Claudius Peters

Clinker Cooler Technology

Picture no. 1

Claudius Peters
Clinker Cooler Technology

Inspection and Maintenance

Picture no. 2

Inspection and maintenance

Picture no. 3

Note: All discrepancies must be documented in writing and in the form of digital photos and sent to Claudius Peters without delay. rust fallthrough in the lower section of the cooler etc. - General status Check the general status and any discrepancies of the clinker cooler. gaps in the air lines.g. plastic bags. 4 . altered running noises. Picture no. e. e. leaks in the hydraulic system. from the ventilator suction area.Inspection and maintenance Daily inspection (visual controls) Foreign bodies Remove foreign bodies.g.

the entire hydraulic plant can incur such damage as to render it non-functioning. Top up the hydraulic oil if necessary. The hydraulic plant should be filled in accordance with the hydraulic operating instructions. The hydraulic oil must not fall below the minimum level.Inspection and maintenance Weekly inspection Once a week The entire interior lighting in the ETA clinker cooler must be switched on once a week. If it transpires that hydraulic oil is leaking. Drive module interior The interior of the drive module must be inspected in the area of the hydraulic cylinder for any leaking hydraulic oil. Visual inspections via the peepholes in the lower section of the cooler should establish whether there is any clinker in the lower section of the cooler interior and whether any areas can be detected in which clinker has collected owing to leakages in the lane seal. the oil level should be checked on the hydraulic plant. the cooler must be switched off and the leak repaired. If the hydraulic oil is not topped up. If it is not possible to switch off the cooler immediately. Picture no. 5 .

The actual situation must be communicated immediately to Claudius Peters in the form of a written description. If possible. digital photos should be taken and enclosed with the report for Claudius Peters. Picture no. 6 . closer inspection and documentation of the actual situation is required.Inspection and maintenance Attention Oil leaks should always be repaired as quickly as possible - If larger volumes of clinker or oil slicks have accumulated in the interior of the lower section of the cooler.

The entire lane bottom sealing system must then be examined for damage. the entire clinker must be removed from the HE module and lane bottoms. The following hard-facing electrodes should be used for this purpose: E10–UM–65GRZ as per DIN 8555. including the protective clinker layer on the lane bottoms. If wear is apparent in other areas where there is no hard-facing.g. If any hard-faced plates reveal signs of extensive wear. 7 . UTP Ledurit 65 or 76 from Böhler. Damaged components must be replaced with new components or repaired if possible.Inspection and maintenance Inspection stop During an inspection stop. whereby the processing information provided by the supplier must be observed - Picture no. such areas can also be protected by means of hard-facing. e. they may be re-faced.

8 . Picture no. If these hard-faced plates show signs of wear.Inspection and maintenance Attention The hard-faced plates in the area of the HE module transverse seal are ground and may not be retrofitted with hard-facing. they should be replaced by new ones.

The share of grains smaller than 16 mm must not exceed 5%. Rounded stones with a smooth and flat circular shape or surface from streams or rivers can be assumed. Bulk density of approx. Specifications as per EN12620. clinker must be spread to a minimum height of 30 cm on all of the grate plates in the HE module. Broken bits may only be present in the smallest of volumes. HE module Before putting the cooler back into operation. Unbroken. natural grains of rock which are washed and only contain low volumes of broken bits or pieces which can become detached.6 t/m³.Inspection and maintenance Guidline for first filling of lanes (pebbles) Grain fraction of 16 to 32 mm. 520 kg/m² can be applied as a guideline for the pebbles volume required. 9 . Picture no. The pebbles specified above can also be used for the first filling of the HE-Module. 1. Lanes The lanes must be filled with pebbles as specified above at least as far as the top edge of the longitudinal seals and/or to the top edge of the lane transverse webs. Gravel is not permitted.

