure, to assemble it in the mill base.

4. Insert the roller assembly, while adjusting the lower end angle of swing
lever using a chain hoist.
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5. Attach the accessories to the roller and pressure lever assembly.

a) Attach the bearing cap. Confirm the match mark.

b) Drive in the positioning parallel pin to the bearing cap. Apply the
seizure-preventing agent.
c) After fitting the bearing cap, make sure that the grease hole is
clear.
d) Assemble the spacer (A) and thrust retainer (B) to the mill base
assembly.
e) Attach the thrust plate (C) to the nut (D).
f) Adjust the clearance in thrust direction, referring to the
assembly drawing.

Measure the clearance at lower part “T”, and make adjustment by using the
Shim (E).

g) After re-confirming the clearance adjustment, lock the bolt.

h) Attach the end cover for the fulcrum shaft.
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9. Swinging out the roller shaft boss assembly

(Section 05.01)

It is recommended to swing out the roller assembly by using the portable

hydraulic unit for the mill spring system. When unable to use the normal
hydraulic unit, perform the work in accordance with the following procedure.

1. Swing out the roller assemblies prior to mounting the mill housing.

2. Secure the sling and wire - during roller swing-out in accordance with
the following figure.
Select a crane having sufficient capacity.

3. Secure the roller by 2 wires respectively.

When (2) cranes are used, it is not necessary to pull the wire by chain hoist.
Note: The center of gravity of the roller will change during swing-out,
causing sudden load to be applied to the wire.

4. After completion of swing-out, perform the rust prevention on the

machined surface of swing lever and roller shaft boss.
Use grease or similar for rust prevention.
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10. Installing the spring box assembly

(Section 05.05)

1. Hang the chain hoist on a suspended beam in swing lever as shown in

the following figure.

2. Lift the spring box assembly and mount it at the desired position.
Tighten the bolts securely.

11. Connecting the hydraulic cylinder to the joint head

(Section 05.04)
1. Preliminary work
a) Dress and clean the joint head.
b) Dress and clean the screw part of the hydraulic cylinder rod and
connecting flange.
c) Preparation of assembling jigs/tools:
- Chain Hoist -Spanner
- Eye bolts -Molub Alloy agent
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- Wire -Hydraulic jack

- Crowbar -Lifting piece

2. Connect the hydraulic cylinder to the joint rod in accordance with the
following figure.

a) Adjust the clearance between the hydraulic cylinder rod and the
joint rod, to the dimension (6 mm) shown in the assembly drawing
by turning the flange.
b) Fix the counter nut by torquing the bolts
c) Adjust the hydraulic cylinder by using a chain hoist.
d) Align the connecting flange to the joint head and tighten bolts
hydraulic to the prescribed value.
e) Mount sealing bellow.
f) Mount ultrasonic grinding bed depth indicator.

Prepare the chain hoist, jack, eye bolt, wires, etc. in advance.
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12. Erecting the steel platform structure

(Section 11.01)
Since the installation work from here on, is mainly performed at a high elevation,
complete the erection of the steel platform structure for the purpose of securing
safety and of shortening the overall process.
Access to the steel platform from surrounding structures must be from
independently supported structures to avoid vibrations propagating. Stairways to
mill foundation and platform are not part of FLS delivery.

13. Installing the mill housing

(Section 02.03 & 02.04)
1. Install the mill housing on the bottom casing. Install the mill housing
with care taken to circumferential direction, refer to layout and
assembly drawing.

2. Center the mill housing. Perform the centering in accordance with the
outer circumference of the table shown in the following figure.

3. Perform the circumferential centering by arranging the connection

dimension between both end surfaces of each roller shaft boss and
window width of the mill housing.
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4. When executing the horizontal centering, measure the horizontal level

at the flange on the upper surface of mill housing. Take measurements
at 8 points on the circumference. Target tolerance is ± 1 mm. When the
horizontal measurement is found to be improper, insert shim between
the lower surface of the mill housing and the bottom casing. (Be sure
to jack up the mill housing).

