09 - en-KD CPT 001 F-Word PDF

Operating manual
en-KD.CPT.001.F
Rotary kiln drive
Code word
YAMAMACEMENT
Order number
D000661
Plant Order Code (POC)

4K1.KD01
en-KD.CPT.001.F Contents
Rotary kiln drive
Contents
1 General information ............................................................................. 1-1

1.1 Information regarding this operating manual.......................................... 1-1
1.2 Additionally applicable documents ......................................................... 1-1
1.3 Limitation on liability ............................................................................... 1-1
1.4 Copyright ................................................................................................ 1-1
1.5 Warranty provisions ................................................................................ 1-1
1.6 Symbol explanation ................................................................................ 1-2
2 Safety ..................................................................................................... 2-1
2.1 Intended use ........................................................................................... 2-1
2.2 Reasonably foreseeable misuse ............................................................ 2-1
2.3 Limits of the machine ............................................................................. 2-1
2.4 Obligation of the owner .......................................................................... 2-2
2.5 Obligation of the personnel .................................................................... 2-3
2.6 Qualifications of the personnel ............................................................... 2-3
2.7 Safety and monitoring equipment........................................................... 2-5
2.7.1 Safety devices to be retrofitted ............................................................... 2-5
2.8 Personal protective equipment ............................................................... 2-6
2.8.1 Personal protective equipment for all work ............................................ 2-6
2.8.2 Personal protective equipment for special work..................................... 2-7
2.9 Fundamental hazards ............................................................................. 2-8
2.9.1 Overview of residual risks ...................................................................... 2-8
2.9.2 Mechanical hazards.............................................................................. 2-10
2.9.3 Electrical hazards ................................................................................. 2-12
2.9.4 Thermal hazards................................................................................... 2-12
2.9.5 Hazards generated by materials and substances ................................ 2-13
2.9.6 Hazards in connection with the environment in which the
machine is used.................................................................................... 2-14
2.9.7 Other hazards ....................................................................................... 2-15
2.10 Safety signs at the machine ................................................................. 2-17
2.10.1 Warning signs at the machine .............................................................. 2-17
3 Technical data....................................................................................... 3-1
4 Components and description of functioning .................................... 4-1
4.1 Components ........................................................................................... 4-1
4.1.1 Girth gear and pinion drive ..................................................................... 4-2
4.1.2 Friction roller drive .................................................................................. 4-9
4.1.3 Protection devices ................................................................................ 4-20
4.1.4 Torque compensator ............................................................................ 4-22
4.1.5 Oil supply system ................................................................................. 4-24
4.2 Description of functioning ..................................................................... 4-26
5 Transportation, storage and assembly .............................................. 5-1
5.1 Transportation ........................................................................................ 5-1
5.1.1 Safety instructions .................................................................................. 5-1
5.1.2 Identifying the transport units ................................................................. 5-2
5.1.3 Checking the transport units ................................................................... 5-3
5.1.4 Packaging ............................................................................................... 5-3
5.1.5 Transporting the transport units ............................................................. 5-3
5.2 Storage ................................................................................................... 5-4
5.2.2 Storage of transport units ....................................................................... 5-4
Contents en-KD.CPT.001.F
Rotary kiln drive
5.2.3 Storage conditions and long-term storage ............................................. 5-5

5.3 Assembly ................................................................................................ 5-6
5.3.2 Tightening torques for bolts with standard thread .................................. 5-8
5.3.3 Tightening torques for bolts .................................................................... 5-9
5.3.4 Preparing for assembly .......................................................................... 5-9
5.4 Assembling the rotary kiln drive ........................................................... 5-10
5.5 Modifying the rotary kiln drive............................................................... 5-12
6 Lubrication ............................................................................................ 6-1
6.1 Safety instructions .................................................................................. 6-1
6.2 Lubrication chart ..................................................................................... 6-2
7 Commissioning..................................................................................... 7-1
7.2 Checking the safety and monitoring equipment ..................................... 7-3
7.3 Checks prior to commissioning .............................................................. 7-4
7.4 Starting the rotary kiln at an ambient temperature of below -10 °C ....... 7-6
7.5 Starting the rotary kiln at an ambient temperature of above -10 °C ....... 7-7
8 Operation............................................................................................... 8-1
8.2 Operation with main drive ....................................................................... 8-1
8.3 Operation with the auxiliary drive ........................................................... 8-2
8.4 Maintenance operation ........................................................................... 8-2
8.5 Operation with a modified drive .............................................................. 8-3
9 Maintenance .......................................................................................... 9-1
9.1 Maintenance work during operation ....................................................... 9-1
9.1.2 Prior to any maintenance work ............................................................... 9-2
9.1.3 Table of maintenance work (Operation) ................................................. 9-2
9.1.4 After any maintenance work ................................................................... 9-2
9.2 Maintenance work during a stoppage .................................................... 9-3
9.2.2 Prior to any maintenance work ............................................................... 9-4
9.2.3 Table of maintenance work (Stoppage) ................................................. 9-5
9.2.4 After any maintenance work ................................................................... 9-6
10 Troubleshooting ................................................................................. 10-1
10.1 Safety instructions ................................................................................ 10-1
10.2 Recommissioning after fault elimination ............................................... 10-1
11 Spare parts .......................................................................................... 11-1
11.1 Suggestions for enquiries and orders of spare parts ........................... 11-1
12 Disassembly and disposal ................................................................ 12-1
12.1 Safety instructions ................................................................................ 12-1
12.2 Before disassembly .............................................................................. 12-2
12.3 Disposal ................................................................................................ 12-2
12.3.1 Safety instructions ................................................................................ 12-2
13 Appendix ............................................................................................. 13-1
13.1 Technical drawings ............................................................................... 13-1
13.2 Subsuppliers' documentation ............................................................... 13-1
en-KD.CPT.001.F General information
Rotary kiln drive 1-1
1 General information
1.1 Information regarding this operating manual
This operating manual enables the user to operate the machine safely and
efficiently. The operating manual is an integral part of the machine and has to be
kept in the direct vicinity of the machine so that it is accessible for the personnel
at any time.
Before commencing any work, the personnel must have read and understood this
operating manual. Compliance with all safety instructions and other instructions
given in this operating manual on actions to be taken is the fundamental
prerequisite for safe working.
The figures contained in this operating manual serve for general illustration and
can deviate from the actual design.
1.2 Additionally applicable documents

In addition to this operating manual, the documents in the overall documentation
also apply. Be absolutely sure to comply with the instructions contained therein –
especially the safety instructions. The additionally applicable documents can be
found in the section Appendix.
1.3 Limitation on liability

thyssenkrupp Industrial Solutions explicitly excludes all liability and warranty
claims, particularly if damage or operational malfunctions originate from the
following:
● Disregarding of the information and/or instructions in the documentation
● Any use other than the intended use
● Maloperation
● Insufficient maintenance or non-observance of maintenance intervals
● Use of consumables (in particular lubricants) not expressly approved by the
manufacturer for the machine in question
● Use of spare parts not expressly approved by the manufacturer for the
machine in question
● Conversions and modifications not approved by thyssenkrupp Industrial
Solutions.
The conditions for liability and warranty stipulated in the contract between the
customer and thyssenkrupp Industrial Solutions shall apply.
1.4 Copyright
thyssenkrupp Industrial Solutions reserves all utilization rights in connection with
this operating manual. Without the written consent of thyssenkrupp Industrial
Solutions, this operating manual may neither be reproduced, nor be made
available to third parties, nor be used in any unauthorised manner.
1.5 Warranty provisions

The warranty provisions are contained in the contract.
General information en-KD.CPT.001.F
1-2 Rotary kiln drive
1.6 Symbol explanation
Safety instructions
DANGER
This combination of symbol and signal word indicates an immediately

dangerous situation which leads to death or severe injuries if it is not
avoided.
WARNING
This combination of symbol and signal word indicates a possibly

dangerous situation which may lead to death or severe injuries if it is not
avoided.
CAUTION

dangerous situation which may lead to slight or minor injuries if it is not
avoided.
NOTICE

dangerous situation which may lead to damage to property and
environmental damage if it is not avoided.
en-KD.CPT.001.F General information
Safety signs
A safety sign is a sign making a general safety statement through a combination
of a specific colour and a geometric form, and making a special safety statement
when a graphical symbol is added to the above combination.
Mandatory sign
A safety sign that stipulates a certain behaviour.
Prohibition sign
A safety sign that prohibits a certain behaviour.
Warning sign
A safety sign that warns of a specific danger.
Note
This symbol highlights useful tips and recommendations, as well as information

for efficient and trouble-free operation.
This symbol can also include a reference to additionally applicable documents.
Distinctions used
In these instructions, the following symbols and means of emphasis are used for
indicating instructions on actions to be taken, lists, references and other elements:
Distinction Explanation
Italics Indicates references to other sections,

additionally applicable documents, foreign-
language terms and button texts
Step 1, 2, 3...: Indicates instructions on actions to be taken
● Indicates lists and list entries or instructions on

actions to be taken, without a specified
sequence
en-KD.CPT.001.F Safety
2 Safety
2.1 Intended use
The intended use comprises:
● Driving the pinion shaft in the case of the girth gear and pinion drive
● Driving the axle journal to the supporting roller in the case of the friction roller
drive
The rotary kiln drive is not a machine that is ready for use.
The rotary kiln drive is intended for use in conjunction with other components to
form a rotary kiln plant.
The rotary kiln drive may only be used if the requirements specified in the section
Technical data are complied with.
The intended use also includes compliance with all instructions in this operating
manual. Any use other than for the specified intended use shall be deemed
misuse.
2.2 Reasonably foreseeable misuse