Picture no.Inspection and maintenance Lane flange fastening The fastenings for all lane flanges must be inspected visually. If the clearance is greater than 13 mm. the screws must be burned off and replaced with new screwed elements. 21CrMoV57 should be used as screw material. whereby the correct electrode must be observed – please refer to the spare parts documentation. The thread in the new screws should be coated with hot grease such as Molycote HSC Plus. The flanges are tightened using 4 x M30 screws. 10 . The screws should be tightened to 880 Nm and the locknuts secured via tackwelding. The specified clearance of 10 mm between the lanes should be measured.

All slot plates should be dismantled. the worn grate plates must be replaced. Clean the aeration system if necessary. 11 . If extensive signs of wear are apparent.Inspection and maintenance HE-Module Slot Plates The HE module Slot Plates must be inspected for wear. they should be cleaned. Picture no. When the grate plates are re-assembled. This will enable inspection of the aeration box underneath in terms of whether clinker has become lodged in the aeration boxes. e.g. the screw threads should be coated with hot grease before assembly. If the slots have become clogged with clinker. using Molykote HSC plus.

If major deformation is established which can lead to operating faults. The refractory concrete must be replaced or repaired in the case of major wear preventing the HE module aeration box from being sufficiently protected against wear and heat. Please ensure that the gap between the hard-faced plate and lane (5-8 mm when new) is not less than 3 mm as otherwise the hard-faced plate can get jammed in the lane. Open gaps through which clinker can get into the space underneath the HE Module can be closed by welding flat steel bars to the transverse sealing plates.Inspection and maintenance HE-Module scraper with refractory The HE module scraper must be inspected for deformation and refractory concrete wear. Picture no. 12 - - . Claudius Peters should be informed and the damage should be documented in the form of a photo. the scraper may need to be removed and aligned or a new scraper installed.

Inspection and maintenance HE-Module scraper without refractory The HE module scraper must be inspected for deformation wear. Claudius Peters should be informed and the damage should be documented in the form of a photo. the scraper may need to be removed and aligned or a new scraper installed. Open gaps through which clinker can get into the space underneath the HE Module can be closed by welding flat steel bars to the transverse sealing plates. If major deformation is established which can lead to operating faults. - Picture no. Please ensure that the gap between the hardfaced plate and lane (5-8 mm when new) is not less than 3 mm as otherwise the hard-faced plate can get jammed in the lane. 13 .

14 - - . the scraper may need to be removed and aligned or a new scraper installed. The protective grates above the cover plates (15) may only be removed for cleaning the space above as long as the hydraulic system is secured against movement and the lanes are fixed in their positions. Please ensure that the gap between the hard-faced plate and lane (5-8 mm when new) is not less than 3 mm as otherwise the hard-faced plate can get jammed in the lane. Open gaps through which clinker can get into the space underneath the HE Module can be closed by welding flat steel bars to the transverse sealing plates. Claudius Peters should be informed and the damage should be documented in the form of a photo.Inspection and maintenance HE-Module with air vessel: scraper The HE module scraper must be inspected for deformation wear. If major deformation is established which can lead to operating faults. Otherwise there is danger of life! Picture no.

15 .Inspection and maintenance Hydraulic cylinder screwed connections on lane The screwed connection between the hydraulic cylinder and lane (front cylinder fastening) must be tightened to 160 Nm and the screwed connection between the hydraulic cylinder and steel construction on the lower cooler section (rear cylinder fastening) must be tightened to 570 Nm alternative hydraulic cylinder installations Picture no.

Picture no. in a protective arrangement within a sheet steel housing. The thermo couplings are located under the first lane (inlet module) and on top of the lane (lane transverse webs).Inspection and maintenance Defective thermocouples - Defective thermo couplings secured to the lanes must be replaced by new ones. 16 .