5. Weld the lower circumference of the mill housing to the bottom casing
in accordance with the welding mark shown in the assembly drawing.
Perform the welding at all times following the resulting deformations in
order to rearrange welding procedure to ensure correct result.
6. Weld in the wear plates taking care not to leave gaps in between
housing and wear plates.

14. Assembling the nozzle ring

(Section 03.02)
1. Arrange each nozzle segment at the table circumference in
accordance with the nozzle assembly drawing.

The nozzle ring segments are to be lowered into the space between
the roller centerlines and then rotated into the positions under the mill
housing openings.
2. Confirm each connection dimension in accordance with the
instructions given on the drawing.
Confirm the outline position every 1/4 circumference.
3. Drive in the wedges in order to press the nozzle segments together
and connect each division point by welding, as shown in the assembly
drawing.
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15. Assembling the ROKS separator

See separate instruction for assembly of separator. Normally the separator
is assembled on the ground next to the mill and lifted up as a complete unit.
The separator bottom flange is delivered match marked together with the
mill housing to ensure a good fit. In case of limited crane capacity, the
separator could be erected on top of the mill, for the cost of less
convenience of erection and safety.
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16. Installing the feed chute

(Section 02.05)

1. Install the feed chute in accordance with the housing assembly and/or
feed chute assembly drawing.

2. After installing the feed chute, make sure that it does not interfere
when the roller swings in.

3. Care must be taken to shield grinding aid pipe installation from air
blast and feed material.

4. The rotary sluice must be connected to the mill inlet via a

compensator.
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17. Installing the hydraulic unit and piping in the field

(Section 06.03)
1. Perform the liner padding under the hydraulic unit in accordance with
the installation drawing.
Set each anchor bolt prior to installation.

2. Install the hydraulic unit on the pad.

Perform the centering for height, horizontal, machine-to-machine
dimension, etc.

3. Fabricate the piping (in the field) in accordance with the hydraulic
piping route diagram. It is preferred to bend pipes compared to using
bent fitting.
(Section 06.01)

4. When welding flange couplings to pipes, remove the O-ring.

5. After temporarily assembling the piping, perform the pickling.

6. Attach the flexible hoses for hydraulic cylinder. Bend the flexible hoses
at the radius specified in the relevant drawings. Be careful not to deform or
stress the flexible hoses.

Be careful to avoid interference with the mill base-opening hole. Install the piping
to each unit in accordance with the piping assembly drawing. See FLS hydraulic
instruction for proper assembly of hydraulic system.
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18. Chemical washing procedure

1. Varnish, paint film, and rust removing agents. Use the selected
chemical washing solutions strictly according to suppliers instructions.

2. Varnish (resin)/oil/grease content adhered to the piping can be

removed by using the APORRY C300 (produced by SAN-AI OIL CO.
LTD) or equal.

3. Use method for above supplier:

- Dipping method 1-2 hour dipping
- Concentration Undiluted solution-25% volume
- Temperature 60-80°C

4. Water washing.
a) Perform the water washing through each branch pipe one by
one, by using the high-pressure washing machine. The water
washing is intended to remove the sealant adhered in the piping
and substance adhered to the socket-weld.

5. Rust preventive filming.

a) Use the APORRY A400 (or equal) for rust preventive filming.
b) Use method:
- Dipping method 20-60 minutes dipping
- Temperature Normal temperature ~50°C

6. Water washing.
a) Perform the water washing at normal temperature for 1 to 2
minutes.

7. Finishing adjustment, neutralization

a) Use the APORRY N400 (or equal) for finishing adjustment,
neutralization.
b) Use method
- Dipping method 1-5 minutes dipping
- Temperature Normal temperature

8. Drying
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a) Perform by natural drying method (air dry) for one to three hours.

9. Checking
a) Check the inside of piping for degree of cleanliness.

10. Sealing
a) Cover the end pipe with vinyl, etc. to avoid the entrance of
foreign material, dust, etc.

19. Oil flushing procedure and pressure test

Oil flushing equipment is not included in FLS scope of supply.

The oil flushing is intended to remove the impurities adhered to the inside
walls of the lubrication piping. This will help prevent the deterioration of oil
performance, early unusual wear and galling of equipment, clogging of
filters, etc. and further to maintain the longevity and desired performance of
equipment.
1. Arrangement of equipment and material.
a) Arrange the tank, pump, filter, hose, header, coupling, etc., and
check for cleanliness.

