INSTRUCTION MANUAL .

OK Roller Mill 70001380-1

Operation & Maintenance

Text reference is made to the following instruction manuals:

General safety regulations on erection site 32031

Hydraulic unit mill spring system 70001379

Hydraulic unit control panel OK-HY-01
Hydraulic unit mill spring system.
Roller lubrication unit. 70001378
Rollers lubrication control panel OK-LU-01
Roller lubrication unit.
MAAG Gear instruction
MAAG Gear control panel OK-GE-01
Process instruction
Erection manual 70001381
Portable power unit for swing out hydraulics
Centralized lube unit.
Grease lubrication. OK-GLU
Grinding aid system
Separator ROKS
FLS key to lubricants 36501-11

VIGERSLEV ALLÉ 77 - 2500 VALBY - DENMARK 2040 AVENUE C - PA 18017-2188 BETHLEHEM – USA CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA
 70001380-1 2

Contents: Page:

1. General information 4
2. Introduction 6
2.1 General
2.2 General description of OK mill grinding system
2.3 External material circulation equipment
2.4 Equipment at lower stream side of mill
3. Operation preparation 10
3.1 Supply of lubrication oil and grease
3.2 Charging nitrogen gas into the accumulators
3.3 Confirmation of motor rotation direction
3.4 Flushing of lubrication and hydraulic piping and air venting from the
piping
3.5 Adjustment of roller stopper and cylinder stroke detection unit
3.6 Confirmation/adjustment of setting value
4. Test operation 14
4.1 No-load independent operation
4.2 No-load overall test operation
4.3 Load test operation
4.4 Re-tightening of bolts
4.5 Notice on operation of OK roller mill
4.6 Relationship between opening area and nozzle velocity
5. Maintenance / Inspection procedures 20
5.1 Daily inspection Items
5.2 Guideline of daily and periodical inspection
5.3 Inspection items during periodical repair
5.4 Inspection of roller bearing
5.5 Adjustment of dam ring height
5.6 Adjustment of nozzle opening area
5.7 Adjustment of cylinder stroke detection unit
5.8 Adjustment of roller stopper
5.9 Adjustment of thrust bearing at fulcrum shaft
5.10 Re-tightening of bolts
5.11 Lubrication/Greasing
5.12 Countermeasure against worn nozzle
5.13 Others

Record sheets:
Data sheet of roller tire wear
Data sheet of table liner wear
Make retightening record of all clamp bolts
6. Maintenance Procedures 30
6.1 Roller swing-out procedure
6.2 Roller swing-in procedure
6.3 Table track, roller tire replacement procedure
6.4 Table track replacement procedure
6.5 Roller tire replacement procedure
6.6 Works after replacement of roller tire/table track
6.7 Roller assembly pull-out procedure
6.8 Roller bearing pull-out procedure
6.9 Hydraulic cylinder replacement procedure
6.10 Main gear reducer pull-out procedure

The information transmitted by this document is the proprietary and confidential property of FLSmidth,
and may not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 3

Appendices:

No appendices

Edited by: DRS Proof reading: Pages: 51

Approved by: WCW Translated by: MGN code: 5B07

 70001380-1 4

Note!
The present instruction manual is concerned with the situations which,
according to the experience of FLS, are the most likely to occur. An ex-
haustive enumeration of all conceivable situations which may occur
during the erection, operation and maintenance of the machine cannot be
provided.
Consequently, if a situation should arise, the occurrence of which is not
foreseen in the instruction manual, and which the operator is/or feels
unable to handle, we would recommend that FLS is contacted without
undue delay for advice on appropriate action.

1. General
SAFETY
It is requested at least to observe the following points, to ensure trouble
free operation.
1. Observe all local and plant safety procedures, practices, and rules
when working in, on, or in the proximity of the mill and its auxiliary
equipment.
2 Be sure to check that all mechanical units are stopped, all motor
breakers, particularly those for the mill motor and separator motor, are
turned off, and that the inside of the equipment is fully ventilated and
cooled, prior to starting the repair or internal checking of the
equipment, or entering the equipment.
Do not use any kind of forced cooling. i.e. water injection.
It is also advised to set up and observe the maintenance / inspection
standard, so that the motor breakers cannot be turned on, without the
acceptance of the maintenance / inspection personnel in charge.
3 Use caution when working near any mill component during or after mill
operation as the surfaces may be at very high temperatures. Never
attempt to touch the bottom casing during and right after starting the
operation, as it reaches high temperatures.
4 Do not open the manhole or inspection ports during operation, or
operate with manhole or inspection port opened.
5 When entering the mill, be sure to put on protective glasses, mask,
gloves and long-sleeved clothing. Avoid wearing loose clothing.
6 Do not attempt to touch the rotating parts.
7 Do not remove the safety cover during operation, or operate with safety
covers removed.
8 Do not use any fire near the lubrication- or hydraulic unit.
9 Do not walk underneath overhung material.
10. Since the hydraulic unit and piping operate under high pressures, take
care around pressure lines. Ensure all pressure and potential energy is
released from the hydraulic lines and components prior to performing

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 5

maintenance. Special care is to be taken when working with systems

including energy storage devices such as hydraulic accumulators and
shock blasters.
11. Since it is possible that the safe allowable lifting load of lifting hooks
within the mill might have been decreased due to wear, be sure to
check it fully for strength, prior to use.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 6

2. Introduction
2.1. General
Thank you for installing the OK roller mill. F.L. Smidth is convinced that
the roller mill we supplied is the type best suited to your requirements, and
will demonstrate the effective and economical performance, as long as it is
used with the proper precautions.
Since the roller mill is used under severe conditions, the performance and
life will greatly depend upon whether the maintenance/inspection is
performed properly. Knowing where, when and how to perform the
maintenance and adjustment prior to the operation, will provide the users
with great advantages.
This instruction manual describes the procedures of the operation,
maintenance, etc. of the roller mill, to allow it to be used in the most
effective manner.
It is requested to fully read this instruction manual prior to operation, and
further to refer to the manual during the use.
For placing an order of parts, or inquiry concerned with the mill supplied,
kindly specify the “Contract No.”, refer to the relevant Parts List No., Sheet
No., Section No., Line No., Drawing No. and Name of part.
General notice on mill operation
1) When the mill starts, enough feed material or ground material must be
spread on the grinding table before lowering the rollers.
2) Prior to the mill start, sufficient warming up shall be carried out.
Especially in winter, it is important for prevention of mechanical
troubles during start-up.
3) The outer part of the roller tire tends to become a thin collar shape as
the wear progress, cracks can occur in this area. Since the thin collar
shaped roller tire leads to a reduction of capacity and increased
vibration, the tire segments should be reversed / replaced before
breakage occurs. This normally coincides with about half the expected
lifetime of the segments.
Also, the outer end of table track may break, at the same time as the
breakage of roller tire. Since large broken pieces of liner segments
are harmful, adjust roller stopper and the setting of operating
conditions etc. to minimize the problems that can occur with rough
operation.
4) Hardfacing on the worn table track and roller tire can be applied, an
interval of 7000-8500 operation hours being suitable for clinker
grinding, based on the experience of the operator. However, this
interval may be varied in accordance with the wear characteristics of
feed material and the operation condition etc. Hardfacing must be
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 7

done by automatic welding. Hand welding is not advisable, only for

minor repairs in the gaps between segments.
2.2 General description of OK mill grinding system
The outline of the equipment is as described in the following. The feed
material before grinding is hereafter named as “Material”, the ground
material dropping through the nozzle as “Circulation material” and after
grinding as “Product” respectively.
OK Roller Mill
Refer to “OK - Roller mill assembly drawing”.
2.2.1 Main gear reducer
Refer to “Instruction manual for main gear reducer”.
The table is rotated by the mill motor through the main gear reducer to
provide the power required for grinding. The weight of the table and the
vertical force applied by the rollers, are supported by the thrust pad
bearings and casing, and the horizontal force by the roller shaft bearings
and mill bases respectively.
Never turn the gearbox without the gear lubrication pump running.
Since the main gear reducer casing supports the force applied by the
rollers, the vibration detector is installed on the gear box foundation to
monitor the grinding condition.
2.2.2 Grinding table and rollers
Refer to:
“Table assembly” and “Roller assembly” and “The pressure lever assembly”.
1) Shape
The grinding portion is provided with the grooved roller tire and further
with the wedge shape, of which clearance between the roller and table is
narrowed toward the outside of the table. This shape is unique to the
OK mill, developed to grind hard materials such as slag, cement clinker,
etc. and obtain the required particle size distribution without undue
vibration. Roller tire is designed for reversing and liners are made from
high chrome cast iron to prolong the service life.
2) Mill spring system
The grinding force is applied to the rollers by the hydraulic cylinders and
accumulators. The hydraulic unit for mill spring system, applying and
controlling the pressure.
The hydraulic system for mill spring system is so designed that the rollers
are raised when the mill is started and are lowered slowly as the material
is fed, to reduce the start-up torque of mill, and further that the severe
movement of the rollers can be controlled during mill operation, to
maintain the pressure applied at a constant level.
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 8