Do this by unscrewing the locknut from the side wall support.Inspection and maintenance Defective halogen lamps - Defective halogen lamps arranged in the individual air chambers within the lower cooler section must be replaced with new ones. 17 . Picture no. The entire lamp can then be removed from the air chamber and a new halogen lamp inserted in the socket.

otherwise they have to be replaced. they can be re-used. In case of re-using existing plates. 18 . Picture no. If they are not excessively worn. they should be reinserted into the fastening pockets turned by 180°( old front side is new back side).Inspection and maintenance Ceramic plates at ends of longitudinal sealing Ceramic plates at the end of the longitudinal sealings have to be taken out of the fastening pockets and inspected for wear.

19 .Inspection and maintenance Roller Picture no.

Inspection and maintenance All rollers All rollers must be fully lubricated using 450 . A pneumatic barrel pump can be used for filling in the lubricating grease. - - Picture no. The clearance between the guide rail and the side flanged wheel on the cover should not be more than 4 mm on either side. In the case of more extensive wear. the worn roller and side flanged wheel should be replaced with new components. But please ensure that the dust fall-through into the lower section can increase with roller wear as the clearances in the longitudinal seals also increase. In the case of more extensive wear. The roller. these screws must be tightened to 110 Nm. the worn covers should be replaced with new ones.e. The cover screws (item 110) must not have slackened but if they have.500 gr LGH B2 lubrication manufactured by SKF. Roller wear may be max. minimum diameter = 222 mm. 8 mm in relation to the diameter. The filling volume can be set by fitting a flow meter. The old grease is forced out by a pipe on the pillow block and can be collected in a basin. i. Grease complying with DIN 51825: KP2N-20 can also be used. side flanged wheel on the cover and the guide rail must be inspected for wear. 20 .

Picture no. the worn grate bars should be replaced. its antenna must be inspected for wear. If it displays extensive signs of wear. 21 . please check whether the PTFE seal needs to be replaced. Please refer to the Saab Tank Radar PRO User Manual. If necessary.Inspection and maintenance All inspection windows All inspection windows in the lower and upper cooler sections must be cleaned thoroughly. Furthermore. Radar level metering device in units 2-7. the aerial must be replaced with a new one. Inspection windows are also fitted in the interior longitudinal partion walls in the first module units (side aeration) on the lower cooler section. Grate bar chute The grate bar chute must be inspected for wear. Level radar If a level radar device is fitted.

Inspection and maintenance Attention The radar device electronics are cooled via a compressed air connection. When the compressed air fails. A water separator must be integrated in the compressed air line as otherwise a water/slick mixture can become deposited in the aerial and an incorrect clinker bed height is displayed. Please refer to the Spare Parts documentation. please document using a digital camera and send the photos along with a written description to Claudius Peters without delay. If damage is established. 22 . Picture no. the electronics are not cooled but rather destroyed. - - Note Only original Claudius Peters parts should be used as spare parts.

6-01: 1 Roller 2 Lane 3 Clamping sleeve a Front end position of cylinder b Clinker flow direction Picture no.185kg Key to Fig. 23 .Inspection and maintanance Dismantling and assembling components Roller.

Inspection and maintenance

Dismantling rollers
Dismantling Drive the hydraulic cylinder into the front end position (max. cylinder stroke = 420 mm); the piston rod is fully extended. Knock out the clamping sleeves. Remove the screws. Support the lane in the roller area. Secure the roller using lifting rope and then pull down from the transverse girder support. Only one roller may be dismantled per lane at any one time. Only once the roller has been fully re-assembled may the next roller be dismantled. Assembly Slide the new roller under the guide rail and position. Knock in the clamping sleeves. Mount the fastening screws and tighten to 380 Nm. Dismantle the provisional lane support.