The reasonably foreseeable misuse of this machine includes:
● Operation of a rotary kiln with unsuitable parameters
● Use of the rotary kiln drive by unauthorised personnel who have not received
special instruction
● Missing protection devices
● Use of unsuitable means of access to the rotary kiln drive
Any use other than the intended use is forbidden. thyssenkrupp Industrial
Solutions is not responsible for damage resulting from any use other than the
intended use. This risk shall be borne exclusively by the plant owner.
2.3 Limits of the machine
Time limits
The rotary kiln drive is designed for a five-year service life, provided that
maintenance work is carried out as stipulated. However, based on the product
monitoring results a longer service life has been observed if maintenance is done
properly and a general overhaul is conducted upon expiry of the specified period
of use including the exchange of all safety components.
Safety en-KD.CPT.001.F
2.4 Obligation of the owner
Owner
The owner is any individual or corporate body who operates the machine for
trade or commercial purposes or makes it available to a third party for
utilisation/application and who, during operation of the plant, bears the legal
product responsibility for the protection of the user, the personnel or third parties.
Fundamental principles
The machine is used for commercial purposes. The owner of the machine is
therefore subject to statutory regulations on occupational safety. Any safety
checks before or during operation depend on the relevant national regulations.
The owner is responsible for the performance and recording of such safety
checks.
In addition to the safety instructions contained in this operating manual, the
regulations on safety, accident prevention and environmental protection
applicable to the range of application of the machine must be complied with. The
following applies:
● The machine is part of an overall plant. The owner has to ensure that the
structural and organisational protective measures applicable to the plant at its
place of installation are implemented and adhered to.
● The owner must incorporate the machine into the safety concept of the overall
plant.
● The owner must seek to obtain all relevant information on the applicable
occupational safety regulations and perform a risk assessment to identify
additional hazards resulting from the special working conditions at the place of
installation of the machine or from installation in the overall plant. The owner
must implement the results of the risk assessment in operating instructions for
the machine.
● The owner is obliged to regularly instruct the personnel. A written record of
this instruction must be kept.
● During the entire operating time of the machine, the owner is responsible for
ensuring that the operating instructions that he/she prepares conform to the
current status of the rules and standards, and for adapting them if necessary.
● The owner is responsible for clearly defining and determining responsibilities
related to assembly, first commissioning, supervision, maintenance, cleaning
and fault elimination.
● The owner shall ensure that all employees who work with the machine have
read and understood this operating manual.
● The owner is responsible for regularly instructing the personnel and informing
on potential hazards arising from the machine and from the overall plant.
● The owner shall provide personnel with the required protective clothing and
equipment in complete and perfectly intact condition.
● The owner may not carry out any technical modifications to the machine.
Overall plant
● The machine is part of an overall plant. The owner has to ensure that the
structural and organisational protective measures applicable to the overall
plant at its place of installation are implemented and adhered to.
● The owner is responsible for informing the personnel working at the machine
on potential hazards arising from the overall plant, and for regularly instructing
the said personnel.
Condition of perfect technical serviceability

The owner is responsible for keeping the machine in a condition of perfect
technical serviceability at all times. The following applies:
● The owner has to ensure that the maintenance intervals specified in this
operating manual are adhered to.
● The owner has to check regularly whether all safety devices are complete and
in proper working order.
2.5 Obligation of the personnel

The personnel must always wear the necessary protective clothing such as safety
shoes, tough top clothes, protective gloves and a safety helmet.
2.6 Qualifications of the personnel
WARNING
Insufficient qualification of personnel

If unqualified personnel perform work on the machine or are within the
danger area of the machine, this gives rise to hazards that may result in
severe injuries and significant damage to property.
I. Keep unqualified personnel away from the danger area.
II. Only permit qualified personnel to perform work.
WARNING
Unauthorised persons in the danger and working areas

All persons who do not possess the qualifications described in the
operating manual are not familiar with the hazards in the working area.
There is a danger of severe injuries or death for these persons.
I. Keep unauthorised persons away from the danger and working areas.
II. Interrupt work as long as unauthorised persons are present in the
danger and working areas.
III. If in doubt, speak to the persons concerned and instruct them to leave
the danger and working areas.
Assembly personnel
The assembly personnel are the persons charged with the task of assembling the
delivered machine. The assigned personnel must be qualified to carry out the
assembly work.
The assembly personnel must be able to perform the assigned work and to
recognise and prevent possible hazards independently due to their professional
training, knowledge and experience as well as their knowledge of the relevant
standards and regulations.
Commissioning personnel
The commissioning personnel are the persons charged with the task of
commissioning the delivered machine. The assigned commissioning personnel
must be qualified to carry out the commissioning work.
The commissioning personnel must be able to perform the assigned work and to
Operating personnel
The operating personnel are the persons charged by the owner of the plant with
the task of operating the delivered machine. The owner of the plant has to ensure
that the assigned operating personnel are qualified to carry out the operating
work.
The operating personnel must be able to perform the assigned work and to
Maintenance personnel
The maintenance personnel are the persons charged by the owner of the plant
with the task of maintaining the delivered machine. The owner of the plant has to
ensure that the assigned maintenance personnel are qualified to carry out the
maintenance work.
The maintenance personnel must be able to perform the assigned work and to
Qualified electrician
The qualified electrician is the person charged by the owner of the plant with the
task of performing work on the electrical equipment. The qualified electrician has
received professional training in his/her special field of activity and is familiar with
the relevant standards and regulations. The qualified electrician must fulfil the
applicable statutory provisions governing the prevention of accidents.
The qualified electrician must be able to perform the assigned work on electrical
equipment and to recognise and prevent possible hazards independently due to
his/her professional training, knowledge and experience as well as his/her
knowledge of the relevant standards and regulations.
2.7 Safety and monitoring equipment
WARNING
Defective safety and monitoring equipment

Defective or deactivated safety and monitoring equipment may result in
bodily injuries and machine damage. This could lead to severe or even
fatal injuries.
I. At regular intervals and whenever work has been performed on the
machine, check whether all safety and monitoring devices are
installed properly and are functioning correctly.
II. Never deactivate or bypass any safety and monitoring devices.
III. Make sure that the safety and monitoring equipment is always easily
accessible.
Be sure to comply with the instructions concerning the extent and the location of
the safety and monitoring devices, in the contractually agreed documents
relating to the electrical equipment, for example:
● Location of electrical devices
● List of measuring points
● List of digital sensors
2.7.1 Safety devices to be retrofitted
WARNING
Unsecured or unmarked hazardous points

Dangerous situations and injuries may arise due to unsecured or
unmarked hazardous points in the working area.
I. Mark hazardous points with appropriate safety signs.
II. Shut off access to hazardous points during operation.
The rotary kiln is intended for use within an overall plant. Before the plant is
commissioned, the owner has to ensure the following:
Securing against restarting

The owner must implement measures to enable the machine to be secured
against restarting during maintenance work.
Guards
The rotary kiln is intended for use within a plant. Before the rotary kiln is put into
operation, install the following guards and integrate them into the safety chain of
the plant control system:
● Protective grating in the operating range of the rotary kiln drive, or locked or
monitored access points, and marking of danger areas by means of suitable
safety signs. Access to entrapment points, trapping points and pinch points
must only be possible when the rotary kiln is stopped.
Integration into an EMERGENCY STOP concept

Before the machine is put into operation, install the EMERGENCY STOP devices
and integrate them into the safety chain of the plant control system.
Connect the EMERGENCY STOP devices such that dangerous situations for
persons and property are excluded in the case of a failure of the power supply or
activation of the power supply following a failure.
The EMERGENCY STOP devices always have to be freely accessible.
2.8 Personal protective equipment

Personal protective equipment serves to protect the personnel against hazards
that can impair their safety and health at work.
The personnel must wear the required personal protective equipment during
different kinds of work at and on the machine. Make absolutely sure that you put
on personal protective equipment before commencing the respective work.
Always be sure to comply with the notices regarding personal protective
equipment that are posted in the working area.
The personal protective equipment that has to be worn during special work is
described separately in the respective sections of this operating manual.
2.8.1 Personal protective equipment for all work
Safety helmet
A safety helmet protects against falling objects, swinging loads and impact with
static objects.
Safety shoes
Safety shoes protect against slipping and against injuries due to falling objects.
The use of safety shoes that are not in proper condition is forbidden. Safety
shoes are not in proper condition if, for instance, they have worn-out treads,
uncovered toe caps or seams that have come apart.
Safety goggles
Tightly-fitting safety goggles protect the eyes from airborne particles and liquid
splashes, dust, chemical splashes, dazzling light, sparks, metal splinters and
dangerous vapours. Dispose of and replace safety goggles that have scratched
or unclear lenses.
Protective clothing
Protective clothing means tight-fitting work clothes with low tear strength, tight
sleeves and without any protruding parts. Protective clothing mainly protects
against being trapped by moving machine parts and against skin contact with
materials and substances.
Protective gloves
Protective gloves protect against abrasions, cuts, skin cracks, punctures,
chemical burns or heat burns, infections and crushing.
2.8.2 Personal protective equipment for special work
Fall protection system

