Roll Crusher For REPOL® POLYTRACK®

Machine Manual
en-21015.002-A
Roll crusher for REPOL® / POLYTRACK®
Code Word
Order-Number
POLYSIUS Order Code (POC)

Machine Manual Contents
Roll crusher for REPOL® / POLYTRACK®
Contents
1 Technical data......................................................................................... 1-1

2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-2
3.2 Mode of functioning................................................................................3-12
4 Transport and assembly........................................................................4-1
4.1 Transport and storage requirements........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Preparation for the test run...................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
6.2 Setting and adjustment.............................................................................6-2
6.3 Test run.................................................................................................... 6-2
6.4 Operation of the roll crusher.....................................................................6-2
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-2
7.3 Trouble shooting.......................................................................................7-3
7.4 Repair....................................................................................................... 7-4
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers’ documentation...................................................................9-1
en-21015.002-A
Machine Manual Technical data
Roll crusher for REPOL® / POLYTRACK® 1
1 Technical data
NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers’
documentation.
Information on the intended use

Feed material.............................................................Cement clinker
See machine manual of the cooler...............................................No.
Basic data
Year of construction............................................................................
Type.....................................................................................................
Nominal width of the roll crusher ......................................................
Number of rolls....................................................................................
Mounting position of the roll crusher ................................................
Rolls
Nominal diameter..........................................................................mm
Speed ......................................................................................... min-1
Torque............................................................................................Nm
Speed of the last grinding roll................................................... min-1
Weight of a grinding roll unit..........................................................kg
Drive of the roll crusher

Type of drive.........................................................................hydraulic
See machine manual ....................................................................No.
2
Assembly data
Drive trunnion (1.7)

Tightening torque of the screws...................................................Nm
Floating bearing shaft (1.8)

Pillow block frame (1.9)

Flange ring (1.13)

Outer flange ring (1.14), floating bearing

Thrust ring (1.16 and1.18)

Dismounting pipe (8.1)

Pulling device (8.3)

Data on mounting the self-aligning roller bearing

Fixed ring (1.12) available........................................................yes/no
Radial gap before mounting.........................................................mm
Reduction of radial gap.................................................................mm
Travel of the withdrawal sleeve...................................................mm
Smallest permissible radial gap after mounting.........................mm
Machine Manual Technical data
Figure 1
4
Cooling of the roll crusher
Roll cooling
Fan No. 1
Design ...................................................................................... radial
Type ....................................................................................................
Volume flow .................................................................................m3/h
Temperature....................................................................................°C
Pressure difference, static........................................................ mbar
Drive motor rating..........................................................................kW
Motor speed.................................................................................min-1
Connecting element between fan and motor ....................................

Type.....................................................................................................
Cross girder cooling

Fan No. 2
Design ...................................................................................... radial
Type ....................................................................................................
Volume flow .................................................................................m3/h
Temperature....................................................................................°C
Pressure difference, static........................................................ mbar
Drive motor rating..........................................................................kW
Motor speed.................................................................................min-1
Connecting element between fan and motor ....................................

Type.....................................................................................................
Temperatures of cooling air in the exhaust air ducts for roll cooling
Setting value: Alarm at............................................................160 °C
Setting value: Switch-off at.....................................................180 °C
Machine Manual Safety
2 Safety
NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.
Use
 The roll crusher is a part of the cooler. Be sure to comply with
the information concerning the specified use of the machine in
the section Technical data.
 Any use of the machinery other than for the specified purpose
is forbidden. POLYSIUS AG is not responsible for any damage
resulting from any other than the specified use of the machine.
That risk is borne solely by the operator.
 The observance of these precautions and of the maintenance
instructions is essential for the proper use.
Transport and assembly

 All transport instructions in this manual refer exclusively to the
transport of the machinery in the plant area.
 Use only suitable hoisting and lifting equipment, which is in
serviceable order and has a sufficient carrying capacity.
 Never work under a suspended load.
Preparations for commissioning
 Do not make any changes (software) to programmable control
units.
Operation
 Any safety checks before or during operation depend on the
relevant national regulations. The operator is responsible for
the performance and recording of such checks.
 If changes relevant to safety of the machine or its operating
behaviour occur, the machine must be immediately stopped.
Maintenance
 Ensure that for the entire duration of the maintenance work, all
machines and motors whose operation might endanger
persons or equipment are switched off, isolated and
safeguarded against restarting.
Safety Machine Manual
2 Roll crusher for REPOL® / POLYTRACK®
 Ensure that all moving parts of the machine have reached a

