MAAGTM PPU gear unit for

roller presses, horizontal mills and kilns

2
Our quality policy
FLSmidth MAAG Gear is committed
to creating long lasting relationships
that establish us as a trustworthy,
reliable and professional partner for
customers, suppliers and employees.
This commitment includes providing
high-quality and high-value solutions,
products and services that result in
satisfied customers.
Certified to ISO 9001 standards
With a clear focus on process man-
agement, we endeavour not only to
meet but exceed international quality
standards while providing appropriate
resources to support and develop our
purpose-designed quality system. Our
quality policies reflect the importance
of meeting our customers’ require-
ments.
Our management regularly defines
and reviews quality goals. Our em-
ployees are committed to the com-
pany’s management system and to
continuously improving not only the
system but our entire organisation.
Also, each employee is aware of the
company vision and strategy and
works to maintain a culture of oppor-
tunities.
We are committed to providing a safe
working environment for our employ-
ees and for those who use our prod-
ucts and systems.
With our suppliers and external part-
ners, we cultivate open communica-
tion and focus on performance-based
results.
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A pioneer of modern
gear technology

FLSmidth MAAG Gear has almost A constant willingness to innovate,

100 years of experience in manufac-
turing gear units. The company was
founded in 1913 and quickly expand-
ed into an international group. FLS-
midth MAAG Gear introduced the
technology of mill gear units for the
cement industry with great success in
1966. Since then over 700 MAAGTM
gear units were sold in this sector.
The company
At the FLSmidth MAAG Gear head-
quarters in Winterthur, Switzerland,
more than 100 employees work in
development, design, finance, project
management, sales, customer ser-
vice and marketing. Production and
assembly takes place in three mod-
ern plants equipped with high-per-
formance machines. In Elblag/Poland,
Milano/Italy and Bawal/India more
than 200 employees manufacture
gear units, drive systems and compo-
nents which satisfy the most demand-
ing quality standards. The company
belongs to the successful FLSmidth
Group, a listed Danish firm.
and close collaboration with our cus-
tomers have helped to ensure that
MAAG gear units continue to operate
reliably throughout the world under
the toughest conditions.
Product range
Today, the product range includes
various gear units for mills, com-
plete drive systems, gear solutions
for bucket wheel excavators and belt
conveyors, as well as maintenance
systems for all types of plant. In addi-
tion FLSmidth MAAG Gear manufac-
tures components such as bevel sets,
girth gears and various replacement
parts.
All MAAG gear units are available as
standard solutions or are customized
to the required needs.

Our strength
The combination of unique precision,
accuracy and modularized solutions
with compact design are leading to
high efficiency products and therefore
low maintenance cost for the custom­
er. Experience, new technical solutions
and the latest manufacturing tech-
niques are regularly incorporated into
the production process.

Intensive development and training

of our engineers assure best under-
standing of how to operate a gear
unit and lengthen its life cycle.
4

Proven technology – geared up

Design concept 1987
The PPU concept of 1987 is established
in the cement and minerals market.
Redesign 2013
With the objective of improving already
proven technologies, MAAG has taken
a critical look at the existing design and
potential areas of use of the MAAG
PPU, taking into consideration techno-
logical advances made in recent years.
The results speak for themselves:
Weight reduction of 25%, 15% smaller
outer diameter, diversity of parts
reduced by 20% all of which lead to
lowered cost.
Originally developed to drive roller
presses, the field of application has
been expanded during the redesign:
The PPU drive train is now an attractive
option to drive small ball mills. The Applications
drive train consists of main motor, gear- • Roller presses, horizontal mills, kilns
box with foot, high and low speed and others
coupling, oil unit, auxiliary drive and • Industries: Cement production, min-
optional water injection. erals, mining and food
Features Design criteria
• Three-stage gear unit with input ANSI/AGMA 2101-C95
stage reduction (e.g. spur gear or ISO 6336 and ISO 1328
bevel stage) and two planetary stag-
es
• Power range up to 4000 kW
• Ratio 45–140
• Input speed: 980–1800 rpm
• Integrated oil tank
• Bearing lifetime L10hm > 100,000
• Left and right gear units are inter-
changeable (for roller presses)

