INSTRUCTION MANUAL .

ROTARY KILN
70000449-1
Supporting bearing for support

Operation and maintenance

In 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 *) Rotary kiln
Supporting bearing for support
Erection
Ref. 5 *) Rotary kiln
Kiln support type SA
Operation and maintenance
Ref. 6 *) Rotary kiln
Axial measuring equipment
Operation and maintenance
Ref. 7 *) Rotary kiln
Alignment of supporting bearings and
supporting rollers. Support type SA.
Erection

*) 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 70000449-1

Contents: Page:
1. General notes .................................................................................. 4
2. Construction and operating principle ................................................ 6
3. Installation ....................................................................................... 8
4. Operation ........................................................................................ 9
4.1 Precautions to be taken in connection with the start-up and turning of kiln .................... 9
5. Maintenance .................................................................................. 10
5.1 Preventive maintenance, survey ................................................................................... 10
5.1.1 Lubrication.................................................................................................................. 11
5.1.2 Cleaning ..................................................................................................................... 12
5.1.3 Inspection and adjustment ......................................................................................... 12
5.1.4 Checking of condition................................................................................................. 13
5.1.5 Replacement .............................................................................................................. 13
5.2.1 Hot-running ................................................................................................................ 14
5.2.2 Causes of hot-running and remedial action. .............................................................. 15
5.2.2.1 Fault 1: .................................................................................................................... 15
5.2.2.2 Fault 2: .................................................................................................................... 15
5.2.2.3 Fault 3: .................................................................................................................... 16
5.2.2.4 Fault 4: .................................................................................................................... 16
5.2.2.5 Fault 5: .................................................................................................................... 16
5.2.3 Repairs....................................................................................................................... 17
5.2.3.1 Replacement of bearing shells................................................................................ 17
5.2.3.2 Installation of new bearing shell .............................................................................. 18
5.2.3.3 Installation of ball race ............................................................................................ 19
5.2.4 Replacement of seal at shaft ..................................................................................... 20
5.2.5 Replacement of supporting roller ............................................................................... 20
6. Key to Appendices ......................................................................... 22

Edited by: KelH Translated by: JRo Pages: 53

Approved by: KelH MGN code: 5A10
 70000449-1 3

Appendices:

App. 1. Sketch of bearing, ball race and bearing shell........................................................... 25

App. 2. Table of bearing clearance ........................................................................................ 26
App. 3. Longitudinal section of bearing .................................................................................. 29
App. 4. Bearing....................................................................................................................... 31
App. 5. Cross section of bearing ............................................................................................ 33
App. 6. Longitudinal section of bearing with through-going bearing journal........................... 35
App. 7. Fixation of bearing shell ............................................................................................. 37
App. 8. Seal at supporting roller ............................................................................................. 39
App. 9. Seal at through-going bearing journal........................................................................ 41
App. 10. Three-way cock........................................................................................................ 43
App. 11. Dismantling of ball race............................................................................................ 45
App. 12. Lifting of supporting roller......................................................................................... 47
App. 13. Lifting of supporting roller......................................................................................... 49
App. 14. Dismantling of supporting roller ............................................................................... 51
App. 15. Dismantling of supporting roller ............................................................................... 53
4 70000449-1

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 operation and maintenance of the bearings 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 bearings for the supporting rollers of the rotary kiln are
self-adjusting slide bearings. The ball race of the bearings will
ensure that full contact is always established for the bearing
journal, even if one bearing is displaced relative to the other,
whether occurring in the vertical or horizontal direction.
Lubrication is based on the hydrodynamic lubrication
principle, i.e. with formation of a supporting oil film between
bearing shell and the journal during rotation.
But because of the low speed of rotation it is essential to
ensure a diameter differential between journal and bearing
shell which will make it possible to attain the wedge action
required to build up the supporting oil film under the journal.
So, the function of the supporting roller bearing is very much
dependent upon the viscosity of the oil, and, therefore, it is
essential to emphsize the importance of ensuring strict
compliance with the directions given in the lubrication manual.