Fall protection systems protect the user against falls, by either preventing or
arresting a free fall. A fall protection system consists of at least one body-holding
device and an attachment system that can be connected to a reliable anchorage.
Heat-resistant protective clothing

Heat-resistant protective clothing protects against thermal radiation. Heat-
resistant protective clothing comprises a safety helmet with visor, a heat-resistant
jacket, heat-resistant trousers, protective gloves and safety boots.
Welding mask
Welding masks protect the face against radiation, heat and sparks during welding
work.
2.9 Fundamental hazards
2.9.1 Overview of residual risks

The following tables list the residual risks, together with the hazard sources:
Mechanical hazards
Hazard Source of hazard
Crushing Entire rotary kiln drive
Moving parts of the rotary kiln and of the rotary

kiln drive
Suspended loads and moving components

during transportation, assembly, maintenance
and disassembly
Drawing-in, trapping or entrapment Entire rotary kiln drive
Moving parts of the rotary kiln and of the rotary

kiln drive
Slipping, tripping or falling Working area of the rotary kiln drive
Uncovered wires or cables
Working at great heights
Falling or ejected objects Transportation of components of the rotary kiln

drive
Suspended loads and moving components

during transportation, assembly, maintenance
and disassembly
Loss of stability Components of the rotary kiln drive
Breakage during operation Corrosion
Components of the rotary kiln drive
Missing, damaged or loose fastening devices

Electrical hazards
Electric shock Live components
Electrical equipment
Damaged cables
Components that have become live due to

faults
Thermal hazards
Burns Hot surfaces of the rotary kiln
Hot surfaces of the rotary kiln drive
Frostbite Cold surfaces
Dehydration Hot work environment
Discomfort Hot work environment
Injuries as a result of radiation from sources of Hot work environment

heat
Heat stroke Hot work environment
Hazards generated by materials and substances
Fire Introduction of easily flammable materials
Emission of a substance that could be Escaping lubricants

hazardous
Consumables: grease, oils, cleaning agents
Hazards in connection with the environment in which the machine is used
Slipping, falling Usage of the machine outdoors

Other hazards
Problems as a result of human error Improper handling of the machine
Modifications to the machine
Illegible lettering and safety signs
Inadequate lighting
Wrong spare parts
Non-observance of the documentation
Loss of direct visibility of the working area Entire rotary kiln drive
Other hazardous events Improper disposal
2.9.2 Mechanical hazards
WARNING
Moving components
If you reach past moving components, parts of your body may be pulled in
and crushed or severed.
I. Operate the machine only with properly mounted protection devices.
II. Only open protection devices, inspection covers, service covers or
inspection doors when the machine is switched off.
WARNING

There is a risk of falling when working at great heights. This could lead to
life-threatening injuries.
I. Wear personal protective equipment and use a fall protection system.
II. Do not remove protection devices.
III. If ladders or working platforms are used, make absolutely sure that
they have a secure footing.
WARNING
Lack of stability
Lack of stability of the rotary kiln drive may result in displacement of the
components. This could lead to severe injuries.
I. Use suitable fastening devices.
II. Replace any missing fastening devices and firmly attach any loose
fastening devices.
III. Regularly inspect the rotary kiln drive for damage and corrosion.
IV. Repair any damaged areas of the anti-corrosion coating.
V. Only use the rotary kiln drive if the mountings are undamaged.
WARNING
Component breakage
Damaged, corroded or loose components may break and cause severe
injuries.
I. Wear personal protective equipment.
II. Before each use, inspect the machine for damage and corrosion.
III. Use suitable fastening devices. Replace any missing fastening
devices and firmly attach any loose fastening devices.
IV. Repair any damaged areas of the anti-corrosion coating.
CAUTION
Uncovered wires or cables

If wires or cables are not covered, they represent a trip and fall hazard.
II. Fasten or cover any uncovered wires and cables.
III. Mark trip hazards with warning tape.
2.9.3 Electrical hazards
DANGER
Electric current
There are live components in and at the machine. In the following cases,
there is danger of death due to electric shock:
● Contact with live parts of the electrical equipment (such as sensor
system, switch boxes and control cabinets)
● Contact with arcs
● Short circuit
I. Only permit qualified electricians to perform work on the electrical
equipment.
II. Before beginning any work, disconnect all poles of the machine from
the electricity supply network and secure it against restarting.
III. Wear personal protective equipment for work on energised electrical
systems when performing work on electrical equipment or devices.
IV. Use suitable tools when performing work on electrical equipment or
devices.
V. Only in exceptional cases should fault localisation be carried out on
the energised machine.
VI. Observe the safety rules.
VII. Never bypass fuses or put them out of operation. When replacing
fuses, observe the correct rated current.
VIII. Keep all live parts dry.
IX. Repair or replace damaged insulation immediately.
X. Operate the machine only if all the protection devices have been
properly mounted.
DANGER
Electric current
The machine contains live parts. During thunderstorms, contact with live
parts means danger of death due to electric shock.
I. Make sure that a lightning protection system has been installed.
II. Do not stay at the machine during a thunderstorm.
2.9.4 Thermal hazards
WARNING
Hot surfaces
Components in contact with the material may heat up during operation, as
may bearings and motors. Skin contact with hot surfaces may cause
severe burns.
Always wear personal protective equipment and heat-resistant protective
clothing when working in the vicinity of hot surfaces.
WARNING
Hot work environment

Staying in an area with a high ambient temperature presents the following
risks:
● Burns
● Heat stroke
● Dehydration
● Nausea
I. Wear personal protective equipment and heat-resistant protective
clothing.
II. Take regular breaks outside the area of high ambient temperature.
III. Drink enough fluids.
IV. If possible, provide additional cooling by fans.
WARNING
Cold surfaces
Touching cold surfaces may cause sensation of pain, numbness or local
skin frostbites.
Wear cold-resistant protective clothing and safety gloves if the ambient
temperature is below 0 °C.
2.9.5 Hazards generated by materials and substances
WARNING
Easily flammable substances

Easily flammable substances, liquids or gases can catch fire and lead to
severe injuries or death.
I. In case of fire, stop all work immediately. Leave the danger area until
the all-clear is given and alert the fire brigade.
II. Never smoke within the danger area or in the immediate vicinity. The
use of open flame, fire and ignition sources of any kind is prohibited.
III. Keep suitable extinguishing agents (fire blanket, fire extinguisher) at
hand.
IV. Immediately report any suspect substances, liquids or gases to the
person in charge.
WARNING
Escaping lubricants
Lubricant may escape at the machine. Contact with lubricants may cause
health damage or lead to injuries due to slipping.
II. Operate the machine only if all the protection devices have been
properly mounted.
III. Avoid any skin contact. If skin contact has occurred, wash the skin
thoroughly.
IV. Avoid any contact with eyes. If eye contact has occurred, thoroughly
rinse the eyes with large amounts of water and, if necessary, consult
a doctor.
V. Immediately remove any lubricants that have escaped.
VI. If necessary, mark the danger areas and cordon them off.
CAUTION
Improper handling of consumables

Consumables such as greases, oils and cleaning agents may contain toxic
substances. If such consumables are released into the natural
environment, they may harm humans, animals and plants.
I. Ensure that the environment is not polluted when consumables are
stored, used or disposed of.
II. When handling consumables, be sure to comply with the applicable
national regulations for the protection of the environment.
2.9.6 Hazards in connection with the environment in which the machine is used
CAUTION
Weather/Slippery ground
If the machine is used outdoors, there is a slip or fall hazard due to rain,
ice or snow. This could lead to minor injuries.
II. Always keep the working area around the machine clean.
III. Remove snow and ice.
2.9.7 Other hazards
WARNING
Improper handling of the machine

Mistakes in handling the machine may result in personal injury.
I. Keep safety signs at the machine legible.
II. Only operate the machine in full compliance with regulations.
III. Operate the machine only if all the protection devices have been
properly mounted.
IV. If safety-relevant changes occur at the machine or in its operating
behaviour, shut it down immediately.
WARNING
Modifications to the machine

Modifications to the machine may result in severe injuries.
I. Never carry out any conversions or make any modifications to the
machine without having first obtained the written consent of the
manufacturer.
II. Carry out separate hazard assessments for conversions or
components subsequently incorporated.
WARNING
Illegible lettering and safety signs

Illegible safety signs, or illegible or erroneous lettering on displays and
control elements, may cause errors and incorrect operation. This could
lead to severe injuries.
I. Mount the displays and control elements such that they can be easily
reached.
II. Keep all displays, control elements and safety signs clean and legible.
III. Immediately replace faulty marking and lettering.
IV. Immediately replace damaged or defective displays, control elements
or safety signs.
WARNING
Inadequate lighting
Faulty, dirty or missing lighting may give rise to dangerous situations.
This could lead to severe injuries.
I. At the place of installation, illuminate the machine so as to provide
the required lighting conditions.
II. Only operate the machine if the lighting is in proper working order
and is adequate.
WARNING
Loss of direct visibility of the working area

Loss of direct visibility of the working area, and unsecured or unmarked
danger areas in the working area, may lead to dangerous situations and
injuries.
I. Secure the access to the danger area by installing protective grating
and locked or monitored access points.
II. Mark the danger areas with appropriate safety signs.
III. Shut off access to danger areas during operation.
IV. Make absolutely sure that safe access is ensured for the specialist
personnel for the entire duration of the maintenance work.
CAUTION
Wrong spare parts

