Polycom High-Pressure Grinding Roll: Machine Manual en-PM - CPT.001.D

Machine manual
en-PM.CPT.001.D
POLYCOM® high-pressure grinding roll
Code Word
MARWAL
Order Number
D000766
Plant Order Code (POC)

8F1.PM01
en-PM.CPT.001.D Contents
®
POLYCOM high-pressure grinding roll
Contents
1 General information ............................................................................. 1-1

1.1 Information about this machine 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 Foreseeable misuse ............................................................................... 2-1
2.3 Limits of the machine.............................................................................. 2-2
2.4 Obligation of the owner........................................................................... 2-2
2.5 Obligation of the personnel..................................................................... 2-3
2.6 Qualifications of the personnel ............................................................... 2-4
2.7 Safety and monitoring equipment ........................................................... 2-6
2.7.1 Safety devices to be retrofitted ............................................................... 2-6
2.8 Personal protective equipment ............................................................... 2-7
2.8.1 Personal protective equipment for all work ............................................ 2-7
2.8.2 Personal protective equipment for special work ..................................... 2-8
2.9 Fundamental hazards ............................................................................. 2-9
2.9.1 Overview of residual risks....................................................................... 2-9
2.9.2 Mechanical hazards .............................................................................. 2-12
2.9.3 Electrical hazards ................................................................................. 2-15
2.9.4 Thermal hazards ................................................................................... 2-16
2.9.5 Hazards generated by noise................................................................. 2-16
2.9.6 Hazards generated by vibration ........................................................... 2-16
2.9.7 Hazards generated by materials and substances ................................ 2-17
2.9.8 Other hazards ....................................................................................... 2-19
2.10 Safety signs at the machine ................................................................. 2-21
2.10.1 Mandatory signs at the machine .......................................................... 2-21
2.10.2 Warning signs at the machine .............................................................. 2-21
3 Technical data ....................................................................................... 3-1
3.1 Central lubrication system ...................................................................... 3-3
3.2 Setting values and maximum permissible wear of the roll surfaces ...... 3-5
3.3 Permissible feed material temperatures during operation...................... 3-8
4 Components and description of functioning..................................... 4-1
4.1 Components ........................................................................................... 4-1
4.1.1 Overview ................................................................................................. 4-2
4.1.2 Roll housing ............................................................................................ 4-4
4.1.3 Central lubrication system ...................................................................... 4-6
4.1.4 Hydraulic system .................................................................................. 4-12
4.1.5 Roll units ............................................................................................... 4-14
4.1.6 Mounting device ................................................................................... 4-18
4.1.7 Wear measuring device ........................................................................ 4-20
4.1.8 Roll frame ............................................................................................. 4-22
4.2 Description of functioning ..................................................................... 4-24
4.2.1 High-pressure grinding roll ................................................................... 4-24
4.2.2 Roll units ............................................................................................... 4-25
4.2.3 Bearing cooling system ........................................................................ 4-25
Contents en-PM.CPT.001.D
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4.2.4 Hydraulic system (4.0) .......................................................................... 4-28

4.2.5 Roll frame ............................................................................................. 4-30
4.2.6 Mill feed system .................................................................................... 4-30
4.2.7 Travel measuring device ...................................................................... 4-31
4.2.8 Central lubrication system (3.0) ............................................................ 4-31
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
5.2.3 Storage conditions and long-term storage ............................................. 5-5
5.3 Assembly ................................................................................................ 5-6
5.3.2 Tightening torques for bolts .................................................................. 5-10
5.3.3 Preparing for assembly......................................................................... 5-11
5.4 Assembly of the high-pressure grinding roll ......................................... 5-12
6 Lubrication ............................................................................................ 6-1
6.1 Safety instructions .................................................................................. 6-1
6.2 Lubrication chart ..................................................................................... 6-2
7 Commissioning ..................................................................................... 7-1
7.1 Safety instructions .................................................................................. 7-1
7.2 Checks prior to the test run .................................................................... 7-3
7.3 Setting the basic gap .............................................................................. 7-5
7.4 Carrying out a test run ............................................................................ 7-7
8 Maintenance .......................................................................................... 8-1
8.1 Maintenance work during operation ....................................................... 8-1
8.1.2 Prior to any maintenance work ............................................................... 8-3
8.1.3 Table of maintenance work (Operation) ................................................. 8-3
8.1.4 After any maintenance work ................................................................... 8-3
8.2 Maintenance work during a stoppage .................................................... 8-4
8.2.2 Prior to any maintenance work ............................................................... 8-7
8.2.3 Table of maintenance work (Stoppage) ................................................. 8-8
8.2.4 Removing the roll units ......................................................................... 8-12
8.2.5 Mounting the roll unit ............................................................................ 8-15
8.2.6 Carrying out wear measurement .......................................................... 8-17
8.2.7 After any maintenance work ................................................................. 8-19
9 Troubleshooting ................................................................................... 9-1
9.1 List of possible faults .............................................................................. 9-1
9.2 Recommissioning after fault elimination ................................................. 9-6
10 Spare parts .......................................................................................... 10-1
10.1 Suggestions for enquiries and orders of spare parts ........................... 10-1
11 Disassembly and disposal................................................................. 11-1
11.1 Safety instructions ................................................................................ 11-1
11.2 Before disassembly .............................................................................. 11-1
11.3 Disposal ................................................................................................ 11-2
11.3.1 Safety instructions ................................................................................ 11-2
en-PM.CPT.001.D Contents
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12 Appendix ............................................................................................. 12-1

12.1 Technical drawings ............................................................................... 12-1
12.2 Measurement records ........................................................................... 12-1
12.3 Special tools ......................................................................................... 12-1
12.4 Further documents, regulations ............................................................ 12-1
12.5 Subsuppliers' documentation ............................................................... 12-1
en-PM.CPT.001.D General information
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POLYCOM high-pressure grinding roll 1-1
1 General information
1.1 Information about this machine manual
This machine manual enables the user to operate the machine safely and
efficiently. The machine 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 to the personnel at
any time.
Before commencing any work, the personnel must have read and understood this
machine manual. Compliance with all safety instructions and instructions given in
this manual on actions to be taken is the fundamental prerequisite for safe
working.
The figures contained in this machine manual serve for general illustration and
may deviate from the actual design.
1.2 Additionally applicable documents

In addition to this machine 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 rights in connection with this
machine manual, including those relating to patent granting or utility model
registration. Without the written consent of thyssenkrupp Industrial Solutions, this
machine 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-PM.CPT.001.D
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1-2 POLYCOM high-pressure grinding roll
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.
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.
en-PM.CPT.001.D General information
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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 may also include a reference to additionally applicable documents.
General information en-PM.CPT.001.D
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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-PM.CPT.001.D Safety
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2 Safety
2.1 Intended use
The intended use comprises:
● Grinding of brittle mill feed material.
The high-pressure grinding roll is not a machine that is ready for use. The high-
pressure grinding roll is intended for use in conjunction with other equipment to
form a grinding plant. The high-pressure grinding roll must not be put into service
until it has been installed in a grinding plant.
The high-pressure grinding roll 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 machine
manual. Any use other than for the specified intended use shall be deemed
misuse.
2.2 Foreseeable misuse

The reasonably foreseeable misuse of this machine includes:
● Operation of the machine with unsuitable parameters or unsuitable material
● Operation of the machine by unauthorised personnel who have not received
special instruction
● Improper assembly and disassembly
● Missing protection devices
● Neglecting to wear the personal protective clothing and equipment
● Use of unsuitable means of access
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.
Technical data en-PM.CPT.001.D
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2.3 Limits of the machine
Spatial boundaries
The spatial boundaries of the high-pressure grinding roll include the upper edge
of the mill feed system (1.0) and the bottom edge of the roll frame (10.0).
Other boundaries
The high-pressure grinding roll must never be started if there is mill feed material
in the roll gap.
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 checks.
In addition to the safety instructions contained in this machine 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 due to 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 machine manual.
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● 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 a 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
them.
Condition of perfect technical serviceability

The owner is responsible for keeping the machine in a condition of perfect
technical serviceability. The following applies:
● The owner has to ensure that the maintenance intervals specified in this
machine 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.
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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
machine manual are not informed about 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
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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.
Qualified hydraulics specialist

The hydraulics specialist is the person charged by the owner of the plant with the
task of performing work on the hydraulic equipment. The hydraulics specialist has
received professional training in his/her area of responsibilities and is familiar with
the relevant standards and regulations.
The hydraulics specialist must fulfil the applicable statutory provisions governing
the prevention of accidents. The hydraulics specialist must be able to perform the
assigned work on hydraulic 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.
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2.7 Safety and monitoring equipment
WARNING
Defective safety and monitoring equipment

Defective or deactivated safety and monitoring equipment may cause
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 equipment is
installed properly and is functioning correctly.
II. Never deactivate or bypass any safety and monitoring equipment.
Be sure to comply with the instructions concerning the extent and the location of
the safety and monitoring equipment, in the contractually agreed documents
relating to the electrical equipment, for example:
● Location of electrical devices
● List of measuring points
● List of digital sensors
EMERGENCY OFF button

When an EMERGENCY OFF button is pressed, the machine automatically cuts
off the power feed without delay or mechanically disengages the drives. The
machine is then switched off. As soon as the fault that prompted the operator to
press the EMERGENCY OFF button has been eliminated, unlock the
EMERGENCY OFF button and switch on the machine again.
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 machine 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.
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Guards
The owner of the plant must ensure that all rotating parts are protected against
accidental contact.
Integration into an EMERGENCY OFF concept

Before the machine is put into operation, install the EMERGENCY OFF devices
and integrate them into the safety chain of the plant control system.
Connect the EMERGENCY OFF 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 OFF devices always have to be freely accessible.
2.8 Personal protective equipment

Personal protective equipment serves to protect persons 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 machine 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 entangled by moving machine parts and against skin contact with
materials and substances.
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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
Hearing protectors
In working areas with high noise development (above 85 dB(A)), hearing
protectors guard against hearing loss.
Face shield
A face shield protects from airborne particles and liquid splashes, dust, chemical
splashes, sparks or metal splinters. A face shield with a scratched or cloudy glass
must be disposed of and replaced.
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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 Closing and opening of inspection doors (2.3),

inspection covers and service covers
Between stationary and moving components of

the drive (5.0)
Rotating components at the drive (5.0)
Rotating roll units
Unexpected start-up
Suspended loads and moving components

during transportation, assembly, maintenance
and disassembly
Bearing blocks (6.1, 7.1) swinging out when

being lifted
Drawing-in or trapping Rotating components of the drive (5.0)
Rotating roll units
Impact Protruding components
Falling material in the outside area or when

working in the interior
Suspended loads and moving components

during transportation, assembly, maintenance
and disassembly
Penetration by pressurised media Escaping hydraulic oil
Escaping cooling water
Escaping lubricants
Slipping, tripping or falling Uncovered wires and cables
Unsafe access points
Loss of stability Improper fastening of the machine
Missing, damaged or loose fastening devices

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Corrosion
Breakage during operation Corrosion
Missing, damaged or loose fastening devices
Falling or ejected objects Suspended loads during transportation,

assembly, maintenance and disassembly
Incorrect tightening torques
Falling components during transportation,

assembly and disassembly
Unexpected start-up Hydraulic system (4.0)
Drive (5.0)
Unauthorised connection of electrical power
Penetration by pressurised media Escaping hydraulic oil at the hydraulic system