2. Installation of equipment and material.

a) Install the equipment/material to use in an area where foreign
material or dust can not enter.

3. Assemble the oil flushing circuit.

a) Fully assemble the oil flushing piping.
b) Check that all pipes are chemically cleaned.
c) Check that the flushing equipment/material (Tank, filter, and
coupling) are completely flushed.

4. Perform the leak test.

a) Use the air (air passed through 5-micron filter) or nitrogen gas
for leak test.
b) Use the soapsuds method for leak test at coupling. If any leak
is found, perform another check and make corrections as
required.
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5. Oil filling: Fill the flushing tank with oil.

6. Pressure test (Applying for 10 minutes at 1.5 times the normal

pressure).
a) Confirm the wiring and rotational direction of the motor.
b) Confirm the Piping Circuit.
c) Confirm that there are no leaks present while oil is circulating.

7. Oil flushing
a) Circulate the oil forcibly by using the flushing pump after
confirming that there are no leaks. In this case, be sure to fit a
200-mesh filter to the Return Pipe.

8. Collection of foreign material

a) Collect the foreign material every 2-3 hours after starting the
pump and collect, arrange and store in vinyl bag.

9. Judgement
a) The flushing accuracy is class ISO4406 18/16/13 (NAS-7).10.
Drain Oil
a) Blow the nitrogen gas through the piping, to remove the oil.

11. Disassembling, sealing

a) Disassemble the piping assembly, with care taken to foreign
material, dust, etc. Keep the end pipe covered with a vinyl bag
and cap for protection.
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20. Preparations prior to roller swing-in

(Section 05.01& 06.05)

1. Clean and arrange the machine area.

2. Make sure that the jigs/tools etc. are not left inside the mill.
Check the rotating unit and sliding parts.
Check again that each bolt/nut is tightened.

3. Apply the grease to the sliding parts.

Apply grease to the sliding parts of the swing lever and roller shaft.
 70001381 42

4. Loosen the roller stopper to lowermost setting.

5. Set wooden blocks on the table in advance.

6. Re-tighten the hydraulic piping.

7. Empty conservation oil from roller.

8. Apply grease to the fulcrum shaft bearing.

9. Vent the air from the portable cylinder on both sides of the piston. This
is done both before installing cylinder and when in place before
connecting to roller shaft boss. For info on cylinder, read separate
instruction manual from manufacturer. Refer to the hydraulic
schematic for connections.

10. Set piston speed to lowest speed and connect cylinder and roller shaft
boss.

11. Perform the centering of the connecting pin by raising and lowering the
portable cylinder rod.

21. Swinging in the roller

(Section 05.01& 05.03)
1. Move the manual changeover valve for the hydraulic cylinder, to the
‘Roller-in’ position.

2. Return the changeover valve to the neutral position when the roller
swing-in operation is executed, causing the roller to make contact with
the wooden block (to prevent metal to metal contact). Check whether
the roller has made contact by watching the movement of the bottom
cylinder pin. When movement is seen, return the valve to the neutral
position.

3. Extend the roller stopper, to make contact with the spring box.

4. Raise the roller slightly, to remove the wooden block (prepared for
prevention of metal contact).

5. Dress the assembly part for roller swing-in.

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6. Perform the centering of taper bush assembling hole prepared for

swing lever and roller shaft.
a) Perform the rough adjustment by operating the hydraulic unit
for the hydraulic cylinder that raises and lowers the roller.
b) Perform the fine centering adjustment by setting a hydraulic jack at
the top end of the roller.
c) Assemble the taper bush, lock pin and retainer plate in order.

Apply the Never-Seize to each part.

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Normally the rollers come fully assembled. But to make sure bolt tightening
tools are functioning, test a few of the roller tire segment bolts for correct
tensioning before starting up the mill.

Mount lubrication block and connect to roller lubrication station.

22. Adjustment of roller stopper and grinding bed depth

Roller stopper is used to prevent metal contact between the roller and
table.
All turning of table only to be done with the main gear pump operating.
Note that the gear flange/grinding table, lifts 0,2-0,5 mm when unloaded.