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Picture no. 24

Inspection and maintenance

Guide rail, 81kg
Key to Fig. 6-02: 1 Guide rail 2 Lane 3 Clamping sleeve a Rear end position of cylinder b Clinker flow direction

Picture no. 25

Inspection and maintenance

Dismantling the guide rail
Dismantling Drive the hydraulic cylinder into the rear end position (max. cylinder stroke = 420 mm); the piston rod is fully retracted. Only one guide rail may be dismantled per lane at any one time. Only once the guide rail has been fully re-assembled may the next guide rail be dismantled. Provide the lane with provisional support. Knock out the clamping sleeves. Remove the screws. Pull out the guide rail. Assembly Slide the new guide rail over the roller. Knock in the clamping sleeves. Secure the guide rail with the screws. Screw torque: 380 Nm. Dismantle the provisional lane support.

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70 to 115kg Dismantling the longitudinal sealing(A) 1 2 3 4 longitudinal sealing Screw to fix longitudinal sealing Steel part. 27 .Inspection and maintenance longitudinal sealing for 2nd module to outlet module. top section Lower side wall 5 6 7 a Bracket Lane Fire-proof Nut filled with grease Picture no.

b Gap 1-2 mm Picture no.Inspection and maintenance Dismantling the longitudinal sealing(B) 1 Screw to fix lengthwise sealing 2 3 4 Adjustable screw Seal flat steel Seal plate a After assembly. seal gaps between sealings with Epple 37. 28 .

If the fireproof area is cut out using a circular saw and cooled with water during the cutting process. The gap should not be wider than 4 mm. - - Picture no. Walking lanes must be covered with wooden panels of at least 20 mm thick as well as high-strength sealing foil to ensure that no water profiles can flow into the walking lane. the following must be observed: All walking lanes and seals must be exhausted until clean. a new seal flat steel must be fitted. If the gap is too wide. 29 . The cooling water must be suctioned out permanently during cutting.Inspection and maintenance Dismantling The fireproof mass on the lengthwise sealing must be removed in this section. Examining the seal flat steel for wear: if the specified gap of 1-2 mm is wider due to wear and the gap can not be set by means of readjustment owing to the extent of wear. The screws for fixing the side sealing can be unscrewed as the nuts are welded to the sheet metal bracket on the lower side wall. clinker can penetrate to the internal seal where it can cause extensive wear in terms of the sealing elements.

If screws in the lengthwise sealing are damaged.g.g. Molycote HSC plus. The following must be observed when mounting longitudinal seals: The longitudinal seal gaps must be sealed using new seals. e. The screws on the internal seal components to a torque of 38 Nm. Carefully coat the fixing screw threads with hot grease such as Molycote HSC Plus.Inspection and maintenance Assembly Fill the nut with hot grease. 30 - . the lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP Picture no. Inject new fireproof mass on to the lengthwise sealings. Screw torque: 100 Nm. ATTENTION!: The walking lane in this area must be covered before injecting the mass. Note: Prior to putting the cooler back into operation. The gap is adjusted by means of an adjustable screw. The longitudinal seals should be set so that the gap between them and the seal flat steel is 1-2 mm. Mount the lengthwise sealing using fixing screws. new screws must be used. A seal bonding agent can also be used instead of seals. e. Epple 37.

31 .Inspection and maintenance Central longitudinal sealing for 2nd module to outlet module. 55 to 82kg Dismantling the central longitudinal sealing 1 Central longitudinal sealing 2 Epple 37 Seal 3 Joggle 4 Fastening screw 5 Retaining washer 6 Washer 7 8 9 a b c Walking lane Sealing plate Sealing flat iron After assembly. seal gaps between lengthwise sealings with Epple 37. Walking lane Gap 1-2mm Picture no.

a new seal flat steel must be fitted Picture no. Detach the joggle Pull out the lengthwise sealing Examine the seal flat steel for wear: if the specified gap of 1-2 mm is wider due to wear and the gap can not be set by means of readjustment owing to the extent of wear. 32 .Inspection and maintenance Dismantling Unscrew the fastening screws.