stillstand before dismantling protective devices or opening
flaps.
 Before performing any work on the machine, make sure that
there is no burning hazard when the machine is touched.
Ensure that there is no hot material inside the machine when
inspection flaps and maintenance flaps are opened.
 Suitable protective clothing must be worn during work on the
hot REPOL / POLYTRACK!
 Ear protection must be worn during the operation of the cooler,
as the noise level can lie above 90 dB (A).
 The interior spaces of the cooler must not be entered during
cleaning of the plant sections preceding the cooler, as hot raw
meal can flow as far as the cooler.
 You must not enter the interior spaces of the machine until you
have sufficiently scavenged them with fresh air and they have
been sufficiently cooled down. You must then make sure that
there is sufficient oxygen inside the machine and that no hot
gases can penetrate.
 When working inside the machine, you must always supply air
(by injection or suction) in order to keep the inhaled air free of
harmful substances. Aeration with pure oxygen is prohibited.
 Keep the machine free from oily and explosive matter. Never
use benzine or other readily flammable substances for
cleaning the machine.
 De-energize the electrical parts before commencing any
maintenance work.
 The hydraulic plant is specially designed for the supplied
machine and must therefore not be used for other purposes
without the authorization of POLYSIUS AG.
 Make sure that hydraulic lines are de-pressurized before they
are dismantled.
 Check the tightness of all connections and joints after any
maintenance work.
 Strictly observe the welding instructions when performing any
welding work.
 Personnel must be protected from coming into contact with
electrically conductive components whilst performing electric
arc welding or cutting.
Machine Manual Safety
 Never situate the source of the welding current in a confined

space where walls have conductive properties. No other than
24 V lamps may be used for lighting the interior spaces.
 If electrical welding is executed on any part within the
machine, the welding current must never be conducted through
sliding or antifriction bearings, other moveable connections or
measuring equipment. The welding current return lead must
always be directly connected to the part to be welded.
 All safeguards have to be re-installed when maintenance work
has been terminated. Make sure that there is nobody in the
interior spaces of the plant component before properly closing
the inspection and maintenance flaps again.
Machine Manual Components and mode of functioning
3 Components and mode of functioning

The roll crusher serves to comminute coarse cement clinker. It is
used in association with grate coolers between two grates or at
the end of the cooler. The effective width of the crusher conforms
to the width of the cooler.
The roll crusher consists of transport and a crushing rolls. The
transport rolls separate small pieces of cement clinker and
transport large pieces to the crushing rolls for comminution.
The transport and crushing rolls are arranged on longitudinal
girders. All grinding rolls are driven by hydraulics.
The grinding rolls and the cross girders are fitted with air cooling.
A dismounting device is provided for repair work on the grinding
rolls.
Components and mode of functioning Machine Manual
3.1 Components
NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract.
The roll crusher consists of the following sub-assemblies:

1.0 Rolls
2.0 Longitudinal girders
3.0 Cross girders
4.0 Attaching parts
5.0 Air cooling
6.0 Drive unit
7.0 Platform (customer’s supply)
8.0 Dismounting device
9.0 Barrier (not shown in the illustration)
NOTE
The barrier (9.0) is only fitted when the crusher is mounted
between two grates.
Figure 2
Itemd relating to grinding rolls (1.0)

1.1 Crushing ring
1.2 Crushing ring with cam (only on the last grinding roll)
1.3 End ring
1.4 Spacer sleeve, fixed bearing side
1.5 Spacer sleeve, floating bearing side
1.6 Crusher shaft
1.7 Drive trunnion
1.8 Floating bearing trunnion
1.9 Pillow block frame
1.10 Self-aligning roller bearing
1.11 Withdrawal sleeve
1.12 Fixed ring, if installed
1.13 Flange ring
1.14 Outer flange ring, floating bearing
1.15 Inner labyrinth ring
1.16 Thrust ring with switch lug for pulse generator
1.17 Outer labyrinth ring
1.18 Thrust ring
1.20 Covering box

1.21 Air connection piece
1.22 Housing sealing box with compressed air connection
1.23 Housing sealing box
1.24 Seal
1.25 Pulse generator
Figure 3
Items shown in the drawings
Longitudinal girders (2.0)

2.1 Longitudinal girder, fixed bearing side (drive system)
2.2 Longitudinal girder, floating bearing side
Cross girders (3.0)

3.1 Cross girder, front of crusher
3.2 Cross girder, end of crusher
3.3 Housing sealing box on cross girder
3.4 Upper protective plates
3.5 Lower protective plates
Attaching parts (4.0)

4.1 Sealing strip
4.2 Packing
4.3 Opposing bearings for torque stay arms
Barrier (9.0)
Figure 4
Air cooling (5.0)

5.1 Supply air duct for roll cooling
5.2 Supply air duct for cross girder cooling
5.3 Feed-regulating slide valve
5.4 Exhaust air duct
5.5 Fan for roll cooling
5.6 Fan for cross girder cooling
5.7 Thermometer (optical)
5.8 Temperature sensor (PT 100)
Drive system (6.0)

Figure 5
Platforms (7.0), customer’s supply

7.1 Platform below the drive systems
7.2 Platform at the floating bearing side
7.3 Platform for access to the upper cooler section
Dismounting device (8.0)

8.1 Dismounting pipe
8.2 Roller block
8.3 Pulling device
8.4 Transport safety device, fixed bearing side
8.5 Transport safety device, floating bearing side
8.6 Supporting trestle, fixed bearing side
8.7 Sliding shoe (only above nominal width 4000)
8.10 Mounting sleeve (for illustration, see the contract-related

