INSTRUCTION MANUAL .

ROTARY KILN 70000448-3

Thrust device, hydraulic type HTD

Erection, operation and maintenance

In the text, reference is made to:

Ref. 1 *) Rotary kiln

General kiln instruction manual
Erection, operation and maintenance
Ref. 2 *) Rotary kiln plant (dry process)
Safety regulations
Ref. 3 *) General safety regulations at sites of erection
Ref. 4 *) FLS Lubricants
Key to lubricants
Ref. 5 *) Hydraulic installations
Installation, preparation and maintenance
Ref. 6 *) Assembly of pipes by means of screwed
Ermeto connections
Installation
Ref. 7 *) Oil hydraulic installations
Pipelines
Installation
Ref. 8 *) Rotary kiln
Axial measurement equipment
Operation and maintenance
Ref. 9 *) Rotary kiln
Alignment of supporting roller bearings and
supporting rollers
Erection
Ref. 10 *) Pump station (equipment supplier instruction
manual)
Diagram for electrical parts

*) See note Instruction manual references in section 1.

VIGERSLEV ALL 77 - 2500 VALBY - DENMARK 2040 AVENUE C - PA 18017-2188 BETHLEHEM USA CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA
2 70000448-3

Contents: Page:
1. GENERAL NOTES ........................................................................... 4
2. CONSTRUCTION AND OPERATING PRINCIPLE ............................ 7
2.1 Construction .....................................................................................7
2.2 Operating principle ...........................................................................8
3. INSTALLATION ............................................................................. 13
3.1 Installation of the mechanical parts................................................13
3.2 Installation of the hydraulic system ................................................15
3.3 Installation of electrical supervisory and control system.................16
3.3.1 Longitudinal transducer 16
3.3.2 Separate limit stop KDS 1 17
3.3.3 Separate limit stop KDS 2 17
3.4 Posting of signs and mounting of guards ................................................ 157
4. OPERATION.................................................................................. 18
4.1 Preparing the mechanical system for operation .............................18
4.2 Preparing the hydraulic system for operation.................................18
4.2.1 Procedure for preparing the hydraulic system 18
4.3 Checking and adjustment...............................................................20
4.4 Day-to-day operational checks during start-up perod.....................20
5. MAINTENANCE ............................................................................. 21
5.1 Preventive maintenance ...................................................................201
5.1.1 Lubrication 22
5.1.2 Cleaning 22
5.1.3 Inspection and adjustment 23
5.1.4 Checking of condition 23
5.1.5 Replacement 24
5.1.6 Performance test 24
5.2 Faults and remedial action .............................................................24
5.2.1 Thrust device failure 24
5.2.2 Kiln tyre runout 25
5.2.3 Position of supporting rollers 25
5.2.4 Position of thrust rollers 26
5.3 Replacement of parts. ....................................................................27
6. KEY TO APPENDICES .................................................................. 28

Edited by: JJJe Translated by: JRo Pages: 47

Approved by: KelH MGN code: 5A123
 70000448-3 3

APPENDICES:
App. 1. Thrust roller .................................................................................... 31
App. 2. Thrust roller with ancillary equipment ............................................. 33
App. 3. Pipe diagram (schematic diagram)................................................. 35
App. 4. Functional diagram ......................................................................... 37
App. 5. Hydraulic cylinder ........................................................................... 39
App. 6. Safety switch, KDS 1 ...................................................................... 41
App. 7. Safety switch, KDS 2 ...................................................................... 43
App. 8. Calibration of transducer ................................................................ 45
App. 9. Dismantling of thrust roller.............................................................. 47
4 70000448-3

NOTE!
The present instruction manual is concerned with the situations which,
according to the experience of FLS, are the most likely to occur. An
exhaustive enumeration of all conceivable situations which may occur
during the installation, operation and maintenance of the thrust device
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 NOTES
The function of the hydraulic thrust device is to transfer the axial
load from the rotary kiln from one to several supports and to
maintain the rotary kiln in the axial direction within a specific area
on the supporting rollers.

References to instruction manuals

In the text of this instruction manual, reference is made to an
instruction manual reference No. where this is deemed to be
relevant.
The titles of all instruction manuals referred to are listed on
the front page of this instruction manual, with indication of the
number referred to.
Reference to other instruction manual numbers is done via
the General kiln instruction manual, ref. 1 in which relevant
instruction manual numbers can be identified on the basis of
the title of the relevant manual.

REQUIREMENT:
Thrust device to be used exclusively for the predefined purpose!
 70000448-3 5

MANDATORY!
The directions outlined in instruction No. ref. 2 "Rotary kiln
plant (dry process), safety regulations must be strictly ob-
served.

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

MANDATORY!:
In connection with arc welding and when operations involving
blowtorching with gouge are carried out, the return cable
must always be attached to the object subjected to welding,
as close as possible to the area of welding.
The return cable must never be attached in a way which will
cause the return current to be passed through parts not con-
nected to the object being welded, for example: moving parts,
bearings, electrical installations or any other parts.
A return current through a bearing may give rise to welding
scars which will cause severe damage to bearing.
A return current through electrical installations may cause
serious damage to protective earth lines (an extremely
hazardous condition!) or electronic equipment.