Wrong or defective spare parts may have a negative effect on safety, and
may lead to damage, malfunctions or complete failure of the machine. This
could lead to severe injuries.
Only use the manufacturer's original spare parts or spare parts that have
been approved by the manufacturer.
2.10 Safety signs at the machine
WARNING
Illegible safety signs

Illegible safety signs may cause errors and incorrect operation, and may
result in severe injuries.
I. Keep all safety signs clean and legible.
II. Immediately replace damaged safety signs.
All safety signs at the machine must always be complete and easily legible.
The following safety signs are located in the operating range of the machine.
They refer to the direct vicinity of the sign's location.
Be sure to comply with the instructions in the drawing (see page 13-1, Technical
drawings) regarding the position of the safety signs.
2.10.1 Warning signs at the machine
Warning of high voltage
Warning of hot surface
Warning of hand injuries
Warning of counter-rotating rollers

en-KD.CPT.001.F Technical data
3 Technical data
General data
Year of manufacture 2017
Type of drive dual drive
Use girth gear and pinion drive
Rotational speed of the kiln with main drive 4.5 rpm
Rotational speed of the kiln 0.11 rpm

with auxiliary drive
Main motor (1.1)

Speed 1200 rpm
Power 950 kW
Main gear unit (1.3)

Type designation P2DA 28
Transmission ratio 1 : 40.635
Auxiliary motor (1.5)

Type designation 1LE1503-2DC29-0AA4-Z
Speed 1180 rpm
Power 45 kW
Auxiliary gear unit (1.8)

Type designation K3UF 7

Technical data en-KD.CPT.001.F
Main motor (2.1)

Speed 1200 rpm
Power 950 kW
Main gear unit (2.3)

Type designation P2DA 28
Auxiliary motor (2.5)

Type designation 1LE1503-2DC29-0AA4-Z
Speed 1180 rpm
Power 45 kW
Auxiliary gear unit (2.8)

Type designation K3UF 7

en-KD.CPT.001.F Components and description of functioning
4 Components and description of functioning

4.1 Components
Some details of the drawings in this operating manual may not be identical to
the drawings of the actually delivered machine.
The following versions of the rotary kiln drive are possible:

● Girth gear and pinion drive
● Girth gear and pinion drive with single drive
● Girth gear and pinion drive with dual drive
● Friction roller drive
● Friction roller drive with one-roller single drive
● Friction roller drive with one-roller dual drive
● Friction roller drive with two-roller single drive
Components and description of functioning en-KD.CPT.001.F
4.1.1 Girth gear and pinion drive
Fig. 1: Girth gear and pinion drive

Fig. 2: Girth gear and pinion single-drive

No. Denomination Description
1.0 Drive
1.1 Main motor
1.2 Cardan shaft
1.3 Main gear unit
1.4 Torque compensator
1.5 Auxiliary motor
1.6 Starting coupling Hydrodynamic design
1.7 Holding brake
1.8 Auxiliary gear unit
1.8.1 Centrifugal brake Installed in the auxiliary gear unit (1.8)
1.8.2 Overrunning clutch Installed in the auxiliary gear unit (1.8)
1.9 Shrink disk For installation on the pinion shaft
1.10 Oil supply system (Not illustrated)
A Kiln shell
B Girth gear
C Pinion With pinion shaft and bearing
D Kiln inlet
E Kiln outlet
Fig. 3: Girth gear and pinion dual-drive

1.0 Drive
1.1 Main motor
1.2 Cardan shaft
1.3 Main gear unit
1.5 Auxiliary motor
1.7 Holding brake
1.10 Oil supply system Not illustrated
2.0 Drive
2.1 Main motor
2.2 Cardan shaft
2.3 Main gear unit
2.5 Auxiliary motor
2.7 Holding brake
A Kiln shell
B Girth gear
C Pinion With pinion shaft and bearing
D Kiln inlet
E Kiln outlet
4.1.2 Friction roller drive
Fig. 4: Friction roller drive

Fig. 5: Friction roller drive with one-roller single drive

1.0 Drive
1.1 Main motor
1.2 Cardan shaft
1.3 Main gear unit
1.5 Auxiliary motor
1.7 Holding brake
1.9 Shrink disk For installation on the supporting roller axle
A Kiln shell
D Kiln inlet
E Kiln outlet
F Tyre
G Supporting roller With axle and bearing

Fig. 6: Friction roller drive with one-roller dual drive

1.0 Drive
1.1 Main motor
1.2 Cardan shaft
1.3 Main gear unit
1.5 Auxiliary motor
1.7 Holding brake
2.0 Drive
2.1 Main motor
2.2 Cardan shaft
2.3 Main gear unit
2.5 Auxiliary motor
2.7 Holding brake
A Kiln shell
D Kiln inlet
E Kiln outlet
F Tyre

Fig. 7: Friction roller drive with two-roller single drive

1.0 Drive
1.1 Main motor
1.2 Cardan shaft
1.3 Main gear unit
1.5 Auxiliary motor
1.7 Holding brake
2.0 Drive
2.1 Main motor
2.2 Cardan shaft
2.3 Main gear unit
2.5 Auxiliary motor
2.7 Holding brake
A Kiln shell
D Kiln inlet
E Kiln outlet
F Tyre

4.1.3 Protection devices
Fig. 8: Protection devices (3.0)

3.1 Protective grating For cardan shaft (1.2, 2.2)
3.2 Heat shield For main gear unit (1.3, 2.3)
3.3 Heat shield For main motor (1.1, 2.1)
3.4 Guard plate For shrink disc (1.9, 2.9)
3.5 Cover Optional, for starting coupling (1.6, 2.6)
3.6 Cover For holding brake (1.7, 2.7)
I Axle journal For supporting roller axle
J Pinion shaft journal

4.1.4 Torque compensator
Fig. 9: Torque compensator (1.4, 2.4)

1.4 Torque compensator For drive (1.0)
1.4.1 Torque arm
1.4.2 Rod
1.4.3 Articulated element
1.4.4 Bearing block
1.4.5 Torsion rod
1.4.6 Connecting element For main gear unit (1.3)
2.4 Torque compensator For drive (2.0)
2.4.1 Torque arm
2.4.2 Rod
2.4.3 Articulated element
2.4.4 Bearing block
2.4.5 Torsion rod
2.4.6 Connecting element For main gear unit (2.3)

4.1.5 Oil supply system
Fig. 10: Oil supply system (1.10, 2.10)

1.10 Oil supply system For drive (1.0)
1.10.1 Pumps With pressure control valve
1.10.2 Filter
1.10.3 Oil-water cooler With cooling water flow controller
1.10.4 Oil storage tank With filling level monitor
1.10.5 Heating system Optional
2.10 Oil supply system For drive (2.0)
2.10.1 Pumps With pressure control valve
2.10.2 Filter
2.10.3 Oil-water cooler With cooling water flow controller
2.10.4 Oil storage tank With filling level monitor
2.10.5 Heating system Optional
d Connection For oil feed flow
e Connection For oil return flow
f Connection For cooling water inlet
g Connection For cooling water outlet

4.2 Description of functioning

A rotary kiln drive generates the torque that is necessary to put a rotary kiln into
continuous rotary motion. The torque is transmitted either via a girth gear and
pinion drive or a friction roller drive.
The main gear unit (1.3, 2.3) is mounted on the drive trunnion of the pinion or the
supporting roller axle by means of a shrink disc (1.9, 2.9). The reaction forces of
the tightening torque are absorbed by a double sided torque compensator (1.4,
2.4). By means of the holding brake (1.7, 2.7) on the auxiliary drive, the rotary kiln
can be secured against unintended turning.
For operation of the rotary kiln drive, the following operating modes are available:
Operation with main drive
The main motor (1.1, 2.1) is switched on from the control panel.
The driving torque generated by the main motor (1.1, 2.1) is transmitted via the
cardan shaft (1.2, 2.2) to the main gear unit (1.3, 2.3).
Operation with auxiliary drive
The auxiliary motor (1.5, 2.5) is switched on from the control panel or locally in
case of maintenance operation.
The driving torque generated by the auxiliary motor (1.5, 2.5) is transmitted via
the starting coupling (1.6, 2.6) to the input shaft of the auxiliary gear unit (1.8, 2.8).
The increased driving torque is transmitted from the auxiliary gear unit (1.8, 2.8)
directly to the main gear unit (1.4, 2.4). Further transmission of the increased
driving torque takes place at a reduced rotational speed via the cardan shaft (1.2,
2.2) to the main gear unit (1.3, 2.3) and from the main gear unit (1.3, 2.3) further
on to the drive trunnion via the shrink disc (1.9, 2.9).
Maintenance operation with auxiliary motor
The auxiliary motor (1.5, 2.5) can only be switched on locally.
The driving torque generated by the auxiliary motor (1.5, 2.5) is transmitted via
the starting coupling (1.6, 2.6) to the input shaft of the auxiliary gear unit (1.8, 2.8).
The increased driving torque is transmitted from the auxiliary gear unit (1.8, 2.8)
directly to the main gear unit (1.3, 2.3). Further transmission of the increased
driving torque takes place at a reduced rotational speed via the cardan shaft (1.2,
2.2) to the main gear unit (1.3, 2.3) and from the main gear unit (1.3, 2.3) further
on to the drive trunnion via the shrink disc (1.9, 2.9).
en-KD.CPT.001.F Transportation, storage and assembly
5 Transportation, storage and assembly

