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TP-Bz/TK-Pt-Man

GEBR. PFEIFFER AG KAISERSLAUTERN - 2005

OPERATING INSTRUCTIONS

BA200500591

for Grinding plant

with roller mill type MPS 4500 B

Order No.: 22347-22366

Manufacturing year: 2005

Customer: Neyzar Qom Cement Co.


No. 14 First Floor
12th Str. Ahmad Qasiv Ave

IR-Tehran

Project: NEYZAR RM

Manufacturer: Gebr. Pfeiffer AG


Barbarossastraße 50 – 54 (goods)
D-67655 Kaiserslautern

Postfach 30 80 (correspondence)
D-67618 Kaiserslautern

Telephone: ++49 (0) 631 / 41 61-0

Telefax: ++49 (0) 631 / 41 61-1 91

- Foreword -

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GEBR. PFEIFFER AG Foreword BA200500591-E/D
KAISERSLAUTERN Edition 04.2006

Foreword to the operating instructions

These operating instructions are designed to familiarize the user with the machine
and its designated use.

The instruction manual contains important information on how to operate the


machine safely, properly and most efficiently. Observing these instructions helps to
avoid danger, to reduce repair costs and downtimes and to increase the reliability
and life of the machine.

The instruction manual is to be supplemented by the respective national rules and


regulations for accident prevention and environmental protection.

The operating instructions must always be available wherever the machine is in use.

These operating instructions must be read and applied by any person in charge of
carrying out work with and on the machine, such as:

- operation including setting up, troubleshooting in the course of work,


evacuation of production waste, care and disposal of fuels and
consumables.

- maintenance (servicing, inspection, repair) and/or

- transport

In addition to the operating instructions and to the mandatory rules and regulations
for accident prevention and environmental protection in the country and place of use
of the machine, the generally recognized technical rules for safe and proper working
must also be observed.

Copyright

The copyright to these operating instructions remains with GEBR. PFEIFFER AG.

The operating instructions are meant for the user and the operating personnel of the
machine. They must not be copied in full nor in part or be used for unauthorized
competition purposes.

- List of Revisions -
Contents -

ge0500591-00.doc Page 2 / 2
department: TP/TK rev.-no.:
revision list made by: Barz/Prägert rev. date:
GEBR. PFEIFFER AG
Kaiserslautern made on: 03.02.2006 checked by: TP-Bz/TK-Pt

no.: 200500591 checked on: 20.04.2006

client: Neyzar Qom Cement Co., Tehran/Iran project: NEYZAR RM - MPS 4500 B order no.: 22347-22366

Rev checked, appoved by date language documents

00 Mr. Barz // Mr. Prägert 20.04.2006 E/D first editon

kved8281.xls 1/1
GEBR. PFEIFFER AG BA200500591-E/D
KAISERSLAUTERN Table of Contents Edition 04.2006

Contents

- Cover sheet
- Foreword
- Revision list
- Table of contents

1. Process data File 1


1.1 Rating data
1.2 Process description
Flow Sheet

2. Fundamental safety instructions


2.1 Warnings
2.2 Basic operation and designated use of the machine
2.3 Organizational measures
2.4 Selection and qualification of personnel –
basic responsibilities
2.5 Safety instructions governing specific operational phases
2.6 Warning of special dangers
2.7 Safety instructions for the user

3. Technical description
3.1 Design and operation
3.2 Description of the main constructional components
3.3 Measuring and regulating equipment

4. Transport and erection


4.1 Transport
4.1.1 Storage
4.1.2 Scope of supply
4.2 Erection
4.2.1 General instructions
4.2.2 Erection site - machine

5. Commissioning
5.1 Measures to be taken before commissioning
5.1.1 Erection control
5.1.2 Performance control
5.2 Commissioning

6. Operation
6.1 Start-up after operational shut-down
6.2 Shut-down
6.3 Start-up after longer downtime periods
General data

7. Malfunctions
7.1 General instructions
7.1.1 Comments on indication of malfunctions
7.2 Table of malfunctions

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GEBR. PFEIFFER AG BA200500591-E/D
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8. Maintenance

8.1 General instructions


Before machine restart

8.2 Inspection and servicing


8.2.1 List of inspection and service works
8.2.2 Description of service works
8.2.2.1 Seal air pressure
8.2.2.2 Marking of a hydraulic hose pipe
8.2.2.3 Checking of the oil level in the grinding rollers
8.2.2.4 Oil change at grinding rollers
8.2.2.5 Check of automatic leveling of grinding rollers
8.2.2.6 Lubrication of classifier bearing
8.2.3 Table: Tightening torques for screws
Table: Wear limits
Table: Gap and wear measurement – pressure frame stop
Leaflet: Wear measurement at grinding elements

8.3 Lubrication instructions


Greasing instructions
Oil lubrication instructions
Lubrication lists
Lubrication chart

8.4 Repair
8.4.1 How to lift the classifier off the grinding plant
8.4.2 Removal and mounting of grinding rollers
8.4.3 Replacement of wear segments of the grinding rollers
8.4.4 Replacement of grinding plate segments
8.4.5 Replacement of liner plates
8.4.6 Removal of one hydraulic cylinder of the tensioning system
8.4.7 Repair of the oil pressure piping to go with the tensioning system
8.4.8 Replacement of roller bearings and radial shaft sealing rings of the grinding rollers
8.4.8.1 Preparatory work
8.4.8.2 Removal of radial shaft sealing rings
8.4.8.3 Fitting of radial shaft sealing rings
8.4.8.4 Removal of roller bearings
8.4.8.5 Fitting of roller bearings
8.4.9 Replacement of pressure yokes
8.4.10 Repair of torque support of the pressure frame
8.4.10.1 Emergency operation with a defective hydraulic buffer
8.4.10.2 Removal of torque support of the pressure frame (complete
8.4.11 Removal of grit cone
8.4.12 Removal of louvre
8.4.13 Removal of separating wheel and separating wheel hub
8.4.14 Removal of classifier drive
8.4.15 Removal of classifier bearing

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GEBR. PFEIFFER AG BA200500591-E/D
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8.4.16 Repair of three-flap gate lock


8.4.16.1 Replacement of hydraulic cylinders
8.4.16.2 Replacement of roller bearings and sealing
8.4.16.3 Replacement of flaps

Annex
Auxiliary equipment for removal of ball sockets
Tool box – packing list
Drawings

9. Spare parts File 2


9.1 General instructions
9.1.1 How to use the spare parts lists
9.2 Spare parts lists / Spare parts drawing
- Mill
- Classifier
- Three-flap gate lock

10. Lists and drawings


10.1 List of machines and equipment
10.2 List of electric consumers
- with flow sheet
10.3 Interlocking diagram
10.4 List of measuring points
- with flow sheet
10.5 Foundation plan

11. Plant components


Operating instruction / Data sheets

11.1 Proportioning station, with Files 3 + 4


- proportioning belt scales

11.2 Fill level measuring in the feed bins File 4

11.3 Pneumatic parts for the two-way chute, with File 5


- inductive proximity sensor

11.4 Overbelt magnetic separator

11.5 Metal detector

11.6 Hydraulic unit for the three-flap gate lock, with


- hydraulic unit
- hydraulic cylinder

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GEBR. PFEIFFER AG BA200500591-E/D
KAISERSLAUTERN Table of Contents Edition 04.2006

11.7 Tension system for the roller mill, with File 6


- hydraulic unit
- hydraulic cylinder, with
- linear displacement transducer system

11.8 Lift-and-Swing System, with File 7


- hydraulic unit
- hydraulic cylinder
- rotary actuator

11.9 Torque support for pressure frame, with


- hydraulic buffer
- flowmeter

11.10 Seal air fan, with


- fan
- pressure measuring

11.11 Water injection, with


- pump, with
- gearmotor
- frequency converter
- flowmeter
- 2/2-port directional valve
- pressure switch
- non-return valve
- corner overflow valve
- filter controller

11.12 Drive for the roller mill, with File 8


- gearbox, with
- coupling
- oil supply unit
- maintenance drive

11.13 Hydraulic bolt tightening tool, with File 9


- manual pump

11.14 Vibration monitoring for the mill gearbox

11.15 Drive for the classifier, with


- gearbox
- coupling
- shrinkage disc

11.16 Cyclone – rotary lock, with


- coupling
- gearmotor

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GEBR. PFEIFFER AG BA200500591-E/D
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11.17 Plant fan, with File 10


- louver flaps

11.18 Flaps in the plant

11.19 Measuring and control device, with File 11


- pressure before mill
- temperature before and after mill
- mill differential pressure and air volume after cyclone

11.20 Hot gas generator File 12 and 13

11.21 Sampler File 13

11.22 Vibration trough conveyor

11.23 Bucket elevator File 14

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GEBR. PFEIFFER AG Chapter 1 BA200500591-E/D
KAISERSLAUTERN Process Data Edition 04.2006

1. Processing data

1.1 Rating data

The vertical roller mill type MPS 4500 B supplied is rated for the combined
grinding and drying of cement raw material according to the following data:

Feed material: cement raw material


with the following composition:
mix
limestone
iron ore

Moisture: 8 % max.

Grain size: 0-100 mm; 10 % > 100 mm max.

Bulk density: 1.3 t/m3

Grinding capacity: 315 t/h

Finished product fineness: 12 % R 0.090 mm max.

Residual moisture: < 0.5 %

Hot gases (upstream of the mill)


for a 8 % feed moisture and 315 t/h
Volume flow: 280,000 nm3/h
Temperature: 313°C

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GEBR. PFEIFFER AG Chapter 1 BA200500591-E/D
KAISERSLAUTERN Process Data Edition 04.2006

1.2 Process description

The process description is based on drawing no. 153 304-0.

The plant can be operated either in by-pass mode (mill off line) or with the mill
running in normal operation.

By-pass mode

Shut-off dampers before and after the grinding plant are closed so that
maintenance and repair works can be carried out.

The electrostatic precipitator de-dusts the pre-heater gases.

Mill-inclusive operation/ compound operation

The shut-off dampers before and after the grinding plant are open, enabling the
exhaust gas from the kiln to pass through the grinding plant.

The proportioning belt scales withdraw metered quantities of material from the feed
bins. Conveyor belts then take the material into the mill. A metal detector is located
over the conveyor belt that transfers the material to the mill. A two-way chute either
takes the material to a heatable rotary lock, arranged upstream of the mill to provide
an air seal, or to an intermediate bin if metal is detected.

The material contaminated with metal is withdrawn from the intermediate bin by a
metering conveyor belt and checked again by a metal detector. Contaminated
material is discharged. The non-contaminated material is returned to the external
material circulation.

Kiln exhaust gases or flue gases from a hot gas generator serve to dry the material.

The material is ground to the required target fineness in the mill while being dried
simultaneously. The target fineness is set by adjusting the speed of the separating
wheel.

Material spilt from the mill is returned to the mill feed material by special conveying
devices.

The finished product is carried out of the classifier with the gas flow from which it is
largely separated by the cyclone battery. The downstream electrostatic precipitator
de-dusts the exhaust gas flow.

The mill fan is arranged downstream of the quadruple cyclone battery.

The gas volume flow is set by modifying the position of the louver flap upstream of
the fan.

The depression upstream of the mill is regulated by adjusting the flap in the
recirculating air ducting.

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GEBR. PFEIFFER AG Chapter 1 BA200500591-E/D
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For taking away any spillage material, the mill is equipped with an external material
recirculation.

Any material falling through the nozzle ring is conveyed by scrapers arranged below
the grinding bowl to the reject chute.

From there the material is returned to the mill feed by means of a vibration trough
conveyor and bucket elevator.

For emptying the mill in case of maintenance work, the material can be conveyed
into the buffer silo by means of the conveying belt and bucket elevator.

The mill is fitted with a water injection system that can be switched on whenever
required.

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GEBR. PFEIFFER AG Chapter 2 BA200500591-E/D
KAISERSLAUTERN Safety Instructions Edition 04.2006

2. Fundamental safety instructions

2.1 Warnings

The following warnings are used in the manual to designate instructions of particular
importance.

Important! (refers to special information on how to use the machine most


efficiently)

Attention! (refers to special information and/or orders and prohibitions directed


towards preventing damage)

Danger! (refers to orders and prohibitions designed to prevent injury or


extensive damage)

2.2 Basic operation and designated use of the machine

The machine has been built in accordance with the state-of-the-art standards and
the recognized safety rules. Nevertheless its use may constitute a risk to life and
limb of the user or of third parties, or cause damage to the machine and to other
material property.

The machine must only be used in technically perfect condition in accordance with
its designated use and the instructions set out in the operating manual, and only by
safety-conscious persons who are fully aware of the risks involved in operating the
machine. Any functional disorders, especially those affecting the safety of the
machine, should therefore be rectified immediately.

The machine is designed exclusively for the purpose described in chapter 1. Using
the machine for purposes other than those mentioned above is considered contrary
to its designated use. The manufacturer/supplier cannot be held liable for any
damage resulting from such use. The risk of such misuse lies entirely with the user.

Operating the machine within the limits of its designated use also involves observing
the instructions set out in the operating manual and complying with the inspection
and maintenance directives.

2.3 Organizational measures

The operating instructions must always be at hand at the place of use of the
machine.

In addition to the operating instructions, observe and instruct the user in all other
generally applicable legal and other mandatory regulations relevant to accident
prevention and environmental protection.

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These compulsory regulations may also deal with the handling of hazardous
substances, issuing and/or wearing of personal protective equipment, or traffic
regulations.

The operating instructions must be supplemented by instructions covering the duties


involved in supervising and notifying special organizational features, such as job
organization, working sequences or the personnel entrusted with the work.

Personnel entrusted with work on the machine must have read the operating
instructions and in particular the chapter on safety before beginning work. Reading
the instructions after work has begun is too late. This applies especially to persons
working only occasionally on the machine, e.g. during setting up or maintenance.

Check - at least from time to time - whether the personnel is carrying out the work in
compliance with the operating instructions and paying attention to risks and safety
factors.

For reasons of security, long hair must be tied back or otherwise secured, garments
must be close-fitting and no jewellery - such as rings - may be worn. Injury may
result from being caught up in the machinery or from rings catching on moving parts.

Use protective equipment wherever required by the circumstances or by law.

Observe all safety instructions and warnings attached to the machine.

See to it that safety instructions and warnings attached to the machine are always
complete and perfectly legible.

In the event of safety-relevant modifications or changes in the behaviour of the


machine during operation, stop the machine immediately and report the malfunction
to the competent authority/person.

Never make any modifications, additions or conversions which might affect safety
without the supplier's approval. This also applies to the installation and adjustment
of safety devices and valves as well as to welding work on load-bearing elements.

Spare parts must comply with the technical requirements specified by the
manufacturer. Spare parts from original equipment manufacturers can be relied to
do so.

Never modify the software of programmable control systems.

Replace hydraulic hoses within stipulated and appropriate intervals even if no


safety-relevant defects have been detected.

Adhere to prescribed intervals or those specified in the operating instructions for


routine checks and inspections.

For the execution of maintenance work, tools and workshop equipment adapted to
the task on hand are absolutely indispensable.

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The personnel must be familiar with the location and operation of fire extinguishers.

Observe all fire-warning and fire-fighting procedures.

2.4 Selection and qualification of personnel - basic responsibilities

Any work on and with the machine must be executed by reliable personnel only.
Statutory minimum age limits must be observed.

In case the machine is not erected and/or commissioned by personnel of the


supplier the operator/buyer has to ensure that adequate and qualified personnel is
available on the erection site.

Employ only trained and instructed staff and set out clearly the individual
responsibilities of the personnel for operation, set-up, maintenance and repair.

Make sure that only authorized personnel works on or with the machine.

Define the machine operator's responsibilities giving the operator the authority to
refuse third party instructions that are contrary to safety.

Do not allow persons to be trained or instructed or persons taking part in a general


training course to work on or with the machine without being permanently
supervised by an experienced person.

Work on the electrical system and equipment of the machine must be carried out
only by a skilled electrician or by instructed persons under the supervision and
guidance of a skilled electrician and in accordance with electrical engineering rules
and regulations.

Work on gas-fuelled equipment (gas consumers) may be carried out by specially


trained personnel only.

Work on the hydraulic system must be carried out only by personnel with special
knowledge and experience of hydraulic equipment.

2.5 Safety instructions governing specific operational phases

2.5.1 Standard operation

Avoid any operational mode that might be prejudicial to safety.

Take the necessary precautions to ensure that the machine is used only when in a
safe and reliable state.

Operate the machine only if all protective and safety-oriented devices, such as
removable safety devices, emergency shut-off equipment, sound-proofing elements
and exhausters, are in place and fully functional.

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Check the machine at least once per working shift for obvious damage or defects.
Report any changes (incl. changes in the machine's working behaviour) to the
competent organization/person immediately. If necessary, stop the machine
immediately and lock it.

In the event of malfunctions, stop the machine immediately and lock it. Have any
defects rectified immediately.

During start-up and shut-down procedures always watch the indicators in


accordance with the operating instructions.

Before starting up or setting the machine in motion make sure that nobody is at risk.

The selector switch must be set to "Normal" and locked.

Never switch off or remove suction and ventilation devices when the machine is in
operation.

2.5.2 Special work in conjunction with utilization of the machine and maintenance and
repairs during operation; disposal of parts and consumables

Observe the adjusting, maintenance and inspection activities and intervals set out in
the operating instructions, including information on the replacement of parts and
equipment. These activities may be executed by skilled personnel only.

Brief operating personnel before beginning special operations and maintenance


work, and appoint a person to supervise the activities.

In any work concerning the operation, conversion or adjustment of the machine and
its safety-oriented devices or any work related to maintenance, inspection and
repair, always observe the start-up and shut-down procedures set out in the
operating instructions and the information on maintenance work.

Ensure that the maintenance area is adequately secured.

If the machine is completely shut down for maintenance and repair work, it must be
secured against inadvertent starting by:

- locking the principal control elements and removing the ignition key

and/or

- attaching a warning sign to the main switch.

To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting tackle and secured. Use
only suitable and technically perfect lifting gear and suspension systems with
adequate lifting capacity. Never work or stand under suspended loads.

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GEBR. PFEIFFER AG Chapter 2 BA200500591-E/D
KAISERSLAUTERN Safety Instructions Edition 04.2006

The fastening of loads and the instructing of crane operators should be entrusted to
experienced persons only. The marshaller giving the instructions must be within
sight or sound of the operator.

For carrying out overhead assembly work always use specially designed or
otherwise safety-oriented ladders and working platforms. Never use machine parts
as a climbing aid. Wear a safety harness when carrying out maintenance work at
greater heights.

Keep all handles, steps, handrails, platforms, landings and ladders free from dirt,
snow and ice.

Clean the machine, especially connections and threaded unions, of any traces of oil,
fuel or preservatives before carrying out maintenance/repair. Never use aggressive
detergents. Use lint-free cleaning rags.

After cleaning, examine all fuel, lubricant and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any defects found must be rectified without
delay.

Always tighten any screwed connections that have been loosened during
maintenance and repair.

Any safety devices removed for set-up, maintenance or repair purposes must be
refitted and checked immediately upon completion of the maintenance and repair
work.

Ensure that all consumables and replaced parts are disposed of safely and with
minimum environmental impact.

2.6 Warning of special dangers

2.6.1 Electric energy

Use only original fuses with the specified current rating. Switch off the machine
immediately if trouble occurs in the electrical system.

Work on the electrical system or equipment may only be carried out by a skilled
electrician himself or by specially instructed personnel under the control and
supervision of such an electrician and in accordance with the applicable electrical
engineering rules.

If provided for in the regulations, the power supply to parts of machines, on which
inspection, maintenance and repair work is to be carried out must be cut off. Before
starting any work, check the de-energized parts for the presence of power and
ground or short-circuit them in addition to insulating adjacent live parts and
elements.

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The electrical equipment of machines is to be inspected and checked at regular


intervals. Defects such as loose connections or scorched cables must be rectified
immediately.

Necessary work on live parts and elements must be carried out only in the presence
of a second person who can cut off the power supply in case of danger by actuating
the emergency shut-off or main power switch. Secure the working area with a red-
and-white safety chain and a warning sign. Use insulated tools only.

Before starting work on high-voltage assemblies and after cutting out the power
supply, the feeder cable must be grounded and components, such as capacitors,
short-circuited with a grounding rod.

2.6.2 Gas, dust, steam and smoke

Carry out welding, flame-cutting and grinding work on the machine only if this has
been expressly authorized, as there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and grinding operations, clean the
machine and its surroundings from dust and other inflammable substances and
make sure that the premises are adequately ventilated (risk of explosion).

Observe any existing national regulations if work is to be carried out in narrow


rooms.

2.6.3 Hydraulic and pneumatic equipment

Work on hydraulic equipment may be carried out only by persons having special
knowledge and experience in hydraulic systems.

Check all lines, hoses and screwed connections regularly for leaks and obvious
damage. Repair damage immediately. Splashed oil may cause injury and fire.

Depressurize all system sections and pressure pipes (hydraulic system,


compressed-air system) to be removed in accordance with the specific instructions
for the unit concerned before carrying out any repair work.

Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that no
connections are interchanged. The fittings, lengths and quality of the hoses must
comply with the technical requirements.

2.6.4 Noise

During operation, all sound baffles must be closed.

Always wear the prescribed ear protectors.

2.6.5 Oil, grease and other chemical substances

When handling oil, grease and other chemical substances, observe the product-
related safety regulations.

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Be careful when handling hot consumables (risk of burning or scalding).