References to instruction manuals

In 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.
 70000449-1 5

REQUIREMENT:
Bearings to be used exclusively for the aforementioned purpose!

MANDATORY!
The directions outlined in instruction No. ref. 2
"General safety regulations at erection site" must be
strictly observed at the site of erection. This
instruction manual must be scrutinized by the client,
the erection contractor and FLS representatives
before erection work is started.

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

MANDATORY!:
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 connected 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
(extremely hazardous condition!) or electronic
equipment.

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 permission
to proceed with the erection work can be given.
6 70000449-1

2. CONSTRUCTION AND OPERATING PRINCIPLE

See Appendices 1 to 10.
The bearing housing consists of a base part (03) of cast-iron,
a mild-steel top part (10) and an end cover (11). The base
part is fixed to the bedplate by means of bolts (41) and it is
equipped with oil sight glass (21) and drain plug (23) for
draining of oil.
By means of an adjusting screw (47), the bearing can be
displaced transversely to the longitudinal direction of the kiln
when the bolts (41) of the bearing housing have been
loosened, see Appendix 5. On completion of installation
procedures and running-in, the position of the bearing relative
to the kiln axis is marked by the brass plates (43) which, after
the final position of the bearing has been determined, have
been adapted by filing to ensure flushing of the plate edges at
(44).
In case of damage to the brass plates, it will still be possible
to establish the original position of the bearings since the
position has been marked off with coinciding chisel cuts at the
base of the bearing and in the guide block (42) which is
welded to the bedplate. The chisel cuts will thus be found
under the brass plates.
In the top part there are two inspection ports (25) providing
access for inspection of the bearing. There are also holes for
inlet and outlet connections for cooling water, a breather pipe
with air filter (37) and also suspension parts for the thermal
sensor (28) of the bearing.
Fitted around the opening for the supporting roller shaft (04)
is a three-part seal (13) which will prevent infiltration of dust
into the bearing. The rubber bushings (38) around the cooling
water connections have the same function.
The base part (03) carries a ball socket (01) of cast iron which
forms the support base for a bearing shell (02) of bronze. The
ball socket rests on a spherical face and is retained by means
of the guide journal (07) so that the dividing face of the ball
socket forms an angle of 30 to horizontal. The ball socket
has internal chambers through which the cooling water is
circulating.
 70000449-1 7

The bearing shell (02) has a fixed thrust collar the surface of
which is chamfered and provided with oil pockets, see Fig. 3
in Appendix 1. This thrust collar must be oriented so that it
faces the support roller. A similar thrust ring (05) is shrunk
onto the journal of the support roller, close to the support
roller hub.
The bearing shell is configured with a bore for creating a
sufficiently large clearance between the journal of the support
roller and the bearing shell. See the table in Appendix 2.
The bearing is protected against radiant heat from the kiln by
means of large anti-radiation guards for protection of
machines and personnel, or by a smaller anti-radiation guard
(45).
Lubrication of the bearing is effected according to a method
whereby the oil cups (09) fitted to a ring screwed onto the
bearing journal will scoop up the oil from the bottom of the
bearing housing to an oil channel (08) which will distribute the
oil across the bearing journal.
Theoretically, the support roller shaft is resting on a generatrix
at the bottom of the bearing shell. When the shaft is rotating
at the sufficient speed, the oil will be drawn into the wedge-
shaped clearance between shaft and bearing shell, causing
the shaft to be carried by a thin oil film. Dependent upon the
speed and temperature, the thickness of this oil film may
approach 0.01-0-02 mm. The wedge action will produce the
pressure characteristics of the oil film - shown in Fig. 2 in
Appendix 1 which are necessary to achieve the correct
lubrication effect, i.e. pure liquid friction.
Cooling of the bearing is accomplished through continuous
water cooling. Cooling is necessary to prevent the lubricating
oil from reaching a temperature which is so high as to
degrade the lubricating properties of the oil. The cooling water
is supplied to the supporting roller bearings through a joint
supply line from which branch lines are extended along each
foundation.
8 70000449-1