Typical roller press application

1. Input stage (sample: spur gear) 7
2. 1st planetary stage
3. 2nd planetary stage 3
4. Cardan shaft
5. Torque limiting safety coupling
6. Balanced torque arm system 2
(sample: FLS design)
7. Shrink disc
1

6
4

Scope of supply
MAAG PPU
The gearbox consists of two stand-
ardized planetary stages and a spur
type pre-stage to adjust the speed.
The oil tank is integrated into the
gearbox and the toothing is splash
lubricated and partially force
lubricated. This also minimizes the
complexity of the oil supply unit.
Thanks to the highly standardised
and modular concept, ratio adjust-
ments have no impact on delivery
times.
Input stage
The MAAG PPU is delivered with a
spur gear input stage. Ratio require-
ments can easily be fulfilled simply by
changing the wheels of the input
stage, thereby providing the highest
possible flexibility.
Lubrication unit
An oil supply unit with low-pressure
pump, double oil filter and oil cooler
are part of the scope of supply. For
roller press drives, we offer a
cost-effective solution with a single
oil unit lubricating both gear units.
The gear unit casing also serves as oil
circulation tank.
Torque arm system
MAAG provides customised torque
arm solutions such as balanced
torque arm system (self-regulating
system without foundation connec-
tion) or a single torque arm with
torsion shaft for torque absorption
into the foundation.
Auxiliary gear drive
The auxiliary gear drive has a high
speed shaft with a sprocket wheel.
Auxiliary drive and gear unit are
connected via roller chains.
5
Standard instrumentation
Allmetra, ABB or equivalent
Shrink discs
Tollok, Stüwe or equivalent
Torque limiting safety
coupling
Voith, Malmedi or equivalent
Cardan shaft
Voith, GKN or equivalent
Spur gear input reduction
Couplings for ball mill applica-
tion
Low speed couplings of type MAAG
ZCF are being used. Apart from the
high power density which the
toothed couplings provides, it allows
some misalignment between mill and
gearbox. Thermal growth of the drive
train can also be compensated.
To connect motor and gearbox,
rubber type high speed couplings are
being used. Torsionally flexible
couplings are beneficial due to Bevel stage input reduction
damping possible resonance condi-
tions and transient dynamic over-
loads.
Optional condition monitoring
system
Excluded from our scope of supply is
the condition monitoring system
which helps to save money by
enabling condition-based mainte-
nance. We offer solutions of
Prüftechnik or Dalog.
Possible torque arm system for roller presses
6

PPU selection diagram

Product range MAAG PPU for roller presses

3200 kW

-56
PPU
-52
PPU
1600 kW
-48
PPU

-44
PPU

-40
PPU
800 kW
-37
PPU
Installed motor power [kW]

-34
PPU
-32
PPU
7
400 kW PPU-2
-30
PPU
5
PPU-2
2
PPU-2

0
200 kW PPU-2

8
PPU-1

Application factor
100 kW
PPU-16 If the MAAG PPU is used for roller presses, we calcu-
late on the appropriate application factor KA = 2 (ISO).