2.7 Safety instructions for the user

The setting into operation of a machine must not be possible other than by
deliberately activating a device specially designed for this purpose.

Always observe the instructions for setting into operation and switching off the
machine (interlocking).

For setting into operation and for indicating any malfunctions, indicators (for audible
and visual indication) with a distinct signal must be provided.

The interlocking must be made in a way as to guarantee that restarting the machine
by mistake is not possible.

Maintenance doors must be opened only when the machine is switched off.
When opening the maintenance doors, be aware that with various machines the
rotating parts can still keep on moving over a period of several minutes after
switching off the machine.

Maintenance doors and openings as well as inspection points on the machine must
allow safe access.

When doing any maintenance work in the machine, proper ventilation must be
ensured. If required, appropriate protection equipment (gloves, goggles, etc.) must
be used.

Only persons that have been instructed in safety regulations are supposed to enter
the machine.

Due to the extreme danger when working inside the switched off machine, a
supervisor must permanently stay in front of the machine to secure the drive.

If any of the surrounding machines is to be set into operation, make sure that this is
coordinated by the supervising personnel.
The machine is not suitable for the processing of explosives.
The MPS mill is operated under depression to prevent dust from escaping.
In addition, the mill must not allow any combustion exhaust gas to get out.
In case of overpressure the risks of intoxication and fire as well as of explosion
(especially with gas burning) must be considered.
Any reaction of the pressure monitoring system can indicate wrong adjustment or
failure of the depression regulation.

Ensure by regular checks that the safety facilities are in stable and safe working
condition.

During operation the machine/plant components show higher wall temperatures.


Ensure that unwanted contact is not possible.

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For repair works on the coat of paint or new painting of these components use a
heat-resistant paint (up to 400°C) to avoid any risk of fire.
Always observe the safety and handling instructions supplied by the respective
manufacturer (see chapter 11) when working on the machines/plant components.

The sound pressure level of the machines/machine components can exceed


85 db(A).
With a sound level exceeding 85 db(A) the use of ear protectors is recommended.
With a sound level exceeding 90 db(A) the use of ear protectors is obligatory.

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GEBR. PFEIFFER AG Chapter 3 BA200500591-E/D
KAISERSLAUTERN Technical Description Edition 04.2006

3. Technical description

The following description of design and operation of the machine will help you to a
better understanding of the functions and make the handling of the machine easier.

3.1 Design and operation

MPS Vertical roller mill

The MPS vertical roller mill is an air-swept vertical roller mill consisting of several
constructional components. The main components -mill and classifier - form a single
and compact unit.

The principal feature of the MPS roller mill are three stationary grinding rollers which
roll on a slowly rotating grinding plate.

Together with one pressure frame and three pull rods the grinding rollers form a
statically determined system which provides a uniform load distribution over the
grinding bed and the segmented thrust bearing of the gearbox. Each grinding roller
is flexibly connected to the pressure frame by means of a pressure yoke which
allows lateral rocking movements of the grinding rollers.

This flexibility of movement and the pneumatic suspension of the tensioning system
ensure an optimum adjustment of the grinding rollers to the grinding bed.

The material, carried in by the feeder, is drawn in and crushed between grinding
rollers and grinding plate.

The forces required for the grinding are produced by pressing the grinding rollers
onto the grinding plate.

The contact pressure is created by a hydro-pneumatic tensioning system and can


be varied during operation if necessary.

The material is ground and conveyed toward the ported air ring by compression and
shear. The gas flowing up through the ported air ring mixes with the material and so
forms a rotating fluidized bed above the ported air ring. The coarser particles fall
back onto the grinding plate and undergo again the grinding process.

The fine-ground particles are caught by the gas stream and carried up to the
classifier. In the separation zone a rotating separating wheel separates the material
into fine finished product and coarse particles (grits). The separating wheel is fitted
with a variable speed drive to adjust the rotation speed to the required finished
product fineness.

The separated finished product is carried by the gas stream to the dust collector
arranged after the mill. The coarse material falls back onto the grinding plate and is
taken back into the grinding process.

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The MPS mill is furthermore designed for operation with external material
circulation. The material falling through the ported air ring when the mill is operated
under increased load is discharged at the reject duct in the mill base. The reject duct
is fitted with a material chute, via which reject material is directed to a vibration
trough conveyor. This in turn transports the material to a bucket elevator.

The bucket elevator takes the material back up to the mill feed material.

The mill is equipped with a water proportioning unit. Water is injected through
nozzles into the grinding gap to stabilize mill operation.

For drying the material hot gases are led into the mill.

3.2 Description of the main constructional components

MPS Vertical roller mill

Foundation frame: The complete mill (mill and classifier) including the mill drive is based on
a section steel construction which is embedded in the mill foundation.
The three pull rod anchors for the fastening of the hydraulic tensioning
cylinders are welded to the foundation frame.
The forces required for the grinding process are transmitted into the
foundation frame through the mill gearbox and the hydro-pneumatic
tensioning system.

Mill drive: A special gearbox - driven by an electric motor -transmits the required
torque to the grinding bowl and at the same time absorbs the forces that
are created by the grinding process affecting the grinding bowl. The
gearbox bearings are connected to a pressure circulating lubrication
system with oil pump and oil cooler.

Service drive: The main mill drive is fitted with an maintenance drive. The maintenance
drive is used for the precise positioning of the grinding plate for
inspection and servicing purposes as well as for repair works (see
chapter 8.2 and 8.4).

For detailed information on the mill drive see the separate operating
instructions in chapter 11.

Grinding bowl: The grinding bowl is positioned on the gearbox output flange which is
based on an adequately dimensioned segmented thrust bearing. The
bottom zone of the grinding bowl is closed against the interior of the mill
by a horizontal flat floor. The clear inner zone of the grinding bowl is
covered by a steel plate cap which prevents the material from falling in.

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Grinding plate: The grinding plate (wear part) is fastened onto the grinding bowl. The
three stationary grinding rollers roll in the trough-shaped track of the
grinding plate.
Caused by the rotating movement of the grinding bowl the material is
drawn in and ground between grinding plate and grinding rollers.
The grinding plate is segmented and fitted to the grinding bowl by means
of clamping elements.

Grinding rollers: The three stationary grinding rollers are arranged equidistantly on the
grinding plate. Each grinding roller is fixed to the pressure frame by
means of a pressure yoke.
Each grinding roller is borne on the axle of the pressure yoke by two
special roller bearings.
The grinding rollers are fitted with crowned wear parts.
The wear parts are segmented and fastened by means of clamping
elements.

ATTENTION!

Make sure that the grinding rollers always roll on a material bed and
never directly on the grinding plate (increased wear/risk of fractures).

Note:
The grinding plate and the grinding roller wear parts are subject to
natural wear. When a certain wear limit is reached these parts have to
be replaced. For details on how to assess the state of wear and on how
to determine the wear limit see chapter 8 - Maintenance.

Tensioning The contact pressure required for the grinding


system: rollers is created by a hydro-pneumatic tensioning system. The pressure
frame which has the shape of an equilateral triangle transmits the forces
created by the tensioning system onto the pressure yokes with the
grinding rollers. Fitted to the ends of the pressure frame are the pull rods
which transmit the forces from the hydraulic tensioning cylinders.

The three hydraulic tensioning cylinders are supplied with oil by one
hydraulic unit which also produces the pressure required for the pre-
tensioning of the grinding rollers.

Each hydraulic tensioning cylinder is fitted with a bag-type pressure


accumulator filled with nitrogen gas which absorbs the shocks and
vibrations occuring during mill operation.

The hydro-pneumatic tensioning system is designed in such a way that


the grinding rollers can be lifted for start-up purposes.

For further details on the hydraulic unit and the hydraulic tensioning
cylinders see the separate operating instructions in chapter 11.

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Ported air ring: The ported air ring is located between grinding plate and mill housing.
The guide channels of the ported air ring show an oblique arrangement
and so create a spiral gas flow. The spiral flow carries the fine material
upwards into the separation zone. The gas stream enters the mill
through an inlet duct which is located below the ported air ring.
Particles falling through the ported air ring are conveyed by a scraper to
the reject duct in the mill base and are then discharged.

The ported air ring and the fitted air guide cone / cover cone are lined.

Seal air system: The seal air system prevents dust from passing through the sealings into
the grinding roller bearings and so protects the sealings from premature
wear.

The seal air fan located outside the mill sucks air through a filter and
carries it through a ring-shaped ducting to the connecting points at the
pressure yokes. The connecting ducts to the pressure yokes are flexible
and can adjust to the movement of the grinding rollers. In the pressure
yoke the seal air flows into an annular gap arranged before the sealing
of the grinding roller bearing and is discharged into the interior of the mill
through a labyrinth gap.

The correct functioning of the seal air system is controlled by monitoring


seal air pressure and power consumption of fan motor.

During the service period and with wear progressing, seal air pressure
drops constantly. Once it has gone down to about 70% of the rate
measured at the time of commissioning, the seal air system will have to
be checked. When seal air pressure has dropped to 50%, mill operation
must be stopped because otherwise dust might get into the bearings and
destroy them (also refer to chapter 8.2).

Classifier: Separation of the fine product is carried out by means of a lamella


classifier type SLS.

The classifier housing is fitted on top of the mill housing and screwed to
it. The bearing of the classifier shaft, the classifier shaft with the lamella
wheel (separating wheel), the louvre with the obliquely arranged blades
and the grit cone are fitted into the classifier housing. The variable speed
drive of the separating wheel is installed outside the classifier.

The grinding product, carried by the gas stream, is taken through the
louvre into the separation zone. The oblique arrangement of the louvre
blades give the particles an additional spin. A pre-separation of the
coarser particles is provided due to the centrifugal forces.

The fine product which shows the required fineness is separated by


means of the separating wheel. The gas stream carries the separated
fine product out of the classifier and into the dust collector arranged after
it.

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The coarser particles (coarse material) that do not yet show the required
fineness do not pass the separating wheel. Together with the material
rejected by the louvre they fall through the grit cone back onto the
grinding plate.

The required end fineness of the product can be steplessly varied within
a wide range by a regulation of the speed of the separating wheel.
Speed increase leads to a higher product fineness; speed reduction
leads to a lower product fineness.

The bearing is protected from dust by means of a seal air sealing. This is
provided by a ducting leading from the outside to the connection socket
at the classifier shaft. Due to the depression in the mill, air is sucked in
from the outside. The sucked air enters the interior of the classifier
through an annular gap located in the classifier shaft sealing and thus
prevents the entering of dust.

The classifier outlet duct and bearing stand support are provided with a
lining.

Separating wheel The separating wheel is driven by an electric motor


drive: with gearbox arranged downstream. Flexible couplings are provided
between electric motor and gearbox, and between gearbox and classifier
shaft. Stepless variation of the gearmotor is carried out by means of a
frequency converter.

For further details on the separating wheel drive see the separate
operating instructions in chapter 11.

Mill housing: Being completely closed, the principle function of the MPS roller mill
housing is to guide the gas stream. With the forces created by the
grinding process being transmitted through the mill gearbox and the
tensioning system into the foundations the housing is largely relieved.

Torque support for


the pressure frame: The housing is further relieved by fixing the torque support for the
pressure frame to it. Moreover the support contributes considerably to
reducing the vibration level of the mill.

The mill housing is provided with a partial lining.

For checks and servicing the following points are provided with doors:

- mill housing bottom (grinding bowl zone)


- mill housing top (grinding roller zone)
- mill housing top (pull rod housing zone)
- classifier housing top (separating wheel zone)

Attention! Do not open the doors unless the machine is switched off.

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Material feed: The feed material is conveyed into the mill by means of a three-flap gate
lock. The gate lock is located above the material chute and prevents
false air from entering into the mill.

The three flaps installed in the gate lock open and close alternately so
that only one flap at a time is open.

Each flap is operated by a hydraulic cylinder. The hydraulic oil supply for
the three hydraulic cylinders is provided through a single hydraulic unit.
The phase is electrically regulated by opening and closing the respective
solenoid valves.
(See also data in chapter 11.)

The gate lock surface over which the material slides into the mill is
heated in order to keep sticky material from clinging to it. The hot gases
required for this purpose are sucked from inside the mill and taken back
to the mill through the hot gas channel of the lock.

MPS Lift-and-Swing The mill is fitted with a Lift-and-Swing


System: System for easy exchange of the grinding rollers for repair works.
(For instructions on the handling see chapter 8.4.)
Supporting arms are mounted to a sinkable central column located in the
mill centre. For the removal of a grinding roller, the pressure yoke is
fastened with the grinding roller to the column.
This done the connection between pressure frame and pressure yoke is
loosened and the pressure frame lifted up.
The grinding plate is turned by means of the maintenance drive allowing
the positioning of each grinding roller exactly at the maintenance door.
When the Lift-and Swing device is fastened to the mill housing exterior,
pressure yoke and grinding roller can be lifted up, swung out and
prepared for being carried away.

Mill fan: The mill fan is arranged after the cyclone collector; it is rated for the
required gas volume flow of the grinding plant.

The gas volume flow is regulated by means of the louver flap arranged
ahead of the mill fan (see also chapter 3.3).
For further details on the mill fan see the separate operating instructions
in chapter 11.

Exhaust gas fan: After the mill fan the air stream is devided in a recirculation air stream
and an exhaust gas stream.

A fan located after the filter draws the exhaust gases through the
system.

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Filter unit: A cyclone collector is used for the separation of the fines carried by the
air stream that comes from the MPS vertical roller mill. The exhaust gas
from the cyclone is dedusted in a filter arranged downstream.

3.3 Measuring and regulating equipment


(For measuring and regulating diagram see chapter 10.4.)

MPS vertical roller mill:

Regulation - feed rate

The purpose of the feed regulation is to keep the differential pressure and thus the
fill level in the mill at a constant level. The effect is that the mill throughput rate is
adjusted to the varying grindability of the material. The differential pressure is taken
by a differential pressure measuring transducer and led to a controller which varies
the feed velocity and thus the material quantity by means of a suitable actuator. The
measuring points for measuring the differential pressure are located in the gas inlet
duct of the mill and ahead of the classifier. For start-up and shut-down of the
grinding plant the feed quantity control is operated manually.

Regulation - gas volume flow

The gas volume flow is measured in a suitable test section by a measuring device. A
differential pressure measuring transducer converts the pressure signal into an
electric signal which is then taken to a controller. The controller regulates the
regulating device (radial damper, jalousie flap etc.) in such a way that the gas
volume flow in the plant is kept at a constant level. For start-up and shut-down of the
plant the gas volume control is operated manually.

Regulation - heat supply

The temperature after mill is kept at a constant level. This guarantees that the
finished product is dried to the required residual moisture. Any deviation from the set
exhaust gas temperature after mill causes a reaction of the controller. If the exhaust
gas temperature is too low the heat supply is increased. If it is too high the heat
supply is reduced. For the protection of components which are sensitive to
temperature such as bearings, dust collection filters, etc., limit values are provided.
These are included in the interlocking and cause an automatic switch-off of the hot
gas supply in case the exhaust gas temperature is too high.

Regulation - depression ahead of mill

The depression ahead of the mill is measured and taken to a measuring transducer
for conversion into electric signals. A limit value indicator and a controller are
arranged downstream of the transducer. If the set limit values are reached alarm is
released. The regulation of the depression is effected by adjusting the position of the
recirculation gas flap.

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Monitoring - temperature ahead of mill

The temperature ahead of the mill is measured by means of a resistance


thermometer, a measuring transducer, a limit value indicator and an indicator. If the
temperature is too high the hot gas supply must be interrupted.

Monitoring – temperature of classifier gearoil

The temperature of the classifier gearoil is monitored by means of a resistance


thermometer, measuring transducer, limit switch, and indicator.
5 switchpoints are provided:

switchpoint 1 LL: classifier cannot be started


switchpoint 2 L: pump of cooling circuit OFF
switchpoint 3 H: pump of cooling circuit ON
switchpoint 4 HH: alarm
switchpoint 5 HHH: classifier drive OFF

Monitoring - tensioning pressure

The tensioning hydraulic is fitted with an electronic pressure switch with measuring
transducer. An indicator shows the actual value of the tensioning pressure.

Monitoring of oil temperatureof mill gear

For the monitoring of the gear oil temperature the gearbox is fitted with two
resistance thermometers which transmit the temperature to a limit value indicator
and an indicator by means of a measuring transducer. The limit value indicators
release alarm if a certain limit value is exceeded. If a second limit value is reached
the machine is automatically switched off.

Monitoring - vibration level

The mill gearbox is fitted with a vibration monitor for the vibration level. Any vibration
exceeding the standard level releases alarm. If the vibration level increases even
further and the maximum limit value is exceeded the mill is shut down. The limit
value which causes the mill to be shut down is determined during commissioning.

Indication - classifier speed

The frequency that is set at the frequency converter and parameterized as speed
signal, is transmitted as analogue signal to the plc.

Indication - flap position

The flap actuators are fitted with a potentiometer. An R/I transducer produces an
electric signal which indicates the flap position.

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GEBR. PFEIFFER AG Chapter 4 BA200500591-E/D
KAISERSLAUTERN Transport and Erection Edition 04.2006

4. Transport and erection

4.1 Transport

Due to the size of the machine, transport is effected in single parts. The packing of
the parts depends on their size and the kind of transport. The packing is in
compliance with the packing regulations HPE or the stipulations of the contract.

Instructions attached to the packing concerning correct positioning for transport,


sling marks and storage are to be observed.

Attention! For transport handle the parts with extreme care to avoid damage
through external force or careless loading and unloading.

Danger! Observe the sling marks attached to the packing and/or the machine
part. The lifting and sling gear used must be suitable for the weights
and sizes of the individual parts.

Attention! For transport and lifting of the grinding rollers use only the high-
strength eye bolts included in GEBR. PFEIFFER AG's scope of
supply.

4.1.1 Storage

The parts are to be stored at a sheltered, dry place.

Danger! Do not stack the parts.

Ensure that no moisture or foreign substances can settle and that the storage place
is sufficiently aired.

The parts are designated for short storage (less than 6 months) in compliance with
the above instructions.

For longer storage periods (over 6 months) external and internal preservation must
be checked on a regular basis and repaired or renewed if necessary.

Observe also the instructions given in the documents on the individual plant part.

In maritime regions the parts must be protected against sea air.

4.1.2 Scope of supply

The scope of supply is listed in the shipping documents. Immediately on arrival


check whether the supply is complete.

Any damages occurred during transport and/or missing parts must be reported in
writing.

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KAISERSLAUTERN Transport and Erection Edition 04.2006

4.2 Erection

4.2.1 General instructions

All erection works are to be carried out with care and so as to ensure the safety.

The erection works must be carried out by qualified personnel only. Where
necessary wear the personal protective equipment.

For transport of the parts and erection (or dismantling) always observe the relevant
safety regulations (see chapter 2).

ATTENTION: Damaged parts, damaged plant components etc. must not be


fitted.

For warranty reasons erection should be carried out and monitored by qualified
personnel only.

Before erection check whether all parts and accessories are complete. The parts are
to be prepared for transport to their final destination specified in the erection plan.

Also provide for suitable and sufficiently sized lifting gear and means of transport.

The erection of the machine is carried out according to the instructions of our
erection specialist.

4.2.2 Erection site - machine

Foundations:
The foundations must be horizontal and flat. They must be designed in a way as to
ensure that no sympathetic vibrations can occur and vibrations cannot be
transmitted to or from other foundations.

Provide suitable recesses in the foundation for fastening screws of the machine
and/or of the supporting structure. Arrangement and dimensions of the recesses are
indicated in the foundation plan.

The recesses are grouted with concrete after alignment of the machine.

Steel structure:
The steel structure provided for supporting the machine must be rigid with the
supporting points being horizontal and on the same level. The steel structure must
be rated corresponding to the weight of the machine and the nature of load.

When determining the erection site of the machine ensure that there is sufficient
space for maintenance works on the machine.

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KAISERSLAUTERN Commissioning Edition 04.2006

5. Commissioning

5.1 Measures to be taken before commissioning

Erection and performance controls have to be carried out before commissioning.

When carrying out these controls observe all relevant regulations on safety and
environmental protection.

5.1.1 Erection control

Check the connections of ductings and units for material feed and discharge.

Clear interior and hollow spaces of foreign bodies (e.g. erection tools/loose screws
etc.)

Check by moving the rotating parts manually (if possible) whether they rotate easily
and without any impediment.

Danger! Ensure that the drive of the respective machine cannot be switched on
unintentionally.

Check whether all fastening and connection screws are tight.

Check whether the protective equipment is fully installed (e.g. coupling protection/V-
belt protection etc.).

Remove preservation from preserved parts (e.g. gearbox).

Check and relubricate the grease lubrication points and check and fill the oil
lubricants (see also chapter 8.3 - Lubrication instructions).

Provide closeable ducts at suitable points for the taking of material samples (feed
material, fine product etc.)

In case of a longer period between erection and commissioning check whether the
machine(s) and all components are in perfect condition.

It is imperative to check whether all inspection and service doors are correctly
closed before carrying out the performance control.

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5.1.2 Performance control

The performance control is carried out on the occasion of commissioning and should
therefore be executed by the commissioning specialist.

The following measures need not be carried out in a particular order. The
commissioning specialist determines which measures are to be carried out when.
Generally, the following checks have to be carried out:

Check the sense of rotation of the individual drives.

Check the flow direction of conveyors.


(The sense of rotation of conveyor drives depends on the flow direction of the
conveyed material.)