(4.0)
Hydraulic hoses whipping around, fittings Hydraulic system (4.0)

breaking off
Electrical hazards
Electric shock Live components
Electrical equipment
Damaged cables
Lack of lightning protection concept
Components that have become live due to

faults
Thermal hazards
Burns Hot surfaces
Escaping hot material, escaping hot dusts or

escaping hot gas when opening inspection
doors (2.3), inspection covers and service
covers
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Scalding Escaping hot liquids
Hazards generated by noise
Hearing loss High noise level in the entire working area
Hazards generated by vibration
Discomfort Entire high-pressure grinding roll
Hazards generated by materials and substances
Breathing difficulties, suffocation Escaping, harmful dusts in the working area of

the high-pressure grinding roll
Harmful dusts in the interior
Escaping material and escaping dusts when

opening inspection doors (2.3), inspection
covers and service covers
Continuing flow of material and a high level of

dust generation when working in the interior
Swirling-up of dust in the interior or in the

outside area
Substances emerging from the refractory lining
Being buried alive Material sliding down or falling down in the

interior
Explosion Improper filling of the piston accumulators (4.1)
Escaping lubricants
Fire Introduction of easily flammable materials
Other hazards generated by materials and Improper handling of consumables

substances
Improper handling of lubricants
Contact with lubricants

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Contact with nut-locking agents
Contact with sealing compound
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
Accidental shutting-in of persons
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
Falling components
In the outside area of the machine, components could fall down and cause
severe injuries.
I. Wear personal protective equipment.
II. Before entering the working area, check the machine for loose
components.
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WARNING
Component breakage
Damaged, corroded or loose components may break and cause severe
injuries.
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.
WARNING
Uncovered piping or hose piping

If piping or hose piping is not covered, it represents a trip and fall hazard.
II. Fasten or cover any uncovered piping and hose piping.
III. Mark trip hazards with warning tape.
WARNING
Hydraulic energy
Hydraulically operated components may move unexpectedly due to stored
residual energy. If any components are damaged, hydraulic oil can spurt
out under high pressure. This could lead to severe or even fatal injuries.
I. Only allow qualified hydraulics specialists to carry out work on the
hydraulic system.
II. Never alter pressure settings to exceed the maximum values.
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WARNING
Jet of fluid under pressure

At hydraulic system components or damaged pressure piping, a jet of
fluid may spurt out under high pressure. Contact with the jet of fluid may
lead to severe or even fatal injuries.
I. In the event of an emerging jet of fluid, immediately press the
EMERGENCY STOP button. If necessary, take further measures to
reduce the pressure and to stop the jet of fluid.
II. Wear personal protective equipment.
III. Only allow qualified hydraulics specialists to carry out work on the
hydraulic system.
IV. Observe the specified maintenance intervals for pressure piping.
V. Regularly check the pressure piping for tightness and proper
surface condition.
VI. Never touch a jet of fluid.
VII. Carefully take up the leaked fluid and dispose of it properly.
VIII. Replace any damaged pressure piping or components.
WARNING
Improper work on pressure accumulators

Improper handling of pressure accumulators can lead to sudden pressure
blasts. This could lead to severe or even fatal injuries.
Only allow qualified hydraulics specialists to carry out work on the
pressure accumulators.
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2.9.3 Electrical hazards
DANGER
Electric current
There are live parts in and at the machine. There is danger of death due to
electric shock in the following cases:
● Contact with energised parts of the electrical equipment (such as
sensor system, switch boxes or 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.
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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.
2.9.5 Hazards generated by noise
WARNING
High noise level

The noise level in the working area may cause hearing loss.
I. Wear hearing protectors
II. Measure noise emission on-site and introduce further protective
measures as required.
III. Do not spend more time than necessary in the working area.
IV. Take breaks at regular intervals and leave the working area.
2.9.6 Hazards generated by vibration
WARNING
Vibrations
Vibrations can occur at the machine. These vibrations may be caused by
the work process or by damage, and may be transmitted via the floor
under the machine. Vibrations can cause health damage.
I. Set up the working platform such that no vibrations can be
transmitted from the machine to the personnel.
II. Check all fastening elements for secure fit after assembly and
regularly recheck during operation.
III. Regularly check the machine for low-vibration running.
IV. Do not use the machine if there is any damage.
V. Regularly clean the machine and, if necessary, balance it.
VI. Replace any worn-out or damaged components.
®
2.9.7 Hazards generated by materials and substances
DANGER
Improper filling of the piston accumulators or bladder accumulators

If piston accumulators or bladder accumulators are filled with oxygen,
they may explode. This could lead to severe or even fatal injuries.
Only allow qualified hydraulics specialists to carry out work on the piston
accumulators or bladder accumulators.
WARNING
Escaping material
Material may escape through leaky points of the machine, or if inspection
covers, service covers or inspection doors are opened during operation.
Contact with escaping material may cause injuries.
I. Only operate the machine with properly installed and closed
inspection covers, service covers and inspection doors.
II. Only operate the machine if the feed and discharge pipes have been
connected properly.
III. Operate the machine only if all the protection devices have been
properly mounted.
IV. Operate the machine only if all fastening devices have been properly
mounted.
V. Only open inspection covers, service covers or inspection doors
when the machine is switched off.
WARNING
Introduction of easily flammable materials

Easily flammable substances, liquids or gases can catch fire and lead to
severe injuries or death.
I. In case of fire, immediately stop all work. Leave the danger area until
the all-clear is given and alert the fire brigade.
II. Never use petrol or other easily flammable substances to clean the
machine.
III. Keep suitable extinguishing agents (fire blanket, fire extinguisher) at
hand.
IV. Immediately report any suspect substances to a 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.
WARNING
Lubricants spurting out

Lubricants may spurt out under high pressure. Contact with lubricants
may cause injuries.
I. Make sure that lubrication piping is properly laid.
II. Regularly inspect the lubricators for damage, and regularly service
them.
CAUTION
Escaping dusts
Dusts may escape through leaky points of the machine, or if inspection
covers, service covers or inspection doors are opened during operation.
The inhalation of dusts can cause breathing difficulties and suffocation.
Contact with eyes can cause irritation or injury.
I. Wear personal protective equipment and a protective filter mask.
II. Ensure that seals have been fitted at flange connections.
III. Only operate the machine with properly installed and closed
inspection covers, service covers and inspection doors.
IV. Only operate the machine if the feed and discharge pipes have been
connected properly.
V. Only open inspection covers, service covers or inspection doors
when the machine is switched off.
®
2.9.8 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 in the machine or its operating behaviour
occur, 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 incorrect operation and errors. 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.
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 incorrect operation and errors, 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 12-1, Technical
drawings) regarding the position of the safety signs.
2.10.1 Mandatory signs at the machine
Use safety harness
2.10.2 Warning signs at the machine
Warning of radioactive substances or ionising radiation
Warning of obstacles on the ground
Risk of falling
®
Warning of hot surface
Warning of automatic start-up
Warning of obstacles in the head zone
Warning of hand injuries
Warning of danger due to material falling out

en-PM.CPT.001.D Technical data
®
3 Technical data
General data
Year of manufacture 2017
Type PM8-24/17M
Throughput 1050 tph
No tramp metal such as metal objects, grinding balls etc. may be present in the
feed material. Unless otherwise feasible with regard to process technology, the
maximum edge length of the tramp metal must be smaller than the set basic gap
S0 (see page 3-5, Setting values and maximum permissible wear of the roll
surfaces).
Specification of the feed material

Feed material iron ore
Material moisture content <4%
Particle size max. 40 mm

3
Bulk material density 2300 kg/m
Material temperature ambient temperature
Ambient conditions
Height above mean sea level 50 - 100 m
Ambient temperature +5° / + 40 °C
Relative humidity mean value: 67 %
Weights
Weight of the heaviest component 108000 kg
Emissions
Noise emission (normal operation) > 80 dB(A)
Limit switch (10.13)

Type XS1-M30MA250
Cooling system of the roll unit

Water cooling system of the bearing yes
blocks
3
Water requirement of each bearing 1 m /h
block (6.1, 7.1)
Water cooling system of the roll shaft yes

Components and description of functioning en-PM.CPT.001.D
®
3
Water requirement of each roll shaft 6 m /h
Solenoid valve 8410901.950
Wear measuring device (9.0)

Mounted on the roll yes
Mounted on the bearing units no
Vibration sensor (10.11)

Type VIBROCONTROL 1000/CV110/VS-068
Setting value: Alarm at 3 mm/sec
Setting value: Shutdown at 5 mm/sec
Mill feed system

See machine manual No. PM.FBJ.002
Feed material guide

See machine manual No. PM.MFU.001
Hydraulic system
See machine manual No. PM.HYS.002
Drive
See machine manual No. PM.DRU.001
Roll unit
See machine manual No. PM.RUN.005
®
Travel measuring device (POLYCOM - Local control system)
See operating instructions No. PM.LOC.002
Hydraulic dismounting device

See machine manual No. PM.FTL.003
Maintenance of the roll bodies

See machine manual No. PM.RUN.003
Vulcanisation instructions
See machine manual No. 22140.250
®
3.1 Central lubrication system

Execution
Single pipe circuit system no
Dual pipe circuit system yes
Heated type no
Grease reservoir including no

submersible pump
Grease barrel including barrel pump yes
Pneumatic actuator
Available yes
Required air pressure 4 to 5 bar
Required air flow rate for a lubrication 300 NL/min

cycle
Electric actuator
Available no
Drive power -
Type of lubrication
Lubricant supply from outside; with yes
inside grease outlet
Lubricant supply from inside; with no

outside grease outlet
Pump (3.3)
Type BF-G
Grease barrel
Volume 200 litres
Inside diameter 570 mm
Lubricant distributor (3.4.4)

Type M 2500
Lubricant distributor (3.4.5)

Type M 2500
®
Operating data
Cycle time (conveyance + waiting 30 minutes
time)
Grease quantity per outer bearing ring 13.2 g/h
Pulses per lubrication cycle 33
Number of lubrication cycles per hour 1
Grease quantity per bearing cover 13.2 g/h
Pulses per lubrication cycle 33
Number of lubrication cycles per hour 1

®
3.2 Setting values and maximum permissible wear of the roll surfaces
Fig. 1: Distances at the high-pressure grinding roll
Condition of the rolls when new (dimensions in mm)
X0s X0w Aø B S0 Y0 D M U T V
30 35 2400 1650 5 725 2460 3270 460 40 438
X0s = Distance from the measuring strip to the surface of the studs/profiling when the rolls are
new
X0w = Distance from the measuring strip to the roll surface when the rolls are new
Aø = Roll diameter in new condition
B = Roll body width
S0 = Basic gap (minimum gap between the rolls, measured between the surfaces of the
profiling/studs, and not between the surfaces of the basic bodies)
Y = Distance between the bearing blocks
D = Centre distance of the rolls for assembly of the gear units
M = Centre distance of the drive motors when the rolls are in new condition
U = Thickness of all compensation plates at the push-back cylinder
T = Thickness of all distance plates at the plunger cylinder
V = Thickness of all pressure plates at the spacer
Table 1: Monolithic rolls, forged roll bodies with hardfacing, roll bodies made of chilled cast iron and forged roll
bodies with studs
®
Wear of the rolls (dimensions in mm)
First wear measurement after hrs.
amax Xmax s D V U Y Ma P W
Table 2: Monolithic rolls, forged roll bodies with hardfacing and roll bodies made of chilled cast iron
®
Wear of the rolls (dimensions in mm)
First wear measurement after 100 hrs.
amax Xmax s D V U Y Ma P W
New roll 30 40 438 460 725 0 0 2390

bodies:
40 40 438 460 705 0 0 2370
30 mm
50 40 438 460 685 0 0 2350
60 40 438 460 665 0 0 2330
Refurbished 70 120 348 385 645 100 55 2310

roll bodies:
80 120 348 385 625 100 55 2290
30 mm
90 120 348 385 605 100 55 2270
100 120 348 385 585 100 55 2250
amax = maximal permissible radial wear of the roll body