50 kW
10 rpm 12 rpm 14 rpm 16 rpm 18 rpm 20 rpm 22 rpm 24 rpm 26 rpm 28 rpm 30 rpm
Roller speed [rpm]

PPU Type 25 27 30 32 34 37 40 44 48 52 56 n Bolts Ø B

Nominal
Torque
472 kNm 590 kNm 756 kNm 940 kNm 1110 kNm 1400 kNm 1740 kNm 2260 kNm 2800 kNm 3500 kNm 4200 kNm
[KA = 1]

d [mm] Ø 330 Ø 360 Ø 400 Ø 450 Ø 460 Ø 480 Ø 530 Ø 600 Ø 640 Ø 700 Ø 760
Ø f
e [mm] Ø 1110 Ø 1200 Ø 1250 Ø 1385 Ø 1480 Ø 1540 Ø 1685 Ø 1820 Ø 2020 Ø 2080 Ø 2270 Ø d
0
f [mm] Ø 1007h8 Ø 1092h8 Ø 1128h8 Ø 1255h8 Ø 1350h8 Ø 1424h8 Ø 1555h8 Ø 1701h8 Ø 1892h8 Ø 1945h8 Ø 2147h8 Ø e Ø D

B [mm] Ø 39 Ø 39 Ø 45 Ø 45 Ø 45 Ø 52 Ø 52 Ø 62 Ø 62 Ø 70 Ø 70 Ø s
t
n [mm] 17 17 17 17 18 17 19 17 19 17 19 L

L [mm] 1851 2001 2072 2162 2265 2370 2505 2732 2819 3060 3209

D [mm] Ø 1007 Ø 1092 Ø 1128 Ø 1255 Ø 1350 Ø 1424 Ø 1555 Ø 1701 Ø 1892 Ø 1945 Ø 2147

O [mm] 262 305 316 336 361 382 410 450 482 502 522

s [mm] Ø 110m6 Ø 110m6 Ø 120m6 Ø 120m6 Ø 130m6 Ø 140m6 Ø 140m6 Ø 160m6 Ø 160m6 Ø 160m6 Ø 180m6

t [mm] 198 198 220 220 234 243 243 320 320 320 282

mass [t] 3.4 4.7 5.3 6.7 7.8 9.3 12.3 15.8 20.3 25.4 31.6

Data for PPU Types 16 (120 kNm), 18 (190 kNm); 20 (260 kNm) and 22 (358 kNm) on request

Features/benefits
• Reduced to the max:
smaller, lighter and more
compact design
• Input stage exchangeable
• Both senses of rotation
possible
• Flexibility with modular
and standardised design
Design
The design of the PPU gear unit is
optimised to suit the power required,
the motor/mill speed and local cir-
cumstances. It is easily adaptable to
different applications thanks to the
flexible input stage concept.
Quality
Production and all activities are moni-
tored by the internal quality assurance
system in strict compliance with ISO
9001.
Production
The latest machines and technical
equipment are used in manufactur-
ing.
Delivery time
Thanks to continuous monitoring of
our production schedule, our clients
are provided with the real time status
of a project at any time.
Installation
The compact design simplifies trans-
port and reduces assembly time.
Test running
Gear units are tested and logged in
detail on our test bed prior to delivery.
7
• Only five different types of
bearings implemented
• Ring gear is part of the
casing
• Cast and welded parts
• long operating life
Spare parts
Spare parts are available throughout
the life of the gear units. Thanks PPU in assembly
to standardisation, fewer different
spare parts are necessary.
Customer service
Customer care by trained and skilled
personnel guarantees professional
after sales support.
Maintenance
High service comfort. Easy accessibil-
ity of gear units due to removable
input stage.
Installation of PPU
Monitoring system
Gear units are equipped with tem-
perature monitoring sensors.
Option
Customised condition monitoring
system VIBROWEB XP – ask us for
more information about this com-
pact solution.
Drive train PPU for ball mills
 CM 10-15 500-21-ENG V2

Copyright ©2015 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth and MAAG are (registered) trademarks of FLSmidth A/S.
This brochure makes no offers, representations or warranties (express or implied), and information and data contained in
this brochure are for general reference only and may change at any time. www.FLSmidthMaagGear.com

FLSmidth MAAG Gear AG

Lagerhausstrasse 11 · P.O. Box
8401 Winterthur · Switzerland
Tel +41 52 260 35 00
Fax +41 52 260 35 35
info@FLSmidthMaagGear.com