Technical drawings)
8.11 Mounting flange (for illustration, see the contract-related
drawing Mounting sleeve)
Figure 6
3.2 Mode of functioning

The cement clinker transported from the grate cooler falls from
the end of the grate via a dead bed onto the front of the roll
crusher located below. In normal operation of the crusher, the
first two grinding rolls serve as classifying and transport rolls.
Their direction of rotation corresponds to the direction of
material flow. Large pieces of cement clinker are conveyed by the
transport rolls.
The grinding rolls located behind the transport rolls comminute
the coarse material. Their direction of rotation is mutually
opposing, so that the cement clinker to be crushed is drawn into
the roll gap.
The torque of the grinding roll conforms to the power requirement
of the crushing process. If one pair of rollers is blocked by the
intake of tramp material (metal) or overloads, the exceeded
limiting torque is detected by a pressure switch and the direction
of rotation is reversed. After a short time, preset on a time
switch, the grinding roll returns to its original direction of
rotation. This procedure can be repeated several times to free the
crushing gap from tramp material. If the roll crusher is unable to
achieve its normal operating state after repeated reversal of the
direction of rotation within a preset time, an alarm is issued and
the roll crusher switches down.
The exhaust air ducts of the roll cooling system are equipped
with optical thermometers (5.7) and electrical temperature
sensors (5.8) for monitoring the temperatures of outflowing
cooling air.
When a temperature sensor (5.8) triggers an alarm signal, it must
be checked whether the exhaust air temperatures at all rolls have
the same level. If this is not the case, the cooling air can be
distributed by throttling or opening the feed-regulating slide
valves (5.3) so that the exhaust air temperatures becomes equal.
When the switch-off temperature is attained at a sensor (5.8), the
cooling grate upstream of the roll crusher is switched off.
Further information is to be found in the machine manual
Hydraulic drive of the roll crusher.
Figure 7
Machine Manual Transport and assembly
4 Transport and assembly
4.1 Transport and storage requirements

The machine is transported in single parts or in sub-assemblies.
It must be observed that suitable lifting equipment is employed in
removing the parts from the transport vehicles and transferring
them to the storage area.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against rain, contamination and
damage. The parts must not be stored directly on the ground.
Motors, couplings, gear units, measurement and control
equipment must be stored in buildings which are well aerated and
must be protected against moisture.
4.2 Assembly
General information
The following assembly instructions do not detail the individual
steps for assembling the unit, but rather give an overview of the
work to be performed.
Changes in the plant layout during the processing of the contract
may lead to deviations from these assembly instructions.
NOTE
Final assembly and assembly inspection by an assembly
specialist from POLYSIUS AG are prerequisites for our warranty.
We recommend that the assembly work is supervised from start
to finish by specialists from POLYSIUS AG.
To ensure correct execution of the assembly work, it is important
to carefully select the tools and appliances to be used as well as
the personnel.
CAUTION
If electrical welding is carried out in any place of the machine, welding
current must never be conducted through plain bearings and antifriction
bearings, other moveable connections or measuring equipment, to prevent
damage to such parts.
Transport and assembly Machine Manual
The welding current return lead must always be directly connected to the
part to be welded.
Mounting sequence
 The lower part of the cooler grate situated in front of the roll
crusher must be completely fitted.
 When the roll crusher is used as an intermediate crusher, all
parts of the cooler located below the roll crusher must be
completely fitted.
 Tightening torques for bolts are to be found in section
Technical data
NOTE
The thread and contact face must be clean and lightly oiled. (no
molybdenum disulphide!)
 Mount and align the longitudinal girders (2.1 and 2.2) and
secure with anchor bolts.
 Align the cross girder (3.1) at the front of the roll crusher and
the cross girder (3.2) at the end of the roll crusher on the
longitudinal girders and bolt them to the longitudinal girders
and the cooler.
 Mount the upper and lower protective plates (3.4 and 3.5).
 Mount the housing sealing box (3.3) on the cross girder (3.1).
 Place the grinding rolls (1.0) on the longitudinal girders so that
the drive trunnions (1.7) point to the designated drive side of
the roll crusher.
NOTE
Ensure that the last grinding roll is fitted with crushing rings (1.2)
with cams.
Align the grinding roll according to the drawing. Ensure the
correct spacing of the grinding roll.
 Remove the transport safety devices (8.4 and 8.5) and retain
them for subsequent dismantling and repair work.
 Screw the pillow block frame (1.9) onto the bearing cover.
(Make sure that the bolts are tightened with the correct
tightening torque)
 Check the spacing between the flange rings (1.13) and the
inner labyrinth ring (1.15) of all grinding rolls according to the
drawing in section Technical drawings. Then screw the pillow
Transport and assembly Machine Manual
block frame (1.9) to the side of the floating bearing.