Check the interlocking of the individual drives and the electric consumers.

Check the interlocking according to the interlocking diagram in chapter 10.3.

Carry out the performance control of all measuring points according to the list of
measuring points and the measuring and regulating diagram (chapter 10.4).
(For details see description of the measuring and regulating equipment in chapter
3.3.)

Check the set values during commissioning and correct them if necessary.

Danger! It may be necessary to open an inspection door on the machine for


checking the sense of rotation.

Ensure

- that the machine cannot be switched on unintentionally;


- that nobody reaches into the machine;
- that the machine is not operated unsupervised.

Immediately close the inspection door after carrying out the checks.

Caution! For checking the drive motor of the MPS mill, the motor must be
disconnected from the mill gear (as the gear must not rotate in a
sense other than specified).

If the gear rotates in the wrong sense, it will be destroyed.

Instructions on the tensioning system

Before switching on the mill for commissioning the pressure values and limit switch
values of the hydro-pneumatic tensioning system have to be set.

Attention! These values must only be set by the commissioning specialist.

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Brief instructions on the setting:


(see also chapter 11 - Tensioning system)

The pretensioning pressure is reduced to the specified nominal value in each bag-
type pressure accumulator. Switching on the oil pump starts the build-up of the oil
pressure. The pressure valves are adjusted corresponding to the data in the
hydraulic diagram (chapter 11 - Tensioning system).

The operating contacts for switching on and off the oil pump and the limit contacts
for the indication of malfunctions (alarm/automatic switch-off) are set.

Check the set values during commissioning and correct them if necessary.

Adjustment of the displacement transducer system in the tensioning cylinders

Adjust the displacement transducer system in the tensioning cylinders in the course
of the initial commissioning and after every replacement of wear parts on the
grinding plate and grinding rollers.

Adjustment is also required in case of wear on the grinding plate and grinding
rollers. The length of the intervals at which this should be done depends on the
amount of wear.

Proceed as follows:
Install grinding rollers in basic position. Make sure there is no material between the
grinding rollers and the grinding plate.

Set the analogue value transmitted by the sensors to zero in the PLC programme.

Adapt the 4-20 mA analogue output signal to the measurement range of the
transmitter.

5.2 Commissioning

Attention! For warranty reasons commissioning is effected by qualified


personnel of the manufacturer.

On this occasion the operating personnel is introduced to the procedures for daily
start-up.

General instructions on commissioning:

Before commissioning the machines undergo a trial run over a period of several
hours (no-load test).

Attention! The mill drive is excluded from the trial run as any mill operation
without material can cause damage to grinding plate and grinding
rollers.

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During the trial run check the machines/plant components concerning

- unusual sounds and vibrations


- excessive temperatures in the bearings
- excessive oil temperatures and
- oil leakage.

After successful conclusion of the trial run commissioning, i.e. the initial mill
operation with material, can be effected.
The switch-on sequence is indicated in the interlocking diagram (chapter 10.3); for
commissioning the machines are switched on manually.
Basically, the switch-on sequence is as follows. Plant-dependent modifications are
included in the interlocking diagram and will be considered during commissioning.

The gear oil supply for the mill drive is switched on together with the material
removal.

After start-up of the material removal the gas routes (filter cleaning/seal air
fan/classifier drive and mill fan) are activated.

To avoid overloading the mill fan drive, ensure that the shut-off or regulating device
(e.g. radial damper) is closed prior to activation.

Frequency-controlled mill fans are run up depending on the load.

After switch-on of the mill fan the hot gases are guided into the mill.

The build-up of the hot gas temperature up to the set value of the controller is
adjusted manually. When the set value is reached the controller is switched to
"Automatic".

Attention!

Heat up of grinding plant:

In order to avoid damages to the grinding bowl, heat up the grinding plant as
described below:

- Heat up with grinding bowl standing still

Heat the mill for a period of 3 hours by means of hot gases at a temperature of 100 -
130 °C, with the grinding bowl standing still.
During these 3 hours turn the grinding bowl every 30 minutes by roughly 180 ° (with
grinding rollers lifted).

If possible (max. mill exhaust gas temperature 120 °C), heat the mill over the last 30
min with hot gases of a higher temperature.
When doing so, take care to turn the grinding bowl every 15 min by 180 °.

This will ensure that the dust separating plant reaches its operating temperature.

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When the plant has reached the operating temperature, start the mill drive and
material feed.

Immediately after switch-on the grinding rollers should roll on a material bed to
prevent damages to grinding plate and grinding rollers. The grinding bed on the
grinding plate should have an average thickness of 70 - 90 mm (also during
operation). The thickness of the grinding bed depends on the feed rate, the tension
pressure and the material properties (e.g. grain size).

The feed rate is increased until the specified differential pressure is reached. After a
prolonged operating period the optimum differential pressure must be established
which will then be the set value for automatic control.

Check the fineness of the removed fine product. To adjust the required end fineness
the speed of the classifier can be readjusted.

If, for process related reasons, it is necessary to cover the nozzle ring this should be
effected according to the relevant drawing (see annex, chapter 5), or pursuant to the
instructions of our commissioning engineer.

During commissioning the commissioning engineer determines and records the limit
values for the monitoring of the vibration level.

The values are appoximately:

Valarm = Voperation + 1 mm/s

Vswitch-off = Voperation + 2 mm/s

If the plant has been operated without any malfunctions over a longer period the set
limit values of the measuring and regulating equipment must be checked and
readjusted if necessary.

Operating data and limit values must be recorded and listed in a table.

After commissioning check again whether the machine and the plant components
are in perfect condition. Check all screws for tight fit. If this is confirmed the machine
is ready for daily operation.

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6. Operation

6.1 Start-up after operational shut-down

This start-up is carried out according to the switch-on sequence specified in the
interlocking diagram and to the sequence determined during commissioning.

Before start-up ensure that a sufficient quantity of material is available and the filling
capacity of the fine product silo is sufficiently large.

It is imperative that the material feed is regular.

Attention! To prevent damages to grinding plate and grinding rollers never


operate the mill without material charge.

Check the operating parameters (power consumption/speed values/temperature


values etc.) regularly during operation and compare them with the values
established during commissioning.

Attention! Heating of the grinding plant

As described in chapter 5.2 above, the grinding plant must be heated


according to instructions.
The heating times depend on the duration of the standstill (see table
below).

heating times
duration of with grinding bowl
standstill standing still
(h) (h)
t<8 0

8 ≤ t < 24 ½

24 ≤ t < 48 1

48 ≤ t < 96 2

t ≥ 96 3

Should any unexpected changes occur, check the machine; if necessary switch it off
until the cause is found and the malfunction is remedied.

We recommend that the principle operating data (e.g. feed rate/end fineness/power
consumption/speed values/pressure values/temperature values etc.) be put down in
a record file.

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6.2 Shut-down

Shut-down (switch-off) of the plant is carried out according to the switch-off


sequence specified in the interlocking diagram.

For downtime periods exceeding 6 months preservation of the plant is necessary.

For preservation purposes observe the instructions and regulations for the individual
plant components (see chapter 11).

6.3 Start-up after longer downtime periods

Before setting the grinding plant into operation after longer downtime periods - e.g.
after considerable repair works - carry out performance controls of the individual
machines and the interlocking (switch-on and switch-off sequence).

Also check whether all protective equipment is correctly mounted (coupling


protection, V-belt protection etc.).

Check the lubricant levels (grease, oil). If necessary relubricate the respective
machine parts and refill the oil.

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General data

operating data: date: ________________

Mill feed material:

components:

_____________________ _________________________ %
_____________________ _________________________ %
_____________________ _________________________ %
_____________________ _________________________ %
_____________________ _________________________ %

grain size: _________________________ mm


moisture: _________________________ %
feed rate: _________________________ t/h

Finished product
moisture: _________________________ %
fineness: __________ % R __________ mm
__________ % R __________ mm
finished product rate: _________________________ t/h

Capacity / Power consumption


mill main motor: ___________ kW __________ Amp/Volt
mill fan: ___________ kW __________ Amp/Volt
classifier motor: ___________ kW __________ Amp/Volt
filter fan: ___________ kW __________ Amp/Volt
seal air fan:

Volume flows
hot gas flow from kiln/cooler: ________________________ m3/h
gas flow mill fan: ________________________ m3/h

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KAISERSLAUTERN Operation Edition 04.2006

Mill data
speed of separating wheel: ________________________ 1/min
tensioning pressure: ________________________ bar
grinding bed thickness (average): ________________________ mm
vibration velocity: ________________________ mm/s
seal air pressure: ________________________ mbar

Temperatures
ahead of mill ________________________ °C
after classifier ________________________ °C
kiln exhaust gas ________________________ °C
cooler exhaust gas ________________________ °C

gearbox of segmented thrust bearing ________________________ °C


gear oil of segmented thrust bearing ________________________ °C

Pressures
ahead of mill ________________________ mbar
after mill ________________________ mbar
after classifier ________________________ mbar
ahead of cyclone ________________________ mbar
after cyclone ________________________ mbar
ahead of filter ________________________ mbar
after filter ________________________ mbar
ahead of fan ________________________ mbar
after fan ________________________ mbar

seal air ________________________ mbar

Differential pressures
mill ________________________ mbar
cyclone ________________________ mbar
filter ________________________ mbar

Other

ge0500591-06.doc Page 4 / 4
GEBR. PFEIFFER AG Chapter 7 BA200500591-E/D
KAISERSLAUTERN Malfunctions Edition 04.2006

7. Malfunctions

7.1 General instructions

When troubleshooting and rectifying malfunctions always observe the safety


instructions given in chapter 2 and in the documents concerning the individual plant
component (chapter 11).

Malfunctions that occur during the guarantee period and require repair works on
single components must only be rectified by our qualified personnel.

In order to rectify malfunctions the cause of which cannot be stated clearly we


recommend to order our service even after termination of the guarantee period.

Malfunctions can generally be avoided if the machines are properly operated and
serviced. Should malfunctions occur read chapters 6 (Operation) and 8
(Maintenance) before starting troubleshooting.

The malfunctions listed in the table of malfunctions can only give you a lead. We
assume that the machine is properly fitted and connected. It is also necessary to
consider all plant components when troubleshooting.

Malfunctions in the electric drives or in the measuring and regulating equipment


cause the relevant machines to be switched off by the plant interlocking. Before
restarting the plant find the cause of the malfunction and rectify it.

Should any malfunction occur that does not cause automatic switch-off but presents
a safety risk immediately switch off the machine and rectify the malfunction directly.

Danger! Before starting troubleshooting ensure that all drives are switched off
and cannot automatically switch on again.

Observe also that works on the electric or hydraulic equipment must be carried out
by qualified personnel only.

If for eliminating a malfunction the personnel is required to enter the mill, it must be
ensured that the drive is locked against involontary start and that the maximum
workplace concentration values are not exceeded.

This is of special importance with heated mills because hot gases have got a
reduced oxygen content.

ge0500591-71.doc Page 1 / 1
GEBR. PFEIFFER AG Chapter 7 BA200500591-E/D
KAISERSLAUTERN Malfunctions Edition 04.2006

7.1.1 Comments on indication of malfunctions

If the plant is shut down due to a malfunction in the drive or in a machine component
(e.g. gearbox) carry out checks according to the relevant operating instructions
(chapter 11 or documents available with the customer).

If malfunctions occur which are not due to machine faults check the performance of
the measuring and regulating equipment according to the values set during
commissioning.

The machine is rated for particular operation requirements. The most important
parameters for these requirements are indicated in chapter 1.1. Any modification of
one of the parameters affects all other parameters.

During commissioning the measuring and regulating equipment is adjusted: if one


parameter is modified all related parameters are adjusted as long as the
modification made keeps within a particular, specified range.

When more considerable parameter changes occur which would require the set limit
values to be exceeded it is necessary to examine for which parameters a
modification of the limit values is possible.

If the limit values cannot be further modified the one parameter whose limit value
has reached its maximum serves as basis for the optimum adjustment.

(Example: The feed moisture is too high. The gas volume flow and/ or the hot gas
temperature has already reached its maximum value so the feed rate must be
reduced to a level which provides the required moisture.)

7.2 Table of malfunctions

Detailed information on the individual malfunctions listed in the following table is


added where necessary.

ge0500591-71.doc Page 2 / 2
GEBR. PFEIFFER AG Chapter 7 BA200500591-E/D
KAISERSLAUTERN Malfunctions Edition 04.2006

Table of malfunctions

malfunctions possible cause remedy

Grinding plant

mill running roughly feed rate too low increase feed rate
(indication/alarm
vibration monitor) feed rate too high reduce feed rate

portion of fines in increase differential


feed material too large pressure
check grain size of
feed material

Attention!
do not stop material feed
completely

depression ahead of feed rate too high/ reduce feed rate


mill too low mill overcharged

main air flap ahead of check position of main


fan not sufficiently air flap (see Operating
opened instructions under mill fan)

recirculation gas flap/ close recirculation gas flap/


fresh air flap opened fresh air flap until
too wide required depression is
reached

insufficient cleaning check filter cleaning


of filter (see separate operating
instructions of filter,
chapter 11)

cyclone clogged check cyclone

ge0500591-72.doc Page 1 / 4
GEBR. PFEIFFER AG Chapter 7 BA200500591-E/D
KAISERSLAUTERN Malfunctions Edition 04.2006

Table of malfunctions

malfunctions possible cause remedy

differential pressure feed rate too high reduce feed rate


mill "max"
ported air ring clogged check if there are any foreign
bodies/material cloggings in
the ported air ring; if
necessary clean ported air ring

pressure gauge tube clean pressure gauge tube


ahead of mill clogged

differential pressure feed rate too low increase feed rate


mill "min"
material feed break- check feed unit and conveyor
down routes
(see also Operating
instructions under feed unit)

pressure gauge tube clean pressure gauge tube


after mill clogged

seal air pressure malfunction - seal air check seal air fan
dropping fan (see also Operating
instructions under seal
air fan)
suction filter soiled

leak in seal air duct check seal air duct


check seal air sealings at
pressure yoke

ge0500591-72.doc Page 2 / 4
GEBR. PFEIFFER AG Chapter 7 BA200500591-E/D
KAISERSLAUTERN Malfunctions Edition 04.2006

Table of malfunctions

malfunctions possible cause remedy

temperature ahead feed rate too high reduce feed rate


of mill too high
moisture of the feed reduce feed rate
material too high

hot gas temperature too reduce hot gas temperature


high

incorrect measurement check measurement

outage of the firing malfunction fuel supply see Operating instructions


under hot gas generator

malfunction hot gas see Operating instructions


generator under hot gas generator

material feed material feed inlet clear clogging


irregular clogged

bridging in feed silo if necessary use discharge


aid

fine product removal conveying unit over- check for damages/wear


charged

malfunction cyclone see cyclone of


discharge rotary lock

conveyor route clogged clear clogging

outage of drive malfunction of drive see relevant operating


instructions

temperature limit find cause and remedy


value exceeded

ge0500591-72.doc Page 3 / 4
GEBR. PFEIFFER AG Chapter 7 BA200500591-E/D
KAISERSLAUTERN Malfunctions Edition 04.2006

Table of malfunctions

malfunctions possible cause remedy

too much material feed rate too high/ reduce feed rate
spillage mill overcharged

gas volume flow check position of main air


too low flap

ported air ring worn replace ported air ring

finished product speed of separating reduce speed


too fine wheel too high

air flow too low increase air flow

finished product speed of separating increase speed


too coarse wheel too low

outage of classifier drive check classifier drive


(see operating instructions
of classifier drive)

air flow too high reduce air flow

separating wheel check separating wheel


damaged or worn

ge0500591-72.doc Page 4 / 4
GEBR. PFEIFFER AG Chapter 8 BA200500591–E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8. Maintenance

8.1 General instructions

The purpose of all maintenance works is to keep the machine in working condition,
to avoid outages, to keep repair costs to a minimum and to prolong the lifetime of
the machines.
A deterioration of the working condition is mainly due to wear, overcharge and
material fatigue (ageing).

Among the reasons for outages are external troubles such as wrong machine
operation or external force as well as deposits and dirty machines.

Therefore, regular checks of the condition of the machine, observance of the service
instructions and repair works are indispensable.

The works to be done are described in the following chapters

8.2 - Inspection and servicing


8.3 - Lubrication instructions
8.4 - Repair

When carrying out these works always observe the relevant regulations on accident
prevention and environmental protection valid for the respective place of erection.
Observe also the safety instructions described in chapter 2 and in the documents on
the relevant plant components (chapter 11).

Before machine restart

When the maintenance works on the machine are terminated the machine must be
in safe and perfect working condition to be restarted.

The termination of the maintenance works must be reported to the responsible


person who declares the machine ready for restart.

ge0500591-81.doc Page 1 / 1
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2 Inspection and servicing

Regular inspections and careful servicing are indispensable to recognize and rectify
possible malfunctions as early as possible.

As operating conditions vary frequently only standard intervals for perfect operation
can be stated. The actual service intervals depend on the local conditions (switch-on
frequency, load, dirt etc.).

Observe also the instructions given in the documents on the relevant plant
components (see chapter 11).

In case of malfunctions or unusual conditions which cause an overcharge of the


machine (e.g. over-load, external force etc.) carry out the inspections immediately.

All service works must be carried out with care and only by personnel assigned to
the job (refer to chapter 2.4).

Service works must be carried out on shut-down machines only. If service works are
to be carried out on operating machines this is explicitly indicated. For these works
take special safety measures.

Observe the fundamental safety instructions laid down in chapter 2.

During operation some parts of the machine become very hot. Risk of burning!
Before carrying out any inspection and service works wait until the machine is
cooled down.

The individual inspection and service measures are listed in chapter 8.2.1 below.

The individual service works are described in chapter 8.2.2.

Danger! Do not enter the grinding zone of the mill when the grinding rollers are
lifted up.

ge0500591-82.doc Page 1 / 1
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.1 List of inspection and service works

machine components intervals remarks


- measures to be taken

General

- check for d with machine switched on


. unusual sounds
. vibrations if necessary switch off
. oil leakage, waste oil machine and rectify the
. obvious damages fault
. and faults
. loose screw connections

Seal air system for grinding rollers

- check seal air pressure w see description of service works,


"Seal air pressure", chapter 8.2.2

- check all ductings for leaks m

Grinding roller item numbers refer to "Spare parts


drawing MPS - grinding roller",
chapter 9

- check oil level m see description of service works,


chapter 8.2.2

- check overpressure valve m item 339

- change oil see description of service works,


chapter 8.2.2,
for intervals see lubrication list,
chapter 8.3

- relubricate the shaft sealing rings for intervals see lubrication list,
chapter 8.3

- check for oil leaks m possible causes of oil leakage:


a) too much oil
b) damaged/worn radial shaft
sealing rings or O-rings

d = daily / w = weekly / m = monthly

ge0500591-8L.doc Page 1 / 11
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.1 List of inspection and service works

machine components intervals remarks


- measures to be taken

- measure wear progress at m see leaflet "Wear measurement at


grinding elements grinding elements", chapter 8.2.3

- check fastening of grinding m item 303


roller segments retighten with torque wrench,
for tightening torque see table
"Tightening torques for screws",
chapter 8.2.3

- check pressure yokes and pressure m


yoke lining for wear

Grinding table item numbers refer to "Spare parts


drawing MPS - group grinding
bowl", chapter 9

- measure wear progress at m see leaflet "Wear measurement at


grinding parts grinding elements", chapter 8.2.3

- check fastening of grinding m item 204


plate segments retighten with torque wrench,
for tightening torque see table
"Tightening torques for screws",
chapter 8.2.3

Grinding zone

- check for wear m


. seal air ductings
. pressure frame
. housing
. lining of housing
. ported air ring
. lining of ported air ring
. air guide cone
. lining of air guide cone
. water injection
and all other components

d = daily / w = weekly / m = monthly

ge0500591-8L.doc Page 2 / 11
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.1 List of inspection and service works

machine components intervals remarks


- measures to be taken

Inner grinding roller stop and strap items 860-885


(see "Spare parts drawing MPS -
inner grinding roller stop",
chapter 9)

- check for wear m see table "Wear limits of grinding


roller stop", chapter 8.2.3.

Replace the grinding roller stop as


soon as the wear limit is reached.

There is a risk of fracture when


the wear limit is exceeded!