From the branch line, pipes are extended to the four bearings
of the support, with circulation of the cooling water through
the water chambers of the bearing shell. From the bearing,
the water is normally recirculated in a closed circuit to a
cooling water system or through a drain pipe to an open
funnel which is connected to a drain line which is common to
all the supports. At the discharge branch of the cooling water
there is a flow indicator (39) so that, at this location, for
closed cooling water systems, it will be possible to monitor the
circulation of the cooling water; see Appendix 5.
To ensure movability of the bearings, the connection between
the cooling water pipes and the bearings is established by
means of rubber hoses.
The cooling water volume for each bearing must be set by
means of a control cock. The flow cock (40) is a three-way
cock provided with T-bore and vent opening. When this cock
is used to shut off the water flow, the water chamber of the
bearing will be connected through the cock to the
atmosphere. The outlet pipe, the mouth of which is located at
a lower level than the bottom of the water chambers will thus
be acting as a siphon, thereby draining the chambers of
water. The water chambers must be emptied if a prolonged
shutdown is required and if temperatures below the freezing
point are anticipated. The outlet pipe will only be able to act
as a siphon if the cross-sectional area of the pipe is filled
with water, i.e. just prior to shutdown for emptying, the cooling
water supply must be fully opened.
The outlet temperature of the cooling water at the drain pipe
must not be more than approximately 10C higher than the
inlet temperature. This is a safeguard against an excessively
high oil temperature, which is difficult to measure.

3. INSTALLATION
Installation to be carried out in accordance with the directions
given in separate erection instruction manual, ref. 4
 70000449-1 9

4. OPERATION
4.1 Precautions to be taken in connection with the start-up and
turning of kiln
During kiln shutdown, the oil in the bearing journals of the
supporting rollers may dry out. Particularly at the hot
supports. Prior to start-up and turning of the kiln, additional oil
must, therefore, be supplied to the bearing journals if they are
ascertained to be dry. In this way it will be possible to
eliminate the risk of seizure occurring between the bearing
journal and the bearing shell in connection with the initial
rotation of the supporting roller before the necessary oil film
has been generated by the lubrication device of the bearing.
The oil must be poured through the observation ports of the
bearing onto the oil channel or directly on the bearing journal
so that it is lubricated by means of oil across its entire
surface.
Oil grade to be equivalent to that which is otherwise used in
the bearings.
10 70000449-1

5. MAINTENANCE

5.1 Preventive maintenance

.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 Supporting roller T M D/M/ T A .
13,29 Bearing seals T . T T .

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

S = weekly the letter indicates the
M = monthly frequency of
A = yearly procedure.
T = see text in instruction For example, 2M =
manual twice a month
 70000449-1 11

5.1.1 Lubrication
Oil quality
In the following, the oil grades are designated with the FLS
symbols from the FLS Key to Lubricants.
The selection of oil grade depends on the ambient
temperature.
At kiln start-up and during kiln operation at ambient
temperatures which are lower than +5C, oil grade FLS Mat
7156 (EP460). or FLS Mat. 7157 (EP680) must be used.
The best approach would be to use synthetic polyalphaolefin
oils which have a low pour point and which can be mixed with
mineral oil.
Example: Mobil Oil SHC-639 or 634, both having a pour point
of -40C.
For kiln start-up and operation at ambient temperatures which
are higher than +5C, oil with the FLS symbol Mat 7157
(EP680) or Mat 7158 (EP1000) must be used.