MANDATORY!
Strict compliance with the directions outlined in instruction
No. ref. 3 "General safety regulations at erection site" must
be ensured. This instruction manual must be scrutinized by
the client, the erection contractor and FLS representatives
before erection work is started.
6 70000448-3

Where ERECTION CHECK is specifically called for in the

erection manual, this means that the FLS erection supervisor
must inspect and approve the parts mounted before permis-
sion to proceed with the erection work can be given.

MANDATORY!
The accumulators must only be charged with nitrogen (N)
to the specified precharging pressure.

MANDATORY!
Disassembly of the hydraulic system to take place only
when the pressure in the hydraulic system has been re-
duced to atmospheric pressure.
 70000448-3 7

2. CONSTRUCTION AND OPERATING PRINCIPLE

2.1 Construction
The thrust device consists of a mechanical part, a hydraulic system
and an electrical supervisory and control system.

Dependent on the size of the load, the thrust device may consist of
one or several mechanical units, which are mounted on separate
supports.
If the thrust device consists of more than one unit, only one unit, i.e.
the master unit, will be connected to the electrical supervisory and
control system. The other unit(s) will serve exclusively as slave
units, which are hydraulically connected only to the master unit.
The master unit is always placed on the support closest to the kiln
drive.
The master unit and slave unit are of identical mechanical design.
One unit consists of a roller whose conical running face is in con-
tact with a similar conical running face on the kiln tyre, as well as a
hydraulic cylinder which will absorb the axial load exerted on the
roller and transmit it to the support.
See Appendices 1 and 2.
The thrust roller (75) runs in a bearing block (83) which is provided
with roller bearings. The suspension of the bearing block from the
two guide shafts (81) will allow the bearing block to be displaced in
the axial direction.
The guide shafts rest in two bearing blocks (80 + 84) which are
fixed to the support. The hydraulic cylinder (45) is placed in the
bearing block which is closest to the kiln outlet.
The roller bearings in the bearing block run in an oil bath.
The bearing bushings (82) of the guide shafts are grease-
lubricated.
The conical running face of the thrust roller is lubricated by a
weighted graphite block (87) fitted in a holder on the bearing block.
The hydraulic system (see Appendix III) consists of a pump station
and a pipe system connecting the pump station to the hydraulic
cylinder(s).
The pump station is a mild-steel frame in which the oil tank as well
as pump unit, filters and valve arrangement are mounted. The pipe
system consists of a pressure system and a return flow system
which can be short-circuited through a needle valve (40).
The pressure system incorporates a hydro-pneumatic accumulator
(23).
The primary function of the accumulator is to absorb pressure
variations in the hydraulic system in case of kiln tyre runout and to
ensure that the thrust roller remains in contact with the kiln tyre
when the upward migration of the kiln occurs.
8 70000448-3
The electrical supervisory and control system consists of a longitu-
dinal transducer (49) and two separate limit stop switches (50) and
(51).
The longitudinal transducer registers the movements of the thrust
roller, and hence the movements of the kiln tyre. In case of any up-
ward movement of the kiln tyre, the thrust roller will be moved ac-
cordingly due to the hydraulic pressure from the accumulator. The
limit stop switches (50) and (51) are actuated, respectively, by the
bearing block through an arm and by the kiln tyre (see Appendices
6 and 7).
2.2 Operating principle
Correctly adjusted, the supporting rollers of the kiln will take up 10-
50% of the axial load of the kiln. This means that the load on the
thrust device will be relieved, but entails also that the remaining
load will be exerted on the thrust device, preventing the supporting
rollers from forcing the kiln away from the thrust rollers.

When the thrust device has one or several slave units in addition to
the master unit, the load will be evenly distributed between the
thrust rollers due to the fact that the hydraulic cylinders are hydrau-
lically interconnected. Therefore, they are capable of compensating
for the changes in the distance between the individual kiln tyres
which may be caused by thermal conditions inside and around the
kiln.
These thermal conditions may, inter alia, be the reason why the kiln
tyre at the master unit is moving away from its zero position.
Since the primary function of the thrust device is to maintain the kiln
in the axial direction, it will react to the kiln tyre migrations, attempt-
ing to keep the centreline (at the master unit) of the kiln tyre within
a range of plus/minus 5 mm from the neutral position. Minor move-
ments within this range - due, for example, to kiln tyre runout - will
be taken up by the hydraulic accumulator.
For kiln equipped with girth gear the neutral position will coincide
with the centreline of the supporting rollers.
For a kiln with drive effected through the supporting rollers, the neu-
tral position will be displaced from the centreline of the supporting
rollers to compensate for the weight of the drive unit. See the posi-
tion drawing of kiln for the position of the neutral point relative to the
centreline of the supporting rollers.
 70000448-3 9

The thrust device will react to the movements of the kiln tyre/kiln in
the following manner:
A downward movement of the kiln tyre, out of the neutral zone,
will trigger the following action:
The longitudinal transducer (49) registers the movement. The oil
pump (08) is started, thrusting the kiln upward again, back to the
neutral zone. See fig. 1.