Ma = Measurement for shifting the motor of the floating roll unit in the direction of the fixed roll
unit, calculated from new condition of the rolls
P = Measurement for shifting the feed material guide in the direction of the fixed roll unit,
calculated from new condition of the rolls
W = Roll diameter
Table 3: Forged roll bodies with studs
®
3.3 Permissible feed material temperatures during operation
Type of roll Temperature of the feed material
Forged monolithic rolls with hardfacing max. 180 °C
Forged roll bodies with hardfacing max. 170 °C
Roll bodies made of compound casting max. 160 °C
Roll bodies made of bainite max. 140 °C
Forged roll bodies with studs max. 60 °C

en-PM.CPT.001.D Components and description of functioning
®
4 Components and description of functioning

4.1 Components
Some details of the drawings in this manual may not be identical to the drawings
of the actually delivered machine.
®
4.1.1 Overview
Fig. 2: High-pressure grinding roll

®
No. Denomination Description
1.0 Mill feed system See separate machine manual
2.0 Roll housing
3.0 Central lubrication system
4.0 Hydraulic system See separate machine manual
5.0 Drive See separate machine manual
6.0 Floating roll unit See separate machine manual for the roll unit
7.0 Fixed roll unit See separate machine manual for the roll unit
8.0 Mounting device
9.0 Wear measuring device
10.0 Roll frame
11.0 Feed material guide See separate machine manual

®
4.1.2 Roll housing
Fig. 3: Roll housing (2.0)

®
2.1 Housing wall For the floating roll unit (6.0)
2.2 Housing wall For the floating roll unit (7.0)
2.3 Inspection door
2.4 Protective grating At the non-drive end
2.5 Cover For the roll frame (10.0)
2.6 Extension Of the bearing block (6.1)
2.7 Seal For the bearing block (6.1, 7.1)
2.8 Setscrew For the seal (2.9)
2.9 Seal For the extension (2.6)

®
4.1.3 Central lubrication system
Fig. 4: Central lubrication system (3.0) with lubricant supply from inside
Fig. 5: Central lubrication system (3.0) with lubricant supply from outside
®
3.1 Pump jack
3.2 Conditioning unit For compressed air
3.3 Pump
3.4 Reversing unit For grease distribution
[1] Lubrication points on the

- high-pressure grinding roll
[8]
®
Fig. 6: Central lubrication system (3.0) - single pipe circuit system (motorised, heated)
Fig. 7: Central lubrication system (3.0) - single pipe circuit system (pneumatic, heated)
Fig. 8: Central lubrication system (3.0) - single pipe circuit system (submersible pump, heated)
®
3.2.1 Stop cock
3.2.2 Conditioning unit
3.2.3 Pressure monitor
3.2.4 Adjusting throttle valve
3.2.5 Solenoid valve For air
3.3 Pump
3.3.1 Air motor
3.3.2 Electric motor
3.3.3 Filling level monitor
3.3.4 Grease reservoir heater Optional
3.3.5 Pressure control valve
3.4.1 Filter With pressure gauge
3.4.3 Solenoid valve For bearing lubrication
3.4.4 Lubricant distributor
3.4.6 Limit switch For lubricant distributor (3.4.4)
3.4.8 Heater For reversing unit (3.4), optional
3.5 Electric trace heating For piping, optional

cable
3.6 Terminal box
3.7 Terminal box For heater, optional

®
Fig. 9: Central lubrication system (3.0) - dual pipe circuit system (motorised, heated)
Fig. 10: Central lubrication system (3.0) - dual pipe circuit system (pneumatic, heated)
Fig. 11: Central lubrication system (3.0) - dual pipe circuit system (submersible pump, heated)
®
3.2.1 Stop cock
3.2.2 Conditioning unit
3.2.3 Pressure monitor
3.2.4 Adjusting throttle valve
3.2.5 Solenoid valve For air
3.3 Pump
3.3.1 Air motor
3.3.2 Electric motor
3.3.3 Filling level monitor
3.3.4 Grease reservoir heater Optional
3.3.5 Pressure control valve
3.4.1 Filter With pressure gauge
3.4.2 Solenoid valve For lubrication of the outer bearing ring
3.4.3 Solenoid valve For lubrication of the bearing cover
3.4.4 Lubricant distributor For lubrication of the bearing cover
3.4.5 Lubricant distributor For lubrication of the outer bearing ring
3.4.8 Heater For reversing unit (3.4), optional
3.5 Electric trace heating For piping, optional

cable
3.6 Terminal box
3.7 Terminal box For heater, optional

®
4.1.4 Hydraulic system
Fig. 12: Hydraulic system (4.0)

®
4.1 Piston accumulator
4.2 Filling device For nitrogen
4.3 Plunger cylinder
4.4 Push-back cylinder
4.5 Bellows
4.6 Hydraulic unit,
4.7 Accumulator throttle block
4.8 Valve block

®
4.1.5 Roll units
Fig. 13: Floating roll unit (6.0)

®
6.1 Bearing block For the floating roll unit (6.0)
6.2 Roll
6.3 Distance plate
6.4 Radially tight fitting key
6.5 Pressure plate For the plunger cylinder (4.3)
6.6 Compensation plates
6.7 Pressure plate For the spacer (10.10)

®
Fig. 14: Fixed roll unit (7.0)

®
7.1 Bearing block For the fixed roll unit (7.0)
7.2 Roll
4.4 Push-back cylinder
10.10 Spacer
®
4.1.6 Mounting device
Fig. 15: Mounting device (8.0)

®
8.1 Slide rail
8.2 Mounting arm For the installation and removal of the roll units
7.0 Fixed roll unit
10.5 Base frame

®
4.1.7 Wear measuring device
Fig. 16: Wear measuring device (9.0), mounted on the roll
Fig. 17: Wear measuring device (9.0), mounted on the bearing unit
®
No. Denomination
9.1 Measuring strip
9.2 Bracket
®
4.1.8 Roll frame
Fig. 18: Roll frame (10.0)

®
10.1 Crossbeam
10.2 Chord plate
10.3 Outlet connection flange Optional
10.4 Locking wedge
10.5 Base frame
10.6 Setscrew
10.7 Anchor bolt
10.8 Compensating strip
10.9 Sealing strip
10.10 Spacer
10.11 Vibration sensor At the non-drive end
10.12 Guide rail
10.12.1 Seal For the guide rail (10.12)
10.13 Limit switch
10.14 Connecting bolts
10.15 Locking wedge
10.16 Travel measuring device
10.17 Pressure block
10.18 Sunk tapered key
L Left side Standing between the pressure blocks (10.17) and

looking at the rolls
R Right side Standing between the pressure blocks (10.17) and

looking at the rolls
®
4.2 Description of functioning
4.2.1 High-pressure grinding roll

The high-pressure grinding roll is used for grinding brittle mill feed material. The
mill feed material is ground between two counter-rotating rolls under high
pressure.
Fig. 19: Grinding principle
After passing the gap between the rolls the mill feed material is fragmented and
generally emerges from between the roll pair as a highly compacted cake.
The drive, the material inward and outward conveying equipment, the hydraulic
system and the lubrication system are monitored during operation. If an important
component (e.g. lubrication system, temperature monitor, vibration monitor,
safety coupling) fails, the high-pressure grinding roll is shut down.
The bearing blocks of the fixed roll unit (7.0) are bolted onto the roll frame (10.0)
of the high-pressure grinding roll. The pressure required for comminution is
transmitted via the floating roll unit (6.0) into the mill feed material. During
operation, the floating roll unit constantly adapts to the changing properties of the
mill feed material by changing its position.
The required grinding forces are generated by a hydraulic system (4.0) and
transferred to the floating roll (6.0) via plunger cylinders (4.3).
The fixed roll unit (7.0) and the floating roll unit (6.0) of a high-pressure grinding
roll are each driven separately by their own drive (5.0).
By means of the feed material guide (11.0), the feed material is guided into the
roll gap.
The wear of the rolls depends on the abrasiveness of the material to be ground.
By means of the wear measuring device (9.0), the wear can be determined.
Depending on the type of the wear measuring device (9.0), it is mounted either on
the roll or on the bearing units.
®
4.2.2 Roll units
Floating roll unit (6.0)

The bearing blocks (6.1) of the floating roll unit (6.0) slide on the guide rails
(10.12) in the roll frame (10.0).
The grinding force is transferred via the pressure plates (6.5) from the plunger
cylinder (4.3) to the bearing blocks (6.1) and to the roll unit (6.0).
With increasing wear of the roll surfaces, the pressure plates (6.5) of the plunger
cylinders (4.3) have to be underlaid with compensation plates (6.6), as the stroke
of the plunger cylinders (4.3) is limited.
At the same time, distance plates (6.3) have to be removed from under the push-
back cylinders (4.4) and pressure plates (6.7) of the spacers (10.10) have to be
removed, too (see page 3-5, Setting values and maximum permissible wear of
the roll surfaces).
Fixed roll unit (7.0)

The compensating strips (10.8) of the fixed roll unit (7.0) are screwed onto the roll
frame (10.0), before the fixed roll unit (7.0) is installed. The locking wedges (10.4,
10.15) form a positive connection between the roll unit and the roll frame (10.0).
As a result, the grinding forces are directly transmitted into the roll frame (10.0).
4.2.3 Bearing cooling system

The bearing cooling system ensures that the bearing temperatures remain low.
Low bearing temperatures result in longer bearing service lives.
Water cooling system of the bearing blocks and rolls

When the high-pressure grinding roll is started, the cooling water supply is closed
(solenoid valve (A) energised/activated). As soon as a bearing temperature of
60 °C is reached (mean value of all 4 bearings), the cooling water supply is
opened (solenoid valve (A) de-energised/deactivated). During further operation,
the cooling water supply remains open, even if the bearing temperature falls
below 60 °C.
®
Fig. 20: Water cooling system of the bearing blocks (6.1, 7.1) and rolls
A Solenoid valve Water cooling system of the roll units
B Solenoid valve Water cooling system of the bearing blocks (6.1, 7.1)
When the high-pressure grinding roll is stopped, the bearing cooling system
remains switched on (solenoid valve (A) de-energised/deactivated). In order to
ensure that the bearing clearance is sufficient at all times, the cooling of the
bearing blocks (6.1, 7.1) is interrupted after the high-pressure grinding roll has
been stopped (solenoid valve (B) energised/activated). When the average
temperature of all 4 bearings is less than or equal to 40 °C, the bearing blocks
(6.1, 7.1) can be cooled again (solenoid valve (B) de-energised/deactivated). The
bearing cooling system must not be switched off until a new start of the high-
pressure grinding roll takes place or at least 8 hours after the high-pressure
grinding roll has been shut down.
®
Water cooling system of the bearing blocks
Fig. 21: Water cooling system of the bearing blocks (6.1, 7.1)
B Solenoid valve Water cooling system of the bearing blocks (6.1, 7.1)
When the high-pressure grinding roll is started, the cooling water supply is closed
(solenoid valve (B) energised/activated). The cooling water supply is not opened
until a bearing temperature of 60 °C (mean value of all 4 bearings) is reached
(solenoid valve (B) de-energised/deactivated). During further operation, the
cooling water supply remains open, even if the bearing temperature falls below
60 °C.
When the high-pressure grinding roll is stopped, the cooling water supply is
closed (solenoid valve (B) energised/activated). When the average temperature
of all 4 bearings is less than or equal to 40 °C, the cooling water supply can be
opened again (solenoid valve (B) energised/activated).
®
4.2.4 Hydraulic system (4.0)