- check for damaged springs m replace damaged springs

Outer grinding roller stop items 766-769


(see "Spare parts drawing MPS,
chapter 9)

- check for wear m see table "Wear limits of grinding


roller stop", chapter 8.2.3.

replace the liner plate (item 768),


replace or hardface grinding roller
stop part (item 766) as soon as
the wear limit is reached

- check the gap and readjust it, m see "Spare parts drawing - MPS"
if required for the required gap width

if the pivoting angle amounts to a


maximum of 4° reduce the
distance by means of shims
(item 769) to 3° or replace the
worn parts

d = daily / w = weekly / m = monthly

ge0500591-8L.doc Page 3 / 11
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.1 List of inspection and service works

machine components intervals remarks


- measures to be taken

Pull rod housing see "Spare parts drawing - MPS",


chapter 9, for item numbers

- check for wear m

. liner plates of housing and item 701 and 702


pressure frame items 706 and 707

. bolts of the torque support item 904


for pressure frame see table "Wear limits of pressure
frame stop", chapter 8.2.3.
Replace worn parts as soon as the
wear limit is reached

- check gap between liner plates m see table "Gap and wear
and possibly readjust it measurement – pressure frame
stop”, chapter 8.2.3

- check articulated connections m


between pressure frame and pull
rods for wear

- check pull rod sealings for wear m see table "Wear limits of seal air
gaps", chapter 8.2.3

Torque support for pressure frame see "Spare parts drawing MPS
torque support for pressure
frame", chapter 9, for item
numbers

- relubricate friction bearings item 909


through lubrication nipples,
for intervals see lubrication list,
chapter 8.3

- lubricate contact and sliding surfaces item 916, 918, 919


on the inside of the torque support for intervals refer to lubrication list,
for pressure frame chapter 8.3

d = daily / w = weekly / m = monthly

ge0500591-8L.doc Page 4 / 11
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.1 List of inspection and service works

machine components intervals remarks


- measures to be taken

- empty grease collecting receptacle when required

- check for wear m see table "Wear limits of pressure


frame stop", chapter 8.2.3.
Replace worn parts as soon as the
wear limit is reached

- check hydraulic buffer for m see also operating instructions


. wear and tightness of the hydraulic buffer, chapter 11
(visual inspection)
. proper retraction for stroke see table "Gap and
(proper functioning) wear measurement - pressure
frame stop”, chapter 8.2.3

- clean piston rod of hydraulic buffer m

Hot gas chamber

- check for foreign bodies m

- check for wear m


. material scraper
. sealing ring
. housing
. lining of housing

- check for wear and tight fit m


. insulation of housing bottom

Gearbox chamber

- check sealing ring (labyrinth ring) m if sealing gap is irregular


for wear reposition the sealing ring

Indicator, grinding bed

- calibrate the indicator with progressing wear at


grinding parts

d = daily / w = weekly / m = monthly

ge0500591-8L.doc Page 5 / 11
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.1 List of inspection and service works

machine components intervals remarks


- measures to be taken

Tensioning device item numbers refer to "Spare parts


drawing MPS - tension device",
chapter 9

- relubricate the articulation bearings item 551.1


at the hydraulic cylinders through lubrication nipples
for intervals see lubrication list,
chapter 8.3

- replace the articulation bearings at for intervals see lubrication list,


the hydraulic cylinders chapter 8.3
for replacement see also
chapter 8.4 "Removal of a
hydraulic cylinder to tensioning
device"

- check automatic leveling during m refer to description of mainten-


lifting of grinding rollers ance work,
chapter 8.2.2

Classifier housing

- check for wear by visual inspection m if wear is considerable line the


or possibly ultrasonic inspection relevant parts

- check the lining for wear m if necessary repair or replace the


lining

- check housing parts (in particular m report to Gebr. Pfeiffer AG;


the weldings) for fractures Gebr. Pfeiffer AG will supply
instructions concerning repair
works

d = daily / w = weekly / m = monthly

ge0500591-8L.doc Page 6 / 11
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.1 List of inspection and service works

machine components intervals remarks


- measures to be taken

Classifying zone

- check for wear: m if wear is considerable line the


. support of classifier relevant parts or replace them
bearing
. louvre
. grit cone
. inlet chute
. and all other internals

Separating wheel

- check lamellas of separating m if necessary replace separating


wheel for wear wheel

- check screws for tight fit m retighten screws;


replace worn screws

- check all other rotor parts for wear m if wear is considerable


report to Gebr. Pfeiffer AG;
Gebr. Pfeiffer AG will supply
instructions on suitable measures

-check gap between upper flange m for item numbers and gap width
of separating wheel (item 160) see "Spare parts drawing SLS",
and wear ring (item 122) chapter 9;
if wear is considerable replace
worn parts;
if wear is only minor readjust gap
width by raising the separating
wheel (see chapter 8.4 "Removal
of separating wheel");

d = daily / w = weekly / m = monthly

ge0500591-8L.doc Page 7 / 11
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.1 List of inspection and service works

machine components intervals remarks


- measures to be taken

Classifier bearing

- monitor bearing noises w if necessary rotate separating


wheel slowly, switch off other
machines;
if in doubt rotate separating wheel
by hand and locate noise source

- lubricate roller bearings see description of service works,


chapter 8.2.2
for intervals see lubrication list,
chapter 8.3

- check seal air inlet on classifier m with mill fan running


drive socket for proper functioning

Three-flap gate lock item numbers refer to "Spare


parts drawing DSK", chapter 9

- monitor bearing noises w bearings items 305 and 355;


if necessary switch off surrounding
machines; find noise source;
Attention! Bearing bushings
become hot.
Risk of burning!

- lubricate roller bearings items 305 and 355


through lubrication nipples;
for intervals see lubrication list,
chapter 8.3

- relubricate sealings at the items 175 and 185,


sealing flanges through lubrication nipple;
for intervals see lubrication list,
chapter 8.3

- check bushings of bearings and m if necessary replace sealings


protruding shaft ends for leakage
of lubricants and damaged sealings
(visual inspection)

d = daily / w = weekly / m = monthly

ge0500591-8L.doc Page 8 / 11
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.1 List of inspection and service works

machine components intervals remarks


- measures to be taken

- lubricate articulation bearings at through lubrication nipples;


hydraulic cylinders for intervals see lubrication list,
chapter 8.3

- check flaps and liner plates m if wear is considerable replace


for wear flaps and/or liner plates

- check tensioning connections m items 400 - 406


at the hydraulic cylinders for check for noises; if necessary
tight fit retighten the nut (item 405);
replace worn parts

Hydraulic ductings

- check fastenings m

- check ducting connections


for tightness m

- check for exterior damage m

Hydraulic hose pipes

- check for m replacement of hose pipes:


. obvious damages, a) when described damages
e.g. chafe marks occur
. brittleness b) at least every 6 years
. unnormal deformation (see description of service
. leaks works "Marking of a
. damage at fittings of hose pipes hydraulic hose pipe",
. working loose of hose pipes chapter 8.2.2)
from fittings
. corrosion of fittings impairing
their functioning and durability

d = daily / w = weekly / m = monthly

ge0500591-8L.doc Page 9 / 11
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.1 List of inspection and service works

machine components intervals remarks


- measures to be taken

Ductings

- check compensators for tightness m

- check flaps for tightness and m


movability

Flanges

- check all flanges for tightness m retighten screws if required

Doors

- check all doors for tightness m if required retighten screws/nuts;


if required replace sealing

Fastening screws

- check for tight fit m if required retighten screws;


replace worn screws

Mill gearbox and oil supply unit see separate operating


instructions, chapter 11

Coupling to mill gearbox see separate operating


instructions,
"Mill gearbox", chapter 11

Hydraulic unit, grinding roller see separate operating


suspension system instructions, chapter 11

Hydraulic cylinder to grinding see separate operating


roller suspension system instructions, chapter 11

d = daily / w = weekly / m = monthly

ge0500591-8L.doc Page 10 / 11
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.1 List of inspection and service works

machine components intervals remarks


- measures to be taken

Pressure accumulator to see separate operating


hydraulic cylinder instructions,
"Hydraulic unit – grinding roller
suspension system",
chapter 11

Seal air fan see separate operating


instructions, chapter 11

Classifier drive see separate operating


instructions chapter 11

Flexible coupling(s) see separate operating


to the classifier drive instructions, "Classifier drive",
chapter 11

Hydraulic unit to see separate operating


three-flap gate lock instructions, chapter 11

Hydraulic cylinders to see separate operating


hree-flap gate lock instructions, chapter 11

Pump for water injection see separate operating


instructions, chapter 11

Plant fan see separate operating


instructions, chapter 11

Flaps see separate operating


instructions, chapter 11

Proportioning belt scale see separate operating


instructions, chapter 11

Rotary lock for the cyclone collector see separate operating


instructions, chapter 11

d = daily / w = weekly / m = monthly

ge0500591-8L.doc Page 11 / 11
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.2 Description of service works

8.2.2.1 Seal air pressure - seal air system vertical roller mill
(The item numbers refer to "Spare parts drawing MPS", chapter 9).

The seal air pressure goes down with increasing wear of the seal air sealing rings
(items 322 and 323) fitted to the grinding rollers.

Furthermore wear can occur at the seal air ducting, especially at the moving parts
such as articulation bearings (items 601.1 and 601.3) and wear bushing (item 606)
which causes the seal air pressure to drop as well.

In our experience the wear limit is reached when wear at the parts ranges between
1 and 2 mm (see table "Wear limits of seal air gaps", chapter 8.2.3) and seal air
pressure drops to 50 % of the value that was recorded during commissioning.

With a seal air pressure of 70 % of the pressure recorded during commissioning, a


general check of the seal air system should be carried out.

Take special care to keep the filter always clean (if required, clean or replace the
filter insert).

Replacement of the seal air sealing rings should be carried out when the seal air
pressure drops to 50 % of the pressure that was recorded during commissioning.

If a sudden or considerable pressure drop occurs, this could mean that there is a
leak in the seal air duct. Immediately repair the leak in order to prevent damage to
the shaft sealing rings and resulting damage to the roller bearings by entering dust.

Important! Record the seal air pressure value at commissioning (with new seal
air sealing rings).

ge0500591-8W.doc Page 1 / 7
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.2.2 Marking of a hydraulic hose pipe

Example of marking for August 1990 and dynamic operating overpressure 250 bar:

* 90 08 PN 250

(1) (2) (3) (4)

(1) marking by manufacturer of hose pipe

(2) year

(3) month

(4) max. allowed dynamic operating overpressure

ge0500591-8W.doc Page 2 / 7
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.2.3 Checking of the oil level in the grinding rollers

(See "Spare parts drawing MPS", chapter 9)

To check the oil level, it is necessary to enter the grinding zone.

Observe the fundamental safety instructions laid down in chapter 2.

Danger! Switch off the machine and secure it against restart.

Danger! During operation the mill housing and inner parts become very hot.
Risk of burns!
Before carrying out any works in the mill wait until the machine is
cooled down.

Danger! For works in the mill interior ensure that it is sufficiently aired. If
necessary wear adequate protection equipment.

There are three oil drain plugs (screw plug item 353.5) on the closed cover of the
bearing (item 353). For checking the oil level, two of the screw plugs must be in
horizontal position on top.
The oil level must reach up to these two screw plugs. For checking purposes
remove one screw plug.

Attention! Carefully clean the surrounding zone around the plug screw in order
to prevent dust from entering the grinding roller.

If the oil level is too low, refill oil (see section "Oil change").

Check the permanent magnet of the oil drain plug for scobs, then carefully clean the
permanent magnet.

Attention! If there are any scobs in the oil, this is probably due to a damage of
the bearing. Check oil more frequently; replace the bearing if
required.

Important! After initial start-up or following a bearing replacement scobs can


frequently be found in the oil. Generally these scobs occur during run-
in. Abrasion of this kind should stop after a few operating hours. Thus
the first oil change is to be carried out after some operating hours (for
intervals see lubrication list, chapter 8.3) to flush away the scobs.
In this case the oil can possibly be re-used after filtering. Please
contact the relevant oil supplier for details.

Screw in the screw plug.

Important! Check the condition of the sealing ring (items 353.6); replace
sealing ring if required.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.2.4 Oil change at grinding rollers

(see "Spare parts drawing MPS", chapter 9)

For carrying out the oil change it is required to enter the grinding zone.

Observe the fundamental safety instructions laid down in chapter 2.

Danger! Switch off the machine and secure it against restart.

Danger! During operation the mill housing and inner parts become very hot.
Risk of burning!

Danger! For works in the mill interior ensure that it is sufficiently aired. If
necessary wear suitable protection equipment.

Important! The oil change should be carried out with oil at operating temperature
as the grinding rollers are filled with highly viscous oil. For carrying
out any works in the heated mill wear suitable protection equipment.

The closed cover of the bearing (item 353) is fitted with three oil drain plugs (screw
plug item 353.5). For oil change purposes one of the screw plugs must be in
bottommost position, the other two must be in horizontal position on top.

Place a suitable receptacle underneath the screw plug.

Remove one of the upper screw plugs in order to air the bearing bushing.

Attention! Carefully clean the surrounding zone around the plug screw in order
to prevent dust from entering the grinding roller.

Remove the lower oil drain plug and let the oil drain out into the receptacle.

Attention! The draining oil is hot - risk of burning.


Wear protective gloves.

Check the permanent magnet of the oil drain plug for scobs, then carefully clean the
permanent magnet.

Attention! If there are any scobs in the oil, this is probably due to a damage of
the bearing. Replace the bearing if required.

Important! After initial start-up or following a bearing replacement scobs can


frequently be found in the oil. Generally these scobs occur during run-
in. Abrasion of this kind should stop after a few operating hours. Thus
the first oil change is to be carried out after some operating hours (for
intervals see lubrication list, chapter 8.3) to flush away the scobs.
In this case the oil can possibly be re-used after filtering. Please
contact the relevant oil supplier for details.

ge0500591-8W.doc Page 4 / 7
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

Screw in the lower screw plug.

To fill in oil remove either the second of the upper screw plugs at the bearing cover
or the oil filling plug on the pressure yoke side (screw plug item 350.2).

Fill in oil until the oil level reaches the level of the two horizontally positioned screw
plugs at the cover of the bearing.

Important! For oil quality and quantity to be used see lubrication list (see chapter
8.3).

Screw in the screw plug.

Attention! Immediately apply oil binder to any oil spilled during oil draining or
filling.

Important! Check the condition of the sealing rings (items 350.3 and 353.6);
replace sealing rings if required.

ge0500591-8W.doc Page 5 / 7
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.2.5 Check of automatic leveling of grinding rollers

Prior to start-up of mill, the grinding rollers are lifted and leveled automatically by
means of the displacement transducers (refer to interlocking diagram, chapter 10.3).
When lowering the grinding rollers, the displacement transducers monitor whether or
not lowering is performed uniformly.

Important: For the functional description, refer to operating instructions of


hydraulic unit for grinding roller tension system (chapter 11).

It is necessary to level and uniformly lower the rollers to make sure


they are put down on the grinding plate simultaneously.

Attention! If the rollers are not put down uniformly, the mill may be damaged.

The proper functioning of the automatic leveling must be checked regularly. For this
purpose, lift off the grinding rollers.

After the automatic leveling of the grinding rollers, the stroke must be measured
directly on the three hydraulic cylinders.

The extended length must be the same on all three hydraulic cylinders, with a
tolerance of +/- 5 mm.

If this is not the case, the system must be checked. A displacement transducer
might be defective or might have to be newly calibrated.

Important: Also refer to operating instructions of displacement transducer


(chapter 11).

ge0500591-8W.doc Page 6 / 7
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.2.2.6 Lubrication of classifier bearing

1. On delivery the roller bearings of the machine and the lubrication pipes are
filled with grease.

2. When new roller bearings are fitted and/or when the lubricant is changed fill
the roller bearings completely, the spaces in the bearing housings 2/3, and the
lubrication pipes 100 % with fresh grease.

3. Relubrication
Use lubrication nipple at classifier drive duct.

When relubricating check whether any grease is pressed into the lubrication
pipe. If the lubrication pipe is clogged, clear it.

Important! For lubrication intervals and quantities and for the grease quality to be
used see our lubrication list (chapter 8.3).

Attention! Too much grease in the roller bearing can cause overheating.

ge0500591-8W.doc Page 7 / 7
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

Chapter 8.2.3

- table: Tightening torques for screws - general

- table: Tightening torques for screws - MPS

- table: Tightening torques for screws - SLS

- table: Tightening torques for screws - DSK

- table: Wear limits of seal air gaps

- table: Wear limits of grinding roller stop

- table: Wear limits of pressure frame stop

- table: Gap and wear measurement - pressure frame stop

- leaflet: Wear measurement at grinding elements

ge0500591-8E.doc Page 1 / 1
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

Chapter 8.2.3

- table: Tightening torques for screws - general

- table: Tightening torques for screws - MPS

- table: Tightening torques for screws - SLS

- table: Tightening torques for screws - DSK

- table: Wear limits of seal air gaps

- table: Wear limits of grinding roller stop

- table: Wear limits of pressure frame stop

- table: Gap and wear measurement - pressure frame stop

- leaflet: Wear measurement at grinding elements

ge0500591-8E.doc Page 1 / 1
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.3 Lubrication instructions

The lubrication points (oil/grease) are indicated in the following lubrication list.

The list quotes the oil and grease qualities to be used (marked according to DIN 51
502) and includes lubrication intervals and quantities.

The lubrication list is complemented by the enclosed lubrication chart.

The chart contains the various lubricant designations, the corresponding marking
according to DIN 51 502 and the lubrication brand names of the respective
suppliers.

Observe also the instructions given in the documents on the individual machine and
its components (chapter 11).

Observe the relevant regulations on environmental protection when using any


lubricants and when disposing of them!

Greasing instructions:

The heating of the greased bearings is checked during commissioning. High


temperature values can be caused by too much grease in the bearing. In this case
check the grease filling (when machine is switched off) and remove any superfluous
grease.

After exchange of the grease filling or after relubrication, higher temperatures can
occur when starting the machine until the grease is evenly spread.
(Check temperature in bearings frequently.)

Oil lubrication instructions:

Observe the intervals for oil changes quoted in the lubrication list.
Before carrying out oil changes carefully clear the housing of oil mud, used oil
remainders and abraded particles. For this purpose use the oil quality which is used
for operation (heat up viscous oil qualities before use).
- use specified oil qualities -

Synthetic oil qualities must not be mixed with mineral or other synthetic oil qualities.
When changing from one oil quality to another (if permitted) rinse thoroughly with
the new oil quality.

ge0500591-83.doc Page 1 / 1
department: TK rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Ranßweiler rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Dreiklappenschleuse Schmierstellen siehe Ersatzteilzeichnung DSK /
1.0 1 DSK 2000 22354 lubrication points acc. to spare parts drawing DSK
three-flap gate lock (Kapitel 9 / chapter 9)
Wälzlager ganz und 2/3 des freien Raumes im
Wälzlager (Zylinderseite) 3 monatlich alle 2 Jahre
1.1 3 22354 K3K-20 1,1 kg X 12 cm Gehäuse mit frischem Fett füllen
fill roller bearing completely and 2/3 of the free
roller bearing (cylinder side) once a month every 2 years
space in housing with fresh grease
Wälzlager Wälzlager ganz und 2/3 des freien Raumes im
3 monatlich alle 2 Jahre
1.2 3 (gegenüber der Zylinderseite) 22354 K3K-20 0,85 kg X 8 cm Gehäuse mit frischem Fett füllen
roller bearing fill roller bearing completely and 2/3 of the free
once a month every 2 years
(opposite side of cylinder) space in housing with fresh grease
Gelenklager der Zylinder alle 3 Tage
3
1.3 6 22354 K3K-20 0,003 kg X 3 cm
articulation bearing of cylinders every 3 days
Abdichtung (Zylinderseite) alle 2 Wochen
3
1.4 3 22354 K3K-20 0,02 kg X 12 cm
sealing (cylinder side) every 2 weeks
Abdichtung (gegenüber der Zylinderseite) alle 2 Wochen
3
1.5 3 22354 K3K-20 0,02 kg X 10 cm
sealing (opposite side of cylinder) every 2 weeks
Hydraulikaggregat ca. / approx. siehe Betriebsanleitung /
1.6 1 Dreiklappenschleuse 22355 HLP 46 270 l 500 - 1.000 h 3.000 - 5.000 h see operating instructions: Hydac
Kapitel / chapter 11.3
hydraulic unit of Füllmenge inkl. Öl-Rohrleitung
three-flap gate lock filling capacity incl. oil ducting
Motor Hydraulikaggregat alle 10.000 h, spät. nach 3 Jahren siehe Betriebsanleitung /
KL3N
1.6.1 1 22355 X see operating instructions: Siemens
motor to hydraulic unit every 10,000 h, at the latest after 3 years Kapitel / chapter 11.3

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.

Etkb1skv.xls DSK01 1 / 12
department: TK rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Pietrek rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Walzenschüsselmühle
2.0 1 MPS 4500 B 22356
vertical roller mill
CLP PG 680 8.000 h oder 1 Jahr,
Mahlwalze Ölprobe alle 3 Monate, Beurteilung und
2.1 3 22356 synth. Öl / oil 75 l 50-100 h abhängig von Öl-
Freigabe durch den Ölhersteller
nur Öle verwenden, die in unserer probe auch > 1 Jahr
grinding roller
Schmierstofftabelle aufgeführt sind 8,000 h or 1 year
oil sample to be taken every 3 months,
only use oils specified in our depending on oil
assessment and release by lubricant manufacturer
lubrication chart sample also > 1 year
Radialwellendichtring zur Mahlwalze bei Dichtungswechsel
2.2 3 radial shaft sealing ring to go with 22356 KP(F)2N-20 0,3 kg X
grinding roller with each replacement of sealing
Hydraulikaggregat ca. / approx. siehe Betriebsanleitung /
2.3 1 Mahlwalzenfederung 22356 HLP 46 625 l 500-1.000 h 3.000-5.000 h see operating instructions: Hydac
Kapitel / chapter 11.4
hydraulic unit of grinding roller Füllmenge inkl. Hydraulikzylinder
suspension system filling capacity incl. hydraulic cylinders
Motor Hydraulikaggregat Lebensdauer geschmiert (Lagerwechselfrist beachten) siehe Betriebsanleitung /
2.3.1 1 22356 K3N X see operating instructions: Siemens
motor to hydraulic unit greased for lifetime (observe the replacement interval for bearings) Kapitel / chapter 11.4
Klüberlub
Gelenklager Hydraulikzylinder 3 3 Lagerwechsel alle 15.000 h
2.4 3 22356 BE 41-1501 48 cm 10 cm 150 h
articulation bearing of hydraulic (KPF2K
replace the bearing every 15,000 h
cylinder mit/with MoS2)
Gleitlager zur ca. / approx.
alle 3 Tage je 2 Schmiernippel pro Drehmomentstütze
2.5 3 Drehmomentstütze für Druckrahmen 22356 Klüberlub 1,3 kg 2 x 40 cm³
sliding bearing to BE 41-1501
every 3 days 2 lubricating nipples each per torque support
torque support for pressure frame
bei Montage und Instandhaltung alle Kontakt- und siehe Ersatzteilzeichnung
Drehmomentstütze für Druckrahmen
2.6 3 22356 Klüberlub Gleitflächen im Innern der Drehmomentstütze neu schmieren MPS - Drehmomentstütze für Druckrahmen
BE 41-1501 provide all contact and sliding surfaces inside the torque see spare parts drawing
torque support for pressure frame
support with new grease during fitting and maintenance MPS - torque support for pressure frame

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.