tightening torque)
 Align the housing sealing boxes (1.22 and 1.23) and screw
them to the longitudinal girders. The housing sealing boxes
must not touch the grinding rolls.
 The seal (1.24) must then be fixed on in such a way that an
even circular air gap to the crusher shaft is ensured.
 Mount the longitudinal profiles of the upper part of the cooler
above the roll crusher.
 Mount the platforms (7.1 and 7.2) at the sides of the roll
crusher.
 Insert the packings (4.2) in the gap between and above the
housing sealing boxes (1.22 and 1.23) and mount the sealing
strips (4.1).
 Moun the abutment (4.3) for the torque stay arms.
 Remove the transport safety device of the thrust ring (1.18).
 Mount the drive systems (6.0) on the drive trunnions (1.7).
See the separate machine manual Hydraulic drive of the roll
crusher.
 Tighten and secure the set screw of the thrust ring (1.18).
tightening torque)
 Mount the barrier (9.0) at the end of the roll crusher.
 Mount the fans (5.5 and 5.6), supply lines (5.1 and 5.2) for the
shaft and cross girder cooling. The exhaust air pipes (5.4) must
then be mounted.
 Mount the hydraulic lines to the drive system (6.0).
See the separate machine manual Hydraulic drive of the roll
crusher and the drawing Hydraulic lines of the REPOL /
POLYTRACK
NOTE
When installing the hydraulic lines at the drive systems, ensure
absolute cleanliness throughout the entire working area.
 Mount the platform (7.3) above the drive systems.

The platform (7.3) must be removable for maintenance work!
Machine Manual Lubrication
5 Lubrication
NOTE
The POLYSIUS table of lubricants with the lubricant reference
numbers is contained in the supplement Important notes on the
documentation. The supplement is to be found in this folder or at
the beginning of the overall documentation. Each lubricant has a
clear reference number to which the lubrication instructions in
this section relate. The table gives a complete list of the suppliers
and products approved by POLYSIUS AG.
It is the responsibility of the lubricant supplier to select
appropriate lubricants corresponding to the reference numbers.
POLYSIUS AG is not responsible for the correctness of this data.
The use of a lubricant not explicitly stated in the table of
lubricants has to be previously approved by POLYSIUS AG.
The supplement Important notes on the documentation also
contains the generally valid Notes on lubrication.
CAUTION
Ensure that the lubricants are stored, used and disposed of in an
environmentally-friendly manner and observe your national environmental
legislation when handling lubricants.
Lubrication Machine Manual
Lubrication chart
Lubrication points Quantity (ltr/kg) Lubrication intervals

per lubrication (weeks)
point
No. Qty. Designation Lubricant Initial Topping Topping First Further
ref. no. filling up up change changes
1 Self-aligning 81 2.0 0.13 12 52 52

roller bearings
of the grinding
rolls [1]
2 Labyrith rings of 81 0.5 0.05 12 52 52

the roller
bearings [1]
3 Hydraulic drive See separate machine manual!

of the roll
crusher
4 Fans See manufacturer’s instructions!
The different makes of lubricant corresponding to the lubricant reference numbers are shown in the
table of lubricants in the supplement Important notes on the documentation. The supplement is to be
found in this folder or at the beginning of the overall documentation.
Explanation of the number

[1]
Manual lubrication at the flange grease nipples (AM 16 x 1.5)
Machine Manual Preparation for the test run
6 Preparation for the test run
NOTE
It is a prerequisite of our warranty that the first test run is carried
out in the presence of and according to the instructions of
specialists from POLYSIUS AG.
6.1 Checks prior to the test run
After completion of the assembly work and prior to the first test
run, check all parts of the plant according to the list below. Take
particular care that all material remnants, tools and assembly
aids are removed.
 Have the foundations for the fan and the longitudinal girders
been properly casted and have the anchor bolts been
tightened?
 (For a steel support, check the screwed connections of these
parts with the steel structure.)
 Have all transport safety devices been removed and has the
motion of the crusher rolls been checked?
 Are the fixing bolts tightened with the specified tightening
torque?
 Are all supply air and exhaust air ducts of the air cooler
correctly installed and fitted air-tight with the correct air
seals?
 Are all feed-regulating slide valves (5.3) in the supply air ducts
for the crusher rolls and the cross girders open?
 Has the direction of rotation of the fan been checked?
 Are the drive systems (6.0) and the torque stay arms
completely fitted? (See machine manual Hydraulic drive of the
roll crusher and manufacturer’s documentation.)
 Have all monitoring devices and interlocks been checked for
correct function?
 Are all cables routed and protected to avoid damage during
maintenance work on the grinding rolls and by thermal
influences?
 Are all bearings lubricated according to specification?
Preparation for the test run Machine Manual
 Is the interior space of the roll crusher free from tramp

material?
 Is the door above the roll crusher tightly closed?
 Are all protective devices and warning signs correctly fitted?
Machine Manual Preparation for the test run
6.2 Setting and adjustment