The hydraulic system (4.0) has the following main functions:
● Pushing the floating roll unit (6.0) forward and backward
● Generating the contact pressure required for the comminution of the feed
material
● Creating a hydropneumatic spring system
● Actuating the gate valves of the mill feed system (1.0) (if installed)
Two plunger cylinders (4.3) are bolted onto each pressure block (10.17).
The pistons of the plunger cylinders (4.3) press the floating roll unit (6.0) via the
pressure plates (6.5) in the direction of the fixed roll unit (7.0).
The working pressure is built up by means of the hydraulic unit (4.6). While the
pistons of the plunger cylinders (4.3) press against the pressure plates (6.5) of
the bearing blocks (6.1), oil pressure is applied to the backs of the pistons. The
backs of the pistons are connected with the oil side of the corresponding piston
accumulator (4.1) via a common oil channel in the pressure block (10.17).
When the floating roll unit (6.0) is pushed back by the grinding forces in the roll
gap during operation, the plunger cylinders (4.3) press oil from the cylinder
chamber into the piston accumulator (4.1). The piston of the piston accumulator
therefore moves upwards against the gas pressure and compresses the gas
volume above the piston. The higher the piston in the piston accumulator is
pressed, i.e. the smaller the gas volume, the harder is the spring. The position of
the piston in the piston accumulator (4.1) is determined by the acting oil pressure
and by the initial filling pressure of the nitrogen in the piston accumulator (4.1).
When the initial filling pressure is applied, the system must be depressurised on
the oil side, i.e. the piston is in contact with the bottom of the piston accumulator
(4.1).
A throttle check valve is located in the oil route between the plunger cylinder (4.3)
and the piston accumulator (4.1). This throttle check valve is installed in such a
way that in the oil-flow direction from the plunger cylinder (4.3) to the piston
accumulator (4.1), the oil can flow practically unthrottled into the piston
accumulator (4.1). However, the oil flowing from the piston accumulator (4.1) to
the plunger cylinder (4.3), has to flow through the throttle check valve. By means
of the throttle valve setting, it is possible to influence the smooth running of the
high-pressure grinding roll.
If the spring has to be hard, a low initial filling pressure is applied (the piston is
located very high during operation).
If the spring has to be soft, a high initial filling pressure is applied (the piston is
located further down during operation).
When the initial filling pressure (PV) has been applied in the two piston
accumulators (4.1), the basic force (FG) is generated at the set basic gap by
adjusting the start-up pressure. The oil pressure (PÖ) and gas pressure (PG)
increase and the piston moves upwards in the piston accumulator (4.1), until a
state of equilibrium is attained.
The basic gap (S0) between the roll units is set by means of spacers (10.10).
®
Fig. 22: Hydropneumatic spring system
PG = gas pressure FG = basic force
PÖ = oil pressure S0 = basic gap
PV = initial filling pressure SA = working gap
PA = working pressure C Piston accumulator (4.1)
P0 = start-up hydraulic pressure D Plunger cylinders (4.3)
Fig. 23: Condition 1: no grinding operation
PÖ = 0
PG = PV
Fig. 24: Condition 2: high-pressure grinding roll is ready for grinding operation
PÖ = P0 = PG
SA = S0
®
Fig. 25: Condition 3: grinding operation
PÖ = PA = PG
4.2.5 Roll frame
Spacers (10.10)
The gap between the floating roll unit (6.0) and the fixed roll unit (7.0) depends on
the capability of the rolls to pull in the feed material, the roll speed and the density
of the mill feed material.
In order to avoid contact of the rolls, a basic gap is set between the rolls by
means of the spacers (10.10) during the first commissioning.
During operation, the grinding surfaces of the rolls are subject to wear and the
working gap moves in the direction of the fixed roll unit (7.0) and gets wider. In
order to maintain the width of the basic gap, the spacers (10.10) have to be
readjusted.
If there is no more adjustment left for the spacer (10.10), the pressure plates (6.7)
for the spacer (10.10) can be replaced.
4.2.6 Mill feed system

Depending on the application, the mill feed system (1.0) of the high-pressure
grinding roll consists of a chute or a feed bin with an adjustable feed shaft.
Depending on the mill feed material, the chute consists either of inclined or of
straight walls and is lined with wear protection in accordance with the
requirements.
The feed bin is supported on a load-cell fixed-bearing system. The weight of the
bin is measured by the load cell. A control loop ensures that there is always an
adequate filling level in the feed bin. The control is implemented by changing the
operating parameters such as the roll speed or the velocity of the feed unit. In
order to prevent the feed bin from overflowing, a filling level monitor is additionally
installed.
By means of the adjustable feed shaft, the width of the vertical feed shaft can be
steplessly adjusted, which allows correction of the feed material pull-in behaviour
and the throughput rate. The adjustable feed shaft can be designed with or
without gate valves.
®
4.2.7 Travel measuring device

The travel measuring device measures by means of non-contact distance
sensors the respective positions of the bearing blocks (6.1) of the floating roll unit
(6.0). The difference between the positions measured indicates the skewing of
the floating roll unit.
In order to preclude the occurrence of damage, the high-pressure grinding roll is
switched off when excessive skewing of the floating roll unit is registered.
4.2.8 Central lubrication system (3.0)

The central lubrication system (3.0) supplies the self-aligning roller bearings of
the roll units with lubricant. Lubrication takes place either via the bearing covers
only (in a single pipe circuit system) or successively and in equal parts via the
bearing covers and the outer bearing rings (in a dual pipe circuit system).
The lubrication pump is driven either pneumatically or electrically.
If a pneumatic drive is installed, the air supply is controlled by means of the
conditioning unit (3.2.2). The pressure monitor (3.2.3) monitors that a sufficient air
pressure is available.
The filling level monitor (3.3.3) monitors the filling level in the grease reservoir or
the grease barrel. When the filling level is low, an alarm is triggered, and after a
certain period the high-pressure grinding roll is switched off.
The lubrication takes place in lubrication cycles, the number of which depends on
the construction size of the machine (see page 3-4).
The lubrication cycle starts when the pump (3.3) is switched on. The grease can
then by supplied to the lubrication points by the pump (3.3) via the filter (3.4.1),
the solenoid valve (3.4.3, 3.4.2) and the lubricant distributor (3.4.4, 3.4.5).
The lubrication points connected to the lubricant distributors (3.4.4, 3.4.5) are
supplied with grease in a cycle, one after the other. During one distributor cycle, a
contact rod is pressed out of the distributor and actuates an electrical limit switch
(3.4.6, 3.4.7).
The signal transmitted by the limit switch (3.4.6, 3.4.7) is used in the machine
controller for monitoring and functional control. The lubrication points connected
to a lubricant distributor (3.4.4, 3.4.5) are supplied with equal lubricant quantities,
independent of the respective counterpressure.
After the limit switches (3.4.6, 3.4.7) of the lubricant distributors (3.4.4, 3.4.5)
have generated the required pulses, the lubrication cycle is finished, and the
solenoid valves (3.4.2, 3.4.3) are de-energised. If the required number of pulses
is not achieved within a specified period, an alarm is triggered.
When the ambient temperatures are low, the central lubrication system (3.0) is
designed as a heated version, in which all heating components are separately
adjustable by means of a thermostat.
®
Fig. 26: Diagram of the central lubrication system (3.0) as a single pipe circuit system
Fig. 27: Diagram of the central lubrication system (3.0) as a dual pipe circuit system
The bearing covers are the lubrication points 1, 2, 3, 4

The outer bearing rings are the lubrication points 5, 6, 7, 8
en-PM.CPT.001.D 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-PM.CPT.001.D
®
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 one or more loose part.
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 [German Federal Association for wooden
packaging, pallets and export packaging] international packaging 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)
● 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)
● Loose part designation
● 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 specified fastening points.
● Do not remove packaging until assembly begins.
● Before transporting, remove the piping and oil pumps on gear units, and close
all pipe sockets and openings with weather-proof and impact-proof sealing
covers to prevent the ingress of foreign matter.
®
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 and 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 Maintenance in the Preservation

conditions case of long-term
storage
Hydraulic system (4.0) Be sure to comply with the instructions in the machine manual of the
hydraulic system.
Drive (5.0) Be sure to comply with the instructions in the machine manual of the
drive.
Floating roll unit (6.0) Be sure to comply with the instructions in the machine manual of the
and fixed roll unit (7.0) roll unit.
Central lubrication Be sure to comply with the instructions in the separate subsupplier's
system (3.0) documentation.
Site assembly material, ● Store in dry

tools, electrodes conditions.
All individual parts for ● Store in dry

bolted connections conditions.
Measurement and ● Store in

control devices closed
rooms.
● Store in dry
conditions.
Machine frames, ● Store ● Exterior paint coat

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

components under a
roof.
®
5.3 Assembly
The following assembly description does not detail the individual steps for
assembling the machine but rather gives an overview of the work to be
performed.
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 repair work 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
Unauthorised connection of electrical power

Unauthorised connection of electrical power during assembly may cause
severe injuries or death of the persons in the working area and the danger
area.
Before commencing any work, disconnect the power supply and secure it
against restarting.
®
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
III. After assembling the machine, make absolutely sure that it is
standing stably and then carry out a test run.
WARNING
Welding or cutting
During welding or cutting work, the heat, smoke, gases, radiation and
spatters may cause injuries.
Wear personal protective equipment and a welding mask.
WARNING
Rotating machine
The machine may rotate accidentally due to the unbalance mass of the
components already installed. This could lead to life-threatening injuries
due to falling components, or cause persons to fall down inside the
machine.
I. Let the machine swing to a complete stop before commencing any
work.
II. Secure the machine by means of a steel cable against accidental
rotation.
III. If ladders or working platforms are used, make absolutely sure that
they have a secure footing.
IV. Wear personal protective equipment and use a fall protection
system.
®
WARNING
Vibrations
Vibrations can occur at the machine. These vibrations may be transmitted
via the floor under the machine, or may be caused by the work process or
by damage. Vibrations can cause health damage.
I. Set up the working platform such that no vibrations can be
transmitted from the machine to the personnel.
II. After assembly, check all fastening elements for tight fitting
CAUTION
Sharp-edged components
Sharp-edged components may cause cuts if handled improperly.
II. Handle open, sharp-edged components with the utmost care.
CAUTION
Nut-locking agents and sealing compound

Contact with nut-locking agents may cause sensitisation or eczemas.
Contact with sealing compounds may cause skin irritation and allergic
reactions. Inhalation of vapours may result in dizziness and drowsiness.
I. Be sure to comply with the manufacturer's safety data sheet.
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
rinse the eyes with large amounts of water and consult a doctor if
necessary.
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.
®
NOTICE
Improperly installed pressure piping

Improperly installed pressure piping may suffer damage. If any pressure
piping is damaged, a jet of fluid may spurt out under high pressure.
I. Do not subject hose piping to tensile loads or twisting.
II. Do not kink the hose piping or lead it over edges.
III. Observe the minimum bending radii for piping.
®
5.3.2 Tightening torques for bolts
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 bolts with standard thread for the
strength class 8.8.
● Threads and contact surfaces must be cleaned and lightly oiled (do not use
molybdenum disulphide lubricants).
Thread Tightening torque (Nm)
M8 24
M10 48
M12 85
M16 200
M20 400
M24 700
M30 1300
M36 2300
M42 3700
M48 5500
M56 9000
M64 14500
M72 21000
®
5.3.3 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 Assembly of the high-pressure grinding roll