Oil volume per bearing

Bearing diameter Litres of oil
(for guidance)

970 120 litres

880 85 litres
790 65 litres
710 50 litres
630 41 litres
560 31 litres
500 26 litres
450 22 litres
400 20 litres
360 19 litres
320 18 litres
12 70000449-1

NOTE!
Do not fill oil into the bearings beyond the mark on the oil
level glass. An excessie oil volume may give rise to spillage.
The oil must be replaced if the oil shows any signs of metallic
glimmer or any other form of contamination, and in case of
hot-running of bearing.
See also sub-section 4.1 for lubrication prior to start-up.
Bearing seals (13) and (29)
Feed grease through the grease nipples (19) and (35) if the
bearing has a through-going shaft, on a regular monthly basis.
See Appendices 8 and 9.
Grease quality: FLS Mat 7445
Quantity: Until grease is discharged at the seal, <300 cm 3
5.1.2 Cleaning
Clean the bearing housing with solar oil and clean the brass
plates very carefully, indicating the position of the bearing so
that the position can be easily checked. To protect the thread
on the adjusting screw (47) of the bearing, the thread should
be lubricated with heavy-duty oil, grease or molybdenum
sulphide, with protective canvass plies wrapped around the
thread.
5.1.3 Inspection and adjustment
Supporting bearing (00)
Period: D (daily)
A daily inspection of the bearing must be conducted, and a
report must be filed if oil spillage is observed or if the vibration
level or heat generation is deemed to be abnormal.
Check the water cooling of the bearing.
Period: M (on a monthly basis)
Check the lubrication system and oil level of the lubrication
system:
Check the oil channel (08). The channel must be adjusted so
that the oil will flow out through all openings in the channel.
The surface of the supporting roller journal must be fully
covered by oil at the point of downward extension of the
surface into the bearing shell.
Make an inspection of the oil cups (09).The oil must be
scooped into the oil channel.
 70000449-1 13

Check the oil level. The level must be somewhere between

the minimum and maximum marks on the oil level glass. Oil to
be replenished in case of inadequate oil volume. Reporting is
needed if the oil level exceeds the upper mark. This may be a
sign of ingress of water into the bearing.
Examine the seals (13) and (29) at the supporting roller shaft.
Replacement of the seals should be contemplated in case of
oil spillage occurring when the oil level is normal or if the
rubber sealing rings (15), (18), (31) and (34) show signs of
wear.
Period: 2A (twice a year)
Check the erection marking (44) or any subsequent marking
of the bearing position. Report on any changes.
Make an inspection of the rubber bushings (38) at the intake
and outlet connections of cooling water. Check cooling water
pipes and hoses for leaks and corrosion, particularly galvanic
corrosion. In case of a high calcium content of the cooling
water, deacidification of pipe lines and water chambers should
be carried out at appropriate intervals.

5.1.4 Checking of condition

The condition of the bearing shell, particularly the thrust collar
of the shell, should always be checked for visible
deformations in case of hot-running of bearing. If the bearing
shell has been damaged, it must be replaced as described in
sub-section 5.2.3.1.
5.1.5 Replacement
Lubricating oil
Change the lubricating oil. In connection with a shutdown of
kiln, the oil must be drained by removing the drain plug (23) of
the bearing. Fresh oil must be charged through the
observation ports.
NOTE!
Following the initial start-up of kiln, the oil must be changed
when the running-in period is over, i.e. after a period of 2-3
months. Subsequent changes of oil should be made at
intervals of approximately 12 months.
14 70000449-1

5.2.1 Hot-running
In case of abnormal operating temperatures, the temperature
rise in a bearing may occur swiftly, and it may result in
damage to the bearing shell in case of the temperature
reaching a level of more than approx. 80 degrees C before
remedial action can be taken.
Therefore, an emergency plan should always be held in
readiness so that action can be taken to keep down the
bearing temperature, while the immediate cause of the hot-
running condition is identified and remedied.
For example, an emergency plan may involve the following
measures:
Cooling the running path of the supporting rollers with water.
Change of oil. See sub-section 5.1.5.
Water cooling of the bearing housing. If the bearing housing is
hot, particularly at the bottom at the oil sump, external water
cooling can be applied using the cooling water return hose
from the affected bearing.
Cooling of the bearing by means of a fan. The cooling air is
directed through the end cover of the bearing but it must not
disrupt the oil supply at the top of the bearing journal.
Cooling of the oil by means of a portable device consisting of
oil pump, oil cooler and oil filter. The oil is pumped from the
oil sump of the bearing through the cooler and filter back to
the top of the bearing journal. Constant readiness of such a
device is a significant safeguard measure. The device is not
included in the FLS supply as standard equipment.
 70000449-1 15