5.1 Transportation
5.1.1 Safety instructions
WARNING
Suspended loads
During lifting operations, loads might swing out or fall down. This could
lead to life-threatening injuries.
II. Only use approved lifting accessories with sufficient load-bearing
capacity.
III. Do not use damaged, cracked or chafed lifting accessories.
IV. Do not attach lifting accessories to sharp edges, and do not knot or
twist them.
V. Only move loads under supervision.
VI. Never work below or in the swivelling range of suspended loads.
VII. Set down the load before leaving the place of work.
WARNING
Loads swinging out

If a load with an eccentric centre of gravity is not properly attached, it may
swing out unexpectedly. This could lead to severe injuries or damage to
property.
I. When lifting a load, prevent it from swinging out.
II. If necessary, adjust the length of the slings.
WARNING
Falling or toppling loads

Loads may have an eccentric centre of gravity. If the load is not attached
correctly, it might tip or fall. This could lead to severe injuries or damage
to property.
I. Pay attention to marks and instructions concerning the centre of
gravity.
II. If you use a crane to move the load, attach the crane hook such that it
is located directly above the centre of gravity of the load.
III. Lift the load carefully and observe whether it tips or not. If necessary,
adjust the attachment.
Transportation, storage and assembly en-KD.CPT.001.F
NOTICE
Improper transportation
If items of freight are not transported properly, they may fall down or tip
over, causing damage to components.
I. Handle the items of freight carefully when unloading them upon
delivery and transporting them on site, and observe the symbols and
instructions on the packaging of the freight items.
II. Only use the specified fastening points.
III. Do not remove packaging until shortly before assembly.
5.1.2 Identifying the transport units

The machine can be divided into several transport units. Transport units may
contain a loose part or multiple loose parts.
Each transport unit can be identified by a marking and the supplied packing list.
Each loose part can be identified by an applied label and the supplied packing list.
Markings on the transport units

All transport units have a waterproof marking with the following details:
● Customer data
● Order data
● Point of delivery
● Port at point of delivery
● Weight (net/gross)
● Number of the transport unit
● Safety symbol according to the HPE international packing directive
Packing list
In addition to the dispatch note, the consignee receives for each delivery a
packing list indicating the contents of each transport unit. The packing list states
all of the loose part items, with the following details:
● Order number
● Packing list number
● Plant Order Code (POC)
● Colour-coded shipping mark
● Quantity delivered
● Loose part designation
● Customer equipment code
● Loose part number
● Number of the transport unit
● Total weight of the transport unit
● Dimensions
Loose part label

For identification purposes, each loose part is provided with a label containing the
following details:
● Order number
● Code word
● Plant Order Code (POC)
● Designation of the loose part
● Designation of the plant section
● Drawing or parts list number, with item details
● Quantity ordered
● Quantity delivered
● Loose part number
5.1.3 Checking the transport units

Check the packaging for damage immediately upon receipt of the delivery. In the
case of externally visible transport damage, proceed as follows:
● Do not accept the delivery, or only accept it with reservation.
● Record the extent of the damage on the shipping documents or on the
delivery note of the carrier.
● Initiate a complaint.
5.1.4 Packaging
The individual transport units were packed according to the expected transport
conditions and the expected storage conditions at the place of installation.
The packaging is intended to protect the individual components until assembly
from transport damage, corrosion and other damage. Do not destroy the
packaging and do not remove it until assembly begins.
5.1.5 Transporting the transport units

Transport the transport units under the following conditions:
● Be sure to observe the safety symbols and instructions on the transport units.
● Cranes and fork-lift trucks must be designed for the weight of the transport
units.
● Handle the transport units carefully when unloading them, when they are
delivered and when transporting them on site.
● Transport the transport units using suitable lifting machinery.
● Only use the designated lifting points.
● Do not remove packaging until assembly begins.
● Before transporting, remove the piping or oil pumps from gear units and close
all pipe sockets and openings with weather-proof and impact-proof sealing
covers to prevent ingress of tramp material.
5.2 Storage
NOTICE
Improper storage
Improper storage may lead to impairment of material properties and to
damage of components.
I. When they arrive at the site, inspect all components for transport
damage.
II. During storage, protect against moisture, soiling and damage.
III. Be sure to comply with the storage instructions of thyssenkrupp
Industrial Solutions and the subsuppliers.
IV. In the case of long-term storage, be sure to comply with the special
instructions of thyssenkrupp Industrial Solutions and the
subsuppliers. If necessary, request additional information.
5.2.2 Storage of transport units

Store the transport units under the following conditions:
● During storage, protect against moisture, soiling and damage.
● Protect against direct sunlight.
● Protect against frost.
● Avoid mechanical jolting.
● Do not expose to aggressive media.
● Store only on a level storage surface.
● Set up escape and evacuation routes, and keep them clear.
● Stack and secure all transport units in such a way that they do not slip, fall or
collapse.
● Stack and secure cylindrical materials in such a way that they do not slip away
from each other or tip over.
● Keep storage areas free from materials that constitute an increased trip
hazard or a fire hazard.
● If a transport unit is stored for more than 3 months, regularly check the
general condition of all parts and of the packaging. If required, replace or
renew the preservation.
5.2.3 Storage conditions and long-term storage
Component Storage conditions Maintenance in the Preservation

case of long-term
storage
Drive (1.0, 2.0) ● Be sure to comply with the instructions in the subsupplier's
documentation.
Site assembly ● Store in dry

material, tools, conditions
electrodes
All individual parts ● Store in dry

for bolted conditions
connections
Measurement and ● Store in closed

control devices rooms
● Store in dry
conditions
Machine frames, ● Store under a roof ● Exterior paint coat

supporting
structures, welded
components
Structural steelwork ● Store under a roof ● Exterior paint coat

components
5.3 Assembly
The following assembly description only provides an overview of the work to be

performed and does not detail the individual steps for assembling the machine.
Changes in the planning of the plant during the processing of the contract may
lead to deviations from this assembly description.
To ensure correct performance of the work, only assign it to personnel that have
received special training for the tasks to be performed.
It is a prerequisite for our warranty and essential for correct assembly that
assembly supervision and assembly inspection are performed by specialists
from thyssenkrupp Industrial Solutions.
WARNING
Improper assembly
Improper assembly may lead to severe injuries or death.
I. Be sure to comply with the assembly instructions in the technical
documentation.
II. Ensure that there is adequate space to perform the assembly work.
III. Keep the assembly area clean and tidy! Components or tools that are
loosely lying on top of each other or lying around on the floor are
potential causes of accidents.
IV. Assemble the components properly.
V. Make sure that there are no unauthorised persons in the working area.
WARNING
Structural failure or falling components.

Platforms and supporting structures may collapse. Insufficiently secured
components may fall down during assembly and cause severe injuries or
even death.
I. Never use platforms and their supporting structures as auxiliary
mounting supports or as storage areas for heavy components.
II. Secure the components until stability is ensured.
WARNING
Lack of stability
Lack of stability may result in the machine tipping over. This could lead to
severe injuries.
I. Make sure that the foundation is level and designed such that it can
support the machine load.
II. Use suitable fastening devices. Replace any missing fastening
devices and firmly attach any loose fastening devices.
III. After assembling the machine, make absolutely sure that it is in a
stable position and then carry out a test run.
NOTICE
Welding current
Moving connecting points, measuring devices or sliding surfaces could be
damaged.
I. Always directly connect the welding current return lead to the part
being welded.
II. Never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring devices.
5.3.2 Tightening torques for bolts with standard thread
WARNING
Incorrect tightening torques

If bolts are tightened to an incorrect tightening torque, components may
come loose. This could lead to severe injuries and damage to property.
I. Be sure to always comply with the relevant directives and design
criteria for bolted connections.
II. Never exceed the maximum permissible tightening torque.
III. Regularly check the tightening torques.
If not stated otherwise in the drawings, the following specifications apply:

● The specified values are applicable to as-new bolts in accordance with DIN
EN.
● Threads and contact surfaces must be cleaned and lightly oiled (do not use
molybdenum disulphide lubricants).
Bolt thread Tightening torque (Nm)
Strength class 4.6 Strength class 5.6 Strength class 8.8
M12 25 30 70
M16 55 75 180
M20 110 140 360
M24 180 250 620
M30 370 490 1240
M36 840 1120 2160
M42 1250 1560 3430
M48 1890 2360 5190
M56 3020 3780 8310
M64 4510 5640 12410

5.3.3 Tightening torques for bolts
WARNING

Regularly check the tightening torques.
I. Be sure to always comply with the manufacturer's instructions
regarding bolted connections.
II. Be sure to always comply with the relevant directives and design
III. Never exceed the maximum permissible tightening torque.
IV. Regularly check the tightening torques.
5.3.4 Preparing for assembly

Before assembly, make sure that the following prerequisites are fulfilled:
Check Correct
The place of installation is dimensioned to enable safe access to the place of

assembly and for performing maintenance and repair work in the future.
The place of installation and the access paths are sufficiently illuminated.
All danger areas, such as floor openings or steps, that are located at the place of
installation or at the access points to the place of installation, have been marked
and secured.
The access paths are free of objects.
Lifting machinery and industrial trucks with a sufficient lifting capacity are available
for the transportation of the transport units and for assembly.
5.4 Assembling the rotary kiln drive