It is also designed to allow the pressure setting to be changed during

operation from the central control room by remote control.
3) Roller/Table metal contact preventing mechanism
To meet the required thin material bed on the table, roller stoppers are
provided for the prevention of metal contact between table track and
roller tire and further the cylinder stroke detection unit is provided for
measuring the thickness of the material bed in unit of “mm”.
The cylinder stroke detection unit is provided with a zero-point
adjustment function, via the local control panel, which allows the re-
alignment of initial setting position, as the wear progress.
4) Dam ring and nozzle ring
The grinding zone is formed at the circumference of table by the dam
ring to secure a proper material bed on the table.
Since the dam ring is constructed by overlaying thin steel plates and
fixed with bolts, it can be adjusted in height.
The circulation gas induced in bottom casing described later on, is
blown toward the upper side of the table through nozzle ring, and serves
not only to dry the material inside the mill, but also to circulate it inside
the mill, which is required for the separation process.
Nozzle ring is provided with interchangeable nozzle liners at its opening,
to allow the area of nozzle opening to be adjusted, and further to assure
the air velocity suitable for the grinding process.
Hardfaced steel plates are used for the nozzle ring to prevent wear.
2.2.3 Bottom casing
As for bottom casing, refer to “Body assembly”. Bottom casing is prepared
at the lower part of the mill body for the introduction of circulation air.
Bottom casing is provided with circulation gas inlet ducts at two positions, to
direct the circulation gas through nozzle ring. Besides, the circulation
material take-out chute is prepared at one position of bottom casing in
which the circulation material dropped downward from the nozzle ring during
grinding is scraped/collected by scraper, and then down to the extracting
conveyor from the chute.
2.2.4 Mill housing
As for mill housing, refer to “Body assembly”. The material may circulate at
high velocity due to the influence of circulation gas blowing up through
nozzle ring described previously. For this reason, steel plate liners are
mounted on the inner surface of mill housing.
Although the amount of material is limited at the start-up, the material
circulation density is increased and stabilized during initial stages of
operation. This condition is observed by measuring the differential pressure
between the mill circulation gas inlet duct and the upper part of mill housing.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 9

2.2.5 Separator
As for the separator, refer to separate instruction. The separator used is a
rotary type separator for separation of fine particles.
The coarse material returning to the grinding table via separator return
cone.
Rotor is driven by the variable speed motor, adjustable from central control
room, through the gear reducer.

2.3 External material circulation equipment

The circulation material dropped from the take-out chute of bottom casing is
loaded on the circulation conveyor.
The circulation material loaded on the circulation bucket elevator is returned
into the mill together with the new feed material.
2.4 Equipment at lower stream side of mill
The product carried out together with the circulation gas from the separator
of the roller mill, is captured by the bag filter.
The circulating fan is arranged after the bag filter to introduce circulation
gas into the mill for drying/separating/carrying-out the product.
The circulation gas discharge from the fan is branched; one part of the gas
is discharged into the atmosphere. Since the other part of the circulation
gas is re-used as circulation gas, it is introduced to the gas inlets of the
roller mill. When mill is cold or drying of material is needed, a heat
generator can be used.
This manual describes the operation procedures for the OK roller mill,
including its test operation.

For operation of individual equipment in the system, refer to the instruction

manual for the specific equipment, which is submitted separately.
After completion of the installation, perform the test operation mainly for the
following purposes.
1. To check that there is no non-conformity in the equipment assembly,
and that each equipment operates properly.
2. To find the actual setting values in operating conditions.
3. To confirm system performance.
Arrange the data obtained during the test operation and utilize it for
operation and maintenance to be performed afterward, as this will provide
an effective guideline and future reference.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 10

3. Operation Preparation
3.1 Supply of lubrication oil and grease
Supply the lubrication oil and grease to each part in accordance with the
lubricant list.
3.2 Charging the accumulators connected to the hydraulic cylinders
Fill the accumulators connected to the hydraulic cylinders for mill spring
system with dry nitrogen gas, at the specified pressure for the initial start-up
grinding pressure. See table in hydraulic instruction.
3.3 Confirmation of motor rotation direction
Check direction of rotation of the motors, referring to the assembly drawing
and instruction manual of each equipment.
3.4 Flushing of lubrication and hydraulic piping, and air venting from the piping
3.4.1 Flushing of piping
If the below mentioned conditions are fulfilled, then operate the lubrication
units and the hydraulic units, using the specified oil in the lubricant list, for a
few days until ISO contamination code 15/12 or better is obtained.
Conditions:
1. The piping has been assembled shortly beforehand, after completing
the pickling and flushing under prefabricated condition.
2. There is no danger of dirt/water entering the piping during assembly
work, generating rust inside of the piping.
Start the oil pump, and check the oil filters, the first time 15 min. after
starting the pump. Check the oil filters every hour after the first check,
to prevent the hydraulic system from damage. See hydraulic instruction
for the hydraulic circuit diagram of mill spring system.
Note:
After completion of above operation, be sure to return the hydraulic circuit to
the standard set-up.
Set all valves to the fully OPEN or CLOSED condition, specified as normal
position and lock.
3.4.2 Air venting from the hydraulic cylinder
Vent the air from the piping after completing the work, described in the
above paragraph.
An air vent plug is provided on both rod- and head side of the hydraulic
cylinder including the portable cylinder.

For the portable cylinder, it is essential that all air is expelled before
attempting to operate the cylinder, when connected to roller. Perform
expelling first in a horizontal position.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 11

Operate the hydraulic unit, move (raise and lower) the cylinder rod
several times and vent the air.
Since the oil contained in the tank is transferred into the piping, as the
air venting progress, stop the pump; while observing the oil level, and
re-supply oil as required.
Also perform the above air venting at the initial stage of mill operation,
to fully discharge the air from the rod side port in particular.
Note:
When moving the hydraulic cylinder, keep the roller stopper protruded,
so that the roller can not make direct contact with the table.
3.5 Adjustment of roller stopper and cylinder stroke detection unit.

As for roller stopper, refer to “roller assembly and pressure lever

assembly” at the same time.
Roller stopper is used to prevent metal contact between the roller and
table.
Roller stopper is used to secure the desired clearance between the
roller and table mechanically. Roller stopper is used to prevent
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 12

troubles due to unfamiliar operation at the time of mill start-up, and in

case of problems with the electrical system.
Even though roller stopper is present, do not fail to check that the feed
is properly administered and that there remains sufficient material on
the table, when the mill is stopped. Since roller stopper needs to be re-
adjusted as the segments are worn, perform the re-adjustment of roller
stopper in accordance with the following procedures.

All turning of the grinding table to be done with the main gear reducer
pump operating.
Note that the gear flange/grinding table, lifts 0.2 - 0.5 mm when
unloaded.
Adjust roller stopper as shown below:
1) Remove the material on the table.
2) Operate the hydraulic pressure unit for mill spring system and the
lube unit for mill gear reducer in the local control mode, to lift the
roller.
3) Loosen nut for roller stopper and unscrew roller stopper
4) Slowly lower the rollers in manual operation, releasing the button as
soon as the roller is lowered, and be careful not to raise the
hydraulic pressure of mill spring system. When the hydraulic
pressure is exerted, press the roller UP button to decrease the
hydraulic pressure to 0.
5) Then, turn roller stopper to make lightly contact with stopper plate.
6) Raise the roller and turn roller stopper by approximately 5 or 6 turns
clockwise. Position of ultrasonic sensor and stopper is on about the
same radius, giving about equal change of distance to movement of
stopper.
7) Lower the roller to make roller stopper to contact with stopper plate.
Set the hydraulic pressure to the normal operating grinding pressure.
8) Measure the clearance between the roller and the table using a steel
scale, and adjust roller stopper setting so, that the gap between roller
and table is 2~4mm.
9) Operate the low/high-pressure pumps of the main gear reducer
lubrication unit under the condition described above during the initial
setting, and turn the input shaft coupling of the main gear reducer
manually to turn the table, to check that the roller does not make any
contact with the table during rotation. If the roller makes contact with
the table, perform the readjustment of roller stopper and adjust the
ultrasonic cylinder stroke detection unit’s set-point, in the local control
panel for hydraulic pump unit, at the contact position.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 13

10) The stopper will require adjustment to prevent the stopper from being
continuously hit during operation as the wear of segments progresses.
To adjust the stopper, loosen nut for roller stopper, turn roller stopper
and make the adjustment, so that the clearance between stopper plate
and roller stopper is again approximately 2∼4mm. Re-adjust the
ultrasonic cylinder stroke detection unit set-point as described in
paragraph 9 above.
11) Note that frequent adjustment of roller stopper is necessary for
preventing damage of the screw of roller stopper and damage to the mill
base.

