Document No.

INSTRUCTION MANUAL KK-24160

Date Edition Page
2011-02-22 1 (45)
From Reg. No.
J. Asplund 821251

WIRE ROD BLOCK

TYPE P-815

SERVICE MANUAL

00 110222 1st issue JaaS JaaS Pebe

Re Date Issue Compiled Checked Approved

1
1. INTRODUCTION

This Morgårdshammar wire rod block type P-815 is designed to produce

quality rod at high finishing speed.

Great attention has been payed to the stiffness of the stands to meet the
market demands of close tolerances.

The 45° arrangement and the ergonomic design are contributing factors to
short stop-times for inspections, roll changes and guide adjustments from
both sides of the block.

In this manual you will find instructions and suggestions for periodic
inspections and repair. The instructions apply generally to roll units type P-
815 (170 mm dia) and P-820 (223 mm dia). They are intended for
installations that are fully complete with regard to both roll units and
auxilliary equipment.

For additional drawings, sub-instructions and spares list, see the order
specifications. When spare parts are ordered, always refer to the
Morgårdshammar order No. and drawings.

2
2. TECHNICAL DATA

2.1 General

No. of stands 4-6-8 or 10

Configuration 45°
Total width 2300 mm
Total height (cover down) 1700 mm (from floor level)
Pass line level +1000 mm

Wire Rod Block with Protection Cover open

3
2.2 P-815 Data

Rolling speed, max 100 m/s

Design speed 110 m/s
Stand c/c spacing 740 mm
Roll diameter change 170/150 mm
Roll shaft distance 150/172 mm
Roll shaft dia, front end 120 mm
Roll shaft dia, rear end 90 mm
Roll ring width 70 (31) mm
No. Of grooves 2
Roll shaft bearing Oil film type
Axial adjustment range ± 0.3 mm
Rolling force, max 18 kN
Rolling torque, max 2000 Nm
Elastic module 30 kN/mm
Entry size, max dia 17 mm
Roll unit weight 1450 kg

2.3 P-820 Data

Rolling speed, max 70 m/s

Rolling speed, min 3 m/s
Stand c/c spacing 740 mm
Roll diameter change 223/197 mm
Roll shaft distance 200/222 mm
Roll shaft dia, front end 160 mm
Roll shaft dia, rear end 120mm
Roll ring width 70 mm
No. Of grooves 2
Roll shaft bearing Oil film type
Axial adjustment range ± 0.3 mm
Rolling force, max 30 kN
Rolling torque, max 5000 Nm
Elastic module 40 kN/mm
Entry size, max dia 25 mm
Roll unit weight 1900 kg

4
3. MAINTENANCE

3.1 General

When the finishing block is in operation a visual inspection should be done

at least once a day by a maintenance man.

Listen for unusual noise coming from bearings and gears. Check the
temperature by reading the automatic monitoring system.

3.2 Facilities

It is very important that a specially equipped service shop is provided where

roll units and gearboxes can be disassembled, inspected and reassembled
in a clean area.

The following facilities should be available:

• Workingtable with lifting devices.

• Lifting hoist for lifting of roll unit.

• Hydraulic jack with equipment for mounting and dismounting of gear

couplings by means of the SKF oil injection method.

• Tools for mounting and dismounting of oil film bearings.

• Optical setting instrument for guide equipment and pass line control.

• Complete set of socket spanners, box spanners, allen keys and torque
spanners.

• Pallets with protective covers.

• Nylon lifting slings.

5
 3.3 Periodic maintenance programme

General recommendation No. of stands: 10 (typical)

WIRE ROD BLOCK STAND NO.