.Set a gap of 1-2 mm.Insert the fixing screws along with the washers and retaining washers.Weld the joggle to the lengthwise sealing transverse fin ensuring the correct electrode.Fill sealing putty. into the lengthwise sealing gap (area covering the lengthwise sealings) Note: Prior to putting the cooler back into operation. the lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP Picture no. Epple 37.Weld half the perimeter of the washer to the lengthwise sealing .Slide in the longitudinal sealing. Please also refer to the module on Spare Parts .Inspection and maintenance Assembly . . . e.g. 33 . new screws must be used.Tighten the fixing screws to a torque of 135 Nm . Carefully coat the fixing screw threads with hot grease such as Molycote HSC Plus .If screws in the lengthwise sealing are damaged.

Inspection and maintenance Side sealing for 1st module (inlet module). 65 to 115 kg Dismantling the side sealing. 1st module 1 2 Hard-faced plate Side sealing inlet module 3 4 Transverse sealing plate Plate fastening Picture no. 34 .

35 .e. the hydraulic cylinder piston rod is fully retracted and in rear cylinder end position Remove the fireproof mass from the longitudinal sealings Disassemble the transverse sealing plate Dismantle the side sealing Examine the internal longitudinal sealing components for signs of wear as well as their gaps - Picture no. i.Inspection and maintenance Dismantling - Use the hydraulic cylinder to pull the side lane towards the cooler outlet.

g.Inspection and maintenance Assembly Fill the nut with hot grease. Please refer to the respective instructions for the next steps in assembling the longitudinal sealing. Install the transverse sealing plate - ATTENTION! The longitudinal sealing’s ground hard-faced plate (in the area of the cross sealing) must be aligned in such a way that it is at right angles to the HE module’s ground hard-faced plate. the lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP Picture no. e. 36 . Molykote HSC Plus If screws in the longitudinal sealing are damaged. new screws must be used. Note: Prior to putting the cooler back into operation. Carefully coat the fixing screw threads with hot grease such as Molycote HSC Plus.

6-07: 1 Roller 2 Lane 3 Clamping sleeve a Rear end position of cylinder b Clinker flow direction Picture no.Inspection and maintenance Central longitudinal sealing for 1st module (inlet module). 1st module Key to Fig. 37 . 73 to 82 kg Dismantling the central longitudinal sealing.

i. Please refer to the respective instructions for the next steps in assembling the lengthwise sealing. Note: Prior to putting the cooler back into operation. please refer to the respective instructions.Inspection and maintenance Dismantling Use the hydraulic cylinder to pull all of the side lanes towards the cooler outlet. Carefully coat the fixing screw threads with hot grease such as Molycote HSC Plus. 38 . the lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP Picture no. The lengthwise sealing secured before that may also have to be dismantled. Assembly If screws in the longitudinal sealing are damaged.e. Dismantle the lengthwise sealing. new screws must be used. Disassemble the transverse sealing plate. Install transverse sealing plate. the hydraulic cylinder piston rod is fully retracted and in rear cylinder end position.

39 . 510 to 950 kg Dismantling the side lane.Inspection and maintenance Side lane for 2nd module to outlet module. 2nd module 1 2 3 Lane Roller Guide rail 4 5 Clamping sleeve 12 mm sealing profile Picture no.

Drive the hydraulic cylinder in the adjacent lane into central position (max. cylinder stroke = 420 mm). 40 . Pull 4 steel cables through the front wall of the inlet chute and through the rear cooler wall and then pretension them. Picture no. D=12 mm steel cables should be used with a strap at the end.Inspection and maintenance Dismantling Drive the hydraulic cylinder into central position (max. cylinder stroke = 420 mm).

Inspection and maintenance Removing lanes 1 2 Grip for cable pretensioning Rope end with strap 3 a Rope (for lifting) Steel cable Picture no. 41 .