3.6 Confirm/Adjustment of setting values

Zeroing of rollers on table

1) Lift the rollers and unscrew the stoppers.

2) Clean up the grinding table.
3) Lower the rollers to the table without grinding pressure.
4) Zero the ultrasonic sensors.
5) Lift the rollers and turn the grinding table 90 degrees.
6) Lower the rollers to the table and note down the ultrasonic sensor
measured distance for each roller.
7) Repeat for every 90 degrees or less. Finish at start point to check zero.
8) You now have a “map” of the table high points. You can make the
mapping as fine as you need, according to the flatness of the table
surface.

Record all setting values for future references. Confirm setting values
are stable when starting after a shutdown.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 14

4. Test Operation

1) Check that the electrical wiring is executed in accordance with the

relevant drawing.
2) Check that each piping is executed in accordance with the relevant
drawing.
3) Check that the oil or grease is filled fully to all necessary points.
4) Check that the bolts and nuts are fastened, torqued and / or tensioned
properly.
5) Check that there is no equipment or material, such as remaining work
material, tools etc. left inside the equipment, or in the vicinity of
moving/rotating parts. That there are no obstacles on any rotating or
sliding parts. Check that no foreign matter remains inside the
equipment.
6) Check that all safety guards and personnel protection components are
properly installed on the mill and the auxiliary equipment.
7) Ensure all foreign material is removed from the mill.
8) Check that everyone is out of the mill. All maintenance or work on the
mill must be finished before starting.
9) Before operation of the hydraulic unit, the low pressure and high-
pressure pumps of lubrication unit for main gear reducer shall be
operated.
After completing the preparations described in section 3, start the test
operation in accordance with the following sequence.
1. No-load independent operation of the equipment.
2. No-load overall operation as a grinding system.
3. Load test operation.
Clean exterior of mill for debris, to avoid injuries from down falling parts.
4.1 No-load independent operation
After completing assembly, installation and operation preparations of the
equipment, operate each unit without load, to check that each unit can
operate properly.
Perform the no-load independent operation of the mill gear reducer and
separator continuously, until the temperatures of bearings become constant.
Minimum 8 hours. Also adjust the hydraulic unit of the mill spring system for
the roller raising/lowering speed and pressure relief speed as per the
instruction manual.
The operation of each equipment is basically performed according to the
instruction manuals.
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 15

Perform the no-load operation in accordance with the following procedure.

1) Set the separator motor to minimum speed and then operate the motor
by inching for the first one second.
2) Since the rotor is turned through the gear reducer, when the separator
motor is turned, check it for rotating direction and then for any unusual
sounds.
3) If no unusual sound is found, start the motor again, for continuous
operation. In this case, check that it is possible to change the separator
speed.
4) After checking that the temperature of the separator bearing has
become constant, stop the motor.
Since the separator rotor, and connected drive components, can be rotated
by the airflow, when the fan is operated, operate the separator lubrication
pump and the separator speed reducer lube system, whenever there is gas
flow through the mill.
4.2 No-load overall test operation
Start and stop the equipment using the operation command from the central
control system, to check that the interlocking system is functioning properly
for a normal start-up sequence.
For the equipment starting and stopping procedures, refer to the operation
scheme and interlock list in the process instruction.
4.3 Load test operation
Starting and stopping
4.3.1 Control required for operation
The control and adjustments, required for operation of the roller mill can be
generally classified into the following.
NOTE:
Operation of the high-pressure/low-pressure pumps of main gear reducer is
required when hydraulic cylinders are operated for setting and adjusting of
the hydraulic pressure of mill spring system.
4.3.2 Mill power control
The mill motor current or power is directly influenced by the grindability of
feed material. The mill feed must be regulated so that the current or power
can be kept at a constant level.
This control is particularly effective in the grinding of feed material, where
the grindability varies over a wide range.
4.3.3 Mill differential pressure control
Keeping the mill differential pressure constant, the amount of material in the
mill can be kept at a constant level. Since this control is used for almost the
same purpose, as the mill power control described above, the mill
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 16

differential pressure control and the mill motor power control can be used
proportionally / interchangeably. Normally the power control is the most
effective.
4.3.4 Mill outlet gas temperature control
Control the damper opening to keep the mill outlet gas temperature
constant, safeguarding the bearings, seals, filter cloth of the bag filter, etc.
from damage due to overheating, and to stabilize the grinding condition
inside the mill and product temperature (gypsum dehydration) during normal
operation.
4.3.5 Gas flow rate control
To stabilize the material circulation inside the mill and the product particle
size distribution, it is necessary to keep the amount of gas passing through
the mill at a constant level. For this purpose, the power (Airflow) of the
circulating fan is monitored to control the gas flow rate.
4.3.6 Product fineness control
The fineness of the product is controlled by the rotating speed of separator.
The higher (lower) the rotations speed is, the finer (coarser) the product
becomes.
Perform the load test operation by supplying the material after checking the
detectors and controllers.
When performing the load test operation, control the mill motor power, mill
inlet/outlet gas temperature, gas volume and hydraulic pressure of the mill
spring system in accordance with the instruction manuals.
Prior to starting the mill operation, some feed material must be fed to the
table to prevent direct contact between rollers and table.
The amount of material is determined at the time of operation.
The calibration of actual feed rate for the constant feed scale and that of
gas flow rate, which are the important preparations, shall be also performed
before starting operation.
Refer to Process instruction.
Adjust the dam ring height, nozzle opening area, hydraulic pressure of the
mill spring system, gas flow rate and separator speed during this load test
operation, and confirm the desired performance / values.
As for relationship between opening area and nozzle velocity refer to
Process Instruction
4.4 Re-tightening of bolts
Re-tighten the bolts after load test operation. For torque/tightening force see
assembly drawings.
Re-tightening should be carried out three times “after 8 hours operation”,
“after 16 hours operation (total 24 hours operation)” and “after 24 hours

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 17

operation (total 48 hours operation)” and keep the results of re-tightening

recorded.

LIST OF BOLTS REQUIRED FOR RE-TIGHTENING

1 st. re-tightening (after 8 hours operation)
1. Clamp bolts for roller tire
2. Clamp bolts for table track.
3. Joint bolts of bearing block
4. Joint bolts of table and outlet flange for gear reducer
5. Installation bolts of mill housing
6. Mounting bolts of roller end cover
7. Installation bolts of support frame for air separator
8. Foundation bolts
9. Joints of hydraulic pressure piping and lubrication piping

2 nd . re-tightening (after 16 hours (total 24 hours) operation)

1. Clamp bolts of roller tire
2. Clamp bolts of table track
3. Loosened bolts from the 1 st . re-tightening

3 rd . re-tightening (after 24 hours (total 48 hours) operation)

1. Clamp bolts of roller tire
2. Clamp bolts of table track
3. Loosened bolts from the 2 nd re-tightening

4 th. re-tightening
1. Re-tightening shall be determined in accordance with the result of 3 rd.
retightening.

Note:
Clamp bolts of roller tire and table track should be checked and re-tightened
by the specified torque/tightening force every 1,000 hours operation after
the above-mentioned re-tightening.