Fig. 1
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The oil pump will be stopped when the kiln tyre has reached the zero
position.
The hydraulic pressure will then be exerted on the non-return valve
(11).
This operating situation will prevail as long as the kiln/kiln tyre are
positioned in the neutral zone. See fig. 2.
The system pressure must now be 50 70 bar.

Fig. 2
 70000448-3 11

An upward movement of the kiln tyre, out of the neutral zone, will trigger
the following action:
The longitudinal transducer (49) will register the movement. The accumu-
lator will ensure that the thrust roller maintains contact with the kiln tyre.
The solenoid-operated directional seat valve (13) is energized. The oil
from the hydraulic cylinders and accumulator can now be recirculated
through the system back to the tank. (See Fig 3). The pressure transducer
(18) will trip alarm in case of a pressure drop to level below 10 bar.
The pressure will not drop to a level below 3 bar because of the non-
return valve (30).
If the kiln is unable to move downward unaided, it will be necessary to ad-
just the position of the supporting rollers.
When thrust roller/kiln tyre/kiln have migrated downward, back to the neu-
tral zone, the voltage from the solenoid-operated seat valve must be de-
energized, and, again, the hydraulic pressure will be exerted on the non-
return valve (11).
Fig. 3
12 70000448-3

As far as the electrical control system is concerned, reference is

made to electrical diagrams and circuit diagrams.

If, in spite of the thrust device, the kiln/kiln tyre is moving more
than 10 mm downwards from the zero position, the longitudinal
transducer will trip an alarm. The kiln motor will be cut out in event
of a further 5 mm downward migration of the kiln/kiln tyre.
See the functional diagram in Appendix 4.

When the kiln is shut down, the valve (40) must be opened/closed
every 24 hours in order to equalize the pressure between the front
side and back side of the piston. This is done to prevent ingress of
dirt and moisture into the cylinder.

For additional safety, the thrust device is provided with two sepa-
rate limit stop switches (50) and (51). The kiln must be stopped in-
stantaneously in case any of these limit stop switches are activated.

This means that the kiln can only be subsequently started by

means of the turning motors until the kiln tyre has been returned to
its predefined control range.
 70000448-3 13

3. INSTALLATION

3.1 Installation of the mechanical parts

It is a prerequisite for satisfactory operation of the thrust device of

kiln that the kiln supporting rollers have been correctly adjusted, as
described in the erection manual for supporting rollers, ref. 9.
It is also very important that the fine alignment of the kiln tyre(s)
with which the thrust device is in contact has been carried out very
carefully.
Functionality of the master unit during the erection of kiln is very
important, i.e. so that it can restrict the movement of the kiln to-
wards the outlet. Therefore, the master unit must be mounted at
earliest possible stage after supporting roller bearings and support-
ing rollers have been mounted.
The mounting of slave units can take place at subsequent point in
time, when deemed appropriate in relation to the overall erection
process.
The master and slave units as well as pump station arrive at site as
preassembled units. The hydraulic cylinder is supplied with a mag-
netic scanner fitted in the piston.

The thrust roller must not be dismantled during erection. After a unit
has been released from the transport frame (96) (see Appendix 1),
it must be mounted in the assembled condition on the bedplate.
Follow the directions given on the arrangement drawing of the
thrust device. At some supports, the unit must be mounted on a
bracket which must first be mounted on the bedplate.
Mount the oil level pipe (85) and air filter (94) on the unit, and fill oil
into the bearing housing up to the mark on the oil level glass (See
Appendix 2).
Oil quality: FLS MAT No. 7158.
Mount the master unit on the bedplate or on the bracket mounted
on the bedplate. The thrust roller must be positioned at the correct
distance away from the centreline of the supporting rollers. The
bearing block of the unit must be centrally positioned on the guide
shafts, i.e. the dimensions "a" and "b" must be of equal size. See
Fig. 1. Distance pieces of identical size are fitted at "a" and "b" to
facilitate the operation. See Appendix 1.
ERECTION CHECK

Align the thrust roller so that its rate of inclination is consistent with
that of the kiln and so that it will be horizontally positioned at right
angles to the kiln axis. The axis of rotation of the thrust roller must
be exactly in the vertical plane of the kiln. See Fig. 4.
14 70000448-3

Fig. 4

Make the necessary adjustment through the insertion of intermedi-

ates between the bearing blocks of the unit and the bedplate, or be-
tween the bedplate and the bracket on which the thrust device is
mounted.
The thrust device must be positioned very accurately to avoid nega-
tive effects from the kiln tyre.
Force the thrust roller into contact with the kiln tyre, and make any
necessary adjustments.
Remove the distance pieces at "a" and "b" and mount the four two-
part distance rings (90) on the guide shafts for the master unit.
These distance rings, which will restrict the migration of the bearing
lock, must only be mounted on the master unit. See Appendices 1
and 4.
The contact level between thrust roller and the kiln tyre must be
checked in the immediate aftermath of kiln tyre installation.
ERECTION CHECK