ACTIVITY 1 2 3 4 5 6 7 8 9 10 FREQUENCY

GENERAL INSPECTION X X X X X X X X X X Once/day

DRIVE SHAFT LUBRICATION X X X X X X X X X X Once/month 2)

ROLL SHAFT SEAL INSP. X X X X X X X X X X Every pass

change

CLEANING OF WATER NOZZLES X X X X X X X X X X Every pass

change

ROLL SHAFT TAPER INSP. Every roll ring

change

ROLL UNIT SERVICE X X After 1) 4000

hours

ROLL UNIT SERVICE X X After 4500 hours

ROLL UNIT SERVICE X X X X After 5000 hours

ROLL UNIT SERVICE After 5500 hours

X X
ROLL UNIT SERVICE After 6000 hours

1) From start of normal production. Periodic maintenance of roll unit based

on section No. 4. Every roll unit should be taken out for service after
approximately 5000 hours in production.
Keep records of the inspection results for each stand.

2) Use Shell, Alvania EP2 or corresponding grease.

(Not relevant for version with oil lubricated drive shafts.)

6
4. ROLL UNIT

4.1 General

The design of the Roll Unit embodies direct transfer of the rolling load
between the roll chocks through a mechanically preloaded mill screw
arrangement, of the same proven design as in the Morgårdshammar
housingless stands. The two rolls are adjusted against the fixed pass line
through the screw arrangement and roll gap setting can be performed with
the block safety hood in closed position.

The roll shafts are radially supported in oil-film bearings of multilayer type in
bush design with groove to ensure stable running at high speed. The axial
support is carried out by an angular contact ball bearing arrangement to
gain maximum stiffness. Axial misalignment between the roll rings grooves
can be corrected through a device, which permits axial adjustment of one of
the roll shafts. The roll chocks are provided with sensors, continously
monitoring the oil temperature from the bearings.

4.2 Removal of a Roll Unit

Precondition:

• Block is stopped and cooling water switched off.

• Oil lubricating system is shut down.

• Air/oil lubricating system for roller guides shall be switched off.

Before a roll unit is separated from the gear box and taken out for service it
must be thoroughly cleaned. Cleaning is recommended with solvent and
hot water washing followed by drying. Avoid direct water splashing into the
sealarrangement behind the roll rings.

7
For removing or installing the roll unit on the gear box, a hand operated
chain hoist is available and shall be put on the mil crane. The mill crane
alone is not satisfactory to control the movement for such operations.

Use wooden blocks or pallet to support the roll unit when it is stored or
transported.

Sequences:

• Dismount the roll rings and guide equipment with lubrication hoses, see
section 5.

• Disconnect the cooling water pipe from the roll unit.

• Remove the protective cover above the junction box for the temperature
sensors.

• Remove one of the inspection covers on the roll unit side so that the
shaft couplings can be seen.

• Disconnect the cable connector from the junction box.

• Fit the lifting eyes to the roll unit and connect the chain hoist. See
sketch how to arrange the lifting eyes.

8
Remove the screws from the joint between the gear box and roll unit.

Note: There are two long screws on the gear box bearing cap.

When a horizontal roll unit is being removed, the remaining oil can be
drained by dismounting drain plug (4D).

• Tension the chain in the chain hoist.

• Fit four M20 dismounting screws into the gearbox flange and press the
roll unit apart from the gearbox.

• Remove the dismounting screws.

• Lift the roll unit approximately 5 mm by means of the chain hoist and
make sure that the roll shaft couplings are completely disengaged
before the unit is taken away by the mill crane. This must be done to
assure that all the bolts are disconnected and to prevent that the
couplings are damaged.

• When the roll unit is removed, clean off mating surfaces on the gearbox
from sealing compound. Be careful to keep dirt out from the gears.

• Protect the gear box by covering it immediately after the cleaning

procedure.

Separation of Roll Unit from Gearbox (typical)

9
4.3 Roll unit assembly

Disassembly must take place in a clean area away from the rolling mill
floor, preferably in the preparation shop for roll units.

Precondition:

• Necessary order specifications and assembly drawings shall be

available.

• Roll rings dismounted according to section No. 5.

• One of the inspection covers on the roll unit side removed.

4.3.1 Roll shaft removal

• Put the roll unit on a table.