For setting and adjustment work on the drive systems (6.0), see
machine manual Hydraulic drive of the roll crusher.
The distance between the pulse generators (1.27) and the switch
lugs of the thrust rings (1.16) must be adjusted to 4 mm.
The feed-regulating slide valves (5.3) in the for the roll and cross
girder cooler must be completely open.
6.3 Test run
After all checks and any adjustment work have been carried out,
a test run can be performed.
This no-load test should be performed without interruptances if
possible.
The function of the electric interlocks of all plant components
relating to the machine must be checked during the test run.
After the test run, check the tightening torque of all screwed
connections and tighten as required.
Observe the information in the manufacturer’s documentation
during the test run of the fan.
Information required for the drive systems (6.0) during the test
run is to be found in the separate machine manual and in the
manufacturer’s documentation.
If faults are detected during the test run, it must first be
terminated and only resumed when the faults have been
eliminated. The roll crusher is ready for use after a successful
test run.
6.4 Operation of the roll crusher
Switching-on sequence
 Switch on the fans (5.5 and 5.6) for the roll and cross girder
cooling
 Start the drive systems of the roll crusher.
 Start the grate cooler
Switching-off sequence
 Switch off the grate cooler
 Switch off the drive systems of the roll crusher
Preparation for the test run Machine Manual
 Only switch off the fans (5.5 and 5.6) when the danger of
overheating of the grinding rolls has passed.
NOTE
If the roll crusher fails due to induction of foreign bodies,
overloading or by other functional disturbances, the operation of
the kiln must be interrupted until the roll crusher is returned to
operation after elimination of the functional disturbance.
Machine Manual Maintenance
7 Maintenance
7.1 Inspection
The inspection work described in the following is divided into:

 Inspections during operation and
 Inspections during long plant standstill periods.
Inspections during operation
No. Work to be performed Frequency Remark
1 General visual checks for leaks daily

2 Check the exit temperatures of the daily
cooling air
3 Inspection work on the fans acc. to
manufacturer’s
instructions
4 Inspection work on the drive system see separate
machine manual
Inspections during long plant standstill periods
WARNING
The roll crusher is hot.
You may suffer burns.
Wait until the roll crusher has cooled. Danger of burns still exists from hot
clinker even after long cooling periods.
1 Checkthe crushing rings (1.1 and 1.2)

for wear
2 Check for damage
 to the fireproof lining of the gross
girders
 to the covering boxes (1.20)
 to the upper and lower protective
Maintenance Machine Manual
plates (3.4 and 3.5)

 to the barrier (9.0)
7.2 Servicing
WARNING
The roll crusher is hot.
You may suffer burns.
Wait until the roll crusher has cooled. Danger of burns still exists
from hot clinker even after long cooling periods.

1 Replace the crushing rings (1.1 or as required when the tooth
1.2) tips of the
crushing rings
are worn by
approx. 80 %
2 Replace the upper or lower protective as required
plates (3.4 or 3.5)
3 Exchange and repair the as required
 Covering boxes (1.20)
 Fireproof lining of the cross girders
 Barriers (9.0)
4 Replace the packing (4.2) as required
when leaks occur in the housing
sealing boxes (1.22 and 1.23)
5 Maintenance work on the fans acc. to
manufacturer’s
instructions
6 Maintenance work on the drive see separate
system machine manual
7.3 Trouble shooting

The most important functions of the roll crusher are monitored
during operation.
Disturbance of these functions generates an alarm. Certain
disturbances stop the roll crusher.
Fault Cause Elimination
Failure of the fans (5.5 Motor is defective Repair or replace motor

or 5.6)
Connecting element Repair or replace
between fan and motor connecting element
is defective
Roll crusher switches Tramp material in the Remove the tramp

down after repeated roll gap (Metall) material manually
changes of the direction
of rotation
Stoppage of one or more Defect in hydraulic drive Repair hydraulic drive;

rolls unit see separate machine
manual
If disturbances occur which are not described above, additional

information on disturbances, their causes and elimination is
included in the separate machine manual Hydraulic drive of the
roll crusher and in the subsupplier’s documentation.
7.4 Repair
Before performing any repair work, make sure that all electrical
components are de-energized.
Ensure the utmost cleanliness at all times during the repair work
in order to guarantee that the bearings, the drive system, the
hydraulic system or other sensitive parts of the machine are kept
free of contamination.
Do not remove or open any flaps or protective equipment before
all rotating parts have come to a halt.
Information for repair work on the drive system (6.0) of the roll
crusher is included in a separate machine manual.
The number of the machine manual is to be found in section
Technical data).
Repair work on the fans is to be performed according to the
manufacturer’s documentation.
Removing a grinding roll with the aid of the dismounting device (8.0)
 Disconnect the monitoring devices.
 Dismantle the pipe bend in the supply air duct (5.1) for the
shaft cooling at the air connection piece (1.21).
 Dismantle the exhaust air duct (5.4) from the housing sealing
box (1.22).
 Rotate the crusher roll so that the transport safety device (8.5)
can be screwed to the housing sealing box (1.22) and the
floating bearing trunnion (1.8).
 Dismantle the platform (7.3) to enable access to the drive
systems.
 Close the stop cocks for the grinding roll which is to be
removed at the tank station and upstream of the hydraulic
motor and disconnect the connection from the hydraulic motor
to the hydraulic hoses.
NOTE
Catch discharged hydraulic oil. Seal hydraulic connections to
protect them from contamination and damage.
 Dismantle the sealing strips (4.1) on the housing sealing boxes

(1.22, 1.23 and 3.3) and the packing (4.2).
 Release the seal (1.24) in the housing boxes (1.23).