4.5 Notice on operation of OK roller mill

4.5.1 Warming up operation
Prior to the mill start, sufficient warming up operation shall be carried out to
pass the hot air of 80-100° C. temperature at mill inlet into the mill and the
system. In winter, it is important for prevention of mechanical troubles
during start up.
4.5.2 Grinding aid
It is necessary to supply the grinding aid (di-ethylene glycol: D.E.G or
similar) with feed material for successful operation in case of clinker

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 18

grinding. Feed rate of D.E.G. is 0.02% weight of material feed rate for OPC
is normal. The percentage is dependent on the fineness ground and the
quality / concentration of the D.E.G.
4.5.3 Constant power control
Basically perform the constant power control (as a result of constant
material feed amount) for the mill.
In this case it is necessary to maintain the gas flow rate, air temperature
etc. at a constant level.
4.5.4 Automatic operation
The manual operation shall be adopted for approx. 30-40 minutes after
starting operation. When the mill operation is stable, start the automatic
control with the gas flow rate and mill motor power kept at a constant level.
Keep the material feeding rate to a slightly low level (approx. 70-80% of
setting value) at the time of mill start, and increase the feed rate up to the
setting value gradually after the rollers has been lowered, in accordance
with hydraulic pressure setting of the roller spring system.
Since the gas flow rate is decreased as soon as the material is fed, it is
necessary to quickly adjust the airflow rate to the desired level.
In this case it is also necessary to pay attention to mill outlet gas
temperature from the mill.
4.5.5 Notice at the time of change of mill operating conditions
Setting of material feed rate, gas flow rate and mill outlet temperature are
three factors to stabilize operation of the roller mill.
Any rapid change of the setting value is not recommendable during starting-
up operation. Because material feed variations may result in unstable
condition even under the stabilised condition.
Such tendency will be more pronounced, at the range close to upper limit of
the mill capacity, which is determined by the setting conditions of the gas
flow rate, hydraulic pressure etc.
It is difficult to determine changing rate of the setting value. The guideline at
initial stage is 2-4% of setting value for the feed rate. (The value can be
increased step by step as the operators get more experienced.)
It is essential to adjust the gas flow rate/temperature as slowly as possible,
while observing the temperature rise (fall) gradient.
Either of the above operations needs to be performed, while checking the
increase in mill power.
4.5.6 Change of setting conditions and movement of parameter
The thickness of the material bed on the table, mill motor power and mill
differential pressure will vary in the same manner.
If the material feeding amount is increased (decreased), the layer thickness
of the material bed, mill motor power and differential pressure will increase
(decrease).
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 19

Since the gas temperature is also changed in this case, it is necessary to

control the gas temperature together with the gas flow rate.
4.5.7 Mill vibration
The mill vibration level is influenced by the thickness of the material bed
and the fineness of the finished product.
In other words, the vibration level is decreased when the thickness is
increased and visa versa.
In addition, it is necessary to monitor the vibration level at all times, as an
increase of mill power may occur due to over feed, insufficient feed,
excessive rise of mill outlet temperature etc. together with an increase of
vibration value.
4.6 Relationship between opening area and nozzle capacity
The nozzle opening area governs the airspeed in the openings and thus the
amount of recirculated material.
The free area can be changed by installing different liner plates. This will
normally be optimized during commissioning, but subsequent major
changes in feed composition can force the change of liner plates.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 20

5. Maintenance / Inspection procedures

Re-tightening should be carried out until the nut does not rotate any more.
In addition, clamp bolts for fixing roller tire and table track should be
checked and re-tightened by the specified torque/tightening force every
1,000 hours operation after the above mentioned re-tightening.

5.1 Daily inspection items

1) Make it a rule to patrol around the equipment once a day while the mill
is operating, to check for unusual noise, vibration, loosened bolts, air/oil
leakage, etc. Also, observe each instrument to check for any failure. If a
defective instrument is found, replace the instrument with a new one at
once.
2) The un-load time of the hydraulic pressure unit for mill spring system will
provide the guideline for the replacement of cylinder piston sealing, or
for the discovery of valve leakage due dirt. Be sure to keep record of
inspection result at the time of daily inspection. When any sudden
change in un-load time is observed, it may indicate a problem.
In such a case, find the leak by using a hearing rod, etc. to locate the
location of leakage. When the un-load time is long, and is shortened
gradually to less than 30 seconds, it is time for piston packing
replacement.
Since the roller mill is used under extremely severe condition, it is
necessary to perform the maintenance and inspection every day and at
the time of shutdown. It is advised to perform the inspection more
frequently, when the equipment is new.
The practice of satisfactory maintenance/inspection will not only serve to
prevent possible accidents, but also to prolong the life of the equipment.
An inventory of spare parts will allow quick repair of any problems.
It is recommended to forecast the replacement of wearable
parts/consumable parts, and to place an order of such parts
immediately.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 21

5.2 Guideline of Daily and Periodical Inspection

Perform the daily and periodical inspection in accordance with the following
schedule.

INSPECTION ITEMS JUDGEMENT CRITERA/REMARKS

1 Make sure that there is not any water or There must not be any water or oil
oil leakage through piping and hoses. leakage.
(Check the internal piping for leakages
while the mill is stopped.)
2 Make sure that there is no point where the There must not be any leakage of
ground material leaks. ground material.
3 Make sure that there is not any unusual There must not be any unusual
vibration generated. vibration generated.
4 Make sure that there is not any unusual There must not be any unusual sound
sound generated. generated.
5 Make sure that each unit is filled with The oil must be filled up to the
proper amount of oil. specified level.
6 Make sure that necessary amount of There must not be any failure in
grease is filled at each greasing point. greasing point and greasing rate.
(For greasing point and greasing rate,
refer to the lubricant list).
7 Make sure that there is not any unusual There must not be any unusual sound
sound generated from bearing metal at generated.
connection of hydraulic cylinder for mill
spring system.
8 Make sure visually that there are no loose There must not be any loose bolts.
bolts.
9 Check the inlet chute for condition of Keep record of each condition.
material adhered, (only for slag mill) and
the chute liner wear. (Perform the above
checks while the mill is stopped.)
10 Monitor the temperature of roller shaft There must not be any unusual
bearing oil and separator shaft bearing. temperature rise.
11 Check the seal between the roller shaft There must not be any failure in roller
boss and the mill housing. shaft boss seal.
12 Check roller and pressure lever assembly There must not be any excesses in
for movement at fulcrum shaft. movement.
13 Make sure that roller stopper is not being Roller stopper must not be hit
hit frequently. frequently.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 22

5.2.1. Every 500 hour inspection

INSPECTION ITEMS JUDGEMENT CRITERA/REMARKS

1 Measure roller tire and table track for wear. Keep record of wear in data sheet.
2 Inspection of mill inside

Check for the following points in

particular: • Keep record.
1) Check housing liner and nozzle for
condition of wear. There must not be any loosened
bolt.
2) Perform hammering to check each bolt
for looseness.
3) Check for oil leakage through roller shaft There must not be any oil leakage.
oil seal.
3 Check the pressure of nitrogen gas filled in The nitrogen gas pressure must be
the accumulators for hydraulic cylinders. at setting pressure.
Grinding pressure un-loaded, mill stopped.

5.2.2 Every 1,000-hour inspection

INSPECTION ITEMS JUDGEMENT CRITERA/REMARKS

1 Make sure that roller tire clamp bolts and Keep record of re-tightening
table track clamp bolts are re-tightened at condition.
specified torque/tightening force. (Including
checks for liner floating and clamp plate
fitting condition)
2 Check that roller tire and table track are not If any crack found, keep record.
cracked
3 Inspection of bottom casing inside

Check for the following points in particular:

1) Check the clearance between
scraper and bottom Refer to table assembly
casing liner
2) Check of scraper for
deformation and wear Keep record.
3) Check of bottom casing for condition
wear Keep record.
4 Check that the hydraulic cylinder rod is not There must not be any damage,
damaged. (Remove the bellows, and check which may lead to oil leakage.
for damage with cylinder held at stroke end.)
5 Check the pressure of nitrogen gas filled in The nitrogen gas pressure must be
the accumulators for hydraulic cylinders. at setting pressure.
Grinding pressure un-loaded, mill stopped.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 23

5.2.3 Every 6-month inspection

JUDGEMENT CRITERI/REMARKS
INSPECTION ITEMS

1 Check roller and pressure lever assembly The max. movement must be within
for the thrust movement amount (Refer to 1mm.
procedure of shimming at thrust bearing)
2 Check spherical bush fitted into joint rod There must be free from any failure.
for condition. Damaged and locked spherical bush
may cause the breakage at the thread
part of cylinder rod.
3 Inspection of separator inside

Check for the following points in particular:

1) Check rotary blade for Keep record.
condition of wear
2) Check guard pipe for condition Keep record.
3) Check the bolt/screw for looseness.
(Where whirl stop is provided, check There must not be any loosened
that it functions properly) bolt/screw
4) Check for grease leakage.
Keep record.
4 Check each bolt for looseness by There must not be any loosened bolts.
hammering.