Required personnel
● Assembly personnel
Necessary personal protective equipment
● Personal protective equipment for all work (see page 2-6)
Prerequisites
● The base plates of the main motor (1.1, 2.1) are pre-aligned and provisionally
safeguarded against shifting.
For assembly of the rotary kiln drive, be sure to comply with the instructions in
the separate subsuppliers' documentation on the individual machines.
Step 1: If necessary, mount torque arms to the main gear unit (1.3, 2.3).
Step 2: Degrease the bore of the hollow shaft and the machine shaft in the area
where the shrink disc (1.9, 2.9) is seated.
Step 3: Push the shrink disc (1.9, 2.9) and the main gear unit (1.3, 2.3) onto the axle
journal (I) of the pinion shaft or the supporting roller (G).
WARNING

I. Be sure to always comply with the relevant directives and design
II. Never exceed the maximum permissible tightening torque.
III. Regularly check the tightening torques.
Be sure to comply with the instructions in the subsupplier's documentation

regarding the tightening torques for bolts. Do not tighten the bolts crosswise.
Make sure that the front faces are properly aligned. If during tightening, the
alignment of the front faces cannot be attained, please contact thyssenkrupp
Industrial Solutions.
Step 4: Subsequently tighten the tensioning screws of the shrink disc (1.9, 2.9)
various times, until the front faces of the outer and inner ring are in true
alignment or the required tightening torque has been reached.
Step 5: Align the rotary kiln drive.
Step 6: Mount and align the torsion rods (1.4.5, 2.4.5) with the bearing blocks (1.4.4,
2.4.4) and the rods (1.4.2, 2.4.2).
Step 7: Provide packing plates for the fastening feet. Position the main motor (1.1,
2.1).
Step 8: Mount and align the cardan shaft (1.2, 2.2).
Be sure to comply with the instructions in the subsupplier's documentation.
Step 9: Align and fix the main motor (1.1, 2.1).

Step 10: Grout the base plates of the main motor (1.1, 2.1).
Step 11: Mount the oil supply system (1.10, 2.10):
11.1 Install and fix the oil supply system (1.10, 2.10).
11.2 Remove screw plugs or blind flanges.
11.3 Clean the connecting hoses and the oil supply system.
11.4 Mount the connecting hoses.
5.5 Modifying the rotary kiln drive

Purpose
Modification of the rotary kiln drive and significant reduction of its rotational speed
in order to enable welding of circumferential weld seams on the rotary kiln shell.
Constraints
● If a dual drive is installed, only use the drive on the outward-turning end.
Required personnel
● Assembly personnel from thyssenkrupp Industrial Solutions
Prerequisites
● Depending on the welding method and on the procedure, the circumferential
speed of the rotary kiln shell is 0.3-0.8 m/min. The rotational speed of the
rotary kiln drive has to be reduced in accordance with the circumferential
speed.
 The rotational speed of the rotary kiln drive can be reduced by means of the
following measures:
 By adding a frequency converter to the auxiliary motor (1.5) or
 by replacing the auxiliary motor (1.5) with an additional drive.
In both cases, the starting coupling (1.6) has to be replaced with a claw
coupling.
thyssenkrupp Industrial Solutions shall not supply the frequency converter, the
additional drive, nor the claw coupling.
en-KD.CPT.001.F Lubrication
6 Lubrication
6.1 Safety instructions
WARNING
Contact with lubricants

Contact with lubricants may cause allergic reactions and skin irritation.
I. Be sure to comply with the manufacturer's safety data sheet.
II. Wear personal protective equipment.
III. Never inhale vapours. Always ensure that the workplace is sufficiently
ventilated.
IV. Avoid any skin contact. If skin contact has occurred, wash the skin
thoroughly.
V. Avoid any contact with eyes. If eye contact has occurred, thoroughly
a doctor.
CAUTION
Improper handling of lubricants

Lubricants such as greases and oils can contain toxic substances. If
lubricants are released into the natural environment, they may harm
humans, animals and plants.
I. Ensure that the environment is not polluted when lubricants are
II. Be sure to comply with the applicable national regulations for the
protection of the environment when handling lubricants.
Lubrication en-KD.CPT.001.F
6.2 Lubrication chart
Lubrication points Quantity (L, kg) per lubrication Lubrication intervals (weeks)
point
No. Qty. Designation Lubricant Initial filling Topping Topping First Further
ref. no. up up change changes
1 2 Main gear unit

see the documentation of the subsupplier SIEMENS
(1.3, 2.3)
2 2 Auxiliary gear
unit (1.8, 2.8)
3 2 Cardan shaft
(1.2, 2.2)
4 2 Starting coupling
(1.6, 2.6)
5 2 Torque
compensator see the documentation of the subsupplier SIEMENS
(1.4, 2.4)
en-KD.CPT.001.F Commissioning
7 Commissioning
It is a prerequisite for our warranty that the commissioning is carried out in the
presence of specialists from thyssenkrupp Industrial Solutions and in
accordance with their instructions.
WARNING
Improper commissioning
Improper commissioning may lead to severe injuries and may cause
damage to property.
I. Make sure that all assembly work has been carried out and completed
in accordance with the specifications and instructions given in the
technical documentation.
II. Make sure that the test run has been carried out and completed in
accordance with the specifications and instructions given in the
technical documentation.
III. Make absolutely sure that nobody is inside the danger area.
IV. Do not start first commissioning until the safety of the complete plant
has been ensured.
WARNING
Moving components
I. Operate the machine only if all the protection devices have been
properly mounted.
II. Only open protection devices, inspection covers, service covers and
III. If adjustment work is necessary, shut down the machine and secure it
against restarting.
IV. Pay attention to the after-running time. Do not open any protection
devices, inspection covers, service covers or inspection doors until
all components have come to a complete standstill.
V. After any adjustment work, mount all protection devices. Close the
inspection covers, service covers and inspection doors properly.
Commissioning en-KD.CPT.001.F
WARNING
Hot surfaces
severe burns.
I. Always wear personal protective equipment and heat-resistant
protective clothing when working in the vicinity of hot surfaces.
II. If adjustment work is necessary, shut down the machine and secure it
against restarting.
III. Before carrying out any adjustment work, allow the surfaces of the
machine to cool down to ambient temperature.
WARNING

risks:
● Burns
● Heat stroke
● Dehydration
● Nausea
clothing.
7.2 Checking the safety and monitoring equipment

Required personnel
● Commissioning personnel
WARNING
Defective safety and monitoring equipment

Defective or deactivated safety and monitoring equipment may result in
bodily injuries and machine damage. This could lead to severe or even
fatal injuries.
I. At regular intervals and whenever work has been performed on the
machine, check whether all safety and monitoring devices are
installed properly and are functioning correctly.
II. Never deactivate or bypass any safety and monitoring devices.
III. Make sure that the safety and monitoring equipment is always easily
accessible.
Step 1: Check all safety and monitoring equipment for proper functioning.
Step 2: If defects occur, eliminate them. Only continue with the commissioning
when the defects have been eliminated.
7.3 Checks prior to commissioning

Prior to commissioning, check the machine in accordance with the following
checklist.
Check Correct
All transporting devices, transport stiffeners and auxiliary assembly devices have
been removed.
The machine is undamaged.
All bolts are tightened to the required tightening torque.
Lubricants of the required quality and of the required amount, in accordance with the
subsupplier's specification, have been filled (see page 6-2).
The starting coupling (1.6, 2.6) has been filled with the correct oil.
The starting coupling (1.6, 2.6) and the overrunning clutch (1.8.2, 2.8.2) move freely.
The external oil supply system (1.10, 2.10) is ready for operation and its monitoring
devices are functioning correctly.
All openings, e.g. the oil filling necks of the gear units and of the oil supply system
(1.10, 2.10), have been closed.
The interlock system of the rotary kiln drive is so designed that only the main motor
(1.1, 2.1) or only the auxiliary motor (1.5, 2.5) can be started.
The direction of rotation of the main motor (1.1, 2.1), the auxiliary motor (1.5, 2.5)
and the overrunning clutch (1.8.2, 2.8.2) has been checked.
The holding brake (1.7, 2.7) and the centrifugal brake (1.8.1, 2.8.1) are ready for
operation.
The holding brake (1.7, 2.7) is open and mechanically locked. The protection cover
has been mounted.
The filling level monitor in the oil storage tank (1.10.5, 2.10.5) is ready for operation.
The shut-off valves of the oil circuit are in their operating positions.
The shut-off valves of the water cooler are in their operating positions.
The heating system (1.10.6, 2.10.6) (optional) is ready for operation.
All electrical components have been correctly wired and are in proper working order.
The operating voltage matches the data on the nameplate.
All components are correctly connected.
All monitoring devices have been connected and are in proper working order. The
correct switching values have been set properly.
Check Correct
All required protection devices have been installed.
All safety signs have been mounted and are easily legible.
All tools have been removed from the machine and from the working area.
There are no persons in the vicinity of the machine.