Constraints
Prerequisites
The contact surfaces of all components are cleaned of the anti-corrosion coating
(e.g. Tectyl).
Required personnel
● Assembly personnel
Required tools
● Be sure to comply with the special tools list (see page 12-1)
● Levelling instrument
● Feeler gauge
● Measuring equipment for distance measurement, such as calliper gauges or
gauge blocks
Required consumables
● Acid-free grease
● Bearing grease (see page 6-2, Lubrication chart)
Necessary personal protective equipment
● Personal protective equipment for all work (see page 2-7)
Step 1: Prepare the foundation:
1.1 Clean the foundation and the anchor holes. Anchor holes with dead ends
must be free of dust.
1.2 Measure the foundation. When doing so, take the height of the cement
grout into account.
For aligning and for the grouting 50 mm are needed.
Step 2: Insert the anchor bolts (10.7) into the anchor holes.
Step 3: In case of through-going anchor holes:
3.1 Fill the free spaces between the anchor bolts (10.7) and the grouted-in
pipes with an appropriate material, in order to prevent grout flowing in.
Step 4: Provide the setscrews (10.6) with a separating agent, to ensure that they
can be slightly loosened (relieved) after the grout has set.
Step 5: Clean the surface of the base frame (10.5) in the area to be grouted.
Step 6: Assemble the base frame (10.5):
6.1 Place the base frame (10.5) upon the foundation.
6.2 Align the base frame (10.5) by means of a levelling instrument and
setscrews (10.6).
Observe the instructions in the installation drawing (see page 12-1, Technical
drawings).
6.3 Manually tighten the anchor bolts (10.7). Make sure that the base frame
(10.5) is not distorted.
Distortion of the base frame (10.5) is not permissible.
®
6.4 Prepare a measuring record prior to the grouting (see page 12-1,
Measurement records).
6.5 Grout the base frame (10.5). To avoid air inclusions, make sure that non-
through-going anchor holes are filled at first.
Observe the information in the Execution instructions for grouting work on

machine foundations (see page 12-1).
Observe the instructions concerning the tightening torque contained in the
machine installation drawing (see page 12-1, Technical drawings).
6.5.1 Leave the grout to harden, loosen (relieve) the setscrews (10.6) and
tighten the anchor bolts (10.7) to the specified tightening torque.
6.5.2 Prepare a measuring record after the grouting (see page 12-1, Technical
drawings).
Step 7: Mount the pressure blocks (10.17):
7.1 Coat the locking wedges (10.15) for the pressure blocks (10.17) with acid-
free grease or other anticorrosive agent and insert them into the base
frame (10.5).
The anticorrosive agent prevents rust formation if water enters the joints.
7.2 Place the pressure blocks (10.17) onto the base frame (10.5).
The piston rods of the plunger cylinders (4.3) must be secured against sliding
out.
When lifting the preassembled pressure blocks (10.17), take care that the
accumulator throttle blocks (4.7) and the plunger cylinders (4.3) are not damaged.
7.3 Align the pressure blocks (10.17).
Grooves on the base frame (10.5) and on the pressure blocks (10.17) serve as
alignment aid.
7.4 Manually tighten the fastening bolts.
7.5 Mount the plunger cylinders (4.3) onto the pressure blocks (10.17). Be sure
to comply with the tightening torque.
Step 8: Mount the floating roll unit (6.0) and the fixed roll unit (7.0).
8.1 Mount and align the guide rails (10.12) with the seal (10.2.1) on the base
frame (10.5). Manually tighten the bolts.
8.2 Grease the guide rails (10.12) with bearing grease.
8.3 Coat the radially tight fitting keys (6.4) with acid-free grease or other
anticorrosive agent and insert them into the floating roll bearing blocks.
8.4 Mount the compensating strips (10.8) and the sealing strips (10.9) onto the
base frame (10.5).
8.5 Mount the necessary distance plates (6.3), compensation plates (6.6) and
pressure plates (6.5, 6.7) on the floating roll unit (6.0) (see page 3-5,
Setting values and maximum permissible wear of the roll surfaces).
8.6 Mount the push-back cylinders (4.4) and the spacers (10.10) on the fixed
roll unit (7.0).
®
WARNING
Lifting the bearing blocks (6.1, 7.1)

The bearing blocks (6.1, 7.1) are not symmetrical and swing round when
being lifted or swing out via the self-aligning roller bearings. This poses a
risk of severe injuries.
I. Only lift the roll units with the transporting device.
II. Never go into the danger area.
8.7 Place the complete floating roll unit (6.0) onto the base frame (10.5).
8.8 Place the complete fixed roll unit (7.0) onto the base frame (10.5).
8.9 Disassemble the transporting device of the roll units.
8.10 Align the fixed roll unit (7.0).
C A
D B
Fig. 28: Aligning the bearing blocks
A Bearing block With fixed bearing of the fixed roll unit (7.0)
B Bearing block With floating bearing of the fixed roll unit (7.0)
C Bearing block With fixed bearing of the floating roll unit (6.0)
D Bearing block With floating bearing of the floating roll unit (6.0)
8.10.1 Align the bearing block (A).

Grooves on the base frame (10.5) and on the bearing block (A) serve as
alignment aid. The tapered key slots in the bearing block (6.1) and the base
frame (10.5) must be exactly one above the other.
®
8.10.2 Manually tighten the fastening bolts.

8.10.3 Coat the locking wedge (10.4) for bearing block (A) with acid-free grease or
other anticorrosive agent and insert it manually or with light hammer blows
into the groove.
8.10.4 Align the bearing block (B): this may require shifting the bearing block (B)
in axial direction of the roll.
8.10.5 Manually tighten the fastening bolts.
8.10.6 Coat the locking wedge (10.4) for bearing block (B) with acid-free grease or
other anticorrosive agent and insert it manually or with light hammer blows
into the groove.
Step 9: Mount the chord plates (10.2).
9.1 Mount and align the guide rails (10.12) with the seal (10.2.1) on the chord
plates (10.2). Manually tighten the bolts.
9.2 Coat the locking wedges (10.4) for the upper tapered key slots of the
bearing blocks (A, B) with acid-free grease or other anticorrosive agent and
place them in the grooves of the bearing blocks (A, B).
9.3 Grease the guide rails (10.12).
9.4 Mount the compensating strips (10.8) and the sealing strips (10.9) on the
chord plates (10.2).
9.5 Set down and align the chord plates (10.2).
Grooves on the pressure blocks (10.17) and the bearing blocks (A, B) serve as
alignment aid.
9.6 Manually tighten the fastening bolts of the chord plates (10.2) to the
bearing blocks (A, B) and to the pressure blocks (10.17).
Step 10: Brace the roll frame (10.0).
10.1 Set the spacers (10.10) in such a way that the floating roll and the fixed roll
cannot possibly come into contact.
10.2 Shift the floating roll unit (6.0) by means of the hydraulic lifting cylinders
supported on the pressure block (10.17) against the spacers (10.10) of the
fixed roll unit (7.0). Preload until the loaded areas of the locking wedges
(10.4, 10.15) in the base frame (10.5), pressure block (10.17) and on the
bearing blocks (A, B) are with zero clearance.
10.3 Tighten the bolts fixing the bearing blocks (A, B) and the pressure blocks
(10.17) to the base frame (10.5) with the necessary tightening torque.
10.4 Press the chord plates (10.2) by means of hydraulic lifting cylinders and
located points in the direction of the pressure blocks (10.17), until the
loaded areas of the locking wedges (10.4) on the chord plates (10.2) and
the bearing blocks (A, B) are with zero clearance.
10.5 Tighten the bolts fixing the chord plates (10.2) to the bearing blocks (A, B)
with the necessary tightening torque.
10.6 Fit the sunk tapered keys (10.18) between the pressure blocks (10.17) and
the chord plates (10.2).
Determine the dimension between the loaded wedge surfaces (a) by means of
suitable measuring equipment, and remachine the sunk tapered keys (10.18)
accordingly.
Be sure to measure the dimension between the loaded wedge surfaces (a) on
both the inside and the outside of the pressure blocks (10.17).
®
Fig. 29: Sunk tapered key (10.18)
10.7 After finish-machining, coat the sunk tapered keys (10.18) with acid-free
grease or other anticorrosive agent and insert them into the grooves using
light hammer blows if necessary. Check the loaded wedge surfaces (a) for
zero clearance by means of a feeler gauge.
10.8 Brace the roll frame (10.0) so that the bearing blocks (7.1) and the
pressure blocks (10.17) are pressed against the locking wedges (10.4,
10.15) and the sunk tapered keys (10.18).
10.9 Tighten the bolts fixing the chord plates (10.2) to the pressure blocks
(10.17) with the necessary tightening torque.
Step 11: Mount the crossbeams (10.1).
In special cases, the chord plates (10.2) and the crossbeams (10.1) can be
welded together to form an upper frame.
Step 12: Align the floating roll unit (6.0).

12.1 Place the measuring bar onto the side face of the rolls and check that there
is no lateral misalignment between the rolls. If necessary, shift the bearing
block (C) together with the guide rails (10.12) until there is no misalignment
of the rolls.
12.2 Align the bearing block (D). This may require shifting the bearing block (D)
with the guide rails (10.12) in axial direction of the roll.
The bearing blocks (C, D) of the floating roll unit (6.0) must be parallel to each
other and at right angles to the roll axis.
12.3 Tighten the fastening bolts of the guide rails (10.12) with the necessary
tightening torque.
Step 13: Secure and seal the wedges.
13.1 Mount the locking plates for the locking wedges (10.4, 10.15) and the sunk
tapered keys (10.18).
13.2 Seal the locking plates (10.10.2) with flexible, splash-proof sealing
compound.
Alternatively, you can place a sealing plate between the locking plate (10.10.2)
and the base frame (10.5).
13.3 Mount the seal (2.7) between the bearing blocks (6.1, 7.1).
®
Step 14: Mount the feed material guide (11.0).
Be sure to comply with the mounting instructions in the machine manual of the
feed material guide.
Step 15: Mount the extensions (2.6), housing walls (2.1, 2.2), protective grating (2.4)
and cover (2.5).
Step 16: Adjust the seal (2.9) with setscrews (2.8).
Step 17: Mount the mill feed system (1.0).
Step 18: Mount the hydraulic system (4.0):
Be sure to comply with the instructions in the machine manual of the hydraulic
system (4.0).
18.1 Mount the accumulator throttle blocks (4.7) and the valve blocks (4.8) onto
the pressure blocks (10.17).
18.2 Mount the piston accumulators (4.1) onto the accumulator throttle blocks
(4.7).
Be sure to comply with the tightening torques specified in the subsupplier's

documentation.
18.3 Drain the slushing oil out of the pressure blocks (10.17) and plunger
cylinders (4.3).
18.4 Install the hydraulic unit (4.6) in a separate dust-free compartment.
The drain oil piping between the lower plunger cylinders (4.3) and the hydraulic
oil tank must have a decline of at least 5 %.
18.5 Install the connecting piping (also see the subsupplier's documentation).
NOTICE
Improperly installed pressure piping

Improperly installed pressure piping may suffer damage. If any pressure
piping is damaged, a jet of fluid may spurt out under high pressure.
I. Do not subject hose piping to tensile loads or twisting.
II. Do not kink the hose piping or lead it over edges.
III. Observe the minimum bending radii for piping.
Step 19: Mount the central lubrication system (3.0):
See the subsupplier's documentation.

®
19.1 Install the pump jack (3.1) and the pump (3.3).
Observe the instructions in the installation drawing.
Make absolutely sure that the barrel has no dents in the steel casing.
If available, install the conditioning unit (3.2) close to the pump (3.3).
WARNING
Lubricants spurting out

Lubricants may spurt out under high pressure. Contact with lubricants
may cause injuries.
I. Make sure that lubrication piping is properly laid.
II. Regularly inspect the lubricators for damage, and regularly service
them.
19.2 Mount the reversing unit (3.4) onto the pressure block (10.17):
Be sure to comply with the instructions in the drawing of the central lubrication
system piping (see page 12-1, Technical drawings).
19.2.1 Bend the lubrication pipes in cold condition, deburr and clean by blowing
out with compressed air.
Bending radius referred to the centre line of the pipe
Pipe D mm 6 8 10 12 20 25 30
diameter
Plate S mm 1 1 1.5 1.5 2 2.5 3

thickness
Bending R mm 12 16 20 23 36 44 50
radius
Ensure utmost cleanliness during installation of the lubrication pipes.