5.2.2 Underlying cause of hot-running and remedial action

In case of hot-running of any bearing, the underlying cause
may be as follows:
5.2.2.1
FAULT 1:
Excessive axial load on the thrust collar of the bearing shell.
REMEDY:
Adjust the position of the supporting roller until the pressure
of the thrust ring against the thrust collar of the bearing shell
has been relieved. See instruction manual for axial measuring
equipment, ref. 6. However, if such remedial action fails to
bring down the bearing shell temperature, or if the
temperature should rise to a level above 80-90 degrees C, it
will be necessary, if an oil of the type FLS Mat 7157 (EP-680)
is used, to switch to an oil type FLS Mat 7158 (EP-1000) or
FLS Mat 7350 (EP-1000 PAO type) for example Mobil SHC
639.
In extreme situations, the oil Mobilgear SHC-3200 with a basic
oil viscosity of 3200cSt can be used.
5.2.2.2
FAULT 2:
Inadequate lubrication which is either caused by a leakage at
the bottom of the bearing housing or in the cooling water
system. In case of a leakage in the cooling water system, the
oil will emulsify with the cooling water, causing a deterioration
of its lubricating properties. Both conditions can be observed
through the oil sight glass or through the inspection ports of
the bearing.
REMEDY:
Locate the leakage and take remedial action. Change the oil if
it shows any signs of contamination. See also sub-section
5.1.5.
16 70000449-1

5.2.2.3
FAULT 3:
Radiant heat from the kiln.
REMEDY:
Check that the anti-radiation guard of the bearing has been
installed. If necessary, an additional guard must be fitted at
the end of the bearing. This applies particularly for the
bearings on support II on UNAX kilns facing in direction
towards the inlet of the cooler.
5.2.2.4
FAULT 4:
Lack of cooling.
REMEDY:
Check the cooling water volume. Clean any plugged pipes and
valves. If necessary, decalcification of the water chambers
and water cooling system must be carried out. The outlet
temperature of the cooling water must not be more than 10
degrees above the inlet temperature.
5.2.2.5
FAULT 5:
Excessive heat input from supporting roller and kiln tyre.
REMEDY:
Cooling of the supporting roller by means of water. This option
may be regarded as being an emergency option since it may
cause pittings to be formed on the supporting roller. If water
cooling is applied, atomized water must be sprayed onto the
supporting roller immediately after the contact with kiln tyre.
All water must have time to evaporate before contact with the
kiln tyre occurs again.
 70000449-1 17

5.2.3
Repairs
See Appendices Nos. 1, 2, 11, 12, 13, 14 and 15.
5.2.3.1
Replacement of bearing shells
If the correct oil grade is used at the right bearing
temperature, pure liquid friction will be attained between the
journals and bearing shells, thus protecting the bearing shell
against wear exposure. There are numerous examples of kilns
which have been in operation for more than 15 years without
any noticeable wear on the bearing shells.
However, if replacement of a bearing shell should become
necessary, due consideration must be given to the following
factors.
The bearing shells are normally supplied with a bore which
corresponds to the original diameter of the supporting roller
journal, with a sufficiently large clearance between the
bearing journal and bearing shell.
The clearance between the supporting roller shaft and the
bearing shell appears from Appendix 2 and it is configured in
accordance with the principles of hydrodynamic lubrication of
the bearing.
Procedure:
Before a replacement of the bearing shell can be made, the
kiln must be shut down, see procedure in general kiln
instruction manual, ref. 1.
The kiln must be moved to its neutral position with the kiln
charge at the bottom of the kiln, see procedure in general kiln
instruction manual, ref. 1.
The kiln must be lifted clear of the supporting rollers and it
must be effectively secured. The clearance between the
supporting rollers and kiln tyre must not be more than 5-10
mm; see procedure in general kiln instruction manual, ref. 1.
The top part must be dismantled from the bearing together
with seals, ring for oil cups and oil channel.
The supporting roller must be lifted clear of the damaged
bearing and it must be effectively secured. See Appendix 12
or 13. The clearance between the supporting roller and the
bearing shell must not be more than 1 mm. See the procedure
below.
18 70000449-1