Check for the following points in particular:

1) Foundation bolts
2) Bolts connecting gear reducer
output shaft flange to table
3) Bolts mounting bearing cap
4) Bolts connecting swing lever to roller
shaft boss
5) Bolts mounting retainer plate for lock
pin
6) Bolts connecting separator casing to
mill housing

5 Check the pressure of nitrogen gas filled The nitrogen gas pressure must be at
in the accumulators for hydraulic cylinders. setting pressure.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 24

5.3 Inspection items during periodical repair

While the periodical repair is performed after the long-time operation, check
the following items in addition to the daily inspection items.
1) Measure table track and roller tire for wear and keep the measurement
result.
The timing to reverse roller tire, to replace roller tire and table track is
determined depending on wear data.
In performing the measurement of wear, use gauge plate supplied as the
measurement instrument and keep record of such measurement record
together with the operation time and total ground amount.
Bear in mind that the power consumption or vibration may increase, or
the long-time continuous operation may become impossible if the re-
operation is started under unusually or excessively worn condition.
Hardface welding can be applied to both worn table track and roller tire.
This should always be done at the same time on both parts to keep a
optimum grinding profile.
Replace / refurbish the table track with a new at the same time as roller
tire is replaced.
2) Check the mill, inside of separator and other parts, which are
inaccessible during operation and repair or replace the parts required.
3) Check that the bolts for the mill and separator are not loosened.
5.4 Inspection of roller bearings
It is not possible to check the roller bearings fully, unless they are drawn out
of the shaft, however, pay attention to the following points during periodical
inspection.
If the oil level in oil tank decreases, the oil seal may be damaged. It is also
possible that the shaft-to-bearing centre is deviated due to worn bearings.
Note that oil level changes with temperature and is lower when mill is in
operation.
Check filters for roller bearing lubrication for metal particles regularly.
Scheduled oil sample testing will give early indication of bearing wear.
5.5 Adjustment of dam ring height
Dam ring attached to the outer circumference of the table is used to hold
the material on the table for a proper thickness of material bed. Since it is
difficult to keep enough material bed if dam ring height is too low, it is
necessary to set dam ring to the proper height. If it is too high, however,
the grinding is inefficient. When the mill motor output is excessively high,
therefore, decrease dam ring height gradually. It is desirable to change
dam ring height at the time when about 10% increase of the mill power
consumption is observed in optimum operation.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 25

The projection, on table rim, shall be used as the guide in setting dam ring
height.
5.6 Adjustment of nozzle opening area
The air velocity at the nozzle arranged to the table is closely related with the
amount of the circulation material spilt through the nozzles. If the air
velocity is increased, the amount of circulating material is decreased;
causing the mill to be more stabilized, resulting in little vibration.
If it is increased excessively, on the other hand, the mill pressure loss is
increased, by which the power consumption of circulating gas fan is
increased or the desired gas flow may not be assured. In such case,
change nozzle liner for adjustment of nozzle opening area, so that the
stabilized operation can be assured.
5.7 Adjustment of cylinder stroke detection unit
Adjust the ultrasonic cylinder stroke detection unit to new set point as wear
progresses, in the local control panel for hydraulic pump unit. See section
3.5.
5.8. Adjustment of roller stopper
See section 3.5.
5.9 Adjustment of thrust bearing at fulcrum shaft
As the wear of thrust plate progresses, roller and pressure lever assembly is
moved largely by the axial thrust shock load generated in grinding. This may
lead to the damage of related mechanical components. If the amount of
movement (Bearing gap) is 1mm or over, adjust the thickness of shims,
referring to the drawing of procedure of shimming at thrust bearing.
1) Measure the amount of movement in accordance with the following
procedure.
2) Thrust plate 1 (4) shall be attached to nut with shim for fulcrum shaft
not attached.
3) Roller and swing lever assembly shall be fully shifted to right using
wedge as shown in this drawing. Wedge shall be supplied by
customer.
4) Nut for fulcrum shaft (3) with thrust plate 1 (4) shall be screwed in up to
shoulder of fulcrum shaft (6).
5) Measure the clearance between thrust retainer (1) and thrust plate 1
(4) after removing the wedge. This clearance is the amount of
movement.
6) Shim plates shall be inserted between nut for fulcrum shaft (3) and
thrust retainer 1 so measured clearance is 0.2mm to 0.4mm gap.
Example: If initial gap is 10.4mm, total installed shim thickness will be
10.0mm to 10.2mm.
7) After adjustment of shim and assembly, wedge shall be detached
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 26

(1) Thrust retainer (6) Fulcrum shaft

(2) Shim for fulcrum shaft (7) Roller shaft boss
(3) Fulcrum shaft nut assembly (8) Swing lever
(4) Thrust plate 1 (9) Bearing cap
(5) Thrust plate 2 (10) Wedge taper 1/5, customer supply

5.10 Retightening of bolts

See section 4.4
5.11 Lubrication/Greasing
For the lubrication/greasing of hydraulic oil/lubricant, refer to the
recommended lubricant list and the instruction manual.
1) Roller oil level.
Since the oil level inside the roller bearing housing is unable to be
checked due to its construction, be sure to run the circulating lube
system to make sure the roller is full of oil before mill operation.
2) Oil level check
Make it a rule to check the units for oil level every day. Sample the oil
from the roller for analysis periodically and use the sampling result for
guideline for the oil exchange. Sampling and analysis on the oil is
carried out once every month at the initial stages.
3) Grease lubrication of plain bearings.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be
duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 27

For information on grease pump, please read separate instruction

Confirm grease is reaching all positions. Failure of lubrication can
lead to serious breakdown of bearings and joint heads.
Grease points: Range volume/hour
Spherical bearing. Cylinder rod side ~0.4-2.4 cm 3/hour
3
Spherical bearing. Cylinder head side ~0.4-2.4 cm /hour
3
Bearing of joint pin. Cylinder rod side ~1.2-5 cm /hour
Bearing of joint pin. Cylinder head side ~1.2-5 cm 3 /hour
Bearing of fulcrum shaft 2 sides ~1.2-5 cm 3 /hour
Total grease volume per roller ~4.4-20 cm 3 /hour

5.12 Countermeasure against worn nozzle

The air nozzle is made up of nozzles and liner plate.
Since the nozzle is constructed by applying hardfacing in part and it
requires time and labor to remove nozzle when it is worn, execute re-
hardfacing for repair of locally worn areas.
Since nozzles are made up of steel plate and are of split type, it can
be applicable to either replace sections or do localized hardfacing.
Determine which method to use, depending on the wear condition.

5.13 Others
1) Be sure to perform the test operation of the hydraulic unit and
lubrication unit prior to re-starting the mill after long shutdowns. It
is also advised to perform the operation check and air venting for
the hydraulic unit.
2) For the other inspection items, refer to the specific manual for
each piece of equipment.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 28

OK mill, roller Plant: Measuring sheet ref. No. Sent by:

Wear measuring Mill size: OK 30-4 Date:
Hour counter for total mill operation hours: Hour counter at last wear parts replacement:
total production counter: Production counter at last wear parts replacement:
Previous wear measuring, date: Sheet ref. No.: Hour counter: Total production counter:
Notice: When measuring the wear, use 10-20 mm distance between measuring point in areas with high wear and
50 mm distance in areas with low wear. The wear is measured in 4 places on the roller circumference.

R Measuring point at mm

O Measure # 1
L Measure # 2
L Measure # 3
E Measure # 4
R Average
1 Comments:
R Measuring point at mm

O Measure # 1
L Measure # 2
L Measure # 3
E Measure # 4
R Average
2 Comments:
R Measuring point at mm

O Measure # 1
L Measure # 2
L Measure # 3
E Measure # 4
R Average
3 Comments:
R Measuring point at mm

O Measure # 1
L Measure # 2
L Measure # 3
E Measure # 4
R Average
4 Comments:

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 29

OK mill, table Plant: Measuring sheet ref. No. Sent by:

wear measuring Mill size: OK 30-4 Date:
Hour counter for total mill operation hours: Hour counter at last wear parts replacement:
total production counter: Production counter at last wear parts replacement:
Previous wear measuring, date: Sheet ref. No.: Hour counter: Total production counter:

Notice: When measuring the wear, use 10 - 20 mm distance between measuring point’s areas with high wear
and 50 mm distance in areas with low wear.

The measures are taken on the table between the rollers:

Measuring point at mm

T
A Measure # 1
B
L Measure # 2
E
Measure # 3

Measure # 4

Average
Comments:

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 30

6. Maintenance Procedures

General Items
Care needs to be taken to the following points when
disassembling/reassembling the mill components.
1) The equipment used to raise or move the part must have
sufficient capacity to move/lift the parts.
2) When removing a bearing or other part with a machined surface,
for correct installation, care needs to be taken not to damage
such part during handling.
3) When removing any machined part having a bearing surface,
which is not resistant to rust, apply oil, and then a rust-preventing
agent to surfaces.
4) When removing parts which has a bearing or machined surface,
care needs to be taken not to allow the finished surface to make
direct contact with the ground.
5) Clean each part and apply oil prior to re-assembly. Be careful not
to reassemble any part without applying lubricant to the bearing
surface.
6) Whenever rollers are lifted and people are inside the mill or
working on swing lever parts, make sure the safety shells /
blocks are inserted between swing lever and mill housing on top
of the roller stoppers.
6.1 Roller swing-out procedure
6.1.1 Removing the housing cover
Remove the seal retainer
Prepare the replacement parts for damaged parts in advance.
1) Bolts.
2) Packings.
Dismantle the roller shaft boss seal covers.
Secure the housing seal (position 02.07.01.03) to avoid damage when
swinging out the roller.
Remove the mill housing cover and pressure lever cover together.
Keep the parts arranged / marked for each roller number.
Remove the bolts connecting the roller shaft boss to the swing lever.
Remove the end cover from the roller shaft boss.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 31

Remove the air breather from the lubrication pipe and attach a cap to
close it of.