Fit the adjustment wedges (91) and fix them by welding to the bed-
plate as indicated in Appendix 2.
Fit the holder (86) for graphite block (87), guard (95) for cylinder
block and the two-part channel (88).
 70000448-3 15

3.2 Installation of the hydraulic system

See separate instruction manual: Hydraulic installations, ref. 5, 6
and 7.
Install the pump station as indicated on erection and foundation
drawing and Fig. 5.
Connect the pump station and thrust roller to the supplied hydraulic
pipes in strict accordance with the pipe diagram.
Prior to shipment, the pipes have been cleaned, rust-proofed and
plugs have been fitted at pipe ends.
The protective plugs at pipe ends must remain fitted until the instal-
lation of the pipe system is about to take place.

Fig. 5

All grates and shavings formed in connection with the adaptation of

the pipes must be removed very carefully.
If the pipes are not mounted immediately after adaptation, they
must be closed with plastic plugs.
These plastic plugs must remain fitted until installation of pipes is
imminent, with renewed checking of pipes to ensure that they are
absolutely clean.
Welding, soldering etc. on pipes must not occur after the pipes
have been installed.
The hydraulic cylinders (45) must be mounted in the cylinder block
(83) so that the venting holes are positioned at highest possible
levels. The venting holes are used in connection with the venting
and testing equipment, and, therefore, the holes must be posi-
tioned in manner providing the necessary space to accommodate
the equipment.
The cylinder is retained in the cylinder block by a five-part locking
ring (92). A screw together with the cover ring will prevent the
cylinder from turning.
It is of paramount importance to avoid any foreign
matter in the hydraulic system. Therefore, it is essen-
tial to avoid contamination of pipes and fittings.
See separate instruction manual for hydraulic installations, ref. 5.
Use only hydraulic oil of a quality corresponding to
FLS MAT No. 7025.
16 70000448-3

3.3 Installation of electrical supervisory and control system

The longitudinal transducer (49) and separate limit stop switches
KDS 1 (50) and KDS 2 (51) must be mounted on the same support
as the master unit.
For running of cables and electrical installation, see wiring
diagrams.
3.3.1 Longitudinal transducer
Mount the protective tube (48) in the cylinder (45). The magnet (46)
and plastic disc (47) are mounted in the piston by the supplier of
the hydraulic cylinder. The longitudinal transducer is mounted in the
protective tube.
Calibration of the longitudinal transducer has been carried out by
the supplier. Electrical connections from the longitudinal transducer
must be established as specified in the electrical documentation.
If recalibration of the longitudinal transducer should be required,
this must be done locally.
Such calibration must be carried out in accordance with the direc-
tions given in the transducer instruction manual.
When calibration is carried out, the piston should be pushed to the
bottom of the cylinder, see Appendix 8.

When the thrust roller is in 0-position, the distance, K, must be

measured between the thrust piece (97), and bottomed piston.
This position corresponds to a = b as indicated in Appendix 4.
The transducer must be released from the protective tube, pulling it
partially out of the tube, to the extent of the distance K, see Appen-
dix 8 Fig. 1. In this position, the transducer will be in 0-position rela-
tive to the magnet in the cylinder, allowing the calibration process to
proceed.
If the transducer is pulled 30 mm out in relation to K, K+30mm, it
will be in a position corresponding to +30mm on the functional dia-
gram, see Appendix 4. This value must be calibrated as setpoint 2,
SP2. See Appendix 8, Fig. 2.

If the transducer is pushed 30mm inward relative to K, K-30mm, it

will be in a position corresponding to -30mm on the functional dia-
gram, see Appendix 4. This value must be calibrated as setpoint 1,
SP1. See Appendix 8 Fig. 3.

The signal between SP1 and SP2 will now be 4-20mA.

 70000448-3 17

3.3.2 Separate limit stop switch KDS 1

Mount the separate limit stop switch on the master unit as indicated
on the arrangement drawing.
The following points are of special importance:
A) Check that the position of the kiln tyre relative to the support-
ing rollers corresponds to the position indicated on the posi-
tion drawing.
B) Check that the dimensions "a" and "b" (see Appendix 4) are of
identical size when the thrust roller makes contact with the kiln
tyre.
C) The lever (58) (see Appendix 6) must be mounted on the
bearing block of the thrust roller so that it is located in the
middle of the holes.
D) Baseplate, bracket with limit stop switch must be pushed un-
der the arm until contact is established. Check that the contact
roller is running in the middle of the lever. Subsequently, the
baseplate and bracket must be pushed 15 mm towards the
kiln outlet.