The method described in Appendix 13 necessitates

manufacture of a bracket (48) which is fixed with bolts to the
end of the supporting roller shaft. Subsequently, the
supporting roller can be lifted by means of a jack (49), firmly
securing the roller.
The method described in Appendix 12 involves lifting by
means of a jack (52) under the supporting roller. Always
remember to insert a piece of hard wood (51) to protect the
surface of the supporting rollers against indentation marks
from the jack.
For both methods, jacks with safety nut are recommended so
that the jack can be secured after the roller has been lifted.
It should be noted that if the kiln is standing on semi-rigid,
SRB, or self-adjusting supports, SA, then the bearing beams
must be secured by means of intermediates (53) to prevent
them from being vertically moved.
Two steel wires are fitted to the eyebolts at two of the corners
of the ball race so that the steel wires are led underneath the
shaft. Steel wires to be held by means of a crane.
The guide journal for ball race must be dismantled.
The ball race must be pulled round so that it is made to rest
on the supporting roller shaft and, subsequently, it must be
secured. Two steel wires are attached to the free corners.
Then, downward lifting is done as shown in Fig. 4, Appendix
1.
The damaged bearing shell must be dismantled in workshop.
The measurements of the ball race must be taken to
determine whether skewing of the race has occurred.
Diagonal measurements must be taken, see Appendix 1, Fig.
5. If skewness is ascertained, the ball race must be discarded
and it must be replaced by a new ball race.
In an emergency situation, the deformed ball race can be
bored out and turned off again on the spherical face and end
faces. However, it should be noted that this is an emergency
option and the outcome of the operation may be doubtful.
5.2.3.2
Installation of new bearing shell
The checking of contact levels and the installation of a new
bearing shell can, after the damaged shell has been
dismantled, be done as described in instruction manual, ref.
4, section 3.
 70000449-1 19

5.2.3.3
Installation of ball race
When the contact between the bearing shell and shaft and the
clearance between bearing shell and shaft are deemed to be
satisfactory, the ball race and bearing shell must be lifted
clear of the shaft to allow oil to be poured over the shaft. At
the same time, oil is applied to the spherical face in the base
part of the bearing. The oil grade used must be equivalent to
that normally used in the bearing. The ball race must be
lowered and rotated down under the shaft. After the ball race
has been fitted, the guide journal must be mounted.
The supporting roller must be lowered to its proper position.
In connection with the remounting of oil cups and ring and of
the oil channel, it is essential to make sure that all screws and
bolts have been effectively secured as described in the
instruction manual ref. 4.
It must be checked that the oil channel reservoir is
horizontally positioned in the transverse direction of the kiln
and that the inclination in the longitudinal direction is correct.
Particular attention is needed to ensure that the inclination of
the oil channel at the bearing on the outlet side of the
supporting roller is sufficient to ensure swift distribution of the
oil across the entire journal.
A thin layer of liquid sealing paste must be applied to all joint
faces in order to make the joints oil-tight.
The sealing rings must be mounted as described in instruction
manual ref. 4.
20 70000449-1