Picture no.0 tonnes. each 2 tonnes. Attach rope pulleys to the steel cable. each 2. Secure the BKS tensions to the short cable attached to the steel claw and rope pulley. Plus 2 2. Secure shackles to the short cable.Inspection and maintenance Per cable. Secure the steel claws to the transverse fins of the lane to be removed using a short cable and strap. 42 . 4 rope pulleys for 12 mm steel cable. one 1.5 tonne grip is required for pretensioning. Pretension the BKS tension chains to secure the lane. ATTENTION! The side lane is not easy to remove as the lane is arranged under the side sealing. 4 shackles. 4 BKS tensions with 3-metre chains for lifting the lane.5 tonne steel claws with short steel cable and straps for lifting the lane.

Inspection and maintenance 2 proposals for dismantling: Picture no. 43 .

Inspection and maintenance Proposal 1: Dismantle the side sealings in the area of the lane to be removed Dismantle the central longitudinal sealing in the area of the lane to be removed For the drive area only: dismantle the cylinder fixture on the lane. please use these components for the new lane. If they can still be used. all parts displaying signs of wear must be replaced with new ones ATTENTION! The remaining lanes in the same lane must be secured in such a way that they are unable to slide longitudinal during assembly and thereby fall from the rollers. As a general rule however. Use the lifting equipment to pull the lane out of the rear wall door using the rope pulleys. Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws. Dismantle all of the lane securing components and examine their function. 44 . Picture no.

45 .Inspection and maintenance Proposal 2: Removing lanes 1 2 3 Guide rail Seal angle Partition wall a b c Burn off nut Lane Shorten the partition wall Picture no.

Inspection and maintenance - Remove the lane beside the side lane and place on top of the other lane. 46 . Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws. Dismantle the guide rail from the side lane to be removed Dismantle the partition wall seal angle. Picture no. Cut off approx. 50 mm of the partition wall under the lane (opposite the roller). For the drive area only: Dismantle the cylinder fixture on the lane.

47 . 40 mm so that the lane can be pulled out sideways from the cover on the side sealing. As a general rule however. please use these components for the new lane. Use the lifting equipment to pull the lane out of the rear wall door using the rope pulleys. Dismantle all of the lane securing components and examine their function. ATTENTION! The remaining lanes in the same lane must be secured in such a way that they are unable to slide longitudinal during assembly and thereby fall from the rollers.Inspection and maintenance - Lower the lane by approx. If they can still be used. all parts displaying signs of wear must be replaced with new ones. Picture no.

- Assembling lanes Key to Fig.g. Pull the lane into assembly position in the cooler. please examine whether it is the right one. 48 . L=590 mm under the two flange areas. SB5 / SB7 – is the same as the marking on the lane plan. Use silicone to attach a new sealing profile D=12 mm. 6-13: 1 Sealing profile 2 Lane flange Picture no.Inspection and maintenance Assembling proposal 2 Before fitting the new lane. This can be established by checking to see if the marking on the underside of the lane – e.

Mount the new screws for securing the lane flange. - Picture no. coat the screw threads with Molycote HSC Plus hot grease. all parts displaying signs of wear must be replaced with new ones Slide the lane under the side sealing. ATTENTION! Prior to mounting all of the screws. Tack the locknuts for securing the flange to the screw threads ensuring the correct electrodes. Use the screws to loosely secure the guide rail. 49 . Slide the guide rail under the lane and secure with the clamping sleeves. Please observe the nut torque.Inspection and maintenance - Mount all of the lane securing components. As a general rule. Tighten the screws to the specified torques.

50 . the lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP Picture no. Mounting the cylinder fixture 1 Cylinder position transmitter. Tighten the screws to the appropriate torque.Inspection and maintenance For the drive area only: Mount the cylinder fixture on the lane. Note: Prior to putting the cooler back into operation. arranged below 2 Steel part. lower section a Walking lane - Dismantle the mounting aids.