 Support the crusher roll in the housing sealing box (1.23) with
the lifting jack.
 Dismantle the screwed connections of the pillow block frame
(1.9) to the longitudinal girders (2.1) at the fixed bearing side.
Figure 8
 Dismantle the screwed connections of the drive trunnion (1.7)

to the crusher roll (1.6).
 Dismantle the entire drive unit, consisting of hydraulic motor,
planetary gear system, drive trunnions (1.7) and pillow block
frame (1.9).
 Mount the roller block (8.2) on the longitudinal girder (2.1).
 Mount the dismounting pipe (8.1) and bolt the flange to the
crusher roll (1.6). (Make sure that the bolts are tightened with
the correct tightening torque)
Remove the lifting jack from below the crusher roll.
 Dismantle the screwed connections of the housing sealing
boxes (1.22, 1.23) with the longitudinal girders (2.1 and 2.2).
 Raise the housing sealing box (1.23) and screw the transport
safety device (8.4) to the flange of the dismounting pipe.
 Dismantle the screwed connection of the pillow block frame

(1.9) with the longitudinal girder (2.2) at the side of the floating
bearing.
 Unscrew the air connection piece (1.21) and thrust ring (1.16)
with switch lugs. Bolt the pulling device (8.3) to the floating
bearing trunnion (1.8).
tightening torque)
 Fit the lifting appliance to the suspension points of the side
wall of the building and the pull-off cap of the floating bearing
trunnion and lift the crusher roll out of the cooler until the
housing sealing box (1.23) lies on the support of the opposing
platform (7.2).
NOTE
Above a nominal width of 4000 mm, a sliding shoe (8.7) must be
employed to support the grinding roll when removing the roll.
Observe the maximum permissible traverse in the drawing
Removing a roll.
Figure 9
 Support the crusher roll or suspend it in a hoisting apparatus

and support the dismounting pipe (8.1) on the longitudinal
girder (2.2). Dismantle the screwed connection between the

dismounting pipe and the crusher roll.
 Bolt the supporting bracket (8.6) to the crusher roll (1.6) and
remount the transport safety device (8.4).
 The crusher roll can now be removed with the hoisting
apparatus.
The assembly of the grinding roll is performed in the reverse

order.
Observe the information in section Transport and assembly.
Removing and fitting the crusher roll bearing arrangement

Fitting work on bearings must be performed in the workshop and
not at the roll crusher. During repairs, the shaft journals must be
removed from the crusher roll and the bearings must be
dismantled and repaired or replaced in the plant workshop.
The self-aligning roller bearings must me dismantled and fitted
with the aid of a hydraulic nut.
Hydraulic nut
Hydraulic nuts are used for fitting and dismantling antifriction
bearings with conical bores.
The components of a hydraulic nut are:
 a threaded steel ring with internal thread and a lateral circular
groove
 an annular piston
 the two O-rings serve as seals between the threaded steel ring
and the annular piston.
Two tap holes in the threaded steel ring provide connections for
the flexible hoses of the hand lever press, one at the outer edge
and one at the end of the threaded steel ring.
The hydraulic nut is delivered with a connecting nipple with a
threaded plug and ball for simple connection to the flexible hose,
which is fitted with a quick-acting coupling.
The superfluous tap hole in the hydraulic nut must be sealed with
the threaded plug.
Oil with a viscosity of 300 mm3/s at room temperature is used as
a pressure medium.
The hydraulic nut is designed for a max. pressure of 1000 bar
(100 MPa).
NOTE
Above a nominal width of 4000 mm, a sliding shoe (8.7) must be
employed to.
The connecting holes must be closed to prevent tramp material
from entering the oil and piston space.
Removing the fixed bearing

 Dismantle the planetary gear system with the hydraulic motor
according to the manufacturer’s instructions (see machine
manual Hydraulic drive).
 Draw off the thrust ring (1.18) and the outer labyrith ring (1.17)
from the drive trunnion.
 Remove the outer flange ring (1.13) from the pillow block frame
(1.9).
 Bolt the hydraulic nut with the annular piston facing inwards
onto the withdrawal sleeve (1.11) until the piston surface
closes tightly on the inner ring of the self-aligning roller
bearing.
WARNING
The withdrawal sleeves pull off the conical seat suddenly.
Your hands could be crushed.
For this reason, the bearing must only be dismantled when
the monuting aid is fitted to secure the shaft seat.
 Connect the flexible hose of the hand lever press to the

hydraulic nut. Apply pressure with the hand lever press to the
piston of the hydraulic nut until the withdrawal sleeve retracts
from the seat of the self-aligning roller bearing.
 The hydraulic nut can be dismounted and the self-aligning
roller bearing can be removed as soon as the withdrawal
sleeve can be moved in the shaft seat.
Removing the floating bearing