Etkb1skv.xls MPS01 2 / 12
department: TK rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Pietrek rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Sperrluftventilator siehe Betriebsanleitung /
2.7 1 22356 see operating instructions: Ventec
seal air fan Kapitel / chapter 11.7
Motor Sperrluftventilator Lebensdauer geschmiert (Lagerwechselfrist beachten) siehe Betriebsanleitung /
2.7.1 1 22356 K3N X see operating instructions: Dutchi
motor to seal air fan greased for lifetime (observe the replacement interval for bearings) Kapitel / chapter 11.7
Schwenksäule der vor jedem Schmierstellen siehe Zeichnung
2.8 1 Walzenausbauvorrichtung 22356 K3K-20 Gebrauch "Walzenausbauvorrichtung" (Kapitel 8 - Anhang)
Lift-and Swing column of before lubrication points acc. to drawing
Lift-and-Swing System every use "Lift-and-Swing System" (chapter 8 - Annex)
Hydraulikaggregat zur ca. / approx. 3 Jahre oder siehe Betriebsanleitung /
2.9 1 Walzenausbauvorrichtung 22356 HLP 46 40 l je nach Ergebnis einer Ölanalyse see operating instructions: Hydac
portable hydraulic unit of 3 years or Kapitel / chapter 11.5
Lift-and-Swing System depending on result of oil analysis
Motor Hydraulikaggregat Lebensdauer geschmiert (Lagerwechselfrist beachten) siehe Betriebsanleitung /
2.9.1 1 22356 K3N X see operating instructions: Siemens
motor to hydraulic unit greased for lifetime (observe the replacement interval for bearings) Kapitel / chapter 11.5

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.

Etkb1skv.xls MPS01 3 / 12
department: TP rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Barz rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Pumpe zur Wassereindüsung siehe Betriebsanleitung /
2.10 1 NM 045 22356 see operating instructions: Netzsch
pump for water injection Kapitel / chapter 11.8

Bolzengelenk bei jedem Öffnen


2.10.1 2 22356 CLP 460 0,022 l X
pin joint when opening the pump for any reason
Getriebemotor siehe Betriebsanleitung /
2.10.2 1 22356 see operating instructions: Nord
gearmotor Kapitel / chapter 11.8
Getriebe alle 10.000 h, spät. nach 2 Jahren
2.10.2.1 1 SK 25 22356 CLP 220 0,7 l X
gearbox every 10,000 h, at the latest after 2 years
Motor Lebensdauer geschmiert (Lagerwechselfrist beachten)
2.10.2.2 1 22356 K3K X
motor greased for lifetime (observe the replacement interval for bearings)

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.
Nur die von dem jeweiligen Getriebehersteller freigegebenen Öle verwenden. Only use oil qualities specified by the individual gearbox manufacturer.

Etkb1skv.xls Eindüs05 4 / 12
department: TK rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Pietrek rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Mühlenantrieb
3.0 1 22357
mill drive
ca. / approx. je nach Ergebnis siehe Betriebsanleitung /
Getriebe CLP 320
1.000 h der Ölanalyse see operating instructions: Flender
3.1 1 KMPS 476 22357 (ISO VG 320) 3900 l
oder je nach (ohne Ölanalyse: Kapitel / chapter 11.9
gearbox
nur vom Getriebehersteller ( = gesamte Ergebnis der alle 18 Monate Öl auf Wassergehalt kontrollieren:
freigegebene Öle verwenden, siehe Betriebsöl- Ölanalyse oder 5.000 h) alle 400 h, min. einmal im Jahr
Flender Schmierstoffempfehlung menge / check oil for water content:
only use oil qualities specified = total 1,000 h depending on every 400 h, at least once a year
by the gearbox manufacturer operating or depending on result of oil analysis Ölanalyse: alle 1.000 h
see Flender list "Recommended oil quantity) result of oil analysis (without oil analysis: oil analysis: every 1,000 h
Lubricants" every 18 months vor Erstinbetriebnahme ist das Getriebe zu Spülen
or 5,000 h) prior to first start-up rinse the gearbox
Motor Niederdruckkreis alle 20.000 h, spät. nach 3 Jahren siehe Betriebsanleitung /
KL3N
3.2.1 1 22357 X see operating instructions: Siemens
motor to low-pressure circuit Esso Unirex N3 every 20,000 h, at the latest after 3 years Kapitel / chapter 11.9
Motor Heizkreis Lebensdauer geschmiert (Lagerwechselfrist beachten) siehe Betriebsanleitung /
3.2.2 1 22357 K3N X see operating instructions: Siemens
motor to heating circuit greased for lifetime (observe the replacement interval for bearings) Kapitel / chapter 11.9
Motor Hochdruckkreis Lebensdauer geschmiert (Lagerwechselfrist beachten) siehe Betriebsanleitung /
3.2.3 4 22357 K3N X see operating instructions: Siemens
motor to high-pressure circuit greased for lifetime (observe the replacement interval for bearings) Kapitel / chapter 11.9
Mühlenmotor keine Lieferung von Gebr. Pfeiffer AG
3.3 1
mill motor not supplied by Gebr. Pfeiffer AG
Wartungsantrieb (Getriebemotor) siehe Betriebsanleitung /
3.4 1 22357 see operating instructions: Flender
maintenance drive (gearmotor) Kapitel / chapter 11.9
siehe ca. / approx. 10.000 h, spät. alle 2 Jahre, Ölbeschaffenheit kontrollieren: alle 6 Monate
Getriebe MOTOX
3.4.1 1 Typenschild X nach 2 Jahren oder 10.000 h check the oil quality: every 6 months
K 108 22357 12,6 l *
see 10,000 h, at the every 2 years * genaue Ölmenge siehe Typenschild
gearbox B7
nameplate latest after 2 years or 10,000 h * exact oil quantity see name plate
Motor Lebensdauer geschmiert (Lagerwechselfrist beachten)
3.4.2 1 22357 X
motor greased for lifetime (observe the replacement interval for bearings)

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.
Nur die von dem jeweiligen Getriebehersteller freigegebenen Öle verwenden. Only use oil qualities specified by the individual gearbox manufacturer.
Etkb1skv.xls Getr09 5 / 12
department: TK rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Hollstein rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Lamellensichter Schmierstellen siehe Ersatzteilzeichnung SLS /
4.0 1 SLS 3750 B 22358 lubrication points acc. to spare parts drawing SLS
lamella classifier (Kapitel 9 / chapter 9)
ca. / approx. Wälzlager ganz und 2/3 des freien Raumes im
Lager unten 3 wöchentlich alle 2 Jahre
4.1 1 22358 KP(F)2N-20 2 kg X 18 cm Gehäuse mit frischem Fett füllen
fill roller bearing completely and 2/3 of the free
bottom bearing once a week every 2 years
space in housing with fresh grease
ca. / approx. Wälzlager ganz und 2/3 des freien Raumes im
Lager oben 3 wöchentlich alle 2 Jahre
4.2 1 22358 KP(F)2N-20 1,6 kg X 6 cm Gehäuse mit frischem Fett füllen
fill roller bearing completely and 2/3 of the free
top bearing once a week every 2 years
space in housing with fresh grease
ca. / approx. Wälzlager ganz und 2/3 des freien Raumes im
Axiallager 3 täglich alle 2 Jahre
4.3 1 22358 KP(F)2N-20 1,6 kg X 12 cm Gehäuse mit frischem Fett füllen
fill roller bearing completely and 2/3 of the free
axial bearing once a day every 2 years
space in housing with fresh grease
ca. / approx. 15.000 h, spät. siehe Betriebsanleitung /
Getriebe
4.4 1 22359 CLP PG 320 64 l 400 h nach 4,5 Jahren see operating instructions: Flender
(ISO VG 320) Kapitel / chapter 11.10
gearbox 15,000 h, at the
(synth. Öl / oil) Öl kontrollieren: min. einmal im Jahr
latest after 4.5 years check oil: at least once a year

Motor Getriebeölpumpe Lebensdauer geschmiert (Lagerwechselfrist beachten)


4.4.1 1 22359 X
motor to gear oil pump greased for lifetime (observe the replacement interval for bearings)
Motor Öl-Kühler Lebensdauer geschmiert (Lagerwechselfrist beachten)
4.4.2 1 22359 X
motor to oil cooler greased for lifetime (observe the replacement interval for bearings)
Sichtermotor keine Lieferung von Gebr. Pfeiffer AG
4.5 1
classifier motor not supplied by Gebr. Pfeiffer AG

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.
Nur die von dem jeweiligen Getriebehersteller freigegebenen Öle verwenden. Only use oil qualities specified by the individual gearbox manufacturer.

Etkb1skv.xls SLS02 6 / 12
department: TP rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Barz rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Dosierbandwaage siehe Betriebsanleitung /
5.0 1 weighfeeder 22351 see operating instructions: Schenk
Multidos MTD-H 1635 T90 Kapitel / chapter 11.1
mix / marl V028523.A01
Getriebemotor siehe Betriebsanleitung /
5.1 1 22351 see operating instructions: Flender
gearmotor Kapitel / chapter 11.1
Getriebe alle 10.000 h, spät. nach 3 Jahren alle 3.000 h, mindestens halbjährlich Öl überprüfen
5.1.1 1 KAZ 108 22351 CLP 220 8,3 l X
gearbox every 10,000 h, at the latest after 3 years check oil every 3,000 h, at least every 6 months
Motor siehe Lebensdauer geschmiert (Lagerwechselfrist beachten)
5.1.2 1 22351 Typenschild X
motor see nameplate greased for lifetime (observe the replacement interval for bearings)
Tragrollen Lebensdauer geschmiert
5.2 22351 X
carrying idler greased for lifetime
Lithiumsseifenfett mit
Antriebstrommel, Umlenktrommel Lebensdauer geschmiert Lagerraum vollständig füllen
5.3 22351 korrosionsschutzzusatz X
Lager bei ungünstigen Betriebsbedinungen wöchentlich siehe Servicehandbuch BVH 2123; Seite 51
der Penetrationsklasse 6
Lithium soap grease with
head pulley, tail pulley greased for lifetime fill bearing completely
corrosion protective additive
bearings in hard operating conditions weekly see operating manual BVH 2123 page 51
of penetration class 3

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.
Nur die von dem jeweiligen Getriebehersteller freigegebenen Öle verwenden. Only use oil qualities specified by the individual gearbox manufacturer.

Etkb1skv.xls Dosier10 (1) 7 / 12


department: TP rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Barz rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Dosierbandwaage siehe Betriebsanleitung /
6.0 1 weighfeeder 22351 see operating instructions: Schenk
Multidos MTD 1235 T70 Kapitel / chapter 11.1
limestone V028524.A01
Getriebemotor siehe Betriebsanleitung /
6.1 1 22351 see operating instructions: SEW
gearmotor Kapitel / chapter 11.1
Getriebe alle 10.000 h, spät. nach 3 Jahren alle 3.000 h, mindestens halbjährlich Öl überprüfen
6.1.1 1 SA 77 22351 CLP 680 1,8 l X
gearbox every 10,000 h, at the latest after 3 years check oil every 3,000 h, at least every 6 months
Vorsatzgetriebe alle 10.000 h, spät. nach 3 Jahren alle 3.000 h, mindestens halbjährlich Öl überprüfen
6.1.2 1 R 37 22351 CLP 220 0,3 l X
intermediate gearbox every 10,000 h, at the latest after 3 years check oil every 3,000 h, at least every 6 months
Motor siehe Lebensdauer geschmiert (Lagerwechselfrist beachten)
6.1.3 1 22351 Typenschild X
motor see nameplate greased for lifetime (observe the replacement interval for bearings)
Tragrollen Lebensdauer geschmiert
6.2 22351 X
carrying idler greased for lifetime
Lithiumsseifenfett mit
Antriebstrommel, Umlenktrommel Lebensdauer geschmiert Lagerraum vollständig füllen
6.3 22351 korrosionsschutzzusatz X
Lager bei ungünstigen Betriebsbedinungen wöchentlich siehe Servicehandbuch BVH 2123; Seite 51
der Penetrationsklasse 6
Lithium soap grease with
head pulley, tail pulley greased for lifetime fill bearing completely
corrosion protective additive
bearings in hard operating conditions weekly see operating manual BVH 2123 page 51
of penetration class 3

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.
Nur die von dem jeweiligen Getriebehersteller freigegebenen Öle verwenden. Only use oil qualities specified by the individual gearbox manufacturer.

Etkb1skv.xls Dosier10 (2) 8 / 12


department: TP rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Barz rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Dosierbandwaage siehe Betriebsanleitung /
7.0 1 weighfeeder 22351 see operating instructions: Schenk
Multidos MTD 1035 T70 Kapitel / chapter 11.1
iron ore V028525.A01
Getriebemotor siehe Betriebsanleitung /
7.1 1 22351 see operating instructions: SEW
gearmotor Kapitel / chapter 11.1
Getriebe alle 10.000 h, spät. nach 3 Jahren alle 3.000 h, mindestens halbjährlich Öl überprüfen
7.1.1 1 SA 77 22351 CLP 680 1,8 l X
gearbox every 10,000 h, at the latest after 3 years check oil every 3,000 h, at least every 6 months
Vorsatzgetriebe alle 10.000 h, spät. nach 3 Jahren alle 3.000 h, mindestens halbjährlich Öl überprüfen
7.1.2 1 R 37 22351 CLP 220 0,3 l X
intermediate gearbox every 10,000 h, at the latest after 3 years check oil every 3,000 h, at least every 6 months
Motor siehe Lebensdauer geschmiert (Lagerwechselfrist beachten)
7.1.3 1 22351 Typenschild X
motor see nameplate greased for lifetime (observe the replacement interval for bearings)
Tragrollen Lebensdauer geschmiert
7.2 22351 X
carrying idler greased for lifetime
Lithiumsseifenfett mit
Antriebstrommel, Umlenktrommel Lebensdauer geschmiert Lagerraum vollständig füllen
7.3 22351 korrosionsschutzzusatz X
Lager bei ungünstigen Betriebsbedinungen wöchentlich siehe Servicehandbuch BVH 2123; Seite 51
der Penetrationsklasse 6
Lithium soap grease with
head pulley, tail pulley greased for lifetime fill bearing completely
corrosion protective additive
bearings in hard operating conditions weekly see operating manual BVH 2123 page 51
of penetration class 3

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.
Nur die von dem jeweiligen Getriebehersteller freigegebenen Öle verwenden. Only use oil qualities specified by the individual gearbox manufacturer.

Etkb1skv.xls Dosier10 (3) 9 / 12


department: TP rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Barz rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Zellenradschleuse siehe Betriebsanleitung /
zum Zyklonabscheider 22362
8.0 2 see operating instructions: SMD-Fördertechnik
rotary lock 22363
to cyclone collector Kapitel / chapter 11.12
je nach Betriebs- * langsam einpressen, bis frisches Fett aus
Wälzlager
22362 bedingungen Dichtring austritt
8.1 4
22363
K2K-20 X *
depending on * press slowly until fresh grease exudes hrough
rolling bearing
operating conditions the sealing
Getriebemotor siehe Betriebsanleitung /
22362
8.2 2 see operating instructions: Flender
gearmotor 22363
Kapitel / chapter 11.12
Getriebe MOTOX ca. / approx. 10.000 h, spät. nach 2 Jahren ** genaue Ölmenge siehe Typenschild
22362 CLP 220
8.2.1 2 DF108 5,7 l ** X
gearbox 22363 ISO VG 220 10,000h, at the latest after 2 years ** exact oil quantity see name plate
B5
Motor 22362 Lebensdauer geschmiert (Lagerwechselfrist beachten)
8.2.2 2 K3N X
motor 22363 greased for lifetime (observe the replacement interval for bearings)

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.
Nur die von dem jeweiligen Getriebehersteller freigegebenen Öle verwenden. Only use oil qualities specified by the individual gearbox manufacturer.

Etkb1skv.xls Zell07 10 / 12
department: TP rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Barz rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Anlagenventilator siehe Betriebsanleitung /
9.0 1 22364 see operating instructions: Venti Oelde
plant fan Kapitel / chapter 11.13
alle 8.000 h, spät. nach 1 Jahr Öl regelmäßig auf Verunreinigungen und
Wälzlager 1 (Festlager)
9.1 1 22364 CLP 68 5,2 l (abhängig vom Zustand des Öls) Oxidationsprodukte prüfen.
ISO VG 68 every 8,000 h, at the latest after 1 year oil to be checked regulary for contaminations and
rolling bearing 1 (fixed bearing)
(dependent on oil condition) oxidations products
alle 8.000 h, spät. nach 1 Jahr Öl regelmäßig auf Verunreinigungen und
Wälzlager 2 (Loslager)
9.2 1 22364 CLP 68 3,3 l (abhängig vom Zustand des Öls) Oxidationsprodukte prüfen.
ISO VG 68 every 8,000 h, at the latest after 1 year oil to be checked regulary for contaminations and
rolling bearing 2 (floating bearing)
(dependent on oil condition) oxidations products
Regelklappe siehe Betriebsanleitung /
9.3 1 22364 see operating instructions: HMT
modulation damper Kapitel / chapter 11.13
AUMA ca. 6 Monate siehe Betriebsanleitung /
Stellantrieb alle 6 - 8 Jahre
9.3.1 1 22364 Kugellagerfett X (wenn Schmiernippel vorhanden) see operating instructions: Auma
AUMA ball approx. 6 months Kapitel / chapter 11.13
actuator every 6 - 8 years
bearing grease (if lubricating nippel existing)
AUMA siehe Betriebsanleitung /
Schneckengetriebe alle 4 - 6 Jahre
Kugellagerfett see operating instructions: Auma
9.3.2 1 22364 X
AUMA ball Kapitel / chapter 11.13
worm gearbox every 4 - 6 years
bearing grease
Motor keine Lieferung von Gebr. Pfeiffer AG
9.4 1
motor not supplied by Gebr. Pfeiffer AG

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.

Etkb1skv.xls Gebl13 11 / 12
department: TP rev.-no.:
Schmierliste
GEBR. PFEIFFER AG made by: Barz rev. date:

Kaiserslautern Lubrication list made on: 26.10.2006 checked by: Prägert


no.: 200500591 checked on: 27.10.2006

client: Neyzar Qom Cement Co. project: Neyzar RM order no.: 22354 - 22365

Nr. Anz. Bezeichnung Auf- Schmierstoff Füllmenge 1. Fül- Nach- Nachschmier- 1. Schmier- weitere Schmier- Bemerkungen
trags- Kennzeichnung nach lung vor- schmier- intervall stoffwechsel stoffwechsel
nr. DIN 51502 handen menge
siehe auch Schmierstofftabelle je X =Ja je
no. qty. designation com. lubricant filling 1st. lubricant relubrication 1st. lubricant further lubricant remarks
no. symbol acc. to DIN 51 502 capacity filling quantity to intervals change changes
see lubrication chart existing be refilled
Öl Fett
oil grease per item X =Yes per item
Jalousieklappe siehe Betriebsanleitung /
10.0 2 22365 see operating instructions: Edelhoff
louvre damper Kapitel / chapter 11.14
Gelenklager KP2N-25 alle 6 Monate Nachfüllen, bis Fett austritt
10.1 12 22365 0,24 kg 70 cm³
articulation bearing Esso Beacon EP2 every 6 months refill until grease exudes
AUMA ca. 6 Monate siehe Betriebsanleitung /
Drehantrieb alle 6 - 8 Jahre
10.2 2 22365 Kugellagerfett X (wenn Schmiernippel vorhanden) see operating instructions: Auma
AUMA ball approx. 6 months Kapitel / chapter 11.14
actuator every 6 - 8 years
bearing grease (if lubricating nippel existing)
AUMA siehe Betriebsanleitung /
Schneckengetriebe alle 4 - 6 Jahre
10.3 2 22365 Kugellagerfett X see operating instructions: Auma
AUMA ball Kapitel / chapter 11.14
worm gearbox every 4 - 6 years
bearing grease
Absperrklappe siehe Betriebsanleitung /
11.0 1 22365 see operating instructions: Edelhoff
shut-off flap Kapitel / chapter 11.14
Gelenklager KP2N-25 alle 6 Monate Nachfüllen, bis Fett austritt
11.1 2 22365 0,24 kg 70 cm³
articulation bearing Esso Beacon EP2 every 6 months refill until grease exudes
AUMA ca. 6 Monate siehe Betriebsanleitung /
Drehantrieb alle 6 - 8 Jahre
11.2 1 22365 Kugellagerfett X (wenn Schmiernippel vorhanden) see operating instructions: Auma
AUMA ball approx. 6 months Kapitel / chapter 11.14
actuator every 6 - 8 years
bearing grease (if lubricating nippel existing)
AUMA siehe Betriebsanleitung /
Schneckengetriebe alle 4 - 6 Jahre
11.3 1 22365 Kugellagerfett X see operating instructions: Auma
AUMA ball Kapitel / chapter 11.14
worm gearbox every 4 - 6 years
bearing grease

Achtung: Bitte beachten Sie die Schmier- und Wartungsanweisungen der einzelnen Hersteller Attention: Please observe the lubrication and maintenance instructions of the
(siehe Betriebsanleitungen und Typenschilder). individual manufacturers (see operating instructions and nameplates).
Vor dem Betrieb sind die Schmierstellen und die Ölfüllungen zu überprüfen. Check lubrication points and oil fillings before putting the machine in operation.