22.1 Adjusting roller stopper

Adjust roller stopper as shown below:
1. Remove all material on the table.
2. Operate the hydraulic pressure unit for mill spring system and the lube
unit for mill gear reducer in the local control mode, to lift the rollers.
3. Loosen nut for roller stopper and unscrew roller stopper
4. Slowly lower the rollers in manual operation, releasing the button as
soon as the roller is lowered, and be careful not to raise the hydraulic
pressure of mill spring system. When the hydraulic pressure is exerted,
press the roller UP button to decrease the hydraulic pressure to 0.
5. Then, turn roller stopper to make lightly contact with stopper plate.
6. Raise the roller and turn roller stopper by approximately 5 or 6 turns
clockwise. Each turn is 6 mm. Position of ultrasonic sensor and stopper
is on about the same radius, giving about equal change of distance to
movement of stopper.
7. Lower the roller to make roller stopper to contact with stopper plate.
Set the hydraulic pressure to the normal operating grinding pressure.
8. Measure the clearance between the roller and the table using a steel
scale, and make roller stopper setting so, that the gap is 2~4 mm.
9. Operate the low/high-pressure pumps of the main gear reducer
lubrication unit under the condition described above during the initial
 70001381 45

setting, and turn the input shaft coupling of the main gear reducer
manually to turn the table, to check that the roller does not make any
contact with the table during rotation. If the roller makes contact with
the table, perform the readjustment of roller stopper and adjust the
ultrasonic grinding bed depth unit’s set-point, in the local control panel
for hydraulic pump unit, at the contact position.

22.2 Confirm/Adjustment of setting values

Zeroing of rollers on table.

1. Lift the rollers and unscrew the stoppers.
2. Clean up the grinding table.
3. Lower the rollers to the table without grinding pressure.
4. Zero the ultrasonic sensors.
5. Lift the rollers and turn the grinding table 90 degrees.
6. Lower the rollers to the table and note down the ultrasonic sensor
measured distance for each roller.
7. Repeat for every 90 degrees or less. Finish at start point to check zero.

A “map” of the table high points is generated. The map can be made as fine
as needed, according to the flatness of the table surface.
Note down all setting values for future references. Confirm setting values are
stable when starting after a shutdown.

23. Mounting the seals around roller shaft boss

(Section 05.01)
1. With the rollers in the lower position, mount the housing covers.
2. Mount seal flange in housing.
3. Operate roller to ensure free movement of roller in housing opening.
4. Adjust seal on roller shaft boss. Tighten bolts.
5. Operate roller to ensure proper operation.
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6. With mill closed and fan running, check for leaks, by listening for
whistles”.
7. Seal minor leaks with silicone compound.

24. Installing the main motor and coupling

Refer to the main motor instruction manual for information on levelling
tolerances etc.
Coupling assembly is covered in the main gear instruction.
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Alignment of main gear frame.

Height from gear frame to top surface of joint block: mm.

Point 1 2 3 4 5 6 7 8 9 10
Planeness *)
Height **)

*) Difference in height /m measured with level gauge 0.02 mm/m.

**) Difference in height measured with optical instrument.
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Mill base alignment, before welding

Point Correction
Base
1 2 3 4 5 6 7 8 9 10 of bearing
1
2
3
4
Height
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Mill base alignment, after welding

Point
Base
1 2 3 4 5 6 7 8 9 10
1
2
3
4
Height
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Bearing alignment, before welding

Measurement
A
B
C
D
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Bearing alignment, after welding

Measurement
A
B
C
D
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Alignment protocol gear/motor

Machine: Mill OK 36-4

Coupling:
Motor-Gear
Gear-Machine

Gear type:

Coupling type:

Shaft speed: rpm

Radial Axial

Radial Difference: mm. Axial Difference: mm.

Tolerance: mm. Tolerance: mm.

Measures taken with dial indicators in 4 points halfway.

Measures taken from main motor.
 70001381 53

Adjustment of fulcrum shaft bearing gap

Shims
Gap

Mill base Gap Torque

1
2
3
4