5.2.4 Replacement of seal at shaft

The procedure for the replacement of seal at the supporting
roller shaft is similar to that employed for the seal at the
supporting roller (13) and the seal at the through-going shaft
(29). See Appendices 8 and 9.
Dismantle the outer two-part sealing ring (20) and (36) and
remove the rubber seals (18) and (34).
Dismantle the centremost two-part sealing ring (17) and (33)
and remove the rubber seals (15) and (31).
Clean the shaft and check for signs of scoring on the shaft. If
signs of scoring are ascertained, the shaft must be polished
very carefully using a fine emery cloth.
Mount the seal with new rubber sealing rings around the shaft
as described in the erection instruction manual, ref. 4, section
3. Do not forget to fill the space between the two rubber
sealing rings with grease.
5.2.5
Replacement of supporting roller
If the supporting roller shaft or the supporting roller has been
damaged so extensively as to require replacement, this must
be done as shown in Appendix 14 or 15.
The kiln must be in neutral position and must be lifted 10 mm,
with kiln being subsequently secured as described in
instruction manual, ref. 1.
Sealing rings, top part, oil cups and oil channel etc. must be
dismantled from the bearings.
The block for adjusting screws must be dismantled.
The bearings must be pushed towards the end of the bearing
beam as indicated in Appendix 14. The bearings must be
pushed in parallel.
The ball race must be in horizontal position before the roller is
lifted. See procedure in sub-section 5.2.3.1
The supporting roller must be lifted with a steel wire which is
attached to one or two of the holes in the body of the
supporting roller profile, see Appendices 14 and 15.
The condition of the ball race and bearing shell must be
checked before a new roller is placed on the bearings. If
necessary, the bearing shell and ball race must be replaced
as described in previous sections.
 70000449-1 21

The necessary clearance and contact level between the

bearing shell and bearing journals must be checked before
the supporting roller is lifted down into the bearings.
Lift the supporting roller down into the bearings.
Move the bearings to their proper position, in parallel.
The position of supporting bearings must be adjusted as
described in separate instruction manual, ref. 7.
The bearings must be remounted with all equipment such as
oil cups, oil channel, top part, seals etc. as described in
erection instruction manual, ref. 4.
When the kiln is restarted, particular attention must be given
to the new roller to ensure that it has been correctly adjusted.
If necessary, it must be re-adjusted in order to re-establish the
axial balance of the kiln.
22 70000449-1

6. KEY TO APPENDICES
1. Ball race
2. Bearing shell
3. Base part, bearing housing
4. Supporting roller shaft
5. Thrust ring
6. Stop iron
7. Guide journal
8. Oil channel
9. Oil cup
10. Top part
11. End cover
12. End cover, two-part
13. Seal
14. Sealing ring
 70000449-1 23

15. Rubber sealing ring

16. Spiral spring
17. Sealing ring
18. Rubber sealing ring
19. Grease nipple
20. Sealing ring
21. Oil sight glass
22. Venting
23. Drain plug
24. Blank flange
25. Inspection port
26. Protective grating
27. Screw for protective grating
28. Thermal sensor
29. Seal
30. Sealing ring
31. Rubber sealing ring
32. Spiral spring
33. Sealing ring
34. Rubber sealing ring
35. Grease nipple
36. Sealing ring
37. Air filter
38. Rubber bushing
39. Flow indicator
40. Three-way cock
41. Screw
42. Guide block
43. Brass plate (erection marking)
44. Faces which must be flush
45. Anti-radiation guard
46. Anti-radiation guard
47. Adjusting screw
24 70000449-1