 Remove the floating bearing trunnion (1.8) from the supported
crusher roll and transport the entire unit to the plant workshop.
 Dismantle the air connection piece (1.21), the pulse generator
(1.25), and the thrust ring (1.16) with the switch lug.
 Withdraw the outer labyrinth (1.17).
 Dismantle the outer flange ring (1.14) from the pillow block
frame (1.9).
 Dismount the self-aligning roller bearing with the aid of the
hydraulic nut.
Mounting the crusher roll bearings

Before mounting, all parts must be freed from corrosion
protection. After cleaning, these parts must be thorougly dried
and immediately protected against corrosion with oil or grease.
NOTE
Before mounting the self-aligning roller bearings, the radial gap
must be measured with a thickness gauge and the value noted.
Place the bearing on a clean surface and rotate the inner ring
several times to allow the roller to assume the correct position.
Always measure between the outer ring and the unloaded roller.
The measured radial gap must be equal for both sets of roll.
 Slide the inner labyrinth ring (1.15), the inner fixed ring (1.12) if
installed and the flange ring (1.13) onto the drive trunnion.
 Slide the self-aligning roller bearing (1.10) onto the drive
trunnion as far as the stop of the labyrinth ring, simultaneously
pushing the withdrawal sleeve (1.11) firmly into place in the
inner ring of the self-aligning roller bearing.
 Bolt the hydraulic nut with the annular piston facing outwards
onto the withdrawal sleeve.
It is necessary that the distance “X“ between the hydraulic nut
and the self-aligning roller bearing is 2 to 3 mm larger than the
maximum axial travel specified in section Technical data to
prevent the hydraulic nut from pressing against the self-
aligning roller bearing during insertion. (See also drawing
Mounting floating roller bearings in section Technical
drawings.)
 Set the withdrawal sleeve (8.10) as an abutment against the
front face of the hydraulic nut and secure it axially on the drive
trunnion.
NOTE
Set the mounting flange (8.11) as an abutment on the side of
the floating bearing against the hydraulic nut and secure it
axially with the thrust ring (1.16). The fixed rings (1.12) are not
required.
 Connect the flexible hose of the hand lever press to the

hydraulic nut press and push the withdrawal sleeve (1.11) into
the inner ring of the self-aligning roller bearing. The travel is
measured between the hydraulic nut and the inner ring of the
self-aligning roller bearing.

Travel: see Technical data.
 Release the pressure on the hydraulic nut by opening the
return valve of the hand lever press.
NOTE
Measure the decrease of the radial gap between the outer ring
and the two bodies of the roll in the unloaded area of the self-
aligning bearing after a pause of ten minutes with a thickness
gauge. The front surfaces of the outer and inner rings must be
concentric. The smallest permissible radial gap must not be
infringed under any circumstances.
 All mounting aids can then be removed.

 Pack the cavities of the self-aligning roller bearing with grease.
See the lubrication schedule in section Lubrication for the
grease type.
 Slide the pillow block frame (1.9) over the self-aligning roller
bearing.
 Slide the outer fixed ring (1.12) if installed into the pillow
block frame at the fixed bearing side as far as the outer ring of
the self-aligning roller bearing and screw the flange ring (1.13)
to the pillow block frame.
 Slide the labyrinth ring (1.17) and the thrust ring (1.18) onto the
drive trunnion.
 The entire unit consisting of the drive trunnion with the fixed
bearing can now be screwed with the preset tightening torque
to the crusher roll (1.6) and the drive system can be mounted.
 Tighten the bolt on the thrust ring to the preset tightening
torque.
 Screw the outer flange ring (1.14) on the side of the floating
bearing to the pillow block frame.
 Slide the labyrinth ring (1.17) onto the floating bearing trunnion
and secure it with the thrust ring (1.16).
 Fit the air connection fitting (1.21).
 The entire unit comrising of the floating bearing trunnion and
the bearing arrangement can now be screwed to the crusher
roll with the preset tightening torque.
CAUTION
After you have completed the repair work, you must check the
machine/plant again according to the section Preparation for
the test run.
Tools and auxiliary equipment

No special tools are required for repair work on the machine.
However, torque wrenches of a bigger size than normal may be
necessary.
In order to easily dismount the antifriction bearings an oil
pressure pump is needed.
Whether you will need auxiliary equipment, such as scaffolding or
hoists, depends on the conditions in your plant.
Machine Manual Spare parts
8 Spare parts
Suggestions for enquiries and orders of spare parts

Dear Customer,
POLYSIUS AG want to make spare part enquiries and spare part

order placement as easy and efficient as possible. For this
purpose we have prepared a table containing all data required by
our spare parts department to ensure optimum processing in the
most speedy and trouble-free manner.
Please copy the title page and the page with the table. Fill in the
columns Quantity and Unit. Please mark those parts which you
require with a cross in the column Order or Enquiry. Send the title
page together with the table to the Spare Parts Department of
POLYSIUS AG.
If the table relates to more than one machine, please also inform
us of the POLYSIUS Order Code (POC) of the machine for which
you require the spare parts.
Spare parts Machine Manual
Figure 10
Spare part-sub-assemblies for a grinding roll
Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry
1.1 Crushing ring 1 set