7.4 Starting the rotary kiln at an ambient temperature of below -10 °C

Required personnel
● Commissioning personnel from thyssenkrupp Industrial Solutions
Required tools
● Pyrometer
● Heat-resistant protective clothing
Step 1: Put the rotary kiln drive into operation in accordance with the subsupplier's
instructions.
Step 2: Measure the temperature of the rotary kiln drive with a pyrometer.
Step 3: If the temperature of the rotary kiln drive is < -10 °C, gradually heat up the
rotary kiln with the clinkering zone burner for roughly 48 hours.
Step 4: Heat up the rotary kiln to operating temperature.
7.5 Starting the rotary kiln at an ambient temperature of above -10 °C

Required personnel
● Commissioning personnel from thyssenkrupp Industrial Solutions
Required tools
● Pyrometer
● Heat-resistant protective clothing
Step 1: Put the rotary kiln drive into operation in accordance with the subsupplier's
instructions.
Step 2: Measure the temperature of the rotary kiln drive with a pyrometer.
Step 3: If the temperature of the rotary kiln drive is > -10 °C, heat up the rotary kiln
to operating temperature.
en-KD.CPT.001.F Operation
8 Operation
The machine operates fully automatically. It is not necessary to carry out
operator control actions at the machine while it is in operation. The operating
personnel operate and monitor the machine via the master control system.
WARNING
Improper operation
Improper operation may lead to severe injuries and damage to property.
I. Operate the machine only if all the protection devices have been
properly mounted.
II. Before starting the machine, make absolutely sure that nobody is
inside the danger area.
III. Never switch off or bypass any safety devices during operation.
8.2 Operation with main drive

Required personnel
● Operating personnel
Prerequisites
● The main motor (1.1, 2.1) is switched off.
● The rotary kiln has swung to a complete stop in its centre of gravity position.
● The holding brake (1.7, 2.7) is open and secured against restarting.
NOTICE
Rotating rotary kiln

The rotary kiln drive may be damaged if the main motor (1.1, 2.1) is started
before the rotary kiln has swung to a complete stop.
I. Let the rotary kiln swing to a complete stop in its centre of gravity
position.
II. Open the holding brake (1.7, 2.7) and secure it against restarting.
Step 1: Select the speed of the main motor (1.1, 2.1) in the control room.
Step 2: In the case of a single drive, switch on the main motor (1.1) from the control
room. In the case of dual drives, switch on the main motors (1.1, 2.1) of the
two drive trains simultaneously.
Operation en-KD.CPT.001.F
8.3 Operation with the auxiliary drive

Required personnel
Prerequisites
● The holding brake (1.7, 2.7) is open and secured against restarting.
In the case of a single drive, switch on the auxiliary motor (1.5) either from the control
room or locally. In the case of dual drives, switch on both auxiliary motors
(1.5, 2.5) simultaneously.
8.4 Maintenance operation

Required personnel
● Maintenance personnel
Prerequisites
● The rotary kiln is empty.
Step 1: Disengage the mechanical locking device of the holding brake (1.7, 2.7).
Step 2: In the case of a single drive, switch on the auxiliary motor (1.5) locally. In
the case of dual drives, switch on both auxiliary motors (1.5, 2.5)
simultaneously.
Step 3: After completion of the maintenance work, the holding brake (1.7, 2.7) has
to be opened and mechanically locked.
en-KD.CPT.001.F Operation
8.5 Operation with a modified drive

Required personnel
● thyssenkrupp Industrial Solutions personnel
Prerequisites
● The measures required for modifying the rotary kiln drive have been carried
out and the installed subassemblies are ready for operation (see page 5-12,
Modifying the rotary kiln drive).
● All units have been supplied with lubricants, as specified in section Lubrication.
● The checks stipulated in the section Checks prior to commissioning have
been carried out for all subassemblies.
● The seals of the rotary kiln inlet and of the rotary kiln outlet are depressurised.
● The hydraulic unit of the rotary kiln axial thrust system is switched off.
● The holding brake (1.7, 2.7) is open.
● The measures required for starting up the rotary kiln at certain ambient
temperatures have been carried out (see page 7-6, Starting the rotary kiln at
an ambient temperature of below -10 °C) (see page 7-7, Starting the rotary
kiln at an ambient temperature of above -10 °C).
● During operation at a significantly reduced rotational speed, the temperature
of all drives, bearings and motors is within the specified range, as stipulated in
the separate operating manuals and the documentation of the subsuppliers.
If a frequency converter has been added to the auxiliary motor (1.5), the
auxiliary motor (1.5) has to be cooled by an additional fan.
thyssenkrupp Industrial Solutions shall not supply this fan.
Start the rotary kiln drive:

1.1 In the case of a single drive, start the auxiliary motor (1.5) or the additional
motor locally or from the control room. In the case of dual drives, start both
auxiliary motors (1.5, 2.5) or the two additional motors simultaneously.
en-KD.CPT.001.F Maintenance
9 Maintenance
9.1 Maintenance work during operation
WARNING
Moving components
I. Operate the machine only with properly mounted protection devices.
II. Only open protection devices, inspection covers, service covers or
WARNING
Hot surfaces
severe burns.
Always wear personal protective equipment and heat-resistant protective
clothing when working in the vicinity of hot surfaces.
WARNING

risks:
● Burns
● Heat stroke
● Dehydration
● Nausea
clothing.
Maintenance en-KD.CPT.001.F
9.1.2 Prior to any maintenance work

Be sure to do the following prior to any maintenance work during operation:
● Only permit authorised and instructed maintenance personnel to perform any
work.
● Ensure that there is adequate space to perform the work.
● Keep the work area clean and tidy. Components or tools that are loosely lying
on top of each other or lying around on the floor are potential causes of
accidents.
● Put up a warning sign: Attention – Maintenance work
9.1.3 Table of maintenance work (Operation)

The following sections describe the maintenance work required for optimal and
trouble-free operation of the plant. If increased wear is detected during regular
checks, shorten the required maintenance intervals to suit the actual signs of
wear.
No. Work to be performed Frequency Qualification Remarks

of personnel
1 Check the temperature of the Daily Maintenance ● Under normal

gearbox case on the shaft bearings personnel conditions, the
temperature is
50-70 °C.
2 Check the main gear unit (1.3, 2.3) Daily Maintenance

and the auxiliary gear unit (1.8, 2.8) personnel
for noise development
3 Inspect the main gear unit (1.3, 2.3), Weekly Maintenance

the auxiliary gear unit (1.8, 2.8), the personnel
couplings and the oil supply system
(1.10, 2.10) for leaks
9.1.4 After any maintenance work

Be sure to do the following after any maintenance work during operation:
● Remove all tools, auxiliary devices, measuring devices, etc. from the machine.
● Mount all protection devices.
● Check all joints and connections for leaks.
● Make absolutely sure that nobody is inside the danger area of the rotary kiln.
9.2 Maintenance work during a stoppage
DANGER
Electric current
There are live components in and at the machine. Contact with live parts
means immediate danger of death due to electric shock.
I. Only permit qualified electricians to perform work on the electrical
equipment.
II. Before beginning any work, disconnect all poles of the machine from
the electricity supply network and secure it against restarting.
WARNING
Moving components
I. Before commencing any work, switch off the machine and secure it
against restarting.
II. Pay attention to the after-running time. Do not open any protection
devices, inspection covers, service covers or inspection doors until
all components have come to a complete standstill.
III. After performing any work, mount all protection devices. Close the
inspection covers, service covers and inspection doors properly.
WARNING

There is a risk of falling when working at great heights. This could lead to
life-threatening injuries.
I. Wear personal protective equipment and use a fall protection system.
II. Do not remove protection devices.
III. If ladders or working platforms are used, make absolutely sure that
they have a secure footing.
WARNING
Hot surfaces
severe burns.
I. Always wear personal protective equipment and heat-resistant
protective clothing when working in the vicinity of hot surfaces.
II. Before commencing any work, switch off the machine and secure it
against restarting. Allow surfaces to cool down to ambient
temperature.
WARNING
Escaping lubricants
Lubricant may escape at the machine. Contact with lubricants may cause
health damage or lead to injuries due to slipping.
II. Operate the machine only if all the protection devices have been
properly mounted.
III. Avoid any skin contact. If skin contact has occurred, wash the skin
thoroughly.
IV. Avoid any contact with eyes. If eye contact has occurred, thoroughly
a doctor.
V. Immediately remove any lubricants that have escaped.
VI. If necessary, mark the danger areas and cordon them off.
9.2.2 Prior to any maintenance work

Be sure to do the following prior to any maintenance work during a stoppage:
● Put up a warning sign stating that maintenance work is in progress.
● Keep the work area clean and tidy. Components or tools that are loosely lying
on top of each other or lying around on the floor are potential causes of
accidents.
● Shut down the rotary kiln in accordance with the owner's instructions and
secure it against restarting.
● Make absolutely sure that the rotary kiln has swung to a complete stop in its
centre of gravity position. Then fix it in position by means of the holding brake
of the rotary kiln drive and secure it against restarting.
● Stop the material feed and secure it against restarting.
● Allow the rotary kiln to cool down.
● Depressurise all pressurised components and bleed them.
9.2.3 Table of maintenance work (Stoppage)

The following sections describe the maintenance work required for optimal and
trouble-free operation of the plant. If increased wear is detected during regular
checks, shorten the required maintenance intervals to suit the actual signs of
wear.

of personnel
1 Align the main gear unit (1.3, 2.3) As required Maintenance ● For permissible
and the auxiliary gear unit (1.8, personnel alignment errors,
2.8) after each readjustment of the see the
pinion shaft or replacement of subsupplier's
individual components documentation.
2 Replace the friction linings of the As required Maintenance

holding brake (1.7, 2.7) personnel
3 Check the centrifugal brake (1.8.1, See Manufacturer's ● See