51 . 2nd module 1 2 3 Lane Roller Guide rail 4 5 a Clamping sleeve 12 mm sealing profile Tacked nut Picture no. 510 to 950kg Dismantling the central lane.Inspection and maintenance Central lane for 2nd module to outlet module.

cylinder stroke = 420 mm). please use these components for the new lane. As a general rule however. If they can still be used. all parts displaying signs of wear must be replaced with new ones. The remaining lanes in the same lane must be secured in such a way that they are unable to slide longitudinal during assembly and thereby fall from the rollers. Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws. 52 . Dismantle all of the lane securing components and examine their function. Use the lifting equipment to pull the lane out of the rear wall door using the rope pulleys.Inspection and maintenance Dismantling Drive the hydraulic cylinder into central position (max. Picture no. Mount the steel cables in the top section of the cooler and tension Dismantle the central longitudinal sealings For the drive area only: Dismantle the cylinder fixture on the lane.

Use silicone to attach a new sealing profile D=12 mm. 6-16: 1 Sealing profile 2 Lane flange Picture no. please examine whether it is the right one.Inspection and maintenance Assembly Before fitting the new lane. SB5 / SB7 – is the same as the marking on the lane plan Pull the lane into assembly position in the cooler. L=590 mm under the two flange areas. This can be established by checking to see if the marking on the underside of the lane – e. 53 . - Assembling lanes Key to Fig.g.

Tack the locknuts for securing the flange to the screw threads ensuring the correct electrodes. all parts displaying signs of wear must be replaced with new ones Mount the new screws for securing the lane flange. 54 . Please observe the nut torque. Tighten the screws to the specified torques. Picture no. coat the screw threads with Molycote HSC Plus hot grease.Inspection and maintenance - Mount all of the lane securing components. - ATTENTION! Prior to mounting all of the screws. As a general rule.

Inspection and maintenance For the drive area only: Mount the cylinder fixture on the lane. 55 . Mounting the cylinder fixture 1 Cylinder position transmitter. the lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP Picture no. Tighten the screws to the appropriate torque. Note: Prior to putting the cooler back into operation. arranged below 2 Steel part. lower section a Walking lane - Dismantle the mounting aids.

6-18: 1 Lane inlet Dismantling side lanes Picture no. 550 to 610 kg) Key to Fig. 56 .Inspection and maintenance Side lane for 1st module (inlet module.

Pull 4 steel cables through the front wall of the inlet chute and through the rear cooler wall and pretension them. D=12 mm steel cables should be used with a strap at the end. - Picture no. the piston rod is fully retracted. 57 . Drive the adjacent central lane into the rear cylinder end position.Inspection and maintenance Dismantling Drive the hydraulic cylinder in to the rear end position (max. cylinder stroke = 420 mm). Please refer to the respective instructions for all other mounting aids and how to secure the lanes. ATTENTION! The side lane is not easy to remove as the lane is arranged under the side sealing.

Use the lifting equipment to pull the lane out of the rear wall door using the rope pulleys. Dismantle the cross sealing from the lane Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws. As a general rule however. please use these components for the new lane.Inspection and maintenance 2 dismantling proposals: Proposal 1: Dismantle the side sealings in the area of the lane to be removed Dismantle the central longitudinal sealings in the area of the lane to be removed. If they can still be used. 58 . all parts displaying signs of wear must be replaced with new ones ATTENTION! The remaining lanes in the same lane must be secured in such a way that they are unable to slide longitudinal during assembly and thereby fall from the rollers. Picture no. Dismantle all of the lane securing components and examine their function.

If they can still be used. As a general rule however. ATTENTION! The remaining lanes in the same lane must be secured in such a way that they are unable to slide longitudinal during assembly and thereby fall from the rollers. Dismantle all of the lane securing components and examine their function.Inspection and maintenance Proposal 2: Remove the central lane positioned beside the side lane and place it on the other lanes Dismantle the guide rail from the side lane to be removed Dismantle the partition wall seal angle. Picture no. Cut off approx. all parts displaying signs of wear must be replaced with new ones. 50 mm of the partition wall under the lane (opposite the roller) Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws Lower the lane by approx. please use these components for the new lane. Use the lifting equipment to pull the lane out of the rear wall door using the rope pulleys. 40 mm so that it can be pulled out sideways from the cover on the side sealing. 59 .