3.3.3 Separate limit stop switch KDS 2

Mount the separate limit stop switch on the master unit as indicated
on the arrangement drawing.
The following points are of special importance:
A) Check that the position of the kiln tyre relative to the supporting
rollers corresponds to the position indicated on the position
drawing.
B) The column (53) must be adapted so that the contact roller can
be placed 50 mm from the outer edge of the kiln tyre. See Ap-
pendix 7.
C) The frame must be pushed towards the kiln tyre in the centre-
line of the kiln until contact is made, and, subsequently, it must
be pulled 15 mm towards the kiln inlet.
D) The frame must be tack-welded to the baseplate; check that
the contact roller is flush with the centreline of kiln.
ERECTION CHECK
3.4 Posting of signs and mounting of guards
Check that all supplied signs and guards have been posted and
mounted as specified in the erection-specific documentation.
18 70000448-3
4. OPERATION

4.1 Preparation of the mechanical system

Check that all bolted connections between thrust device, bedplate
and bearing supports have been tightened.
Check that the adjustment wedges (91) have been secured by
welding.
Check that the four two-part distance rings (90) are mounted on the
master unit.
Check that the thrust device has been lubricated. (See sub-section
5.1.1).
ERECTION CHECK
4.2 Preparation of the hydraulic system
Check that the hydraulic cylinder has been mounted in correct man-
ner with the combined venting and measuring nipples fitted at the
top and with the five-part locking ring with holding ring correctly po-
sitioned, guiding the cylinder as intended.
4.2.1 Procedure for preparation of the hydraulic system
See Appendices 3, 4 and 5
The entire procedure must be closely monitored by the erection su-
pervisor.
1) Remove the front panel from the pump station to ensure ac-
cessibility of valves, filters and pressure gauges.
2) Unscrew the air filter (26) from the filler branch and fill the tank
with pure hydraulic fluid. The hydraulic oil to be used should
be of a grade corresponding to FLS MAT No. 7025. Use a
funnel with a sieve cloth conforming to DIN 0.12 for filling. Oil
to be filled to the upper mark on the oil level glass. The capac-
ity of the tank is approx. 150 litres. Check the alarm and safety
functions for level switch (27) during the oil filling process.
3) Check that the pump housing (08) is filled with oil. If not, the
pump housing must be filled through the hose (10).
4) Check that valve (04) is entirely open.
5) Check all pipe joints from pump station to each cylinder (45).
6) Close the valves (12), (29), (40) and (41).
7) Precharge the accumulators with nitrogen to 30 bar.
See separate instruction manual from the supplier, ref. 10.
8) Start/stop the pump motor (06) and check the direction of
rotation of the pump.
9) Start the pump with the coil of valve (13) de-energized.
10) Open the valves (40) one at a time. Flush out the pipeline to
the cylinder during a period of minimum 60 minutes. Repeat
the operation for the other cylinders.
 70000448-3 19

11) There must be a pressure of approx. 3 bar in the system when

the flushing of pipes is being carried out. Check all assemblies
and joints for leaks.
12) Vent all cylinders, one at a time, at both ends, by opening the
valve (41) (valve (40) is already open). Use the venting equip-
ment (35, 36, 37, 38, 39), Appendix 5, but avoid use of tools in
connection with the mounting and dismantling of the hose un-
ion (35). Place an appropriate reservoir under the pipe (36) for
collection of oil during venting process. The collected oil
must not be re-used. Do not forget to check the oil level
during the venting process. On completion of venting, refit the
protective caps on the nipples (42) and (43).
13) Close all valves (41).
14) Adjust the pump for a low pressure during the initial pressure-
testing of the pressure system. See separate instruction man-
ual from the supplier, ref. 10.
15) Close all valves (40). As a result, all pressure lines will be
pressurized. Check for leaks.
16) Raise the test pressure slowly, and check the tightness of the
system on an ongoing basis. Maximum testing pressure: 160
bar.
17) Set the over-pressure valve (21) for opening at a pressure of
150-160 bar.
18) Check the oil level.
19) Set the system pressure for 75 bar on the pump.
20) Check the oil level in the tank and open all valves (41).

The hydraulic system will now be ready for operation.

20 70000448-3
4.3 Final inspection and adjustment
Finally, check the position of the bearing housing on the guide
shafts. Write down the dimensions "a" and "b" for all units, see Ap-
pendix 4, in the erection report, with kiln in cold as well as hot con-
dition.
It should be noted that on the master units the dimensions are
those between the two-part distance rings and the bearing block.
Determine the actual heat expansion of kiln, and the calculated
value must also be indicated in the erection report.