2.8.1) for the following: subsupplier's experts subsupplier's
● Worn-out brake linings instructions. information.
● Dust from lining abrasion ● Linings

contaminated by
● Other contamination problems oil have to be
replaced
immediately.
● Search for the
cause of
contamination.
● Replace any
worn-out linings.
4 Change the lubricant for the After one Manufacturer's ● See

following components: year at the experts subsupplier's
● See subsupplier's information. latest. information.
● Main gear unit (1.3, 2.3)

● Auxiliary gear unit (1.8, 2.8)
● Oil supply system (1.10, 2.10)
5 Service the rotary kiln drive See Manufacturer's ● See

subsupplier's experts subsupplier's
instructions. information.
6 Service the pump (1.10.1, 2.10.1) See Manufacturer's ● See

7 Filter (1.10.3, 2.10.3) See Manufacturer's ● See


of personnel
8 Align the main gear unit (1.3, 2.3) See Manufacturer's ● Permissible
and the auxiliary gear unit (1.8, subsupplier's experts alignment errors
2.8) instructions. according to the
subsupplier's
instructions.
9 Inspect the main gear unit (1.3, Weekly Maintenance

2.3), the auxiliary gear unit (1.8, personnel
2.8), the couplings and the oil
supply system (1.10, 2.10) for
leaks
10 Lubricate the grease labyrinths at Every 6 Maintenance

the shaft seals of the main gear months personnel
unit (1.3, 2.3) and the auxiliary
gear unit (1.8, 2.8)
11 Check the lubricant filling level on Every 6 Maintenance

the following components: months personnel
● Main gear unit (1.3, 2.3)
● Auxiliary gear unit (1.8, 2.8)
● Oil supply system (1.10, 2.10)
12 Inspect the friction linings of the Annually Maintenance

holding brake (1.7, 2.7) for wear personnel
13 Check the fastening bolts for tight Annually Maintenance

fit personnel
14 Check the tooth gearing for the Annually Maintenance ● Request service
following: personnel personnel from
● Wear thyssenkrupp
Industrial
● Pitting Solutions.
● Scuffing ● Use the
inspection ports.
9.2.4 After any maintenance work

Be sure to do the following after any maintenance work during a stoppage:
● After any maintenance work, carry out the checks stipulated in the section
Checks prior to commissioning (see page 7-4, Checks prior to commissioning).
● Remove all tools, auxiliary devices, measuring devices etc. from the machine.
● Mount all protection devices.
● Check all joints and connections for leaks.
● Make absolutely sure that nobody remains inside the rotary kiln.
● Open the holding brake of the rotary kiln drive.
en-KD.CPT.001.F Troubleshooting
10 Troubleshooting
WARNING
Improper troubleshooting
Improper performance of fault-elimination work may lead to severe injuries
and damage to property.
I. Before commencing the work, ensure that there is adequate space to
carry it out.
II. Keep the work area clean and tidy. Components or tools that are
loosely lying on top of each other or lying around on the floor are
potential causes of accidents.
III. If components have been removed, make sure that assembly is
carried out properly. Remount all fastening elements and be sure to
comply with the specified tightening torques.
IV. Perform and complete fault-elimination work in accordance with the
instructions in the technical documentation.
V. If, for the purpose of eliminating faults, work has to be performed in
the danger area, shut down the machine and secure it against
restarting.
VI. Never deactivate protection devices during operation.
VII. Depending on the type of fault, only permit appropriately qualified
personnel to perform fault elimination.
Observe the additional information about faults, their causes and their
elimination, in the subsuppliers' documentation.
10.2 Recommissioning after fault elimination

After the fault has been eliminated, carry out the following steps:
1. Remove all tools from the machine.
2. Make absolutely sure that nobody is inside the danger area.
3. Close all components previously opened.
4. Ensure that all safety devices are fitted and in proper working order.
5. Reset the EMERGENCY OFF devices as necessary.
6. Acknowledge the fault message at the control system.
7. After any maintenance work, carry out the checks stipulated in the section
Checks prior to commissioning (see page 7-4).
en-KD.CPT.001.F Spare parts
11 Spare parts
11.1 Suggestions for enquiries and orders of spare parts
Spare parts can be enquired about and ordered via the Professional Spare
Parts Navigator (PSPN), the electronic spare parts catalogue from thyssenkrupp
Industrial Solutions.
en-KD.CPT.001.F Disassembly and disposal
12 Disassembly and disposal

WARNING
Improper disassembly
Improper disassembly may result in the machine tipping over, or may
cause components to fall down. This could lead to severe injuries.
I. Make absolutely sure that suitable lifting machinery is employed for
securing the components against falling.
II. Use one hoist to secure the mounted components and a further hoist
to move the components that are to be dismounted.
III. Only remove the lifting machinery when the components have been
safely dismounted with all the specified fastening devices.
WARNING
Suspended loads
During lifting operations, loads might swing out or fall down. This could
lead to life-threatening injuries.
II. Only use approved lifting accessories with sufficient load-bearing
capacity.
III. Do not use damaged, cracked or chafed lifting accessories.
IV. Do not attach lifting accessories to sharp edges, and do not knot or
twist them.
V. Only move loads under supervision.
VI. Never work below or in the swivelling range of suspended loads.
VII. Set down the load before leaving the place of work.
Disassembly and disposal en-KD.CPT.001.F
12.2 Before disassembly

Be sure to do the following before disassembly:
● Keep the place of work clean and tidy. Components or tools that are loosely
lying on top of each other or lying around on the floor are potential causes of
accidents.
● Switch off the machine and secure it against restarting.
● Allow the machine to cool down to ambient temperature.
● Stop the material feed.
● Close the shut-off devices.
12.3 Disposal
Contract a specialist company to dispose of the machine. Ensure that disposal

is carried out in accordance with local conditions and statutory provisions.
WARNING
Contact with lubricants

Contact with lubricants may cause allergic reactions and skin irritation.
I. Be sure to comply with the manufacturer's safety data sheet.
II. Wear personal protective equipment.
III. Never inhale vapours. Always ensure that the workplace is sufficiently
ventilated.
IV. Avoid any skin contact. If skin contact has occurred, wash the skin
thoroughly.
V. Avoid any contact with eyes. If eye contact has occurred, thoroughly
a doctor.
CAUTION
Improper handling of lubricants

Lubricants such as greases and oils can contain toxic substances. If
lubricants are released into the natural environment, they may harm
humans, animals and plants.
I. Ensure that the environment is not polluted when lubricants are
II. Be sure to comply with the applicable national regulations for the
protection of the environment when handling lubricants.
en-KD.CPT.001.F Appendix
13 Appendix
13.1 Technical drawings
For drawing numbers, please refer to the table of contents of this folder.
13.2 Subsuppliers' documentation
Designation Subsupplier
Main motor (1.1, 1.2) SCHNEIDER ELECTRIC
Auxiliary motor (1.5, 2.5) SIEMENS
Main gear unit (1.3, 2.3) SIEMENS
Auxiliary gear unit (1.8, 2.8) SIEMENS
Starting coupling (1.6, 2.6), SIEMENS
Centrifugal brake (1.8.1, 1.8.2) SIEMENS
Oil supply system (1.10, 2.10) SIEMENS
Heating system (1.10.6, 2.10.6) SIEMENS

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Operating manual

Rotary kiln drive

Plant Order Code (POC)

1 General information ............................................................................. 1-1

5.2.3 Storage conditions and long-term storage ............................................. 5-5

1.2 Additionally applicable documents

1.3 Limitation on liability

1.5 Warranty provisions

1.6 Symbol explanation

This combination of symbol and signal word indicates an immediately

This combination of symbol and signal word indicates a possibly

This combination of symbol and signal word indicates a possibly

This combination of symbol and signal word indicates a possibly

A safety sign that stipulates a certain behaviour.

A safety sign that prohibits a certain behaviour.

A safety sign that warns of a specific danger.

This symbol highlights useful tips and recommendations, as well as information

Italics Indicates references to other sections,

Step 1, 2, 3...: Indicates instructions on actions to be taken

● Indicates lists and list entries or instructions on

2.2 Reasonably foreseeable misuse

2.3 Limits of the machine

2.4 Obligation of the owner

Condition of perfect technical serviceability

2.5 Obligation of the personnel

2.6 Qualifications of the personnel

Insufficient qualification of personnel

Unauthorised persons in the danger and working areas

2.7 Safety and monitoring equipment

Defective safety and monitoring equipment

2.7.1 Safety devices to be retrofitted

Unsecured or unmarked hazardous points

Securing against restarting

Integration into an EMERGENCY STOP concept

2.8 Personal protective equipment

2.8.1 Personal protective equipment for all work

2.8.2 Personal protective equipment for special work

Fall protection system

Heat-resistant protective clothing

2.9 Fundamental hazards

2.9.1 Overview of residual risks

Hazard Source of hazard

Crushing Entire rotary kiln drive

Moving parts of the rotary kiln and of the rotary

Suspended loads and moving components

Drawing-in, trapping or entrapment Entire rotary kiln drive

Moving parts of the rotary kiln and of the rotary

Slipping, tripping or falling Working area of the rotary kiln drive

Uncovered wires or cables

Working at great heights

Falling or ejected objects Transportation of components of the rotary kiln

Suspended loads and moving components

Loss of stability Components of the rotary kiln drive

Breakage during operation Corrosion

Components of the rotary kiln drive

Missing, damaged or loose fastening devices

Hazard Source of hazard

Electric shock Live components

Components that have become live due to

Hazard Source of hazard

Burns Hot surfaces of the rotary kiln

Hot surfaces of the rotary kiln drive

Frostbite Cold surfaces