This can be established by checking to see if the marking on the underside of the lane – e. SB1 / SB3 – is the same as the marking on the lane plan. - Assembling lanes Key to Fig. Use silicone to attach a new sealing profile D=12 mm.g.Inspection and maintenance Assembly Before fitting the new lane. 60 . 6-20: 1 Sealing profile 2 Lane flange Picture no. L=590 mm under the two flange areas. please examine whether it is the right one. Pull the lane into assembly position in the cooler.

Please observe the nut torque. Dismantle the mounting aids. 61 . As a general rule. Position the central lane arranged beside the side lane and mount. please refer to the module of Spare Parts. ATTENTION! Prior to mounting all of the screws. Mount the new screws for securing the lane flange. Tack the locknuts for securing the flange to the screw threads ensuring the correct electrodes. All components must be set to the specified gaps. - Picture no. all parts displaying signs of wear must be replaced with new ones Slide the lane under the side sealing. Slide the guide rail under the lane and secure with the clamping sleeves.Inspection and maintenance Mount all of the lane securing components (internal sealing parts). Use the screws to loosely secure the guide rail. Mount the central longitudinal sealings Re-weld the partition wall and mount the partition wall seal angle if dismantling is in accordance with Proposal 2. coat the screw threads with Molycote HSC Plus hot grease. Tighten the screws to the specified torques.

590 kg Dismantling the central lane 1 Lane inlet Picture no. 62 .Inspection and maintenance Central lane for 1st module (inlet module).

the piston rod is fully retracted. Dismantle the central longitudinal sealings in the area of the lane to be removed Dismantle the cross sealing from the lane Picture no. 63 . cylinder stroke = 420 mm).Inspection and maintenance Dismantling Drive the hydraulic cylinder in to the rear end position (max.

please use these components for the new lane. Dismantle all of the lane securing components and examine their function. D=12 mm steel cables should be used with a strap at the end. As a general rule however. Secure the lane with the lifting equipment. Use the lifting equipment to pull the lane out of the rear wall door using the rope pulleys.Inspection and maintenance Pull 4 steel cables through the front wall of the inlet chute and through the rear cooler wall and pretension them. all parts displaying signs of wear must be replaced with new ones - ATTENTION! The remaining lanes in the same lane must be secured in such a way that they are unable to slide longitudinal during assembly and thereby fall from the rollers Picture no. 64 . If they can still be used. Burn off the screwed connections at the hexagonal nuts on each side of the lane flange and knock out the screws.

65 .Inspection and maintenance Assembly Before fitting the new lane. - Assembling lanes Key to Fig. please examine whether it is the right one. Pull the lane into assembly position in the cooler. Use silicone to attach a new sealing profile D=12 mm.g. SB2 – is the same as the marking on the lane plan. L=590 mm under the two flange areas. 6-23: 1 Sealing profile 2 Lane flange Picture no. This can be established by checking to see if the marking on the underside of the lane – e.

please refer to the Full Module documentation. coat the screw threads with Molycote HSC Plus hot grease. Mount the new screws for securing the lane flange. Mount the cross sealing. 66 . ATTENTION! Prior to mounting all of the screws. Tack the locknuts to the screw threads ensuring the correct electrodes. the lanes and seal areas must be filled with pebbles in accordance with the specifications outlined by CP.Inspection and maintenance Mount all of the lane securing components. As a general rule. Dismantle the mounting aids. Tighten the screws to the specified torques. all parts displaying signs of wear must be replaced with new ones. Note: Prior to putting the cooler back into operation. Please observe the nut torque. Lift the lane into position. All components must be set to the specified gaps. - Picture no.