6.1.2 Removing the lock pin

Start the hydraulic oil unit to raise the roller.
Start the lubrication oil unit of the main gear reducer prior to starting
the hydraulic oil unit.
Un-screw the roller stopper.
Lower the roller onto the table.
Start the pump of the hydraulic oil unit to relieve the pressure.
Thrust the disassembling bolt in the lock pin press out the pin little by
little. (Tools section 13.02.01)
When the lock pin comes out slightly, lift it with a chain hoist and
lower it onto the deck.
Since the taper bush may be pulled out at the same time, use a taper
bushing clamp (position 13.02.01.04).
Dress the surface of lock pin pulled out, and apply rust preventing
grease.

6.1.3 Removing the taper bush

Operate the hydraulic cylinder and execute the centering so that the
clearance is equal on all outer circumference of the taper bush.
Since pulling out the taper bush) forcibly may cause seizure, execute
the centering carefully in advance.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 32

Pull out the taper bush by using the disassembling puller. (Tools
section 13.02.03).
Dress the inner surface of taper bush, swing lever and roller shaft
boss, and then apply rust preventing grease.
After the taper bush has been pulled out to some extent, lift it with a
chain hoist and pull it out little by little, while hammering the bush with
a wooden hammer and executing the centering.

6.1.4 Swinging out the roller

Remove the movable floor plate from the rear side of the pressure
lever.
Put the scaffolding plate at the part where the floor plate was removed
for protection of opening.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 33

Confirm the connection port of hydraulic hose referring to the drawing.

Start the portable pump unit and operate the manual changeover
valve to relieve the air from the portable cylinder. This is best done
while the cylinder is still in horizontal position.
Adjust the hydraulic pressure of pressure control valve and monitor
the hydraulic pressure at all time.
It is very important that no air is trapped within any side of the
cylinder, as this will make it impossible to arrest the movement of the
rollers when it passes the equilibrium position
Mount the portable cylinder. Mount the two safety pins.

Clean the sliding surfaces. Make sure that there is no point of contact
during the roller swing-out.
Turn the manual changeover valve to “Roller In” to stretch the
portable cylinder rod.
Centre and assemble the upper pin for the portable cylinder.
Turn the manual changeover valve to “Roller Out” to swing out the
roller.
Observe the stopper of the roller shaft boss carefully, as it may make
contact with the mill base after completion of swing-out.
Turn the manual changeover valve to the neutral position as soon as
the hydraulic pressure is increased abruptly.
Perform the work carefully, as negligence of this work may result in
damage of the equipment.
Open the pressure relief valve of the portable pump unit to relieve the
pressure and disconnect the hydraulic hoses.
Remove the portable cylinder.
6.2. Roller swing-in procedure
6.2.1 Swinging in the roller
Remove the scaffolding from the platform.
Same as roller swing-out.
Attach the portable cylinder in accordance with the same procedure
as “Swing-out”.
Place a wooden piece between the roller and table to avoid metal
contact.
Turn the manual changeover valve to “Roller in” to swing in the roller.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 34

Since the hydraulic pressure is increased abruptly when the roller

swing-in is completed, turn the manual changeover valve to neutral
position as soon as the hydraulic pressure is increased abruptly.
Perform the work carefully as the negligence of this work may result in
the deformation of the cylinder rod.
Relieve the pressure and remove the portable cylinder.
6.2.2 Assembling the taper bush
Operate the hydraulic cylinder to align the roller shaft boss with the
pinhole of the swing lever.
Align the roller shaft boss securely with the pinhole of swing lever.
Lift the taper bush (1) and drive in the end surface little by little by
using a wooden hammer.
Apply the Molub-Alloy to the outer circumference of the taper bush.
6.2.3 Assembling the lock pin
Clean the inner surface of the taper pin and outer circumference of
the lock pin.
Apply a thin coat of machine oil to the outer circumference of the lock
pin. (Never use grease).

Thrust the lock pin (2) until the taper surface is stuck closely.
Drive in the lock pin with a medium hammer etc. thereafter with a
stiffening plate applied to the end surface.
In this case be careful not to damage the screw hole prepared for lock
pin disassembling.
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 35

Attach the retainer (3) and tighten bolts.

6.2.4 Attaching the housing cover
Attach the mill housing cover.
Attach the housing silicone seal and adjust.
Attach the end cover to the roller shaft.
Adjust the thickness of packing at lower side of the housing cover as
required.
Attach the roller bearing oil lubrication system.
6.3. Table track, roller tire replacement procedure
6.3.1 Outline work procedure
In the following a standard procedure the change of roller tires inside
the mill is described.
Preparation. Tools/jigs required

No. Part names Quantity required Note

Table track Roller tire
replacement replacement
1 Portable cylinder 1 1 With small articles such as
hydraulic hose, pin etc.
For roller swing-out/in
2 Lock pin 1 1 For roller swing-out/in
disassembling bolt
3 Taper bush slip-off 1 1 For roller swing-out/in
preventing jig
4 Taper bush pull-out 1 1 For roller swing-out/in
jig
5 Table track lifting jig 1
6 Roller tire lifting jig 2
7 Clamp Plate fall – 1
preventing plate
8 Torque wrench 1 1 For clamp bolt tightening
Hydraulic tensioner
9 Offset wrench 1 1 For clamp bolt tightening
10 Hydraulic jack 2 For table track
assembling
11 Chain hoist 1 2 For table track lifting
12 Hexagon socket 1 1 For dam ring
screw key disassembling

Preliminary preparation
Operation of main gear reducer lubrication.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 36

While replacing the table track/roller tire be sure to keep the low-
pressure pump and high-pressure pump of the reducer operating, for
protection of reducer thrust bearing.
Inching of reducer.
When it becomes necessary to turn the reducer (table) by inching, for
cleaning of material on the table or for loading/unloading of table track
always operate main gear lubrication.
To turn table, wind a wire rope at the boss with the cover removed
from the reducer coupling and set a chain hoist (approx. one ton)
between the wire rope and foundation bolts of the mill base to turn the
reducer. Normally it can be turned by hand.
Replacement parts:
1) When replacing table track
- Table track
- Spacer
- Clamp plate (as required)
- Clamp bolt (with nut, washer)
2) When replacing roller tire
- Roller tire
- Side liner, clamp plate (as required)
- Clamp bolt (with nut, washer)

6.3.2 Table track replacement procedure

1. Preliminary preparation
2. Cleaning of material on table
3. Disconnection of wiring
4. Removing the housing covers
5. Installing the portable cylinder swing-out
6. Removing the lock pin and taper bush
7. Swinging out the roller
8. Measurement of table track wear
9. Removing the clamp plate
10. Removing the table track spacer
11. Removing/carrying out the table track
12. Dressing the upper surface of table replacement
13. Carrying/assembling the table track
14. Installing the clamp plate
15. Machining/assembling the table track spacer
16. Measurement of table track dimension
17. Roller swing-in
18. Assembling the lock pin and taper bush
19. Removing the portable cylinder swing-in
20. Installing the housing cover
21. Wire connection
22. Adjustment prior to operation
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 37

23. Load operation

24. Bolt re-tightening (*)
*Bolt re-tightening interval
st
1. 1 8 operation hours after starting operation
2. 2 nd 16 operation hours after 1 st re-tightening
3. 3 rd 24 operation hours after 2 nd re-tightening

6.3.3 Roller tire reversing/replacement procedure

1. Preliminary preparation
2. Measurement of roller tire wear
3. Disconnection of wiring
4. Removing the housing covers
5. Removing the clamp plate
6. Removing the roller tire
7. Dressing the bearing housing replacement
8. Installing the roller tire
9. Installing the clamp plate
10. Installing the housing cover
11. Wire connection
12. Measurement of roller tire dimensions
13. Adjustment prior to operation
14. Load operation
15. Bolt re-tightening (*)
* Bolt re-tightening interval
1. 1 st 8 operation hours after starting operation
nd
2. 2 16 operation hours after 1 st re-tightening
3. 3 rd 24 operation hours after 2 nd re-tightening

6.4. Table track replacement procedure

6.4.1 Removing the clamp plate
Clean the material on the table.
Remove the table cover manhole.
Remove clamp bolts. Remove protective hex head bolts. Replace
with jacking bolts. Using two jacking bolts per clamp, turn jacking
bolts to release clamp plate.
Remove the second clamp plate by driving a wedge between the
clamp plate and table or using jack bolts.
When removing the clamp plate fully, be careful as it may come of
abruptly.
Dress the contact surface of the clamp plate.
6.4.2 Removing the spacer
Remove the spacer (2) fixed by welding, by gouging etc.
Care must be taken not to damage the table.
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 38

Pull out the spacer (1) by hitting it in direction of outer circumference.