19.2.2 Mount the lubrication pipes. Fasten the pipes at specified intervals (see the
following table) and at the ends as well as upstream of hose connections.
Pipe diameter mm 6 to 14 15 to 22 23 to 28
Distance between mm 900 1200 1500

clamps
Table 4: Fastening the lubrication pipes
®
19.2.3 Fill the lubrication pipes with lubricant:

Disconnect the grease hoses from the lubrication points of the high-
pressure grinding roll (see figure 5, page 4-6).
Using the pump (3.3), convey the lubricant into appropriate collecting tanks
until approx. 100 g of lubricant have escaped from each hose/lubrication
point.
This prevents impurities from the lubrication pipes getting into the bearings.
Connect the grease hoses again to the lubrication points.
Step 20: Mount the drive (5.0).
Be sure to comply with the mounting instructions in the machine manual of the
drive.
en-PM.CPT.001.D Lubrication
®
6 Lubrication
The table of lubricants with the lubricant reference numbers is contained in this
folder or at the beginning of the overall documentation. Each lubricant has a
unique lubricant reference number to which the lubrication instructions in this
section relate. The table of lubricants gives a complete list of all manufacturers
and products that are approved for this machine. It is the responsibility of the
lubricant supplier to select appropriate lubricants corresponding to the lubricant
reference numbers. thyssenkrupp Industrial Solutions accepts no liability for the
correctness of this data. If you wish to use a lubricant that is not listed in the
table of lubricants, you have to obtain approval for this from thyssenkrupp
Industrial Solutions.
6.1 Safety instructions
WARNING

Contact with lubricants may cause skin irritation and allergic reactions.
thoroughly.
necessary.
CAUTION

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 you store, use and
dispose of lubricants.
II. Be sure to comply with the applicable national regulations for the
protection of the environment when handling lubricants.
Lubrication en-PM.CPT.001.D
®
6.2 Lubrication chart
Fig. 30: Lubrication points/Filling points on the high-pressure grinding roll
Lubrication points/Filling points Quantity (L, kg) per Intervals (weeks)

lubrication point/filling
point
No. Qty. Designation Lubricant Initial Topping Topping First Further

ref. no. filling up up change changes
1 1 Grease reservoir/Grease
barrel of the central
lubrication system (3.0) 80 ○ 180 [1] as required
[1]
2 1 Hydraulic system (4.0) [2]
3 1 Drive (5.0) [2]
Explanation of the icons
● Initially filled
○ Not initially filled
Explanation of the numerals in square brackets
[1] Check the grease reservoir/grease barrel weekly. Top up at the latest, when the filling level monitor (3.3.3)
responds.
[2] See separate machine manual.

en-PM.CPT.001.D 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
inspection doors when the machine is switched off.
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-PM.CPT.001.D
®
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.
NOTICE
Mill feed material in the roll gap

If the high-pressure grinding roll is started while there is still mill feed
material in the roll gap, the drive might be damaged.
I. Never start the high-pressure grinding roll, if there is mill feed
material in the roll gap.
II. Observe the permissible feed material temperatures specified in the
section Technical data.
®
7.2 Checks prior to the test run

Prior to the first test run without material, check the machine in accordance with
the following list.
Check Correct
All transporting devices and transport stiffeners have been removed.
The machine is undamaged.
All checks have been carried out in accordance with the checklists in the
subordinated machine manuals.
The anchor bolts (10.7) have been properly tightened.
All bolts connecting the following components have been tightened to the required
tightening torque:
● Bearing blocks (7.1) with base frame (10.5) and chord plates (10.2)
● Pressure blocks (10.17) with base frame (10.5) and chord plates (10.2)
● Plunger cylinders (4.3) with pressure blocks (10.17)
● Accumulator throttle block (4.7) with pressure blocks (10.17)
● Guide rails (10.12) with base frame (10.5) and chord plates (10.2)
● Bearing covers with bearing blocks (6.1, 7.1)
● Drive (5.0) with the roll
The compensating strips (10.8) at the fixed roll unit (7.0) are mounted on the base
frame (10.5) and on the chord plates (10.2).
The seal (2.7, 2.9) is properly mounted and adjusted.
The seal of the inspection covers, service covers and inspection doors (2.3) have
been inserted. All inspection covers, service covers and inspection doors (2.3) have
been securely closed.
The filling keys (6.4) have been mounted at the bearing blocks of the floating roll unit
(6.0).
The spacers (10.10) have been installed and the basic gap has been checked and
recorded in writing.
The mill feed system (1.0) is free of feed material and tramp material.
The roll units have been measured by means of the wear measuring device (9.0).
The measurement results have been recorded in writing (see page 8-17, Carrying out
wear measurement).
The travel measuring device (10.16) has been mounted, connected and adjusted.
The temperature sensors in the bearing blocks (6.1, 7.1) have been connected and
calibrated.
The push-back cylinders (4.4) have been retracted.

®
Check Correct
The cooling water system has been installed and bled of air. Sufficient cooling water
in the prescribed water quality is available.
The central lubrication system (3.0) has been filled with lubricant and is ready for
operation.
The lubrication pipes are free of leaks.
The piston accumulators (4.1) have been filled with nitrogen and the hydraulic
system (4.0) is ready for operation.
The direction of rotation of the drive (5.0) is correct.
All electrical components have been correctly wired and are in proper working order.
The operating voltage matches the data on the type plate.
All components are correctly connected.
All lubrication points are filled with lubricants.
All monitoring devices are connected and in proper working order. The correct
switching values have been set properly.
All required protection devices have been installed.
The safety interlocks are correct.
All safety signs are mounted and easily legible. Be sure to comply with the
instructions regarding the position of the safety signs in the drawing Safety signs (see
page 12-1, Technical drawings).
All tools have been removed from the machine and from the working area.
There are no persons in the vicinity of the machine.

®
7.3 Setting the basic gap

Purpose
During operation, the grinding surfaces of the rolls are subject to wear and the
working gap moves in the direction of the fixed roll unit (7.0) and gets wider. In
order to maintain the working gap between the roll units, among other things, the
basic gap must be readjusted. See Setting values and maximum permissible
wear of the roll surfaces (see page 3-5).
The basic gap "S0" is defined during commissioning.
The dimensions "A", "S0", "Y0" and "D" correspond to the dimensions in new
condition.
Required personnel
● Commissioning personnel
Prerequisites
● A reference measurement of the wear on the roll surfaces has been carried
out (see page 8-17, Carrying out wear measurement).
● The wear of the roll surfaces has been measured (see page 8-17, Carrying
out wear measurement) and compared with the reference measurement.
®
Fig. 31: Spacers (10.10) and basic gap
No. Denomination
10.10 Spacer
10.10.1 Thrust pieces
10.10.2 Locking plates
Step 1: Loosen the fastening bolts of the locking plates (10.10.2).

Step 2: Shift the locking plates (10.10.2) so that the thrust piece (10.10.1) can be
turned.
Step 3: Turn the thrust piece (10.10.1) until the required length "Y" (see page 3-5,
Setting values and maximum permissible wear of the roll surfaces) of the
spacers (10.10) has been reached.
All four spacers (10.10) must be set to the same length. For better orientation,
there are markings at intervals of 45° on the thrust pieces (10.11.1).
Step 4: Insert the locking plates (10.10.2) into the grooves of the thrust pieces
(10.10.1) and tighten the fastening bolts of the locking plates (10.10.2).
®
7.4 Carrying out a test run

Purpose
By means of a test run without material, all machine components are checked for
operational capability.
Required personnel
● Commissioning personnel
Step 1: Start the high-pressure grinding roll and run for 4 hours at a hydraulic
pressure of approx. 50 bar. During the test run, pay attention to the
following:
● Smooth fitting of the gear unit on the roll shaft
● Abnormal noises
● Freedom form leaks of the incoming and outgoing piping of the central
lubrication system (3.0), hydraulic system (4.0) and the cooling water system
● Temperature of the gear oil
● Correct roll gap (the rolls do not come into contact with each other)
● Correct alignment of the feed material guide (11.0) (the rolls do not come into
contact with the feed material guide plates)
● The cycle times and the grease quantities of the central lubrication system
(3.0) correspond to the specifications (see page 3-4)
Step 2: Check all bolted connections and retighten if necessary.
en-PM.CPT.001.D Maintenance
®
8 Maintenance
8.1 Maintenance work during operation
DANGER
Electric current
There are live parts in and at the machine. Contact with live parts means
immediate danger of death due to electric shock.
equipment.
II. Wear personal protective equipment for work on energised electrical
III. Use suitable tools when performing work on electrical equipment or
devices.
WARNING
Moving components
I. Operate the machine only with properly mounted protection devices.
II. Only open protection devices and inspection doors when the
machine is shut down.
WARNING
Falling material
In the outside area of the machine, material could fall down and cause
severe injuries.
Wear personal protective equipment.
WARNING
Falling components
In the outside area of the machine, components could fall down and cause
severe injuries.
II. Before entering the working area, check the machine for loose
components.
III. Observe the maintenance intervals and regularly check the
connecting elements.
Maintenance en-PM.CPT.001.D
®
WARNING
Lack of stability
Lack of stability may result in the machine tipping over. This could lead to
severe injuries.
II. Regularly inspect the machine for damage.
III. Use suitable fastening devices. Replace any missing fastening
WARNING
Emerging jet of hot fluid

If pipes or machine parts burst, a jet of hot fluid may shoot out. Contact
with the jet of hot fluid may lead to severe scalding.
I. In the event of an emerging jet of fluid, immediately press the
EMERGENCY STOP button. If necessary, take further measures to
reduce the pressure and to stop the jet of fluid.
III. Observe the maintenance intervals for piping.
IV. Never touch a jet of fluid.
V. Carefully take up the leaked fluid and dispose of it properly.
VI. Repair or replace any damaged or faulty components.
WARNING
Vibrations
Vibrations can occur at the machine. These vibrations may be transmitted
via the floor under the machine, or may be caused by the work process or
by damage. Vibrations can cause health damage.
I. Do not use the machine if there is any damage.
II. Regularly check the machine for low-vibration running.
III. Regularly check all fastening elements for tight fitting.
IV. Replace any worn-out or damaged components.
®
NOTICE
Damaged pressure piping

If the maintenance intervals are not adhered to, pressure piping may suffer
damage. If any pressure piping is damaged, a jet of fluid may spurt out
under high pressure.
I. Observe the specified maintenance intervals for pressure piping.
II. Regularly check the pressure piping for tightness and proper
surface condition.
8.1.2 Prior to any maintenance work

Ensure the following prior to any maintenance work during operation:
● Ensure that there is adequate space to perform the work.
● 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.
8.1.3 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 of personnel
1 Check the high-pressure grinding roll Daily Maintenance personnel

for abnormal noises and leaks
2 Check the hydraulic system (4.0) for Weekly Maintenance personnel

leaks
3 Check the central lubrication system Weekly Maintenance personnel

(3.0) for leaks
8.1.4 After any maintenance work

Be sure to do the following after any maintenance work carried out during
operation:
● Check all joints and connections for leaks.
● Remove all tools from the machine.
● Mount all protection devices.
● Close the inspection covers, service covers and inspection doors properly.
®
8.2 Maintenance work during a stoppage
DANGER
Electric current
There are live parts in and at the machine. Contact with live parts means
immediate danger of death due to electric shock.
equipment.
II. Wear personal protective equipment for work on energised electrical
III. Use suitable tools when performing work on electrical equipment or
devices.
DANGER
Improper filling of the piston accumulators or bladder accumulators

If piston accumulators or bladder accumulators are filled with oxygen,
they may explode. This could lead to severe or even fatal injuries.
I. Only allow qualified hydraulics specialists to carry out work on the
piston accumulators or bladder accumulators.
II. Before carrying out any work, switch off and completely
depressurise the hydraulic system.
III. Only use pure nitrogen with the permitted nitrogen quality for filling
the piston accumulators or bladder accumulators.
DANGER
Accidental shutting-in of persons

There is a risk of being shut in when working on the machine. If the
machine is then started up, any persons shut-in may be killed.
I. Before commencing any work, switch off all poles of the machine
and secure it against restarting.
II. Carry out work only in the presence of another person. The second
person must stay outside the machine.
III. After finishing all work, make absolutely sure that nobody is in the
machine.
®
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
Closing or opening of inspection covers, service covers or inspection

doors
Limbs may be crushed when inspection covers, service covers or
inspection doors are closed or opened.
II. Never reach into the danger area.
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
Hydraulic energy
Hydraulically operated components may move unexpectedly due to stored
residual energy. If any components are damaged, hydraulic oil can spurt
out under high pressure. This could lead to severe or even fatal injuries.
II. Only allow qualified hydraulics specialists to carry out work on the
hydraulic system.
III. Never alter pressure settings to exceed the maximum values.
IV. Before carrying out any work, switch off and completely
depressurise the hydraulic system.
V. Check that the hydraulic system is depressurised.
WARNING
Contact with material in the interior