• Disconnect the cooling water pipes and remove the guide attachments.

• Pull out ring (10A) and dismount seal cover (10B) with the V-seals.

• Remove inner ring (10C).

10
• Put the lock nut (5) onto the roll shaft. (See section No. 5).
• Fit an eyebolt M56 (included in the supply) to the roll shaft end.
• Connect a dismounting screw, jack, sleeve and nut to the drive side of
the rollshaft. These parts will serve as a stop when the gear coupling is
dismounted by the SKF oil injection method.
• Connect the oil injector to the gear coupling hub and apply the
necessary pressure. Remove the coupling.
• Remove the dismounting screw with jack, sleeve and nut.
• Dismount the lock nut KM12 and washer MB12 behind the thrust
bearings. Use corresponding tool.

• Connect the pressure screw (4E) with nut (4F), washer and bearing
(4G) to the drive end of the roll shaft. Fit the attachment (4H) to the
housing.
• Press the roll shaft (4C) out from the bearing housing (4B) by turning
nut (4F). Let the pressure screw remain to the roll shaft.
• Remove the roll shaft out from the housing and use the pressure screw
for lifting purpose.

Note: Be careful not to damage the sensitive surfaces of the oil film
bearings and the roll shaft. Appendix rubber hose can be put over the
pressure screw as protection.

• Put the roll shaft in wooden V-blocks.

• Remove the other roll shaft in the same way.
• Examine the oil film bearings and the roll shafts. Replace any damaged
or worn parts.

Check the condition of the thrust bearings. Replace damaged or worn

bearings. (See 4.3.3).

Note: The thrust bearings are matched and must be replaced with respect
to that.

11
4.3.2 Oil film bearings

The oil film bearings are of multilayer type bushings. There are three
different sizes in use:

• Front bearing P-815 ID = 120 mm L = 80 mm

• Front bearing P-820 ID = 160 mm L = 100 mm

• Rear bearing P-815 ID = 90 mm L = 80 mm

• Rear bearing P-820 ID = 120 mm L = 80 mm

Front bearing dismounting:

• Fit dismounting washer (4J), sleeve (4K), counter washer (4L), The-
screw with nut (4M) and bearing (4N) to the roll chock.

Note: There is a temperature sensor just behind the bearing.

• Pull out the bearing by turning the nut on the T-screw.

12
Front bearing mounting

Check that the designation is correct with respect to direction of rotation.

This is related to the location of the stand in the block, horizontal or vertical,
see below.

• Clean the bearing seats in the housings carefully with solvent and dry.
Examine the bearing bore. It must be free of damage of any kind. Apply
clean oil in the bore.

• Put the Oil Film Bearing into correct position, according to the above.
Apply clean oil on the outer surface of the bearing.

Connect washer (4L), T-screw with bearing (4M) and washer (4P).

Press the bearing into the seat by turning the nut on the T-screw. Correct
position is flush with the front end of the housing.

Note: The front bearing can be replaced with the thrust bearings kept in
the housing.

13
Rear bearing dismounting:

• Remove the thrust bearing housing.

• Fit the dismounting washer (4R), washer (4L), T-screw with nut (4M)
and bearing. Compare with front bearing dismounting.

• Pull the Oil Film Bearing into the housing and take it out.

Rear bearing mounting:

• Compare front bearing mounting.

• Fit the dismounting washer (4R), the T-screw with bearing and washer
(4M) to the roll chock.

• Pull in the bearing to the correct position (flush with the housing).

Note: The rear bearing can be replaced with the front bearing kept in the
housing.

14
4.3.3 Film bearing examination

When the used Oil Film Bearings are examined, there are two things to
look for, scratches or damage caused by contaminated oil, and wear
caused by shaft misalignment or overload.

The bearing should be replaced if it shows:

Deep circumferential scratches where the copper can be seen.

Wear in the load zone so that the first layer has been passed through.