48. Block for adjusting screw

49. Jack
50. Bracket
51. Intermediate
52. Jack
53. Intermediate
 70000449-1 25

Appendix 1. Sketch of bearing, ball race and bearing shell

26 70000449-1

Supporting roller bearings, type RKB. Bearing clearance

Bearing Bearing journal Bearing shell Clearance Mean

at side clearance
D dt h8 dp IT8 rp - rt dp - dt
min cold
max
[mm] [mm] [mm] [mm] [mm]
0 +0.410 0.170
240 240 240 0.376
-0.072 +0.340 0.206
0 +0.480 0.200
280 280 280 0.481
-0.081 +0.400 0.281
0 +0.550 0.230
320 320 320 0.550
-0.089 +0.460 0.320
0 +0.630 0.265
360 360 360 0.615
-0.089 +0.530 0.360
0 +0.700 0.305
400 400 400 0.700
-0.089 +0.610 0.395
0 +0.790 0.350
450 450 450 0.794
-0.097 +0.700 0.444
0 +0.890 0.395
500 500 500 0.889
-0.097 +0.790 0.494
0 +1.000 0.495
560 560 560 1.050
-0.110 +0.890 0.555
0 +1.150 0.502
630 630 630 1.132
-0.110 +1.040 0.630
0 +1.310 0.559
710 710 710 1.377
-0.125 +1.180 0.718
0 +1.470 0.670
790 790 790 1.468
-0.125 +1.340 0.798
0 +1.660 0.770
880 880 880 1.663
-0.125 +1.540 0.893
0 +1.850 0.855
970 970 970 1.850
-0.140 +1.710 0.995
0 +2.050 0.940
1060 1060 1060 2.148
-0.165 +1.880 1.208
0 +2.250 1.045
1150 1150 1150 2.173
-0.165 +2.090 1.128
0 +2.470 1.150
1240 1240 1240 2.468
-0.165 +2.300 1.318
0 +2.690 1.250
1340 1340 1340 2.693
-0.195 +2.500 1.443

Appendix 2. Table of bearing clearance

 70000449-1 27

Text relating to Appendix 3, see page 28.

28 70000449-1

1. Ball race
2. Bearing shell
3. Base part, bearing housing
4. Supporting roller shaft
5. Thrust ring

8. Oil channel
9. Oil cup
10. Top part
11. End cover

13. Seal
 70000449-1 29

Appendix 3. Longitudinal section of bearing

30 70000449-1

21. Oil sight glass

22. Venting
23. Drain plug
24. Blank flange

37. Air filter

38. Rubber bushing
39. Flow indicator
40. Three-way cock
41. Screw
42. Guide block

45. Anti-radiation guard

46. Anti-radiation guard
 70000449-1 31

Appendix 4. Bearing
32 70000449-1

3. Base part, bearing housing

7. Guide journal
8. Oil channel

25. Inspection port

26. Protective grating
27. Screw for protective grating
28. Thermal sensor

41. Screw
42. Guide block
43. Brass plate (erection marking)
44. Faces which must be flush
45. Anti-radiation guard

47. Adjusting screw

48. Block for adjusting screw
 70000449-1 33

Appendix 5. Cross section of bearing

34 70000449-1

12. End cover, two-part

29. Seal
 70000449-1 35

Appendix 6. Longitudinal section of bearing with

through-going bearing journal
36 70000449-1

1. Ball race
2. Bearing shell
6. Stop iron
 70000449-1 37

Appendix 7. Fixation of bearing shell

38 70000449-1

13. Seal
14. Sealing ring
15. Rubber sealing ring
16. Spiral spring
17. Sealing ring
18. Rubber sealing ring
19. Grease nipple
20. Sealing ring
 70000449-1 39

Appendix 8. Seal at supporting roller

40 70000449-1

29. Seal
30. Sealing ring
31. Rubber sealing ring
32. Spiral spring
33. Sealing ring
34. Rubber sealing ring
35. Grease nipple
36. Sealing ring
 70000449-1 41

Appendix 9. Seal at through-going bearing journal

42 70000449-1

40. Three-way cock

 70000449-1 43

Appendix 10. Three-way cock

44 70000449-1

Appendix 11, see page 45

 70000449-1 45

Appendix 11. Dismantling of ball race

46 70000449-1

51. Intermediate
52. Jack
53. Intermediate
 70000449-1 47

Appendix 12. Lifting of supporting roller

48 70000449-1

48. Block for adjusting screw

49. Jack
50. Bracket
51. Intermediate
52. Jack
53. Intermediate
 70000449-1 49

Appendix 13. Lifting of supporting roller

50 70000449-1

Appendix 14, see page 51

 70000449-1 51

Appendix 14. Dismantling of supporting roller

52 70000449-1

Appendix 15, see page 53

 70000449-1 53

Appendix 15. Dismantling of supporting roller