When working in the interior of the machine, contact with material may
cause damage to health. The potential hazard depends on the material that
has been fed in.
II. Avoid contact with material.
III. Following contact with harmful material, clean the affected parts of
the body and change out of dirty clothing.
IV. Mount all protection devices when the work has been completed.
WARNING
Incrustations or material falling down

In the interior, incrustations or adhering material may come loose, fall
down and cause injuries. There is also a danger of being buried alive.
II. Before entering the interior, check it for incrustations.
III. Eliminate incrustations from the walking surfaces and grab handles
first, before entering the interior.
IV. Before entering the interior, suitably cover such material as is
present.
®
WARNING
Dust generation due to continuing flow of material

When work is being performed in the interior of the machine, material may
continue to flow. A large amount of dust may be generated. There is a
danger of being suffocated.
Wear personal protective equipment and a protective filter mask.
CAUTION
Escaping dusts
Dusts may escape through leaky points of the machine, or when
inspection covers, service covers or inspection doors are opened. The
inhalation of dusts can cause breathing difficulties and suffocation.
Contact with eyes can cause irritation or injury.
II. Regularly check the machine for escaping dusts.
III. Regularly check the bolted connections for tight fitting.
IV. Regularly clean the machine.
V. Before carrying out any work, stop the material feed and wait until
the dust has settled. Shut down the machine.
8.2.2 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.
● Switch off the machine and secure it against restarting.
● Depressurise any components under pressure.
● Allow the machine to cool down to ambient temperature.
● Stop the material feed.
● Close the shut-off devices.
● Before carrying out work on the central lubrication system (3.0) with
pneumatically operated pump (3.3): disconnect the pump (3.3) from the
compressed-air supply system.
● In case of prolonged stoppages and if there is a risk of sub-zero temperatures:
drain the cooling water.
®
8.2.3 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.
No. Work to be performed Frequency Qualification Remarks
of personnel
1 Replace the wear parts of the mill As required Maintenance ● Be sure to

feed system (1.0) and of the feed personnel comply with the
material guide (11.0) instructions in
the separate
machine manual
of the mill feed
system (1.0) and
the feed material
guide (11.0).
2 Clean the dirt trap in the cooling As required Maintenance

water supply system personnel
3 Vent the cooling water system As required Maintenance

personnel
4 Take a grease sample from the As Maintenance ● There are

bearings of the roll units and necessary, at personnel sampling
analyse the grease. least every 3 openings in the
months bearing covers
of the roll units
5 Carry out the wear measurement The first wear Maintenance ● If more than half
of the roll surfaces measurement personnel of the hard weld
has to be layer of the
carried out hardfacing is
after the worn out, wear
operating measurements
hours must be carried
prescribed in out at shorter
the section intervals.
Technical ● (see page 8-17)
data.
● If necessary,
adapt the
compensation
plates (6.6) on
the pressure
plates (6.5) and
the distance
plates (6.3).
6 Check the central lubrication See Manufacturer's

system (3.0) for proper functioning subsupplier's experts
instructions.
®

of personnel
7 Check the hydraulic system (4.0) See machine Qualified ● Be sure to

for proper functioning manual hydraulics comply with the
specialist instructions in
the separate
machine manual
of the hydraulic
system.
8 Briefly turn the roll units by Weekly Maintenance ● In order to avoid

switching on the drive (5.0) personnel standstill marks
on the
antifriction
bearings during
prolonged
stoppages.
9 Clean the area around the spacer Weekly Maintenance

(10.10) personnel
10 Check the outer bearing seals for Weekly Maintenance

wear personnel
11 Check the gas pressure in the Weekly Maintenance ● The oil side of
piston accumulators (4.1) personnel the piston
accumulator
(4.1) must be
depressurised.
● Be sure to
comply with the
instructions in
the separate
machine manual
of the hydraulic
system.
12 Check the working gap between Every 4 Maintenance ● (see page 3-5,
the roll units weeks personnel Setting values
and maximum
permissible wear
of the roll
surfaces)
● If necessary,
reset the
spacers (10.10)
(see page 7-5,
Setting the basic
gap).
®

of personnel
13 Clean the filter (3.4.1) Every 4 Maintenance ● Be sure to

weeks personnel comply with the
cleaning
instructions in
the subsupplier's
documentation
for the central
lubrication
system (3.0).
14 Check the gap between the feed Every 3 Maintenance ● Adjust the
material guide (11.0) and the roll months personnel specified
end faces dimension if
necessary
● Be sure to
comply with the
instructions in
the separate
machine manual
of the feed
material guide.
15 Check the bearing seals of the roll Every 3 Maintenance ● Be sure to

units for proper functioning and months personnel comply with the
wear instructions in
the separate
machine manual
of the roll unit.
16 Check the following components Annually Maintenance

for leaks: personnel
● Seal (2.7) between the bearing
blocks (6.1, 7.1)
● Seal (2.9) of housing walls and
inspection doors (2.3)
17 Check the push-back device of the Annually Maintenance

floating roll unit (6.0) for proper personnel
functioning
®

of personnel
18 Check the following bolted Annually Maintenance

connections for tight fitting: personnel
● Bearing blocks with base frame
(10.5) and chord plates (10.2)
● Pressure blocks (10.17) with
base frame (10.5) and chord
plates (10.2)
● Guide rails (10.12) with base
frame (10.5) and chord plates
(10.2)
● Plunger cylinders (4.3) with
pressure blocks (10.17)
● Accumulator throttle block (4.7)
with pressure block (10.17)
● Drive (5.0) with rolls
®
8.2.4 Removing the roll units

Required personnel
● Maintenance personnel
Prerequisites
● The high-pressure grinding roll is shut down and secured against restarting.
Step 1: Prepare for dismounting of the roll units:
1.1 Disconnect the hose connections of the lubrication points at all the bearing
blocks (6.1, 7.1) and tightly close the resultant openings in the piping with
plugs.
1.2 Disconnect the connections to the push-back cylinders (4.4) and close all
openings.
1.3 Disconnect the supply and discharge connections for cooling water for the
bearing block and gear oil cooling systems, and tightly close the resultant
openings with plugs.
1.4 Dismount the travel measuring device (10.16).
1.5 Dismount the speed monitor.
1.6 Dismount the temperature sensor.
1.7 Dismount the piping, the monitoring devices and the sealing air hoses (if
installed) of the roll units.
1.8 Dismount the drives (5.0).
Be sure to comply with the instructions for dismounting the drives, in the
machine manual of the high-pressure grinding roll drive.
1.9 Dismount the housing walls (2.1, 2.2):

1.10 Dismount the components of the mill feed system (1.0) and of the feed
material guide (11.0).
Be sure to comply with the instructions for dismounting the mill feed system and
feed material guide in the machine manual of the mill feed system and in the
machine manual of the feed material guide.
Step 2: Unscrew the left and right fastening bolts (K) of the fixed roll unit (7.0) by at
least 10 mm (a) (figure 32, 8-13).
®
Fig. 32
Step 3: Unscrew and remove the remaining fastening bolts (K) of the fixed roll unit
(7.0).
Step 4: Loosen and unscrew the upper fastening bolts on the left and right
pressure blocks (10.17) by at least 5 mm.
Step 5: Insert the plate (M) between the lifting cylinder (L) and the heads of the
fastening bolts (K). Slightly lift the fixed roll unit (7.0) and lower it again
(figure 32, 8-13).
This takes the load off the surfaces of the locking wedges (10.4, 10.15) and sunk
tapered keys (10.18), making it easier to dismount the locking wedges (10.4,
10.15) and the sunk tapered keys (10.18).
Step 6: Withdraw the locking wedges (10.4, 10.15) and sunk tapered keys (10.18), or
knock them out with light hammer blows on an intermediate wooden pad.
Step 7: Lift the chord plates (10.2) with the crossbeams (10.1) by at least 15 mm (s)
and secure them (figure 32, 8-13).
Step 8: Mount the mounting arms (8.2) in extension of the longitudinal beams of the
base frame (10.5).
If space conditions permit, the mounting arms (8.2) may remain mounted.
Step 9: Dismount the spacers (10.10).
Step 10: Lift the fixed roll unit (7.0) by at least 10 mm (a) (figure 32, 8-13).
Step 11: Grease the slide rails (8.1) and insert them into the grooves provided up to
the bearing blocks (6.1) of the floating roll unit (6.0) and fasten them on the
mounting arms (8.2) and on the base frame (10.5).
Step 12: Set down the fixed roll unit (7.0).
®
Step 13: Unscrew the fastening bolts (K).

Step 14: Pull out the fixed roll unit (7.0) onto the mounting device (8.0).
WARNING
Lifting the bearing blocks (6.1, 7.1)

The bearing blocks (6.1, 7.1) are not symmetrical and swing round when
being lifted or swing out via the self-aligning roller bearings. This poses a
risk of severe injuries.
I. Only lift the roll units with the transporting device.
II. Never go into the danger area.
When withdrawing the roll units (6.0, 7.0) onto the mounting device (8.0), take
care that the bearing blocks (6.1, 7.1) are always at right angles to the roll shaft.
For this purpose, the bearing blocks (6.1, 7.1) can be connected to an auxiliary
profile.
Step 15: Mount the transporting device onto the fixed roll unit (7.0) and move the
fixed roll unit (7.0) away from the mill.
Step 16: Pull the floating roll unit (6.0) from the guide rails (10.12) onto the mounting
device (8.0).
Step 17: Mount the transporting device onto the floating roll unit (6.0) and move the
floating roll unit (6.0) away from the mill.
Be sure to comply with the instructions on the storage and repair of the roll units
in the machine manual of the roll unit.
®
8.2.5 Mounting the roll unit

Required personnel
Prerequisites
● On the floating roll unit (6.0), pressure plates (6.5) and radially tight fitting keys
(6.4) are mounted.
● Compensating strips (10.8) and guide rails (10.12) are mounted on the base
frame (10.5) and on the chord plates (10.2).
Step 1: Lower the floating roll unit (6.0) onto the mounting arms (8.2) and pull it via
the slide rails (8.1) onto the guide rails (10.12).
When pulling in the roll units (6.0, 7.0) from the mounting device (8.0) into the roll
frame (10.0), take care that the bearing blocks (6.1, 7.1) are always at right
angles to the roll shaft. For this purpose, the bearing blocks (6.1, 7.1) can be
connected to an auxiliary profile.
Step 2: Lower the fixed roll unit (7.0) onto the mounting arms (8.2) and pull into
position.
2.1 Screw in the fastening bolts (K), leaving a gap of 10 mm (a) (figure 33, 8-
15). Lift the fixed roll unit (7.0) by means of the plates (M) and the lifting
cylinders (L), pull out the slide rails (8.1) and lower the fixed roll unit (7.0).
Fig. 33
®
2.2 Lower the chord plates (10.2) and fit the bolts (only slightly tighten by hand).
2.3 Check that the grinding surfaces of the roll units are parallel and make sure
that the rolls are not offset laterally.
2.4 Insert the locking wedges (10.4, 10.15).
Step 3: Mount the spacers (10.10) and set the basic gap.
Step 4: Press the floating roll unit (6.0) by means of the hydraulic system (4.0)
against the spacers (10.10).
The bearing blocks (6.1) are pressed against the locking wedges (10.4, 10.15) at
a hydraulic pressure of approx. 20 bar.
Step 5: Insert the sunk tapered keys (10.18) and check whether the loaded flanks of
the sunk tapered keys (10.18) are in perfect contact with zero clearance. If
not: replace the sunk tapered keys (10.18).
Step 6: Tighten the connecting bolts (10.14) to the stipulated tightening torque.
Step 7: Mount all other machine components such as drive (5.0), mill feed system
(1.0), feed material guide (11.0), piping, monitoring devices and protection
devices.
®
8.2.6 Carrying out wear measurement

Purpose
The wear measurement provides information about what adaptations to the high-
pressure grinding roll are necessary. The wear of the roll surface, the profiling or
of the hard metal studs depends on the abrasiveness of the mill feed material.
A baseline measurement has to be carried out during commissioning. The
measured difference between the check measurement and the baseline
measurement is the wear that has occurred.
Required personnel
Required tools
● Wear measuring device (9.0)
● Depth calliper gauge
Prerequisites
● The high-pressure grinding roll is shut down and secured against restarting.
Step 1: Open the inspection doors (2.3) in the housing walls (2.1, 2.2).
Step 2: Mount the wear measuring device (9.0):
2.1 Mount the measuring strip (9.1) onto the brackets (9.2).
Step 3: Measure the distance between the measuring strip (9.1) and the grinding
surface by means of a depth calliper gauge.
Step 4: Record the measurement results (see page 12-1, Measurement records):
®
Fig. 34
A = monolithic roll/roll body, forged, with hard facing and profiling

B = roll body made of chilled cast iron with profiling
C = roll body, forged, with studs
D = drive end
———► Sequence of measuring points, starting at the drive end
Step 5: Transfer the measurement results to thyssenkrupp Industrial Solutions.