• A wiped surface which may follow disruption of the oil film due to
extreme loading. In this case the block is stopped automatically
because of the temperature supervision. Before such a bearing is
replaced, the housing bore must be checked with respect to ovality
caused by overheating. Remachining might be necessary.

If the bearing shows light scratches and burnishing in the load zone, they
do not need to be replaced.

We recommend that the oil film bearings are examined according to the
above after approximately 4000 – 5000 hours in use.

4.3.4 Roll shaft assembly

See photos.

• Install the thrust bearing housing to the roll chock.

• Use the pressure screw (4E) to lift the roll shaft into the roll chock.

Note: Be careful not to damage the sensitive surface of the oil film
bearings.

• Install the attachment (4H).

• Fit the washers and bearing (4G) on the outside of the pressure screw.

15
Pull the roll shaft into the housing by turning the nut against the attachment.

Install the thrust bearing housing to the roll chock.

Fit the thrust bearings in O-arrangement. Put on the washer and lock nut
KM12 to the roll shaft.

Remove the cover (4S) and release the axial setting screws (4T). Zero the
axial setting by use of the setting cover (4U).

Mounting of Rollshaft

16
 Mounting of Rollshaft

Checking distance 15.8 mm

• Check the measure 15.8 mm between front plate and roll shaft as
shown on sketch and measured in point indicated below. If necessary,
adjust with shims between the roll chock and the thrust bearing
housing.

17
• When the 15.8 mm has been obtained, fit the gear type couplings to the
roll shaft according to section N0. 8.2.

• Raise the roll unit to an upright position.

• Fit the inner ring (10C), the seal cover (10B) and the ring (10A).

• Install the water cooling pipes and the guide attachments to the
housing.

Note: Be sure that the cooling water nozzles are cleaned before assembly.
(See section No. 9).

Mounting of thrust bearing lock nut

Preloading of thrustbearings by shimsing

18
4.3.5 Temperature sensors

The finishing block is provided with RTD sensors type PT-100, continously
monitoring the bearing temperatures in the roll units. There are also
sensors mounted the high speed shaft bearings on the last four gear boxes
in the block.

When a roll unit roll unit is disassembled, an electrical performance test

shall be carried out, using a measuring instrument to check the resistance.

If a sensor has to be replaced, dismounting shall be carried out by means

of a special spanner 9341699. There are two different sizes of RTD
sensors used, check with the order specification to be sure.

RTD Arrangement

19
5. ROLL RINGS

5.1 General

A unique roll ring mounting system is used to ensure that the cemented
carbide rings are free from radial stress. The fastening is a true axial
clamping of high pressure type which will result in a minimum of roll
breakages and low maintenance for the roll shafts. The axial clamping
method makes it possible to use different width of the carbide rings without
loosing clamping force. Easy and quick roll mounting/removal is carried out
by a hydraulic tool. The carbide rings are watercooled through special
cooling pipes with nozzles.

5.2 Ring sizes

The following Roll Ring dimensions are used:

P-815 OD max/min-ID 170/150 – 91 mm

Width 70 mm

P-820 OD max/min-ID 223/197 – 131 mm

Width 70 mm

Tolerances:

OD tolerance ± 0.05 mm

Width tolerance + 0.10 mm

Difference within the same stand Max 0.05 mm

Difference between two stands Max 0.5 mm

Difference within a block Max 1.0 mm

Matching of the Roll Rings is important to keep a fixed pass line and
eliminate effects from overpressure or underpressure due to diameter
differences. Such effects are often increased wear on roll rings and roller
guides, as well as, flutter on the rolled material.

20
5.3 ROLL CHANGING

5.3.1 Precondition

• Block is stopped and cooling water switched off.

• Air/oil lubricating system for the roller guides shall be switched off.

The roll assembly comprises the following parts (see sketch):

• (1) Roll shaft with tapered neck.

• (2) Tapered sleeve.

• (3) Roll ring.

• (4) Clamping ring.

• (5) Thrust ring.

• (6) Lock nut.