ERECTION CHECK
4.4 Daily operational checks during start-up period
1. Always ensure that the protective caps are fitted to the
measuring nipples (20), (24), (42) and (43).
2. Make sure that the cover plates and panels have been fitted
on the pump station.
3. Check the visual indicator of the return filter.
4. Check the oil level in the tank of the pump station.
 70000448-3 21

5. MAINTENANCE

5.1
Preventive maintenance, survey

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

Pos. Text .1 .2 .3 .4 .5 .6
00 Thrust device . S . . . .
01 Pump station . S S A T 2A
03 Suction filter . A . . . .
23 Accumulator . . A A . .
26 Air filter/sieve . A . . . .
28 Return filter . . . S A .
45 Cylinder . . . 2A . .
50 Limit switch KDS1 . . . S . 2A
51 Limit switch KDS2 . . . S . 2A
75 Thrust roller T . D . . .
77 Roller bearing S . . . A .
78 Roller bearing S . . . A .
79 Roller bearing S . . . A .
82 Bearing bushing M . . . . .
83 Bearing block . . D . . .
94 Air filter . A . . . .

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

S = weekly letter indicates the fre-
M = monthly quency of procedure.
A = yearly For example, 2M = twice
T = see text in instruction a month
manual
22 70000448-3
5.1.1 Lubrication
Oil products corresponding to the FLS symbols used for lubricants
appear from the FLS Key to Lubricants No. 36501 forwarded under
separate cover.
Thrust roller (75)
Lubrication of the running path of the thrust roller is effected by
means of a graphite block (87) which is pressed against the path of
the roller by means of a counterweight.

Roller bearings (77), (78) and (79)

The bearings run in an oil bath. Check the oil level. The level must
reach up to the midway mark on the glass.
Oil grade: FLS MAT 7158.

Bearing bushings (82) for guide shafts

Feed grease through the grease nipples (89). There are four nip-
ples for each thrust roller.
Grease quality: FLS MAT 7425
Grease quantity/nipple: 10 cm.
5.1.2 Cleaning
General cleaning of the thrust device and its surroundings.
Pump station (01)
General cleaning of the pump station and its surroundings.
Filters (03), (26) and (94)
Clean suction filter (03)
Clean air filter/filling sieve (26)
Clean air filter (94)
Spare filter elements must always be kept in stock!
 70000448-3 23

5.1.3 Inspection and adjustment

Inspect pump station, pipelines and cylinders for leaks.
Check the oil level on oil gauge glass of tank.
Top up oil if oil level is too low.
Oil grade: FLS MAT 7025
Accumulators (23)
Check the precharging pressure. See separate instruction manual,
ref. 10.

Limit stop switch (50) and (51)

Check that the mounting bolts of the switch and frame are ade-
quately tensioned.

Thrust roller (75)

Check that the graphite block is moving unimpeded in the graphite
holder and that it provides the necessary lubrication of the running
path of the thrust roller.
Bearing block (83)
Inspect the bearing block. Check for generation of heat.
Check that the guide shafts are free from contaminants and foreign
matter between the bearing block and distance rings.
5.1.4 Checking of condition
Pump station (01)
At least once a year, a sample of the hydraulic oil must be taken for
to the oil suppliers laboratory for analysis. The analysis will deter-
mine whether an oil change is required or not.

Accumulator (23)
Check the precharging pressure. In case of a significant drop in
pressure, and if a leakage is suspected, the accumulator must be
checked as described in the suppliers instruction manual, ref. 10.

Return filter (28)

Inspect the visual filter indicators.
The "red " indicator on filter (28) is an indication of filter element
contamination.

Cylinder (45)
Cylinders to be vented every 6 months, see sub-section 4.2.1.
24 70000448-3
Limit stop switch KDS1 (50)
Check that the position of the roller arm on the switch and that of
the activation frame (58) are correct.

Limit stop switch KDS2 (51)

Check the position of the switch in relation to the neutral position of
the kiln tyre, see Appendix 7.
5.1.5 Replacement
Pump station (01)
The time of replacement for the hydraulic oil depends on the oil
analysis performed at the laboratory. An oil sample must be ex-
tracted and analyzed at least once a year. See sub-section 5.1.4.
Oil quality FLS MAT. 7025.

Return filter (28)

Renew the filter element at least once a year.

Roller bearings (77), (78) and (79)

Replace the oil in the bearing block (80) on a regular annual basis.
Oil quality: FLS MAT 7158.
The bearing block is equipped with a vent filter (94) to allow the air
to escape during oil filling procedure.
5.1.6 Performance test
Pump station (01)
Test the function of pressure filter alarm switch (28) and level
switch (27).
Limit stop switches (50) and (51)
Test the function of switches and check that the movable parts op-
erate smoothly.
5.2 Faults and remedial action
5.2.1 Thrust device failure
Each thrust roller is individually capable of absorbing the full axial
load of kiln during a short period of time.
In case of oil pump failure, the hydraulic pressure will still be main-
tained due to the non-return valves of the system.
In event of pump failure or pump motor failure when the kiln is in
excessive upward position, the kiln can be made to migrate
downward by manually setting the pressure-limiting valve (21) for a
very low pressure.
 70000448-3 25

If the pump or pump motor should fail when the kiln is "in downward
position", and the kiln must be lifted to neutral position, this can be
done by means of a hydraulic hand pump which is connected to
measuring nipple (20) or (42).
The hand pump must only be operated with very small oil quanti-
ties.
In case of a pipe rupture on the pressure side, the kiln will force the
thrust rollers downward towards the outlet, until the bearing block of
the master unit is made to rest on the distance ring (90). At this
point in time, an alarm has already been triggered by the monitoring
system, and if no further action is taken, the kiln motor will be cut
out automatically.