Etkb1skv.xls Klapp01 12 / 12
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4 Repair

Observe the fundamental safety instructions laid down in chapter 2.

Repair works must be carried out on shut-down machines only. Ensure that the
machine cannot be switched on unintentionally.

During operation some parts of the machine become very hot. Risk of burning!
Before carrying out any repair works wait until the machine has cooled down.

Repair works must be carried out by maintenance personnel assigned to the job
(refer to chapter 2.4). Beside standard repair works special works are required
which demand further specific knowledge of the machine.

We recommend therefore, to have these repair works carried out by one of our
qualified supervisors.

Should these repair works be carried out without our experts, we cannot be held
liable for these works nor for possible consequential damages.

Repair works occurring within the guarantee period must be carried out by our
qualified supervisors or with our written approval.

Should repair works be necessary which are mentioned neither in the following
chapters nor in the documents on the relevant plant components (chapter 11)
contact GEBR. PFEIFFER AG.

All parts required for repair works, such as lifting gear, lifting aids, fastening parts
etc., must be checked for damages and wear before use. Damaged or worn parts
must not be used any longer and must be replaced by new original parts.

If repair works are to be carried out for which the existing platforms are not
sufficient, suitable working platforms (e.g. lifting platforms) or scaffolds must be used
in compliance with the local regulations for accident prevention.

Several parts are provided with threads for eye bolts for transport and erection
purposes. These threads are sealed with hexagon head bolts or set screws. After
erection remove the eye bolts and seal the threads to protect eye bolts and set
screws from wear.

Attention! Once they have been loosed, replace self-locking nuts with new ones.

Danger! Do not enter the grinding zone of the mill when the grinding rollers are
lifted up.

ge0500591-84.doc Page 1 / 38
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

Weights

These are the weights to be considered for repair works on the plant:

- mill gearbox (without oil filling) 77,000 kg

- grinding bowl (without grinding plate) 46,000 kg

- grinding plate segment I. 440 kg


II. 144 kg

- grinding roller, complete 36,600 kg

- pressure frame 27,000 kg

- classifier, complete 55,500 kg

- outlet duct with bearing and


separating wheel 27,000 kg

- classifier top part without outlet duct, 13,200 kg

- classifier top part with outlet duct


bearing and separating wheel 40,000 kg

- classifier bottom part with


components 15,300 kg

- three flap gate lock 12,000 kg

For further details on the individual weights see the spare parts lists (also see
chapter 9) and the documents on the relevant plant components (chapter 11).

Drawing reference

The following chapters on repair include references to various drawings. These


drawings are enclosed in the annex of chapter 8, the drawings of spare parts are
included in chapter 9.

ge0500591-84.doc Page 2 / 38
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.1 How to lift the classifier off the grinding plant

Observe basic safety instructions contained in chapter 2 and the instructions in


chapter 8.4.

Danger! Switch off machine and secure it against restart.

Danger! Machine is operated at high temperatures.


Risk of burns!
Wait for machine to cool down before carrying out any work on the
classifier.

Important! Be sure to take into account that the weights stated increase and the
max. capacity of the rope has to be adapted according to the
additions and the modifications made by the customer (e.g.
insulation, additional platforms, additional lining etc.).

Danger! The complete classifier must not be lifted up if the weight has
increased or if the wall thickness has decreased due to wear. The
max. mass that can be lifted up must be recalculated.

Danger! Ensure that all electric lines are dead.

Remove the electric connection cable of the classifier drive.

Remove the section of the ducting at the classifier outlet duct.

Proceed to section C for instructions if only the outlet duct and the separating wheel
need to be removed.

Remove infeed chute on the material inlet of classifier top part.

If the complete classifier has to be lifted, continue with section B.

ge0500591-84.doc Page 3 / 38
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

A) How to lift the classifier top part off the classifier bottom part

(The item numbers refer to the "Spare parts drawing SLS".)

Either remove top part of the classifier (item 150) complete with outlet duct
(item 185), or lift off classifier top part separately after removing the outlet duct
(refer to section C).

Open the door to the classifier top part (item 151).

Provide a suitable scaffold allowing access to the classifier top part.

Loosen the screw connections between louvre and grit cone (item 120).

Loosen screw connections between classifier top part and classifier bottom
part (item 103).

Danger! Do not suspend the outlet duct by the ribs (item 176).

Use suspension eyes (item 171) to suspend top part of the classifier together
with the outlet duct and lift it off, or else remove outlet duct first, then suspend
classifier top part by the flange and lift it off.

Important! Fasten ropes, chains or rods in such a way that no pressure is


applied onto the gear and motor. If this is not possible, remove
the gear and motor first (see chapter 8.4.14).

Set down the classifier top part at a suitable place.

The erection of the classifier top part is carried out in reverse order.

Important! Before placing the classifier top part onto the classifier bottom
part it might be necessary to stick a new sealing cord (item 104)
onto the flange of the classifier bottom part.

ge0500591-84.doc Page 4 / 38
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

B) How to lift complete classifier off the mill

(The item numbers refer to the "Spare parts drawing MPS" or the "Spare parts
drawing MPS or SLS").

The classifier can be removed either completely, i.e. in one part, or in two
parts (i.e. first the classifier top part as described in section A, then the
classifier bottom part).

Loosen fastening screws of central fall pipe (item 121.1) and pull the latter into
the grit cone (SLS-item 121) by means of grab hoists.

Remove the differential pressure measuring line (MPS-item 750) at the


transition to the classifier.

Loosen the low pressure hoses (MPS item 924) from the ring mains of the
water cooling system for the torque support of pressure frame (MPS item
900).

Loosen the screw connections between mill and classifier bottom part (MPS-
items 722-724).

Danger! Do not suspend the complete classifier from the ribs (SLS-item
176) welded to the classifier outlet duct!

Hang up the classifier bottom part (by the flange) and lift it up or lift up the
complete classifier and put it down in a suitable place. For this, use the three
suspension eyes (SLS-item 171).

Important! Fasten ropes, chains or rods in such a way that no pressure is


applied onto the gear and motor. If this is not possible, remove
the gear and motor first (see chapter 8.4.14).

Important! Since the grit cone (SLS-item 121) projects from the bottom of
the classifier bottom part, use appropriate supports when
putting the classifier bottom part onto its flange.

The erection of the classifier is carried out in reverse order.

Important! Before placing the classifier onto the mill it might be necessary
to stick a new sealing cord (MPS-item 721) onto the mill flange.

ge0500591-84.doc Page 5 / 38
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

C) How to lift the outlet duct off the classifier top part

(The item numbers refer to the "Spare parts drawing SLS".)

Loosen screw connections (item 187) between outlet duct and top part of the
classifier.

Lift off outlet duct (item 185) with bearing (item 200) and separating wheel
(items 160-169) using the suspension eyes (item 171).

Important! Fasten ropes, chains or rods in such a way that no pressure is


applied onto the gear and motor. If this is not possible, remove
the gear and motor first (see chapter 8.4.14).

Attention! Do not place the outlet duct on the separating wheel.

Danger! When putting the outlet duct down, secure it against falling
over.

Put outlet duct down in a suitable place.

Important! As the separating wheel (item 160-169) protrudes downwards,


provide outlet duct with suitable substructure.

The erection of the outlet duct is carried out in reverse order.

Important! Before placing the outlet duct on the classifier top part, it might
be necessary to stick a new sealing cord (item 188) onto the
classifier top part.

ge0500591-84.doc Page 6 / 38
GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.2 Removal and mounting of grinding rollers

The removal and mounting of the grinding rollers is carried out by means of the Lift-
and-Swing System shown in the drawing "Lift-and-Swing System" (see chapter 8 -
Annex).

The item numbers 200 - 999 refer to the "Spare parts drawing MPS" (see chapter 9).

The item numbers indicated “SLS item XXX” refer to the “Spare parts drawing SLS”
(see chapter 9).

A suitable working platform must be available for the removal of the grinding rollers.
Observe the swing radii of the maintenance door and the grinding roller!

Observe the basic safety instructions provided in chapter 2 and the instructions in
chapter 8.4.

Important! For removing the grinding rollers make sure they are positioned on
the grinding plate at an angle of 15° + 0.5°.
If the angle is greater, lift the grinding rollers briefly with the tension
hydraulics causing them to swing inside. After lowering the grinding
rollers, get them to the right angle using the maintenance drive.

Danger! Switch off the machine and secure it against restart.

Danger! During operation the machine becomes very hot.


Risk of burns!
Before carrying out any works on the mill, wait until the machine has
cooled down.

Danger! For works in the mill interior ensure that it is sufficiently aired. If
necessary wear suitable protection equipment.

Danger! Wear a safety harness, or enlarge the existing platform using a


suitable working platform.

Attention! Observe the tightening torques indicated in the drawings.

Remove torque support of pressure frame (item 900) in the pivoting area of the
maintenance door as described in chapter 8.4.10, or, alternatively, remove the door
completely from the mill after opening it.
Open the maintenance door and swing it aside.

Attention! When opening the maintenance door do not slam it against the torque
support of the pressure frame!

Remove the lining segments of the air guide cone (item 223) from around the door
as well as the detachable segment of the ported air ring.

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Remove the parts of the water injection system (item 735) from the grinding zone.

Loosen covers (item 866) from the pressure yokes (item 360) so that the grinding
roller stop parts (items 865-877) hang freely.

Dismantle and remove the three seal air ducts (item 601) from the grinding rollers.

Important! Cover the seal air openings to protect them from dust.

Fasten the covers (item 9) to the pressure yokes (item 360).

Open the door to the grit cone (SLS item 121.4).

Mount an appropriate scaffold for accessing the grit cone (SLS item 121) in a way
that the hub locking component of the classifier bearing (SLS item 127) can be
reached.

Replace screw plug (item 83) with lifting eye bolt (item 82).

Suspend a grab hoist from these lifting eye bolts.

Loosen fastening screws of central fall pipe (SLS item 121.1).

Then pull up fall pipe into grit cone by means of grab hoist and fasten fall pipe onto
grit cone by means of safety plates (item 85).

Suspend a grab hoist between the transportation eye (item 32) of the grit cone and
the lifting eye bolt of the sinkable central column (item 243).

Remove the manhole cover in the cover hood (item 240).

Remove the fastening screws from the sinkable central column, pull the central
column out of the cover hood (item 240) by means of the hoist and secure the
central column (item 243) with the same fastening screws.

Mount the three supporting arms (item 4) with the jibs (item 5) to the central column
proceeding as follows:

First possibility

- put the three supporting arms with the jibs down onto the grinding bowl and
fasten them with screws (item 56) onto the central column (item 243),

- slightly tighten screws (item 56),

- pull up the three supporting arms by means of grab hoists and fasten them with
screws (item 46) onto the cover of the central column,

- then clamp the three supporting arms by means of the screws (item 56).

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

Second possibility

- lift the first supporting arm with two jibs by means of the hoist and fasten it to the
central column using the screw (item 46),

- lift the second supporting arm and fasten it to the central column,

- when the third supporting arm is lifted clamp the three supporting arms by means
of the screws (item 56).

Mount the bracket (item 6) to the pressure yoke.

Attention! Keep a distance of about 10 mm between the brackets and the


supporting arms to avoid unnecessary bending loads.

Important! Slightly loosen the screws (item 56) to adjust the height of the
supporting arms by means of the screws (item 46) and to adjust the
supporting arms by turning.

Use the cotter bolts (item 7) to connect the brackets with the supporting arms.

Important! Slightly loosen the screws (item 53) to adjust the length of the
supporting arms by moving the jibs (item 5). The brackets can be
aligned after loosening the screws (item 61).

Danger! Use wood wedges to secure the grinding rollers against rolling on the
grinding track.

Remove the covers of the three openings in the classifier flange and screw the three
lifting eye bolts (item 45) into the pressure frame.

Remove the six connecting butt straps (item 862) between grinding rollers and
pressure frame.

Raise the pressure frame with the tensioning hydraulics and secure it with the three
bolts (item 15). Fasten the bolts by means of screws (item 43). Then switch off the
hydraulic unit.

Danger! Do not enter the mill until the pressure frame is secured with the
bolts.

Important! For raising and lowering of the pressure frame see operating
description of the tensioning hydraulics (Operating instructions
"Hydraulic unit - Grinding roller suspension system", chapter 11).

Remove the six rollers (item 712) from the pressure yokes.

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Important! If the roller sockets (item 710 or 711) are removed from the pressure
frame (item 400) or from the pressure yoke (item 360), the fitting
position of the roller sockets must be written down before they are
removed (also refer to drawing “Grinding roller – arrangement
drawing” in chapter 8 (Annex).

Mount the Lift-and-Swing device (items 1 - 3) to the mill housing exterior. Proceed
as follows:

- remove, in the classifier bottom part, the lid over the opening for the rotary
actuator,

- put the Lift-and-Swing column onto the console of the mill housing and hook the
bottom flange of the Lift-and-Swing device onto the supporting stand (items
10+11),

- fasten a hoist to the Lift-and-Swing device and the lifting eye bolt (item 244.6) in
the sinkable central column.

Attention! Ensure that the lifting eye bolt screwed into the central column is a
high-strength lifting eye bolt (recognizable by its octagonal shape).

- pull over the Lift-and-Swing column by means of the hoist and fasten it with the
screws (items 51 and 79),

- then remove hook and hoist.

Connect the hydraulic unit (item 20).

Attention! Ensure that the hose pipes (items 28 and 29) for the hydraulic
cylinder (item 21) and the rotary actuator (item 22) are correctly
connected.

Important! The connections on the unit are fitted with quick-action couplings, i.e.
the hydraulic oil remains in the hoses when these are disconnected
and the pressure is kept up.

Swing the supporting foot (item 3) into the mill.

For removal of the grinding rollers move them with the maintenance drive to position
them exactly over the supporting foot.

Important! For details on the operation of the maintenance drive see operating
instructions from the supplier of the gearbox – chapter 11.

Use the two turnbuckles (items 40, 41 and 42) and the bolts (item 12) with the spring
cotters (item 37) and the screw (item 49) to fasten the grinding roller to the Lift-and-
Swing column. Fill the distance to the screw with the compensating plates (item 77)
so that after tightening the screw the pressure yoke and the head of the screw fit
tightly.

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Danger! The spring cotters (item 37) must be inserted to secure the bolts (item
12).

Pull out the cotter bolts (item 7).

Raise the grinding roller by means of the hydraulic cylinder by activating the relevant
valve at the hydraulic unit (see Operating instructions "Hydraulic unit - Grinding
roller suspension system", chapter 11).

Danger! Before swinging out the grinding roller secure the raised Lift-and-
Swing column using the locking bolt (item 14) and the spring cotters
(item 34).

Important! To avoid unnecessary frictions ensure that the locking bolt does not fit
tight. The washer (item 19) must be placed underneath.

If necessary, remove the jib (item 5) before swinging out the grinding roller.

Swing the grinding roller out of the mill housing by means of the rotary actuator by
activating the relevant valve at the hydraulic unit.

Important! The motor is fitted with shock absorption in limit position which is set
at the manufacturer’s works. (For details on the motor see separate
operating instructions, chapter 11).

Important! For activating the Lift-and-Swing device lubricate it at the lubrication


points indicated in the drawing.

For transport of the grinding rollers use the hooks on the sides of the pressure yoke.

Important! The lining of the pressure yoke can be removed around the hooks to
facilitate the fastening of the ropes.

When the grinding roller is suspended from the crane, loosen the turnbuckles by
pulling out the bolt (item 12) on the pressure yoke and then loosen the screw or the
threaded rod (item 49) and lift up the grinding roller.

The mounting of the grinding rollers by means of the Lift-and-Swing device and the
removal of the parts of the Lift-and-Swing device is carried out in reverse order.

The grinding rollers must be placed onto the supporting foot (item 3) at an angle of
15°.

Important! Make sure to suspend the rollers from the crane at 15° already.

The jibs (item 5) removed during disassembly must be fitted back into their original
position to make sure the rollers are refitted in their original position during assembly
(which is important for lowering the pressure frame).

Refit the roller sockets (items 710 and 711) into the position they were in before the
removal of the grinding rollers.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
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Important! When mounting the rollers and roller sockets (items 710 to 712), also
observe drawing “Grinding roller – arrangement drawing” in chapter 8
(Annex).

When lowering the pressure frame ensure that the grinding roller stop parts (items
865-877) do not get jammed at the pressure yokes (item 360).

When lowering the pressure frame ensure that the rollers (item 712) are fully
inserted in the sockets of the pressure frame.

After removal of the Lift-and-Swing device seal all threads in housing, pressure
frame and pressure yoke, which were used for mounting the individual parts, with
screws to protect them from wear.

Important! After removal of the Lift-and-Swing system grease or oil the Lift-and-
Swing column and ensure that all parts of the Lift-and-Swing device
are stored in a corrosion-proof place.

Note: The grinding rollers can also be removed by lifting them up from
above the mill with dismantled classifier. For this purpose, support the
grinding rollers by means of the sinkable central column as described
above.

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KAISERSLAUTERN Maintenance Edition 04.2006

8.4.3 Replacement of wear segments of the grinding rollers

(See "Spare parts drawing MPS grinding roller", item 301.)

Observe the basic safety instructions provided in chapter 2 and the instructions in
chapter 8.4.

For replacement of the wear segments remove the grinding rollers as described in
chapter 8.4.2.

Put down the grinding rollers with the pressure yokes facing upwards (item 360);
use a suitable substructure for this purpose.

Danger! For removal secure the relevant wear segment so that it cannot fall
out after loosening the clamping element (e.g. by slinging a chain
around the segment).

Loosen the studs (item 303) from the secured wear segment.

Remove the clamping bow (item 302).

Important! The clamping bows are provided with threaded holes for screwing in
eye bolts. These threaded holes are closed with threaded pins to
protect them against wear and contamination. Put the studs back in
after erection.

Screw the eye bolt into the side of the wear segment and remove the wear segment
after taking away the securing device.

Then remove all other wear segments according to the above instructions.

Before fitting of the wear segments, check the contact surface on the roller body
(bearing bushing, item 320). If it is not in perfect condition, remachine it.

Prior to fitting the new wear segments also check whether the edges of the contact
surfaces are rounded or slanted to prevent pressure from being caused by the
edges.

Divide the bearing bushing (item 320) into 12 equal sections along the
circumference, starting from the centre of the carrier plate, and mark (mounting aid).

Place the first wear segment centrically on one of the carrier plates on the retainer
ring (item 304) and secure it in the same way as for removal.

Press the wear segment with the help of a pressing device or a hydraulic pump
firmly on the grinding roller body until the clamp bows are placed and the studs are
tightened with a torque wrench.

Use a feeler gauge after mounting each wear segment to check if it fits properly all
around the bearing bushing. Maximum permissible gap: 0.05 mm.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
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Also check the fit along the lateral contact surfaces for the stop ring (item 304) and
for the clamp bow (item 302). Maximum permissible gap: 0.1 mm.

Important! Should one of these requirements not be met, remachine the relevant
part. This is done by grinding off the segment with a portable hand
grinder. For emergency repair the fit of the wear segments can be
improved by applying Diamant Multi Metall (= two-component metal
putty) to the bearing bushing.

Apply the clamping bow (item 302).

Mount the studs (item 303) and tighten the nuts with a torque wrench.

Important! For tightening torque see list of tightening torques for screws, chapter
8.2.3.

Important! When fastening the wear segments ensure that the relevant wear
segment is not lifted from the contact surface by tightening the nut. If
this is the case, remachine the lateral contact surface at the wear
segment.

Attention! Ensure a proper fit!


Non-compliance with the specified tolerances might lead to damages
to the equipment and consequently to a plant failure.

Mount the second wear segment centrically on the second carrier plate (displaced
by 180° to the first wear segment) and fasten it with the studs.

Then fit the other wear segments in the remaining spaces, proceeding either to the
left or the right. Make sure they sit closely at the cams between the contact surfaces
of the wear segments.

Leave a gap of 0.5 mm to 2 mm between the cams of the wear segments when
fitting the last segment in each of the three spaces so that the gaps around the
circumference add up to between 1.0 mm (min) and 4.0 mm (max).

Important! If new segments are fitted, regrind the cams at the contact surfaces of
the last wear segment to go into each of the three remaining spaces
to ensure snug fit.

Attention! If the last wear segment to go into each of the remaining spaces is
squeezed in so that no clearance remains, the wear segment and the
roller body may suffer severe damage due to the wedging effect.