• (7) Safety cap.

A hydraulic tool (8) shall be used for the roll changing and a special service
carriage provided with hydraulic pump is available.

21
5.3.2 Dismounting procedure

• Run the service carriage into the block. Check the oil level for the
pumpunit and refill if necessary.

• Check the outside diameters of the newly ground roll rings (3).

• Premount the tapered sleeve (2) into the roll ring. The small end of the
sleeve must be 5 mm from the inner edge of the roll ring when it is in
the right position.

• Remove the safety cap (7) from the roll neck.

• Thread the hydraulic tool (8) onto the roll neck.

• Connect hose from pumpunit to the hydraulic tool.

• Reset the hydraulic tool to zero so that remaining oil will be drained out.
Turn the tool against the roll neck shoulder and release 45° before next
step is carried out.

• Start the hydraulic pump. Sufficient pressure will be applied to the tool
and the lock nut (6) released.

• Back off the lock nut 3 – 4 turns.

Note: There are right-hand and left-hand threads.

• Stop the hydraulic pump and relieve the pressure.

• Disconnect the hose from the hydraulic tool.

• Unscrew the hydraulic tool. Do not remove the lock nut (6).

• Connect the hose to nipple (9) on the roll shaft.

• Start the hydraulic pump once again. When sufficient pressure is

reached the roll ring will become loose quickly and stopped by the lock
nut.

• Disconnect the hose.

• Remove the lock nut (6).

• Remove the thrust ring (5) with its pretensioned set of cupsprings.

• Remove clamping ring (4).

• Remove the roll ring (3) together with the tapered sleeve (2).

• Clean the tapered roll shaft carefully with solvent and dry. Do not leave
the roll neck open and unprotected for long periods.

22
23
5.3.3 Mounting procedure

See sketch.

Sequence No. 1:

• Clean and examine the surface of the tapered roll neck. For a proper
function of the roll mounting method the taper surface must be in good
condition.

• Lubricate the tapered roll neck lightly with oil.

• Push carefully the roll ring (3) with the tapered sleeve (2) onto the roll
shaft.

• Fit clamping ring (4) to the shaft.

• Fit thrust ring (5) to the shaft.

• Tighten the lock nut (6) to the shaft, far enough to engage all threads.

Sequence No. 2:

• Thread the hydraulic tool onto the roll shaft. Connect the hose and reset
the hydraulic tool against the neck shoulder so that remaining oil is
drained out. Release 45° (1/8 of a turn).

• Start the hydraulic pump.

• When the preset pressure is reached the pump will stop automatically.

Note: 640 bar will create a clamping force of 300 kN. Handle the tool and
hose with care to avoid accidents.

Sequence No 3:

• Tighten the lock nut by using the tool (pin) provided for this purpose.

• Stop the hydraulic pump and releave the pressure. Disconnect the
hose.

Sequence No. 4:

• Remove the hydraulic tool.

• Install the safety cap (7).

24
25
5.4 Roll gap setting

Procedure:

• The desired roll gap shall be set in accordance with the rolling
schedule. Gauge rods are available for the different sizes.

• Insert the counterbalancing cylinder between the roll shafts to

compensate for the play between roll shaft and bearing.

• Connect compressed air from the service carriage to cylinder nipple.

• Insert the gauge rod (desired dimension) in the calibration opening

between the roll rings.

• Use the roll setting tool to screw the rolls together until the gauge rod
fits between the rolls without any clearance.

26
ROLL UNIT TYPE P-815

Rollshaft Thrustbearings & Axial Adjustment

Mill Screw Arrangement

27
5.5 Axial adjustment

The roll unit is provided with possibility to make an axial adjustment of one
of the roll shafts in case of misalignment between the roll ring grooves. The
top (horizontal) or outer (vertical) roll shaft can be moved axially by a
setting screw arrangement connected to the pivot yoke in the rear end of
the roll shafts.

Maximum adjustment range: ± 0.3 mm.