When the spacer fails to be removed by performing the above
procedure execute the gouging on the entire surface of spacer.

6.4.3 Removing/carrying out the table track

Turn the table to align the spacer position to the carry-out opening.

When disassembling the 1 st . table track, lift it right upward.

Hang a table track lifting wire rope from the inside of air separator or
by attaching a beam and trolley to the housing and reject cone.
When carrying out the table track, execute the slinging work carefully
so as to not drop it.
Lift the table track by using a wire rope together with crane truck etc.
from the outside to carry out the table track.
Turn the table to align the table track to be removed next with the
carry-out opening. Perform the above work similarly to disassemble
and carry out the table track sequentially.
6.4.4 Dressing the table
Clean the table elaborately.
Dress the points where the contact surface between the table track
and clamp plate is damaged, elaborately by using a disc grinder etc.
Execute the dressing to such extent that the table segment has full
contact.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 39

6.4.5 Carrying/assembling the table track

Set the spacer fitting position and turn the table to align it with the
carry-out opening.
Align the joint of table track with that of clamp plate.
Carry in the table track by reversing the carry-out procedure.
Fix the proceeding table track temporarily to eliminate the clearance
between each table track and push the table track against the other
table track having been set by using hydraulic jack and push it against
the outer circumference by using the clamp plate.
Fix the table track by using the clamp plate.
nd
Turn the table to align the opening with the 2 table track mounting
position.
Carry the 2 nd table track and set the clamp plate while pushing it
st
closely against the 1 table track.
Drive in a wedge at the clearance with the last table track to minimize
the clearance.
Perform the above operation similarly to mount all table tracks
sequentially.
6.4.6 Assembling the clamp plate
Set the clamp plate in accordance with the table track.
Since the clamp plate (2) is important for stopping the table track
movement, set the clamp plate securely.
Tighten the centre clamp bolt at specified torque/tightening force.
(See assembly drawing)
When tightening the clamp bolt, hammer the clamp plate for
stabilization.
Tighten the right (left) clamp bolt at specified torque/tightening force.
Tighten the left (right) clamp bolt at specified torque/tightening force.
Tighten the centre bolt/right bolt/left bolt in order until they do not turn
further.
Confirm the tightening torque/tightening force of clamp bolt.
Attach the blind bolt to the clamp plate.
Make sure that there is no clearance between clamp plate, table and
table track.

6.4.7 Measure the clearance between table tracks

Machine the spacer (1) to the thickness of “Clearance - 0.3 mm”.
Measure the clearance between table tracks at more than two points
(inside/outside).
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 40

Drive in the spacer (1) while adjusting the thickness by using a disc
grinder.
Be careful not to allow any clearance to be generated between the
spacer (1) and table track.
Cut the spacer (1) by field adjustment and drive it in. Keep the spacer
(2) wedged.
Fix the spacer (1) to the wedge (3) by welding (4).
Grind the upper surface of spacer by using a disc grinder in
accordance with the shape of upper surface of table track.

6.5. Roller tire replacement procedure

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 41

6.5.1 Preparation
Prepare and clean the area. Install lifting equipment attachement
points. Remove housing covers.
6.5.2 Removing the clamp plate
Position roller rotation so that segment to be removed is at top center
position. Wedge tire in both directions to prevent accidental rotation
due to unbalanced load as segments are removed.
When the nuts fails to be removed, remove it by gas cutting.
(It is necessary to prepare spare part.)
Disassemble the clamp bolt.
Lift the clamp plate with a crane truck etc. to lower it onto the ground.
Dress the clamp plate.
6.5.3 Disassembling the roller tire
Set the roller tire-lifting jig securely on the segment. Ensure the tips
of the lifting fingers engage the cast depressions in the segment
sides.
Lift the roller tire segment to lower it onto the ground. Use caution
when lifting. Use a safety sling as back up for lifting jig.
6.5.4 Dressing the bearing housing
Clean off material adhered to the bearing housing.
Dress hit marks, defects, burrs, projections, etc. carefully.
Dress the sideliner, clamp plate mounting surface.
Dress the roller tire-fitting surface of bearing housing.
6.5.5 Installing the roller tire
Lift the roller tire to put it on the bearing housing.
Be careful not to allow any foreign matter to be caught between the
roller tire and bearing housing.
Arrange each roller segment, referring to the numbering on the rollers,
so that the clearance between each roller tire is equal.
6.5.6 Installing the clamp plate
Make sure that there is no clearance between the clamp plate, claw
edge and roller tire and also between the sideliner claw edge.
Tighten the centre clamp bolt/left clamp bolt/right clamp bolt
repeatedly in order at the specified torque/tightening force.
When tightening the clamp plate temporarily, hammer the roller tire
with a “soft hammer” so that it can be seated properly.

6.6. Works after replacement of roller tire/table track

6.6.1 Measurement of dimension
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 42

1. After replacing the roller tire and table track measure the dimension
right after the replacement for determination of proceeding
replacement period (or reversing period for roller tire).
6.6.2 Adjustments prior to operation
Perform the following adjustments after replacing the roller tire and
table track.
1. Adjustment of cylinder stroke detection unit.
2. Adjustment of roller stopper position.
3. Adjustment of dam ring height.
4. Adjustment of setting value of hydraulic pressure for mill spring
system (when changing hydraulic unit setting value).
5. Adjustment of relief valve setting value (when changing hydraulic
unit setting value).
6. Adjustment of accumulator nitrogen gas pressure (when changing
hydraulic unit setting value).
6.6.3 Re-tightening of clamp bolt
1. Re-tightening the clamp bolt after replacing the roller tire and
table track. Even when the roller tire is reversed, re-tighten the
tire clamp bolt similarly.
2. Re-tighten each bolt at the following interval until the nut cannot
be turned further when bolt is stretched.
- 1 st re-tightening 8 operation hours after operation
- 2 nd re-tightening 16 operation hours after 1 st re-tightening
rd nd
- 3 re-tightening 24 operation hours after 2 re-tightening
- 4 re-tightening Determined in accordance with result of 3 rd re-
th

tightening
3. Continue to re-tighten each clamp bolt until the nut does not turn
further.
For the clamp plate which uses three bolts, re-tighten the centre
bolt/left bolt/right bolt in order.
For the bolt re-tightening torque/tightening force, refer to the
assembly drawing.
4. Re-tighten each bolt at the specified tightening torque/tightening
force every 1,000 hours of operation after completion of above
re-tightening.

6.7. Roller assembly pull-out procedure

Basically the roller can be serviced in two ways.
1) Remove roller housing from shaft.
2) Remove roller incl. shaft from roller shaft boss
6.7.1 Discharging the lubrication oil

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 43

Use the oil circulation unit to empty rollers after swinging out the
roller.
Take care not to overfill oil tank.
It is basically advised not to re-use the lubrication oil.
When the lubrication oil needs to be re-used, fully clean the oil
container etc. in advance.
6.7.2 Pulling out the roller assembly
After the roller swing-out remove the end cover plug.

Remove the end cover (1).

Take every possible precaution not to allow any foreign matter, dust,
etc. to enter the inside of the bearing Housing.

Remove the thrust plate (2).

Keep the small parts cleaned and arranged.
Cover the bearing with transparent vinyl sheet.
Fit the lifting jig (6) to the roller assembly.
Confirm the gravity centre of lifting cargo and tension of wire rope.
Set the jacks (3) at 4 points between the roller assembly and roller
shaft boss to raise it evenly. After confirming that the roller assembly
is raised by the jacks, lift the roller assembly to pull it out from the
roller shaft.
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 44

Clean and dress the roller shaft.

When setting the bearing temporarily, take proper measures against
humidity, to prevent rust etc.
Visually check the inside of roller shaft oil hole.
If any foreign matter is found, fully clean the part.

6.7.3 Dismounting the roller shaft assembly

When there is access to a clean workshop with a crane. It is advisable
to perform any service of the rollers there.
After swinging out the roller, remove the conical sleeve from the back
of the roller shaft. Use cylinder plate 13.02.02.19 together with
hydraulic jack to press out sleeve. Install retainer ring 13.02.02.20 to
stop sleeve from falling. Prepare a support underneath mill platform
for lowering retainer ring and sleeve down onto.
Use cylinder plate 13.02.02.19 across back of Roller Shaft Boss
together with hydraulic jack for pressing up roller Shaft.
Notice: When lifting out the roller from roller shaft boss, take care not
to drop top conical sleeve from the shaft.
Use standard procedures for the rest of dismantling.