Attention! Retighten the studs with a torque wrench after approximately 24 - 36


hours of operation.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.4 Replacement of grinding plate segments

(see "Spare parts drawing MPS - Group grinding bowl", item 201)

The replacement of the grinding plate segments (partial segments I + II) is carried
out with the help of the Lift-and-Swing System shown in the drawing "Removal
device for grinding plate segments" (see chapter 8, Annex).

The item numbers 201 - 249 refer to the "Spare parts drawing MPS - Group grinding
bowl" (see chapter 9).

Observe the basic safety instructions provided in chapter 2 and the instructions in
chapter 8.4.

Remove the grinding rollers as described in chapter 8.4.2.

Then fasten the work arm (item 1) to the Lift-and-Swing device.

Loosen the hexagon nuts of the clamp screws (item 204.3) and remove clamp
pieces (item 203).

Start removing the grinding plate segments with an inner one (partial segment I).

Important! During the grinding process, material enters into the spaces between
the individual grinding plate segments. Therefore, clear these spaces
of the material compressed between the segments before removal of
the first grinding plate segment.

After removing the first grinding plate segment, place the round sling (item 2) around
it.

Lift up the grinding plate segment with the help of the hydraulic cylinder by activating
the relevant valve on the hydraulic unit (see operating instructions for the hydraulic
unit, chapter 11).

Danger! Before swinging out the grinding plate segment, secure the raised
Lift-and-Swing column using the locking bolt and the spring cotters.

Important! To avoid any unnecessary friction, ensure that the locking bolt does
not fit tightly.

Swing grinding plate segment out of the mill housing with the help of the hydraulic
rotary actuator by operating the corresponding valve on the hydraulic unit.

Danger! Never put more than one grinding plate segment down on the
platform at a time to ensure that the maximum allowable load for the
platform is not exceeded.

Lower the grinding plate segment onto the platform by retracting the hydraulic
cylinder and carry the segment away.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
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Then remove the other grinding plate segments.

Before mounting the grinding plate segments, carefully check the contact surface of
the grinding bowl. If it is no longer in perfect condition, remachine it.

Before mounting the grinding plate segments, also check whether the edges of the
contact surfaces of the cast cams are rounded or beveled so that no pressure is
caused by the edges on the contact surface of the grinding bowl.

Swing the first grinding plate segment into the mill using the Lift-and-Swing device
and install it.

Important! When mounting the grinding plate segments, ensure that the cast
cams of each small segment (partial segment II) fit properly. Also
ensure that all segments are well set in the grinding bowl. This is
checked with a feeler gauge. The gap width on the contact surface
must not exceed a maximum of 0.05 mm. If one of these
requirements is not met, rework is necessary. This is done by
grinding the segment with a portable hand grinder. For emergency
repair the fit of the grinding plate segments can be improved by
applying Diamant Multi Metall (= two-component metal putty) to the
grinding bowl.

Attention! Ensure a proper fit!


Non-compliance with the specified tolerances might lead to damages
to the equipment and consequently to a plant failure.

After inserting three segments each (one large inner segment and two smaller outer
ones), fit clamp pieces (item 203) and tighten hexagon nuts of the clamp screws
(item 204.3) with a torque wrench.

Important! For tightening torque see list of tightening torques for screws, chapter
8.2.3.

Then mount the other grinding plate segments and fasten them with the clamp
pieces.

Important! Note that the grinding plate segments must be wedged laterally
against the adjacent segments with compensation plates (item
201.2).

Then remove work arm from the Lift-and-Swing device.

Attention! Retighten the hexagon nuts of the clamp screws with the torque
wrench after about 24 - 36 hours of operation.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.5 Replacement of liner plates

(see "Spare parts drawings MPS", items 701, 702, 706 and 707.

Replacement of liner plates is carried out through the erection opening in the
classifier flange.

For replacement of the liner plates suitable working platforms must be provided.

Observe the fundamental safety instructions laid down in chapter 2 and the
instructions laid down in chapter 8.4.

Danger! Switch off the machine and secure it against restart.

Danger! During operation mill housing and inner parts become very hot.
Risk of burning!
Before replacing the liner plates wait until the machine is cooled
down.

Danger! Completely release the pressure from the tensioning device (see
operating instructions "Hydraulic unit -Grinding roller suspension
system", chapter 11).

Open the upper door to the pull rod housing.

Remove the erection cover from the classifier flange.

Remove the front row (as seen from the door) of the fastening screws of the liner
plate to the pull rod housing (stud item 702.1) on the side of the pull rod housing.

Loosen the back row of fastening screws and pull out the shims (item 703) to the
side. (The back row of through holes in the shims are designed as slots.)

Screw the eye bolt in the top of the liner plate.

Remove worn liner plate of the housing (item 702) through the erection opening in
the classifier flange by means of a hoist.

Completely remove torque support of pressure frame as described in chapter


8.4.10.

After having removed the torque support of pressure frame, the liner plate of the
housing (item 701) can be replaced.

Screw in eye bolt into liner plate of housing (item 701).

Loosen the 2 fastening screws (item 701.2) in the mill and remove shims (item 708).
Then remove liner plate through the erection opening in the classifier flange with the
help a grab hoist.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
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Remove the fastening screws of the liner plates to the pressure frame (item 706.1,
707.1) inside the pressure frame and remove the worn liner plates of the pressure
frame in the classifier flange (items 706, 707) through the erection opening.

Mount new liner plates of the pressure frame and firmly tighten the screws.

Fit new liner plate of the housing (item 701) with shims.

Mount torque support for pressure frame.

Mount the new liner plate of the housing (item 702) and at first fasten it only with the
back row screws.

Adjust the slot between the liner plates indicated in the spare parts drawing by
means of the shims (item 703). For this insert from the side the shims between each
liner plate and housing. (Shims are included in the scope of supply and are supplied
in various thicknesses.)

Important! See table "Gap and wear measurement – pressure frame stop”,
chapter 8.2.3.

Screw in the front row fastening screws and firmly tighten all screws.

Important! For tightening torques see table "Tightening torques for screws",
chapter 8.2.3 .

Close the door to the pull rod housing, and mount the erection cover to the classifier
flange.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.6 Removal of one hydraulic cylinder of the tensioning system

(see "Spare parts drawing MPS", item 550)

Observe the fundamental safety instructions laid down in chapter 2 and the
instructions laid down in chapter 8.4.

Danger! Switch off the machine and secure it against restart.

Danger! Completely release the pressure from the tensioning system (see
operating instructions "Hydraulic unit -Grinding roller suspension
system", chapter 11).

To remove one hydraulic cylinder completely, first drain the oil from the hydraulic
cylinder.

Attention! Immediately apply oil binder to any spilled oil.

Fasten the hydraulic cylinder on two grab hoists.

Remove the bolt of the tensioning system (item 541) as shown in the drawing
"Fitting of tension cylinder bearing system" (see chapter 8 - annex).

To remove the hydraulic cylinder take down the hose pipes and loosen the socket
(items 535 and 537).

When fitting the hydraulic cylinder fill the articulation bearing with new grease.

Important! The lubricant quantity as well as the grease quality to be used can be
seen from our lubrication list (see chapter 8.3).

After fitting vent the hydraulic cylinder and the ducting.

Attention! Make sure to completely fill the following items with hydraulic oil:
hydraulic cylinders, pressure ducting "A" (connection via hose pipe
item 567), suction ducting "B", pressure ductings for lifting "B1, B2,
B3" (connection via hose pipe item 568).

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.7 Repair of the oil pressure piping to go with the tensioning system

Observe the fundamental safety instructions laid down in chapter 2 and the
instructions laid down in chapter 8.4.

Danger! Switch off the machine and secure it against restart.

Danger! Completely release the pressure from the tensioning system (see
operating instructions "Hydraulic unit -Grinding roller suspension
system", chapter 11).

Take care to collect the hydraulic oil in a suitable vessel when separating the pipings
or removing the hydraulic hoses.

Attention! Immediately apply oil binder to any spilled oil.

Attention! Upon completion of repair works and before restart take care to flush
the oil pressure piping in order to remove any impurities.

Flushing of the oil pressure piping is effected as described in the drawing "flushing
equipment" (see chapter 8 - annex).

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.8 Replacement of roller bearings and radial shaft sealing rings of the grinding rollers

(See "Spare parts drawing MPS", items 341 and 342 as well as 331).

8.4.8.1 Preparatory work

Observe the basic safety instructions provided in chapter 2 and the instructions in
chapter 8.4.

Remove the grinding rollers as described in chapter 8.4.2.

Put down the grinding rollers with pressure yokes (item 360) facing upwards and
shim them as appropriate.

Remove pressure yoke (item 360) as described in chapter 8.4.9.

Attention! During assembly of grinding roller, tighten all screws with the help of
a torque wrench.

Important! Refer to table "Tightening torques for screws", chapter 8.2.3.

8.4.8.2 Removal of radial shaft sealing rings

Preparatory work to be carried out as described in chapter 8.4.8.1.

First of all loosen the screws (item 353.1) of the closed bearing lid (item 353) in
order not to shift the roller bearings when removing the open bearing lid (item 321).
For this, loosen one screw (item 353.1) after the other and retighten them manually.

Then remove the inner seal air sealing ring (item 322) and open bearing lid (item
321) with the radial shaft sealing rings (item 331).

Remove the radial shaft sealing rings from the open bearing lid.

8.4.8.3 Fitting of radial shaft sealing rings

Before fitting the radial shaft sealing rings, check the surface of the wear bushing
(item 330). If it is not OK, the wear bushing must be replaced as well.

Mount the first shaft sealing ring (item 331) in the open bearing lid (item 321)
according to drawing and glue by applying one layer of anaerobic adhesive on the
bottom and on the outside.

Attention! Remove excessive adhesive. Make sure there is no adhesive on the


sealing lips!

Leave to harden for several hours.

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Before mounting the open bearing lid, check the fit of the roller bearings. Make sure
that the front surface of the cylindrical roller bearing (item 342) is flush with the
supporting surface of the open bearing lid (item 321).

Insert new O ring (item 333) into the groove.

Grease the lips of the radial shaft sealing ring (item 331) and the bevel of the wear
bushing (item 330).

Slide the open bearing lid (item 321) with the first radial shaft sealing ring over the
greased wear bushing (item 330); align it on the bearing bushing and fasten it.

Tighten screws (item 353.1) on the closed bearing lid (item 353) with the required
torque.

Attention! Bearing lid (item 353) must not fit tightly, leave a gap.

Carry out leak test (pressure test) with 0.2 bar:

- Screw manometer onto the bore in the middle of the axle (item 350)

- Spray radial shaft sealing ring (item 331) with leak detecting spray

- Apply 0.2 bar compressed air onto the axle

Remove compressed air system.

Insert spacer ring (item 337).

Slide the second radial shaft sealing ring (item 331) over the greased wear bushing,
fit it into the open bearing lid (item 321) according to the drawing and glue on the
outside with anaerobic adhesive.

No extra time required for hardening.

Fit in inner seal air sealing ring (item 322).

Fit pressure yoke (item 360) as described in chapter 8.4.9.

After refitting the grinding rollers into the mill, check oil level as described in chapter
8.2.2.3 and refill oil if required.

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8.4.8.4 Removal of roller bearings

Preparatory work to be carried out as described in chapter 8.4.8.1.

Remove the wear segments (item 301) as described in chapter 8.4.3. This will make
it easier to replace the roller bearings (e.g. turning the grinding roller) and heat up
the bearing bushing (item 320).

Drain oil completely from the grinding rollers through the oil drain plugs (item 353.5)
and collect oil in an appropriate receptacle.

Attention! Any spilled oil must be removed immediately with a bonding agent.

Clean oil drain plug and screw it back in.

Important! Check condition of sealing ring (item 353.6) and replace it if


necessary.

Remove inner seal air sealing ring (item 322) and open bearing lid (item 321) with
the radial shaft sealing rings (item 331).

Turn grinding roller by 180°.

Remove closed bearing lid (item 353).

Remove safety disc (item 351).

Place a hydraulic cylinder on the axle.

Screw threaded bolts into the bearing bushing (item 320).

Slide a plate disc over the threaded bolts until it rests on the cylinder, then tighten
the plate disc with nuts.

Push the axle (item 350) together with the inner ring of the cylindrical roller bearing
(item 342) out of the bearing seat by using the hydraulic cylinder.

Remove hydraulic cylinder.

Pull the inner ring of the cylindrical roller bearing off the axle. (Heat up inner ring if
required.)

Place a plate disc on the outer ring of the self-aligning roller bearing (item 341) (the
diameter of the plate disc being smaller than the outer diameter of the bearing).

Put the hydraulic cylinder on the plate disc.

Slide the plate disc back over the threaded bolts until it rests on the cylinder, then
tighten the plate disc with nuts.

Use the hydraulic cylinder to push the two roller bearings and the spacer bushings
(items 346 and 347) down and out.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
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Important! For ease of removal, use the two injector pumps. For this purpose,
there are two drilled connection holes on each side of the bearing
bushing.

8.4.8.5 Fitting of roller bearings

Important: When replacing the roller bearings, use new radial shaft sealing rings
(items 331) as well as new O-rings (items 332 to 335).

Fasten 4 stop plates on the pressure yoke side of the bearing bushing (item 320)
using the threaded holes of the screws (item 321.1).

Rest bearing bushing on iron stands with the stop plates facing downwards.

The roller bearings are fitted either with the help of the oil injection method when the
bearing bushing is cold or by heating up the bearing bushing. In the latter case, use
an annular burner (gas burner) or three propane burners to heat it evenly to 90°C –
100°C, approximately. The use of a hood is recommended for this purpose.

Attention! Never use welding torches for heating the bearing bushing!

Press the outer ring of the cylindrical roller bearing (item 342) into the bearing
bushing until the outer ring rests on the stop plates.

Fit outer spacer bushing (item 347) into the bearing bushing so that the spacer
bushing sits closely on the outer ring of the cylindrical roller bearing.

Press the self-aligning roller bearing (item 341) into the bearing bushing.

Heat the inner ring of the cylindrical roller bearing (item 342) in an oil bath to about
50°C – 60°C and slide it over the axle (item 350).

Stand the axle vertically with the pressure yoke side facing downwards.

Slide inner spacer bushing (item 346) over the axle so that it sits on the inner ring of
the cylindrical bearing.

After approx. 3 – 5 hours the bearing bushing, while still warm, is lifted above the
axle with the help of a crane and lowered into the bearing seat.

Important! Waiting time is required in order to ensure that the inserted roller
bearings are heated uniformly.

After the bearing bushing has cooled down to ambient temperature, mount safety
disc (item 351) on self-aligning roller bearing.

Insert O-ring (item 334) and fit closed bearing lid (item 353).

Attention! At first, only tighten screws (item 353.1) by hand, do not apply
specified tightening torque until the open bearing lid (item 321) has
been mounted.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
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Turn grinding roller by 180° and remove impact plates.

Insert O-ring (item 332) and mount wear bushing (item 330) together with spring-
type straight pin onto the axle.

Fit the radial shaft sealing rings as described in chapter 8.4.8.3.

Install the lining of the bearing lid (item 328).

Insert inner seal air sealing ring (item 322).

Refit wear segments (item 301) as described in chapter 8.4.3.

Fit pressure yoke (item 360) as described in chapter 8.4.9.

After installing the grinding rollers in the mill, fill oil into rollers as described in
chapter 8.2.2.4 (oil change on grinding rollers).

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.9 Replacement of pressure yokes

(see "Spare parts drawing MPS", item 360)

Observe the fundamental safety instructions laid down in chapter 2 and the
instructions laid down in chapter 8.4.

Remove the grinding rollers as described in chapter 8.4.2.

Carry out further removal and mounting of the pressure yokes as indicated on the
drawing "Assembly and disassembly device of grinding roller" (see chapter 8 -
Annex).

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.10 Repair of torque support of the pressure frame

(The item numbers refer to the "Spare parts drawing MPS – torque support of
pressure frame".)

Observe the fundamental safety instructions laid down in chapter 2 and the
instructions laid down in chapter 8.4.

Danger! Switch off the machine and secure it against restart.

Danger! The hydraulic buffer (item 903) is under pressure.

Ensure that the piston rod (plunger) of the hydraulic buffer is entirely extended. If
required, pull pressure frame backwards until piston rod is completely extended.

Important! For reference dimension of extended pull rod (dimension “z”) and
buffer pre-tension (dimension “v”), see table "Gap and wear
measurement – pressure frame stop”, chapter 8.2.3.

Attention! With the stated dimension “z”, the piston has a residual stroke
(= buffer pre-tension) of “v” mm.

8.4.10.1 Emergency operation with a defective hydraulic buffer (item 903)

If one of the hydraulic buffers is not functioning properly, it is possible to operate the
mill under emergency operating mode.

Replace hydraulic buffer with the stop supplied (spare buffer, item 926). Remove
round head bolt (item 918), round head bolt guidance (item 920) and ball socket
(item 919) and replace with bolt head (item 917).

This way the torque support of pressure frame becomes a rigid stopping device.

Important! During operation with the stop (item 926) there is a gap between the
retainer rings (item 922).

Attention! The mill must not be operated longer than one week under the
emergency operating mode!

The mill may only be operated this way for a short period of time as the liner plate
(item 706) and the bolt (item 904) will suffer increased wear and the mill run will
generally run less smoothly.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
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8.4.10.2 Removal of torque support of the pressure frame (complete)

Remove connection to the water cooling system (item 914).

Disconnect connection cable of the temperature sensor (item 903.8) from the
terminal box.

Suspend torque support from a crane or a hoist.

Remove screws (items 901.1 and 901.3) and the torque support of the pressure
frame.

8.4.10.3 Removal and repair of hydraulic buffer (item 903) and the internals of the torque
support of the pressure frame

(For this it is not required to remove the entire torque support of the pressure frame.)

Disconnect connection cable of the temperature sensor (item 903.8) from the
terminal box.

Pull water cooling system (item 914) off the hydraulic buffer.

Screw eye bolt into the plate (item 902).

Suspend plate from a crane or a hoist.

Loosen nuts of the screwed connection (items 902.1 – 3) evenly (approx. “v” mm)
until piston rod is fully extended. Then remove screws (item 902.1) and plate with
hydraulic buffer.

Attention! Take care that the temperature sensor (item 903.8) and mini-
measuring valve (item 903.9) are not damaged during removal or
when being put down.

After the hydraulic buffer has been removed, it is possible to replace the buffer head
(item 916) as well as the round head bolt (918), round head bolt guidance (item
920), ball socket (item 919) and bolts (item 904).

Important! If only the head of the bolt (item 904) is worn, it can be regenerated.
Please contact Gebr. Pfeiffer AG for details.

The repair of the hydraulic buffer requires special tools and specialist expertise. The
repair of the hydraulic buffer therefore must be carried out by qualified specialists.
Please turn to Gebr. Pfeiffer AG.

Danger! Hydraulic buffer is under pressure.


Release pressure on the nitrogen side and the oil side first before
carrying out any works on the hydraulic buffer.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
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Important: For further information on the repair of the hydraulic buffer, please
refer to the separate operating instructions in chapter 11.

When mounting the hydraulic buffer, pre-tension (“v” mm) the piston rod with the
help of shims (items 903.4 – .7). Check pre-tension against dimension “z”.

When fitting the hydraulic buffer or the torque support of the pressure frame, make
sure that the fastening screws are tightened with the required torque.

Important! For tightening torques see table "Tightening torques for screws",
chapter 8.2.3.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.11 Removal of grit cone

(see "Spare parts drawing SLS", item 121)

Observe the fundamental safety instructions laid down in chapter 2 and the
instructions laid down in chapter 8.4.

Lift up the classifier top part as described in chapter 8.4.1.

Remove screws (items 123).

Lift up grit cone with central fall pipe. (Central fall pipe might also be lifted up first
and then grit cone.)

Attention! When putting down the grit cone secure it against falling over.

Remount the grit cone in reverse order. Adjust the dimension between grit cone
(item 121) and louver (item 118) indicated on the spare parts drawing. For this
purpose insert shims between support of grit cone (item 134) and flange of grit cone.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.12 Removal of louvre

(see "Spare parts drawing SLS", item 118)

Observe the basic safety instructions provided in chapter 2 and the instructions
according to chapter 8.4.

Lift up the classifier top part as described in chapter 8.4.1.

Remove the cover of the material inlet (item 519).

Provide a suitable substructure, then remove the screws (item 119); or fasten the
louvre to three hoists and put it down after loosening the screws (item 119).

Then lift up the classifier top part.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.13 Removal of separating wheel and separating wheel hub

(see "Spare parts drawing SLS", items 160 to 169)

Observe the fundamental safety instructions laid down in chapter 2 and the
instructions laid down in chapter 8.4.

The separating wheel can be loosened with the classifier mounted or after lifting off
the classifier outlet duct.

a) with classifier mounted:

Danger! Switch off machine and secure it against restart.

Danger! Machine is operated at high temperatures.


Risk of burning!
Wait for machine to cool down before carrying out any work on
the classifier.

Remove door to gas outlet duct (item 155).

Fit appropriate scaffold if required for access to gas outlet duct.

Remove two-part flange (item 115) from the classifier outlet duct.

Remove all-purpose packing wool, to the extent possible, to gain access to the
three suspension eyes.

Suspend three lifting cables between these suspension eyes and the ones on
the cone of the separating wheel (item 162).

Open the door to the classifier top part (item 151), and remove the screwed
louvre blades (item 118), or open door to the grit cone (item 121.4).

Provide a suitable scaffold to provide access to the classifier top part; ensure
that the hub retainer (item 127) and the shrink disk (item 128) are accessible.

Remove the hub retainer (item 127).