5.2.2 Kiln tyre runout

During kiln operation the hydraulic accumulators will compensate
for any kiln tyre runout. The extent of kiln tyre runout during one kiln
revolution can be read off on the guide shafts of the bearing block.
To some degree, the accumulators will equalize the pressure varia-
tions occurring as a result of the runout. Substantial pressure varia-
tions during one kiln revolution will be an indication of accumulator
damage, The pressure variations recorded while the accumulator is
in operation must be much smaller than when the cylinder, and
hence the accumulator, is disconnected.
The pressure variations in a cylinder can be checked with the pres-
sure gauge (33) mounted on the measuring nipple (42) on the pres-
sure side of the cylinder when the cylinder is disonnected. Discon-
nection is accomplished by closing the valve (41) for the specific
cylinder. See Appendix 3.
Valve (41) must be opened entirely on completion of
the check-up procedure.
5.2.3 Position of supporting rollers
In case the load on the thrust rollers is extremely large or extremely
small, this will normally be ascribable to the fact that the supporting
rollers are no longer positioned exactly as they should be. Exact
positioning of the supporting rollers is of crucial importance for the
operation of kiln and thrust device. See instruction manual for axial
measuring equipment, ref. 8.
26 70000448-3
5.2.4 Position of the thrust rollers
It is very important that the thrust rollers tread with their entire con-
tact surface against the kiln tyres. If an adjustment is necessary, it
must be done by inserting intermediates between thrust device and
bearing block.

It is also essential to ensure that the diameter of the thrust rollers -

at right angles to the kiln axis is horizontal, and that the axis of ro-
tation of the thrust roller is lying in the vertical plane of the kiln axis.
Non-compliance with these conditions will result in an effect similar
to that occurring in case of skewing of a supporting roller, i.e. the
thrust roller will either follow the kiln tyre some distance upwards or
the pressure which is exerted in downward direction will be excep-
tionally large. See Fig. 6.

Fig.6
 70000448-3 27

5.3 Replacement of parts.

In connection with major maintenance and repair work, involving,
for example, the replacement of bearings, it may become neces-
sary to dismantle the entire thrust device.
The thrust device must be detached from the baseplate and the ad-
justment wedges (91) must be removed.
The thrust device can now be displaced onto a support (99) moun-
ted on a forklift truck, as illustrated in Appendix 8.
To avoid excessive loading of the forklift truck during displacement,
the support (99) must be supported on the thrust roller foundation
and on the forks close to the mast. See Appendix 9.

For determination of the forklift truck capacity, the weight of com-

plete thrust devices is indicated below.

HTD 31.5 3300 kilos

HTD 50 5500 kilos

HTD 80 8700 kilos

HTD 110 11800 kilos

HTD 140 17600 kilos

28 70000448-3
6. KEY TO APPENDICES

01 Pump station
02 Pump station oil tank
03 Suction filter
04 Ball valve
05 Hose. Suction side of pump
06 Motor for pump
07 Coupling between motor and pump
08 Pump
09 Hose. Pressure side of pump
10 Hose. Drain from pump
11 Spring-loaded non-return valve
12 Ball valve
13 Directional valve, electrically controlled
14 Pressure gauge for system pressure
15 Hose. Pressure gauge
16 "Mini-Mess"-coupling for pressure gauge
17 Hose. Pressure transmitter
18 Pressure transmitter
19 "Mini-Mess"-coupling for pressure transmitter
20 "Mini-Mess"-coupling for system pressure control
21 Pressure-limiting valve
22 Flow control valve
23 Hydraulic accumulator
24 "Mini-Mess"-coupling for return flow pressure control
25 Emergency stop
26 Air filter
27 Level switch: Trips alarm in case of low oil level in oil tank
28 Return flow filter
29 Ball valve
30 Spring-loaded non-return valve in return line
31 Oil level glass
32 Drain cock
33 Pressure gauge
34 "Mini-Mess"-coupling
35 Hose for test pressure gauge Testing and
36 Vent pipe venting equipment
37 Fitting
38 Stop valve
39 "Mini-Mess"-coupling
40 Stop valve
41 Stop valve
42 Measuring nipple. Pressure side on cylinder
43 Measuring nipple. Piston rod side of cylinder
45 Hydraulic cylinder
 70000448-3 29

46 Magnet
47 Plastic disc
48 Protective tube
49 Longitudinal transducer
50 Limit stop switch, KDS1
51 Limit stop switch, KDS2
53 Frame for KDS2
56 Baseplate
57 Bracket and baseplate for limit stop switch, KDS1
58 Arm for activation of limit stop switch, KDS1
75 Thrust roller
76 Thrust roller shaft
77 Upper spherical roller bearing
78 Lower spherical roller bearing
79 Spherical axial roller bearing