Step 6: If maximum permissible wear is determined (wear amax), carry out the
following work (depending on the type of roll):
● Refurbish hardfacing.
● Change the roll body made of chilled cast iron.
● Change the roll body with studs.
Step 7: If the measured wear does not yet reach the maximum permissible value
(wear amax), carry out the following work (depending on the type of roll):
7.1 Set the spacer (10.10) to the length Y (see page 7-5, Setting the basic gap).
7.2 Insert compensation plates (6.6) of thickness T under the pressure plates
(6.5).
7.3 Insert distance plates (6.3) of thickness U for the push-back cylinders (4.4).
7.4 Insert pressure plates (6.7) of thickness V for the spacers (10.10).
®
8.2.7 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 the test run (see page 7-3).
● Check all joints and connections for leaks.
● Remove all tools from the machine.
● Make absolutely sure that nobody remains in the interior of the machine.
● Mount all protection devices. Close all inspection doors (2.3) previously
opened.
en-PM.CPT.001.D Troubleshooting
®
9 Troubleshooting
9.1 List of possible faults
Fault Cause Qualification of Elimination

personnel
The bearing Lubricant supply too Maintenance ● Check the lubricant

temperature is too high low or interrupted personnel supply.
● Check the central
lubrication system
(3.0).
Temperature of mill Operating ● Improve the aeration

feed material too high personnel of the high-pressure
grinding roll.
● Increase the cooling
water flow rate for
the bearing blocks
and rolls.
A bearing is faulty Maintenance ● Replace the bearing

personnel (see machine
manual of the roll
unit).
Cooling system faulty Maintenance ● Check the water

personnel cooling system.
The floating roll unit Skewing when the ● See fault 3

(6.0) cannot be pushed floating roll unit (6.0) is
backward pushed backward
The hydraulic system Qualified ● Repair the hydraulic

(4.0) is faulty hydraulics system (4.0) (see
specialist machine manual of
the hydraulic
system).
Distance plates (6.3) Maintenance ● Install distance

under the push-back personnel plates (6.3) with the
cylinders are missing or necessary
are too low thickness.
Troubleshooting en-PM.CPT.001.D
®

personnel
Excessive skewing Tramp material Maintenance ● Remove the tramp

when the floating roll between the bearing personnel material.
unit (6.0) is pushed block (6.1) of the
backward floating roll unit (6.0)
Indication and the pressure block
(10.17)
Travel measuring
device (10.16) Fault in the hydraulic Qualified ● Repair the hydraulic
system (4.0) hydraulics system (4.0) (see
specialist machine manual of
the hydraulic
system).
The travel measuring Maintenance ● Repair the travel

device (10.16) is faulty personnel measuring device
or maladjusted (10.16).
Excessive skewing Material feed at one Maintenance ● Modify the mill feed
Indication side only personnel system (1.0).
Travel measuring The hydraulic system Qualified ● Repair the hydraulic

device (10.16) (4.0) is faulty hydraulics system (4.0) (see
S > S max. specialist machine manual of
the hydraulic
system).
Leakage losses on the Qualified ● Compensate for the

gas side of the piston hydraulics leakage losses.
accumulator (4.1) specialist ● Find and eliminate
the leak. Replace
the seals of the
piston if necessary.
Excessive gap between Tramp material in the Maintenance ● Remove the tramp
the roll units roll gap personnel material.
Indication
Oil loss in the hydraulic Qualified ● Check the hydraulic
Travel measuring system (4.0) hydraulics system (4.0) for
device (10.16) specialist leaks.
● Eliminate the leaks.
Gas loss in the piston Qualified ● Check the seals and

accumulators (4.1) hydraulics shut-off devices
specialist ● Replace damaged
parts
®

personnel
The floating roll unit The roll units are in Maintenance ● Check and correct
(6.0) cannot be pushed contact, which means personnel setting of the basic
up to the spacer (10.10) that the setting of the gap (see page 7-5,
spacers (10.10) is too Setting the basic
short gap).
Tramp material Maintenance ● Remove the tramp

between the bearing personnel material.
blocks (6.1, 7.1)
The compensation Maintenance ● Install compensation

plates (6.6) under the personnel plates (6.6) and
pressure plates (6.5) pressure plates (6.5)
are missing or are too with the required
low thickness.
The floating roll unit Excessive basic gap Maintenance ● Adjust smaller basic
(6.0) fails to move off personnel gap (see page 7-5).
the spacers, or only
moves a short distance, Feed rate for mill feed Operating ● Check the feed rate.
when material is fed system (1.0) is too low personnel ● Check the control
system of the mill
feed system (1.0).
Wear of the roll units Maintenance ● Carry out wear

personnel measurement (see
page 8-17).
● Refurbish the
hardfacing if
necessary.
Filling level in the Fault in mill feed control Operating ● Check the control
material feed unit is too system personnel system of the mill
high feed system (1.0).
Vertical feed shaft Maintenance ● Eliminate the

clogged personnel blockage.
®

personnel
The coarse fraction in Quantity of mill feed Maintenance ● Check the mill feed
the ground material is material is too low personnel system (1.0).
too great
The grinding surfaces Maintenance ● Carry out wear
of the rolls are worn out personnel measurement (see
page 8-17).
Excessive basic gap Maintenance ● Set the basic gap

personnel (see page 7-5).
Mill feed material is not Maintenance ● Refurbish the

pulled into the roll gap personnel profiling (see the
machine manual for
the roll unit).
The hard-metal liner Maintenance ● Replace the hard-

plates in the vertical personnel metal liner plates
feed shaft are worn out (see machine
manual for the feed
material guide).
The wear plates in the Maintenance ● Replace the hard-

vertical feed shaft are personnel metal liner plates
worn out (see machine
manual for the feed
material guide).
Power consumption of Insufficient material Operating ● Increase the

the motors decreases feed rate personnel material feed rate.
Wear on the rolls Maintenance ● Carry out wear

personnel measurement (see
page 8-17).
● Set the basic gap
(see page 7-5).
The two main motors The distribution of the Maintenance ● Make the material
have widely differing feed material on the roll personnel feed uniform.
power consumptions units is too uneven
®

personnel
Insufficient number of Pipe breakage or leaky Maintenance ● Check and repair

switching pulses at the pipe unions personnel the piping and the
lubricant distributor pipe unions.
Indication
Lubricant distributor Maintenance ● Check the lubricant
Signal from limit switch (3.4.4, 3.4.5) blocked personnel distributor (3.4.4,
(3.4.6, 3.4.7) 3.4.5) for blockages
and clean it.
Faulty limit switch Maintenance ● Replace the limit

(3.4.6, 3.4.7) personnel switch (3.4.6, 3.4.7).
Due to the low Maintenance ● Heat the grease

temperature, the grease personnel reservoir.
is too stiff; the pump
(3.3) is not sucking in
enough grease
The solenoid valves Maintenance ● Check the power

(3.4.2, 3.4.3) are not personnel supply. Replace
switching solenoid valves
(3.4.2, 3.4.3) if
necessary.
Faulty pump (3.3) Maintenance ● Check the drive side

personnel and the pressure
side of the pump
(3.3) and repair it.
The screen filter of the Maintenance ● Clean the screen

filter (3.4.1) is clogged personnel filter.
The pump (3.3) is Maintenance ● Grease the seal.

sucking air in because personnel
the seal at the pump
rod is leaky
The grease reservoir is Maintenance ● Replace the grease

bulged personnel reservoir.
The filling level monitor Not enough grease in Maintenance ● Replace the grease
(3.3.3) of the barrel the grease reservoir personnel reservoir by a filled
responds grease reservoir.
Indication
Level switch ≤ min.
Observe the additional information about faults, their causes and their
elimination, in the subsuppliers' documentation.
®
9.2 Recommissioning after fault elimination

After the fault has been eliminated, carry out the following steps:
1. Remove all tools from the plant.
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.
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 the test run (see page 7-3).
en-PM.CPT.001.D Spare parts
®
10 Spare parts
10.1 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-PM.CPT.001.D Disassembly and disposal
®
11 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 are safely
dismounted with all of the specified fastening devices.
11.2 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.
● Stop the material feed and wait until there is no longer any material in the
machine.
● Switch off the machine and secure it against restarting.
● Allow the machine to cool down to ambient temperature.
Disassembly and disposal en-PM.CPT.001.D
®
11.3 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 may cause skin irritation and allergic reactions.
thoroughly.
necessary.
CAUTION

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 you store, use and
dispose of lubricants.
II. Be sure to comply with the applicable national regulations for the
protection of the environment when handling lubricants.
en-PM.CPT.001.D Appendix
®
12 Appendix
12.1 Technical drawings
For drawing numbers, please refer to the table of contents of this folder.
12.2 Measurement records
Designation
®
PM.01, POLYCOM baseframe
12.3 Special tools
List of special tools
12.4 Further documents, regulations
Designation
Grouting work on machine foundations
12.5 Subsuppliers' documentation
Designation Subsupplier
Central lubrication system DELIMON
Power torque wrench WAGNER

(POC: 8F1.ZT01)
Solenoid valve BUSCHJOST
Limit switch SCHNEIDER ELECTRIC
Vibration sensor BRÜEL & KJAER VIBRO

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POLYCOM® high-pressure grinding roll

Plant Order Code (POC)

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

4.2.4 Hydraulic system (4.0) .......................................................................... 4-28

12 Appendix ............................................................................................. 12-1

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 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

Qualified hydraulics specialist

2.7 Safety and monitoring equipment

Defective safety and monitoring equipment

EMERGENCY OFF button

2.7.1 Safety devices to be retrofitted

Unsecured or unmarked hazardous points

Securing against restarting

Integration into an EMERGENCY OFF concept

2.8 Personal protective equipment

2.8.1 Personal protective equipment for all work

2.8.2 Personal protective equipment for special work

2.9 Fundamental hazards

2.9.1 Overview of residual risks

Hazard Source of hazard

Crushing Closing and opening of inspection doors (2.3),

Between stationary and moving components of

Rotating components at the drive (5.0)

Rotating roll units

Suspended loads and moving components

Bearing blocks (6.1, 7.1) swinging out when

Drawing-in or trapping Rotating components of the drive (5.0)

Rotating roll units

Impact Protruding components

Falling material in the outside area or when

Suspended loads and moving components

Penetration by pressurised media Escaping hydraulic oil

Escaping cooling water

Slipping, tripping or falling Uncovered wires and cables

Unsafe access points