Loosen and remove the shrink disk (item 128).

Place separator wheel and hub on the grit cone.

Now remove the classifier outlet duct with bearing, however, without
separating wheel as described in chapter 8.4.1.

The separating wheel can now be lifted out of the classifier.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
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b) with classifier outlet duct lifted off:

Lift off the classifier outlet duct and the separating wheel as described in
chapter 8.4.1.

Important! When putting the classifier outlet duct down, provide a suitable
substructure to ensure that the hub locking component (item
127) and the shrinkage disk (item 128) are still accessible.

Fasten three lifting cables as described above or provide a suitable


substructure for the separating wheel (if required with lifting cylinders).

Remove the shrinkage disk and put the separating wheel down or lift off the
classifier outlet duct.

Remount the separating wheel and the hub in reverse order.

Important! When mounting the separating wheel observe the gap between
upper flange of the separating wheel and wear bushing (item
122) (see spare parts drawing).

Important! Observe the instructions given in the supplier's documents in


chapter 11 for mounting the shrinkage disk (item 128).

Important! Ensure that there is a small gap between shrinkage disk (item
128) and hub locking component (item 127) (see spare parts
drawing); if required remachine hub locking component.

After mounting of the separating wheel rotate it by hand and check for
scraping noises.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.14 Removal of classifier drive

(see "Spare parts drawing SLS", items 190 and 191)

Observe the fundamental safety instructions laid down in chapter 2 and the
instructions laid down in chapter 8.4.

Danger! Switch off the machine and secure it against restart.

Remove the coupling protection (item 192).

Separate the two coupling halves of the flexible coupling (item 193).

Danger! Ensure that all electric lines are dead.

In case the motor (item 190) is disassembled remove the electric connection cable
from the classifier drive.

Fasten the motor to the crane and lift it up after loosening the fastening screws.

Important! For removal of the gearbox and of the classifier bearing the motor
need not be disassembled.

Fasten the gearbox (item 191) to the crane.

Remove the screws (item 109) if gearbox and intermediate flange (item 110) are to
be disassembled; remove the screws (item 111) if only the gearbox without
intermediate flange (item 110) is to be disassembled.

Lift up the gearbox with the coupling half of coupling item 117 located on the
gearbox side.

Remount the classifier drive in reverse order.

Important! During erection adjust the gaps between the coupling halves of the
two couplings (items 117 and 193) indicated on the spare parts
drawing.

Important! For mounting and removal of the couplings observe the supplier's
instructions in chapter 11.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
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8.4.15 Removal of classifier bearing

(see "Spare parts drawing SLS", item 200)

Observe the fundamental safety instructions laid down in chapter 2 and the
instructions laid down in chapter 8.4.

Remove gearbox (item 191) with intermediate flange (item 110) as described in
chapter 8.4.14.

Danger! During operation the machine becomes very hot.


Risk of burning!
Before carrying out any works on the classifier wait until the machine
is cooled down.

Open the door to the classifier top part (item 151), and remove the screwed louvre
blades (item 118), or open the door to the grit cone (item 121.4).

Provide a suitable scaffold to provide access to the classifier top part; mount the
scaffold so that the hub retainer (item 127) and the shrinkage disk (item 128) are still
accessible.

Lower the separating wheel (items 160-169) onto the grit cone (see description
chapter 8.4.13 "Removal of separator wheel and hub to separating wheel").

Important! Observe the removal height of the bearing.

If there is not enough space to enter the classifier interior or if the removal height
above the classifier is not sufficient, lift up the classifier top part and lower the
separating wheel to the ground as described in chapter 8.4.13.

Remove lubrication pipes (item 140) and seal air duct (item 173) from the drive duct
(item 108).

Open the door to the classifier outlet duct (item 155).

If required mount a suitable scaffold providing access to the classifier outlet duct.

Remove the two-part flange (item 115) in the classifier outlet duct.

Remove support of the bearing (item 129) in the classifier outlet duct.

Remove the fastening screws of the classifier bearing (item 199) in the drive duct
(item 108).

Screw the lifting eye bolt into the upper shaft face of the classifier bearing.

Pull out the classifier bearing by means of a crane.

Attention! Use wood wedges to secure the classifier bearing against rolling.

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Remount the classifier bearing in reverse order.

Important! Observe mounting position concerning the position of lubrication pipe


and seal air duct.

For mounting the bearing support ensure that the bearing is correctly centered.

After mounting the classifier and before mounting the drive rotate the separating
wheel by hand; ensure that it is centered and check for scraping noises.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

8.4.16 Repair of three-flap gate lock

(The item numbers refer to "Spare parts drawing DSK".)

Observe the basic safety instructions according to chapter 2 and the instructions in
chapter 8.4.

Danger! Switch off the machine and secure it against restart.

Danger! Some parts of the three-flap gate lock become very hot.
Risk of burns!
Before carrying out any repair work on the machine, wait until it has
cooled down.

Danger! Completely depressurise the hydraulic unit of the three-flap gate lock
(see operating instructions "Hydraulic unit of the three-flap gate lock",
chapter 11).

For repair purposes the flaps (item 165) can be kept open with the help of the flap
locking device (item 167).

Attention! After the completion of the repair works, make sure that the flap
locking device (item 167) is removed and close threaded bores with
the locking screws (items 168).

8.4.16.1 Replacement of hydraulic cylinders (item 440)

Drain oil from the hydraulic cylinders (see operating instructions "Hydraulic unit of
the three-flap gate lock", chapter 11).

Loosen the hydraulic hoses on the cylinders.

Attention! Remove any spilled oil immediately using oil binder.

Suspend hydraulic cylinders and secure them against falling down.

Remove cover of the articulation bearing (item 470/475).

Remove split pins (item 406) and loosen nut (item 405).

Dismantle clamping piece (item 401) with slotted nut (item 410).

Pull out bolt (item 400) and remove cylinder.

Carry out assembly in reverse order.

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
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8.4.16.2 Removal of flaps (item 165) and replacement of roller bearings (items 305 and 355)
and seals

Disassemble hydraulic cylinder as described in section 8.4.16.1.

Remove the cover of the motion monitor (item 450).

Unscrew and remove covering plate (item 185 or 195 or 205).

Remove cover of plummer-block bearing housings (items 300 and 350).

Remove top parts of the two-part sealing flanges (items 175 and 180).

Suspend flap from the welded eyes and lift it out of the housing together with the
roller bearings.

Put flap down in a suitable place.

Replace roller bearings and seals (items 175.1, 180.1, 307 and 357).

Important! Check the surfaces of the spacer bushings (items 310 and 315 as
well as items 360 and 365) for damages, if damaged replace the
spacer bushings.

Carry out assembly in reverse order.

When fitting the roller bearings fill the hollow spaces with new grease.

Important! For the lubricant quantity and grease to be used, please refer to the
lubrication list (see chapter 8.3).

Attention! Insert fixed rings (items 306 and 356) into the plummer-block
bearings (items 300 and 350).

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GEBR. PFEIFFER AG Chapter 8 BA200500591-E/D
KAISERSLAUTERN Maintenance Edition 04.2006

Chapter 8 - Annex

Attached sheet: Auxiliary equipment for removal of


ball sockets

Parts list: Tool box - packing list

List of drawings:

Template - grinding roller Drawing No. 146 721-3

Template - grinding plate Drawing No. 146 722-3

Grinding roller arrangement drawing Drawing No. 125 608-3

Assembly / disassembly device


for grinding roller Drawing No. 154 230-1

Lift-and-Swing System Drawing No. 148 160-0

Lift-and-Swing System -
removal device for
grinding table segments Drawing No. 146 650-0

Fitting of tension cylinder


bearing system Drawing No. 138 475-1

Rinsing equipment Drawing No. 153 700-0

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GEBR. PFEIFFER AG Chapter 9 BA200500591-E/D
KAISERSLAUTERN Spare Parts Edition 04.2006

9. Spare parts

9.1 General instructions

You should keep the most important spare and wear parts in stock on site to
guarantee the continuous availability of the equipment.

Please use the spare parts list to order spare parts. For further details please see
the relevant spare parts drawing included in the spare parts list.

For details on the plant components see also chapter 11.

We grant a guarantee only for the original spare parts supplied by us.

Attention: Do not mount or use otherwise any spare parts and accessories
which are not checked and released by GEBR. PFEIFFER AG.

Our warranty does not cover any damages occurred due to the use of parts other
than the original parts and accessories.

9.1.1 How to use the spare parts lists

For all orders for spare parts please quote:

- Spare parts list No. ....................

- Machine ....................

- Size ....................

- Order No. ....................

- Part No. ....................

- Quantity ....................

Comments on the spare parts list:

Part No. XXX: Spare part indicated in the spare


parts drawing.

Part No. XXX.1,


XXX.2 etc.: Spare parts that are part of the scope of supply of
part XXX, but that are not always indicated in the
spart part drawing; if these parts are not required
together with part XXX please quote accordingly in
your order.

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GEBR. PFEIFFER AG Chapter 9 BA200500591-E/D
KAISERSLAUTERN Spare Parts Edition 04.2006

Ident No.: For internal purposes only.

9.2 Spare parts lists/Spare parts drawing

List of documents:

Machine MPS 4500 B

Spare parts list

Spare parts drawing

- assembly drawing no. 155 573-0


- group grinding bowl (part no. 201-299) drawing no. 148 167-2
- grinding roller (part no. 301-399) drawing no. 155 041-2
- tensioning device (part no. 501-599) drawing no. 144 599-2
- seal air ducting (part no. 601-699) drawing no. 155 040-2
inner grinding roller
stop part (part no. 860-885) drawing no. 142 342-2
- torque support for
pressure frame (part no. 901-926) drawing no. 155 024-1

Machine SLS 3750 B

Spare parts list

Spare parts drawing

- assembly drawing no. 157 133-1


- bearing (part no. 201-299) drawing no. 152 921-2

Machine DSK 2000

Spare parts list

Spare parts drawing drawing no. 149 363-2

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GEBR. PFEIFFER AG Chapter 10 BA200500591-E/D
KAISERSLAUTERN List of equipment Edition 04.2006

10.1 List of equipment

Machine

Designation: vertical roller mill


Type: MPS 4500 B

with: air-swept lamella classifier


Type: SLS 3750 B

Design: with hydro-pneumatic tension system


with device for removal of grinding rollers
with maintenance door
with three-flap gate lock DSK 2000
with vibration trough conveyor

Sound pressure level: approx. 90 dB(A)

The mill is of depression design.

Order no.: 22347 - 22366

Equipment / Components

Grinding roller diameter: 2,500 mm


Grinding roller width: 900 mm
Number of grinding rollers: 3
Design of wear parts: segmented
Material of wear parts: Ni-Hard IV
Number of wear parts: 12
Weight per wear part: 714 kg

Grinding plate

Outer diameter of grinding track: 4,500 mm


Working diameter of grinding track: 3,550 mm
Design of wear parts: segmented

Part segment I:
Number: 13
Material: Ni-Hard IV
Weight: 440 kg

Part segment II:


Number: 26
Material: Ni-Hard IV
Weight: 144 kg

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GEBR. PFEIFFER AG Chapter 10 BA200500591-E/D
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Material infeed

Proportioning belt scale for mix

Manufacturer: Schenck MTD


Type: Multidos H 1635 T90
Number: 1

Motor see list of electric consumer

Proportioning belt scale for limestone

Manufacturer: Schenck
Type: Multidos MTD 1235 T70
Number: 1

Motor see list of electric consumer

Proportioning belt scale for iron ore

Manufacturer: Schenck
Type: Multidos 1035 T70
Number: 1

Motor see list of electric consumer

For further details see separate operating instructions – chapter 11.

Troughed belt conveyor by client


Number: 2
Belt width: 1,000 mm

Overbelt magnetic separator

Manufacturer: to be procured by customer


Type: to be procured by customer

Motor to be procured by customer

For further details see separate operating instructions – chapter 11.

Metal detector

Manufacturer: Eriez
Type: QM 3500 / BR, TX, RX

For further details see separate operating instructions – chapter 11.

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GEBR. PFEIFFER AG Chapter 10 BA200500591-E/D
KAISERSLAUTERN List of equipment Edition 04.2006

Storage silo of the mill to be procured by client

with bin closing slide

Silo for mix


Designation: steel
Capacity: 300 m³
Dimension:
Square height:
Conical height:

Overfill protection sensor


Principle: load cell
Manufacturer: Schenck
Type: RTN 150

Closing slide
Designation: needle slide
Length: 1,800 mm
Widht: 1,000 mm

Storage silo of the mill to be procured by client

with bin closing slide

Silo for limestone


Designation: steel
Capacity: 200 m³
Dimension:
Rectangular height:
Conical height:

Overfill protection sensor


Principle: load cell
Manufacturer: Schenck
Type: RTN 100

Closing slide
Designation: needle slide
Length: 1,400 mm
Width: 600 mm

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GEBR. PFEIFFER AG Chapter 10 BA200500591-E/D
KAISERSLAUTERN List of equipment Edition 04.2006

Storage silo of the mill to be procured by client

with bin closing slide

Silo for iron ore


Designation: concrete silo
Capacity: 180 m³
Dimension:
Rectangular height:
Conical height:

Overfill protection sensor


Principle: load cell
Manufacturer: Schenck
Type: RTN 150

Closing slide
Designation: needle slide
Length: 1,400 mm
Width: 600 mm

For further details see separate operating instructions – chapter 11.

Two-way chute

Compressed air cylinder


Manufacturer: Joyner
Type: DIM 200/320

Solenoid valves
Design: 5/2-port directional valve
Manufacturer: Joyner
Type: MH 511 121

For further details see separate operating instructions – chapter 11.

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GEBR. PFEIFFER AG Chapter 10 BA200500591-E/D
KAISERSLAUTERN List of equipment Edition 04.2006

Feed unit

Designation: Three-flap gate lock


Manufacturer: Gebr. Pfeiffer AG
Type: DSK 2000
Number of flaps: 3
Operation pressure: 160 bar maximum

Hydraulic unit
Manufacturer: Hydac-System GmbH
Type: compact unit for three-flap gate lock
Oil receptacle: 250 l
Type of pump: constant pump

Motor see list of electric consumer

For further details see separate operating instructions – chapter 11.

Tension system

Tension cylinder
Manufacturer: Hydrosaar
Number: 3
Design: double-acting

Pressure bag accumulator


Number: 6

Loading pressure: P0min = P1 x 0.33


P0max = P1 x 0.66
Operating pressure: P1 = 200 bar
P1max = 240 bar

Hydraulic unit
Manufacturer: Hydac-System GmbH
Type: unit for suspension of grinding rollers
to go with MPS 4500 B

Oil receptacle
Type: NG 400
Type of pump: radial piston pump
Volume flow: Q = 10 l/min

Motor see list of electric consumer

For further details see separate operating instructions – chapter 11.

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GEBR. PFEIFFER AG Chapter 10 BA200500591-E/D
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Compact unit for the Lift-and-Swing System

Manufacturer: Hydac Technology GmbH


Type: compact unit
Oil receptacle: NG 40
Type of pump: gearwheel pump

Motor
Manufacturer: Siemens
Type: BG 100 L
Power: 3.0 kW
Speed: 1,450 rpm
Design: IMB5/V1

For further details see separate operating instructions – chapter 11.

Torque support for pressure frame

Manufacturer: Gebr. Pfeiffer AG


Type:

Buffer
Manufacturer: Saalfelder Hebezeugbau
Type: KP 160 x 100 EF-E-HT

For further details see separate operating instructions – chapter 11.

Seal air fan

Manufacturer: Ventec
Type: VHR-250x180 MB
Static pressure increase: 80 mbar
Volume flow: 0.76 m³/s

Motor
Manufacturer: Dutchi
Type: 160 M-2
Power: 15 kW
Speed: 2,925 rpm
Design: IMB3

For further details see separate operating instructions – chapter 11.

Water pump

Manufacturer: Netzsch
Type: NM 045 BY 02 S 12B
Pumping medium: water
Flow rate: 2-6 m³/h

Spure type gearmotor see list of electric consumer

Speed variation via frequency converter see list of electric consumer

For further details see separate operating instructions – chapter 11.

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KAISERSLAUTERN List of equipment Edition 04.2006

Mill drive

Mill main motor to be procured by client


Manufacturer: ELIN
Type: HRR 010 B06
Power: 2,500 kW
Speed: 990 rpm
Design: IM B3

Mill main gearbox


Manufacturer: Flender
Type: KMPS 496
Power: 2,500 kW
Transmission ratio: i = 44.1
Output speed
- main drive only: 22.45 rpm
- with maintenance drive: approx. 0.16 rpm
Thrust bearing: segmented thrust bearing
Static load: normal 7,000 KN
Dynamic load: maximal 20,200 KN

Oil lubrication system: high pressure lubrication circuit


with oil pump and motor
Power: 4 x 7.5 kW
Speed: 1,455 rpm
Oil flow: 3 x 3.3 l/min

low pressure lubrication circuit


with oil pump and motor
Power: 30 kW
Speed: 1,470 rpm
Oil flow: 720 l/min

Coupling motor/gearbox
Manufacturer: Flender
Type: Rupex RWN 710

Maintenance drive
Manufacturer: Flender
Transmission ratio: i = 210.72

Chain drive
Number of teeth: Z1 = 15
Z2 = 45
One roller chain: 32 B-1

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Gearmotor for the maintenance drive see list of electric consumer


Manufacturer: Flender
Type: Motox K 128 M132 SB4
Power: 5.5 kW
Speed: 20.64 rpm
Design: B7-00A

For further details see separate operating instructions – chapter 11.

Vibration monitor
Manufacturer: Bruel & Kjaer
Type: Vibrocontrol 920

For further details see separate operating instructions – chapter 11.

Classifier

Designation: air-swept lamella classifier


Manufacturer: Gebr. Pfeiffer AG
Type: SLS 3750 B
Number of blades at louver (stator): 72
Number of blades at separating
wheel (rotor): 96

max. speed of separating wheel: 96 rpm

Gearbox
Manufacturer: Flender
Type: B3SV7
Transmission: 17.692
Output speed: 96 rpm (max.)
Design:

Motor to be procured by client


Manufacturer:
Type:
Power: necessary 122 kW
installed 132 kW
Speed: 1,487 rpm
Design: IMB3

Frequency converter to be procured by client


Manufacturer:
Type:
Power:
Speed control: 20-60 Hz

For further details see separate operating instructions – chapter 11.

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GEBR. PFEIFFER AG Chapter 10 BA200500591-E/D
KAISERSLAUTERN List of equipment Edition 04.2006

Rotary lock for the cyclons (2 pieces)

Manufacturer: SMD
Type: 800

Motor see list of electric consumer

For further details see separate operating instructions – chapter 11.

Plant fan

Manufacturer: Venti Oelde


Type: DHRV 45-S1600/K
Capacity: 630,000 am³/h
Total differential pressure: 9,425 Pa

Motor see list of electric consumer

For further details see separate operating instructions – chapter 11.

Sampler to be procured by client


Designation:
Manufacturer:
Type:

Gearmotor

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GEBR. PFEIFFER AG Chapter 10 BA200500591-E/D
KAISERSLAUTERN List of equipment Edition 04.2006

Dampers

Control damper in hot gas ducting

Manufacturer: Edelhoff
Type:
Nominal width (DN): 3,200 mm
Number of blade: 4

Actuator (manual control) see list of electric consumer

Control damper in fresh air ducting

Manufacturer: Edelhoff
Type:
Nominal width (DN): 1,000 mm
Number of blade: 1

Drive see list of electric consumer

Control damper in recirculating air ducting

Manufacturer: Edelhoff
Type:
Nominal width (DN): 2,500 mm
Number of blade: 2

Drive see list of electric consumer

For further details see separate operating instructions – chapter 11.

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GEBR. PFEIFFER AG Chapter 10 BA200500591-E/D
KAISERSLAUTERN List of equipment Edition 04.2006

Expansion joints

Classifier
Manufacturer: Korema
Type: U-shaped expansion joint
Opening: 3,300 mm (inner diameter)
Installation length: 210 mm

Mill inlet
Manufacturer: Korema
Type: U-shaped expansion joint
Opening: 2,000 x 1,150 mm
Installation length: 230 mm

Heating ducting
Manufacturer: Korema
Type: tape expansion joint
Opening: 355 mm (inner diameter)
Installation length: 230 mm

Hot gas duct


Manufacturer: Korema
Type: U-shaped expansion joint
Opening: 1,800 x 1,400 mm
Installation length: 230 mm

Seal air duct


Manufacturer: Korema
Type: tape expansion joint
Opening: 245 mm (inner diameter)
Installation length: 320 mm

For further details see separate operating instructions – chapter 11.

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GEBR. PFEIFFER AG Chapter 10 BA200500591-E/D
KAISERSLAUTERN List of equipment Edition 04.2006

Measuring and control technology

Manufacturer: Endress & Hauser


Type:

Air volume control: transmitter


low-pressure change-over cock
shut-off valve

Differential pressure
measurement of mill: transmitter
low-pressure change-over cock
shut-off valve

Pressure monitoring ahead of mill: transmitter


low-pressure change-over cock
shut-off valve

Temperature control after classifier: low pressure screwed resistance


thermometer

Temperature ahead of mill: low pressure screwed resistance


thermometer

For further details see separate operating instructions – chapter 11.

External recirculation

Vibration trough conveyor


Manufacturer: to be procured by customer
Type:

Bucket elevator
Manufacturer: Aumund (to be procured by client)

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