1.2 Crushing ring with cam 1 set
1.3 End ring 1 set
1.4 Spacer sleeve, 1 piece
fixed bearing side
1.5 Spacer sleeve, 1 piece
floating bearing side
1.6 Crusher roll 1 piece
1.7 Drive trunnion with 1 piece
screws
1.8 Floating bearing 1 piece
trunnion with screws
1.9 Pillow block frame 2 piece
with screws
1.10 Self-aligning roller 2 piece
bearing
1.11 Withdrawal sleeve 2 piece
1.12 Fixed ring, if installed 1 set
1.13 Flange ring with screws 3 piece
1.14 Outer flange ring, 1 piece
floating bearing with
screws
1.15 Inner labyrinth ring 2 piece
1.16 Thrust ring with switch 1 piece
lug and screws
1.17 Outer labyrinth ring 2 piece
1.18 Thrust ring with screws 1 piece
1.20 Covering box 2 piece
1.21 Air connection piece 1 piece
1.24 Seal 2 piece

5.7 Thermometer (optical) 1 piece
5.8 Temperature sensor 1 piece
Dismounting device (8.0)
Figure 11

8.1 Dismounting pipe 1 piece

with screws
8.2 Roller block 1 piece
8.3 Pulling device with 1 piece
screws
8.4 Transport safety device, 1 piece
fixed bearing side

8.5 Transport safety device, 1 piece
floating bearing side
8.6 Supporting trestle, 1 piece
fixed bearing side
8.7 Slide shoe 1 piece
(above nominal width
4000)
8.10 Mounting sleeve 1 piece
8.11 Mounting flange 1 piece
Figure 12
3.4 Upper protective plates 1 set
3.5 Lower protective plates 1 set
4.1 Sealing strips 1 set
4.2 Packing 1 set
9.0 Barrier 1 set

Machine Manual Appendix
9 Appendix
9.1 Technical drawings
NOTE
For drawing numbers, please refer to the table of contents of this
folder.
Designation Drawing no.
Roll crusher
Crusher roll complete
Removing the roll
Assembly of the self-aligning roller bearing
Hydraulic nut
Mounting sleeve
9.2 Subsuppliers’ documentation
Fan

Roll Crusher For REPOL® POLYTRACK®

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Roll Crusher For REPOL® POLYTRACK®

Diunggah oleh

Hak Cipta:

Format Tersedia

Machine Manual

Roll crusher for REPOL® / POLYTRACK®

POLYSIUS Order Code (POC)

1 Technical data......................................................................................... 1-1

Information on the intended use

Drive of the roll crusher

Drive trunnion (1.7)

Floating bearing shaft (1.8)

Pillow block frame (1.9)

Flange ring (1.13)

Outer flange ring (1.14), floating bearing

Thrust ring (1.16 and1.18)

Dismounting pipe (8.1)

Pulling device (8.3)

Data on mounting the self-aligning roller bearing

Cooling of the roll crusher

Connecting element between fan and motor ....................................

Cross girder cooling

Connecting element between fan and motor ....................................

Transport and assembly

 Ensure that all moving parts of the machine have reached a

 Never situate the source of the welding current in a confined

3 Components and mode of functioning

The roll crusher consists of the following sub-assemblies:

Itemd relating to grinding rolls (1.0)

1.20 Covering box

Items shown in the drawings

Longitudinal girders (2.0)

Cross girders (3.0)

Attaching parts (4.0)

Items shown in the drawings

Air cooling (5.0)

Drive system (6.0)

Items shown in the drawings

Platforms (7.0), customer’s supply

Dismounting device (8.0)

8.10 Mounting sleeve (for illustration, see the contract-related

3.2 Mode of functioning

4 Transport and assembly

4.1 Transport and storage requirements

block frame (1.9) to the side of the floating bearing.

 Mount the platform (7.3) above the drive systems.

Lubrication points Quantity (ltr/kg) Lubrication intervals

1 Self-aligning 81 2.0 0.13 12 52 52

2 Labyrith rings of 81 0.5 0.05 12 52 52

3 Hydraulic drive See separate machine manual!

4 Fans See manufacturer’s instructions!

Explanation of the number

6 Preparation for the test run

6.1 Checks prior to the test run

 Is the interior space of the roll crusher free from tramp

6.2 Setting and adjustment

6.3 Test run

6.4 Operation of the roll crusher

The inspection work described in the following is divided into:

Inspections during operation

No. Work to be performed Frequency Remark

1 General visual checks for leaks daily

Inspections during long plant standstill periods

No. Work to be performed Frequency Remark

1 Checkthe crushing rings (1.1 and 1.2)

plates (3.4 and 3.5)

No. Work to be performed Frequency Remark