80 Rear bearing block (cylinder block))

81 Guide shaft
82 Bearing bushing
83 Bearing block
84 Front bearing block
85 Oil level pipe
86 Graphite holder
87 Graphite block
88 Split channel for thrust roller
89 Grease nipple
90 Split distance ring (only on master unit)
91 Split adjustment wedge
92 5-part locking ring for hydraulic cylinder
93 Cover ring
94 Air filter
95 Guard for cylinder block
96 Transport frame
97 Thrust disc
98 Forlklift truck
99 Lifting table with overhang
100 Temporary support for overhang of lifting table
30 70000448-3

Text relating to Appendix I

45 Hydraulic cylinder
49 Longitudinal transducer
75 Thrust roller
76 Thrust roller shaft
77 Upper spherical roller bearing
78 Lower spherical roller bearing
79 Spherical axial roller bearing

80 Rear bearing block (cylinder block)

81 Guide shaft
82 Bearing bushing
83 Bearing block
84 Front bearing block
89 Grease nipple
90 Split distance ring (only on master unit)
96 Transport frame
97 Thrust disc
 70000448-3 31

Appendix 1. Thrust roller

32 70000448-3

Text relating to Appendix II

85 Oil level pipe

86 Graphite holder
87 Graphite block
88 Split channel for thrust roller
91 Split adjustment wedge
94 Air filter
95 Guard for cylinder block
 70000448-3 33

Appendix 2. Thrust roller with ancillary equipment

34 70000448-3

Text relating to Appendix III

M Master unit
S Slave unit
01 Pump station
02 Pump station oil tank
03 Suction filter
04 Ball valve
05 Hose. Suction side of pump
06 Motor for pump
07 Coupling between motor and pump
08 Pump
09 Hose. Pressure side of pump
10 Hose. Drain from pump
11 Spring-loaded non-return valve
12 Ball valve
13 Directional valve, electrically controlled
14 Pressure gauge for system pressure
15 Hose. Pressure gauge
16 "Mini-Mess"-coupling for pressure gauge
17 Hose. Pressure transmitter
18 Pressure transmitter
19 "Mini-Mess"-coupling for pressure transmitter
20 "Mini-Mess"-coupling for system pressure control
21 Pressure-limiting valve
22 Flow control valve
23 Hydraulic accumulator
24 "Mini-Mess"-coupling for return flow pressure control
25 Emergency stop
26 Air filter
27 Level switch: Trips alarm if oil level in oil tank is too low
28 Return flow filter
29 Ball valve
30 Spring-loaded non-return valve in return line
31 Oil level glass
32 Drain cock
33 Pressure gauge
34 "Mini-Mess"-coupling
35 Hose for test pressure gauge Testing and
36 Vent pipe venting equipment
37 Fitting
38 Stop valve
39 "Mini-Mess"-coupling
40 Stop valve
41 Stop valve
42 Measuring nipple. Pressure side on cylinder
43 Measuring nipple. Piston rod side of cylinder
45 Hydraulic cylinder
 70000448-3 35

Appendix 3. Pipe diagram (schematic diagram)

36 70000448-3

Text relating to Appendix IV

08 Pump
13 Directional valve, electrically controlled
18 Pressure transmitter
50 Limit stop switch, KDS1
51 Limit stop switch, KDS2
49 Longitudinal transducer
 70000448-3 37

Appendix 4. Functional diagram

38 70000448-3

Text relating to Appendix V

33 Pressure gauge
34 "Mini-Mess"-coupling
35 Hose for test pressure gauge Testing and
36 Vent pipe venting equipment
37 Fitting
38 Stop valve
39 "Mini-Mess"-coupling
42 Measuring nipple. Pressure side on cylinder
43 Measuring nipple. Piston rod side of cylinder
45 Hydraulic cylinder
46 Magnet
47 Plastic disc
48 Protective tube
49 Longitudinal transducer
 70000448-3 39

Appendix 5. Hydraulic cylinder

40 70000448-3

Text relating to Appendix VI

50 Limit stop switch, KDS1
56 Baseplate
57 Bracket and baseplate for limit stop switch, KDS1
58 Arm for activation of limit stop switch, KDS1
83 Bearing block
 70000448-3 41

Appendix 6. Safety switch, KDS 1

42 70000448-3

Text relating to Appendix VII

51 Limit stop switch, KDS2

53 Frame for KDS2
 70000448-3 43

15

Appendix 7. Safety switch, KDS 2

44 70000448-3

Text relating to Appendix VIII

45 Hydraulic cylinder
49 Longitudinal transducer
97 Thrust disc
 70000448-3 45

Appendix 8. Calibration of transducer

46 70000448-3

Text relating to Appendix IX

98 Forklift truck
99 Lifting table with overhang
100 Temporary support for overhang of lifting table
 70000448-3 47

Appendix 9. Dismantling of thrust roller

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