6.7.4 Assembling the roller assembly

Reverse the pull-out procedure to assemble the roller assembly.
Assemble the roller assembly slowly, while adjusting the roller
assembly by a chain hoist or overhead crane, in accordance with
inclination of the roller shaft.

6.8. Roller bearing pull-out procedure

6.8.1 Cleaning
Remove the material, dust, rust, etc. adhered on the outer
circumference of the bearing housing.
6.8.2 Removing the seal housing
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 45

Remove the seal housing from the bearing housing.

Observe the used condition of oil seal to check that there is no
harmful defect etc.
Clean the seal housing.
6.8.3 Inverting the bearing housing

Attach the upper lifting plate for roller assembly and lower lifting plate
for roller assembly and to the bearing housing.
Invert the bearing housing to direct the tapered roller bearing
downward.
Attach the cover temporarily, as a countermeasure to prevent the
bearing form falling.
6.8.4 Preparations
Prepare the stool (5), weight (1), gas burner etc. at work position.
Prepare a ram weight of ~2 tons.
6.8.5 Pulling out the bearing (tapered roller bearing side)

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 46

Lay the pad (4) etc. at the position where the bearing falls; so as to
prevent any damage of bearing when it falls.
High pressure oil or grease can be applied to the bearing seats
through the holes in the bearing housing, enabling the bearing to be
pressed out without heating.
If this cannot be achieved, heat the outer circumference at tapered
roller bearing of the bearing housing by using a gas burner.
Make it a rule to execute the heating evenly at the full circumference
of the bearing Housing.
Execute the heating at the maximum bearing housing temperature of
less than 300°C, while measuring and controlling the temperature with
a contact thermometer.
Lift the weight (1) by a crane etc. and rest it lightly on the column pipe
(2) to apply the load little by little using some steel rails (3) to load the
bearing (4).
If possible perform the work by using a forklift truck or a compact type
lifter when the bearing has come to be pulled out little by little, so that
the support stand can move in accordance with the bearing falling.
This work should not be performed when the bearing is open.
When the work described in above is not executable minimize the
falling distance as much as possible.
Dress the bearing removed after checking it for scar etc.
When any rust is generated remove such rust by using an emery
paper of #1200 or over.
Apply the rust preventing treatment to the bearing having been
dressed and keep it stored in a wooden box.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 47

6.8.6 Inverting the bearing housing

Attach the lifting plate for roller assembly (1) and (2).
Invert the bearing housing to direct its tapered roller bearing side
downward.
6.8.7 Pulling out the bearing (cylindrical roller bearing side)
The procedure to pull out the bearing is the same as that of tapered
roller bearing.
6.8.8 Seal assembly and installation
SEALING RINGS MUST BE HANDLED WITH CARE.
The seal housing is split and can be dismantled to inspect seals even
when the roller is in place.
Inspect the O-ring and seals for damage. Make sure rubber components
are not slit or cracked.
6.9. Hydraulic cylinder replacement procedure

6.9.1 Dismounting the joint head / Cylinder assembly.

Insert a wooden piece between the roller stopper and swing lever or
table track and roller tire.
Support the hydraulic cylinder by a chain hoist within the mill base, so
that no load is applied to the assembly.
Be sure to match mark at disassembling points.
Loosen nuts with the hydraulic tool.
Remove the nuts and stud bolts.

6.9.2 Removing the hydraulic cylinder assembly.

Fully close the main valves of the mill spring system.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 48

Remove the flexible hoses for the hydraulic cylinder, close all
openings to avoid foreign matter entering.

Lift the hydraulic cylinder by a chain hoist to free the joint pin.
Match mark prior to removing the pin.
Push out the joint pin by using the hydraulic jack and jig.
When pushing out the joint pin make sure in advance that there
nobody within the mill base.
Lift the hydraulic cylinder assembly from outside of mill base by using
a chain hoist within the mill base together with the crane truck etc. to
carry it to the outside.
6.9.3 Disassembling/checking the hydraulic cylinder
Disassemble/check the hydraulic cylinder in accordance with the
instruction manual.
6.9.4 Restoring the hydraulic cylinder
Lift the hydraulic cylinder assembly with a crane truck etc. to insert it
in the mill base.
Lift the hydraulic cylinder at the inside of the mill base to align the
joint pin hole insertion position.
Assemble the joint pin after applying the Molub-Alloy agent to the joint
pin having been dressed.
Assemble the joint pin with care taken to direction of grease hole
referring to the assembly drawing and match marking.
Restore all piping.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 49

Adjust the clearance between the joint head and hydraulic piston rod
to 6 mm.
The two parts must never make contact during operation.
Dress the mating parts elaborately.
Perform the non-destructive test periodically to check for cracks etc.
Lift the hydraulic cylinder with a chain hoist and attach it to the joint
head.
Install stud bolts and tighten the nuts to the specified tension
hydraulically.
Restore the ultrasonic transducer.

6.9.5 Confirmation items before and after load operation

Perform the zero-point adjustment for the cylinder stroke detection
unit.
Fill the grease to each grease point.
1. Filling of grease to lower joint pin.
2. Filling of grease to hydraulic cylinder rod.
Check or adjust the accumulator nitrogen gas pressure.
Check or adjust the relief pressure.
Make sure that there is no oil leakage through each piping connection.

6.10. Main gear reducer pull-out procedure

6.10.1 Cleaning
Clean away the material on the table.
Clean away the material within the bottom casing.
6.10.2 Swinging out the roller
Swing out the rollers in accordance with “Roller swing-out procedure”.
6.10.3 Lifting the table assembly

Remove the table manhole cover.

Inch the table to enable space for the lifting jacks in between scraper
inside the bottom casing.

Remove the bolts connecting the reducer to the table.

Remove the bolts carefully as it is tightened at the specified
torque/tightening force.

Set 4 jacks between the jack seat and other jack seat to jack up the
table assembly on four pylons from the foundation.
Perform the jack-up work while checking level every approx. 10 mm.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 50

Perform the above steps repeatedly to jack up the table to the

specified level.
Jack up the table to a height where the reducer can be pulled out.
Lock the jack and jack seat in position.
Take proper measures to prevent the table from swaying, by
supporting it from the mill housing.

6.10.4 Removing the bottom casing liner bolt

Remove the bottom casing liner bolt (2) arranged at the reducer
output flange width at motor side.
This work is performed to help the reducer jack-up.
Remove the felt seal and sealing, recording positions.
When the bolt is hard to remove, it may be cut with gas cutting.
In such a case prepare a spare part in advance.
6.10.5 Removing the main motor
Disconnect the electrical wiring.
Separate the coupling from the reducer.
Remove the motor.
Record coupling centring prior to disassembling.
6.10.6 Jacking up the reducer
Discharge the lubrication oil from reducer.
Disconnect the electrical wiring from reducer system.
Disassemble the hydraulic piping.
Remove the bolts (1) and locating pins.
Set the jacks (3) on the supports.
Jack up the reducer higher than the positioning blocks, to allow it to
be pulled out.
Perform the jack-up work while checking level every approx. 10 mm.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 51

Make sure that the jack-up is executed to minimum height, taking the
thickness of roller, floor plate etc. (required for drawing-out) into
consideration.
Make sure that the output flange of the reducer should not interfere
with the lower surface of bottom casing.
6.10.7 Pulling out the reducer
Install the equipment/material necessary to pull out the reducer.
Set the roller, winch, sheaves, wire rope etc. depending on the
situation of the field.
Jack down the reducer, onto the rollers (1).
When jacking down the reducer, lower it carefully little by little in the
same manner as jack-up operation.
Remove the hydraulic jack.
Pull out the reducer on rollers using a winch or similar.

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.
 70001380-1 52

6.10.8 Manufacturing/installing the temporary table support (3)

Manufacture and install the temporary support shown, right after the
reducer has been carried out. Jack up (2) to support table (Safety
procedure)
6.10.9 Disassembling/checking the reducer
Disassemble the reducer and replace/check each part in accordance
with the instruction manual.
Do not turn gear flange without operating HP pumps.
6.10.10 Assembly of reducer/table
Assemble parts in reverse order taking care to tighten bolts etc.
according to assembly drawings.
For start up follow manufacturers’ procedures and compare settings
etc. with previous records. Follow re-tightening schedule.

---oOo---

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may
not be duplicated, disclosed, or utilized without written consent from FLSmidth.