Moving the roll towards the drive side:

• Loosen the setting screw closest to the gearbox.

• Tighten the setting screw on the opposite side.

Moving the roll away from the drive side:

• Loosen the setting screw closest to the rolls.

• Tighten the setting screw on the opposite side.

28
The axial movement is carried out from a pivot arrangement at the rear end
of the roll shafts. The two rolls are connected through a yoke which is
provided with plain bearings, see drawing.

New bearings are clamped onto the shafts and the radial play must be zero
to keep the axial stability on the roll shafts.

When a roll unit is taken out for service, the condition of the plain bearings
should be checked and new bearings installed if necessary.

29
5.6 Pass line setting

If a roll unit has been removed and disassembled for service, the pass line
must be checked as follows:

• Install the optical guide setting device on the guide attachment. Ensure
that the surface is thoroughly clean.

• Insert the counterbalancing cylinder between the rolls, connect the air
supply and press the rolls apart.

• Check that the roll ring diameters are within the recommended
tolerances. See 5.2.

• Check that the setting instrument is properly zeroed.

• Read any deviation shown on the optical setting device.

• Adjustment of the pass line is carried out by adding or removing shims

between the cover (6H) and the mill screw device.

Note: Before any adjustment is made the bolts, holding the worm screw
cover must be loosen to prevent bending of the worm screw.

30
6. ROLL CHOCKS

6.1 General

The two roll chocks are joined together in the front end by the mill screw
arrangement and the rear end is connected in the pivot point with a yoke.
The yoke is adjustable to permit axial movement of one of the roll shafts
through a special screw arrangement located in the roll unit housing. The
mill screw device is bolted to the housing as well.

6.2 Checking

• Raise the roll unit to an upright position.

• Remove roll unit front plate (4A). Clean off mating surfaces from sealing
compound.

• Examine the seal located in the worm screw cover for the roll gap
adjustment.

• Check the pipes, hoses and fittings (6B) used for the lubricating oil
supply.

• Check the parallelism (6C) for the chocks.

• Check the joint bushings between the mill screw and worm wheels (6D).

• Check the guide surfaces (6E) on the roll chocks by dismounting the
four support units (6F).

• Remove the two set screws (6G) used for axial adjustment. Clean and
lubricate them.

31
6.3 Roll chock disassembly

• Put the four spacers (6C, 10.4 mm) in position between the roll chocks
and set the rolls together so they pinch the spacer.

• Remove the cover which supports the mill screw machinery (6H).

• Disconnect all the electrical connections to the temperature sensors in

the junction box on the outside of the roll unit.

32
• Disconnect the lubricating oil hoses (6B) from the roll chocks.

• Remove the four caps (6J) from yoke (6K) on the chocks.

• Arrange a lifting sling as shown on photo. Carefully lift out the roll
chocks. Make sure that the electrical cables for the temperature
sensors are not damaged.

• A temperature sensor can now be replaced as described in section No.

4.3.5.

• Reassemble by carrying out the same steps but in opposite sequence.

Paint the connecting surface on the housing with Permatex No. 3 or
similar before the front plate is installed.

• Check the front plate position by use of a feeler gauge.

33
7. GEAR BOXES

7.1 General

The finishing block drive is achived from the end of the block via
synchronising primary gearbox with two output shafts, one for the horizontal
and the other for the vertical stands.

The reduction gear boxes are placed on the fabricated steel frame and
connected to the main drive shafts through bevel gears, all with the same
fixed ratio. The second stage in the reduction gear box has individual ratio
determined with regard to the rolling speed and location in the block.

The primary gearbox and the block frame are provided with foundation
bolts, adjustable nuts and spherical washers to facilitate levelling to the
foundation at erection.

The power transmission to the roll unit is of a unique design as it is made

direct to the roll shafts from the reduction gear boxes over torsionally rigid,
self-aligning gear couplings. This simplifies the design of the roll shafts as
they are plain shafts without gears which means easy replacement and low
maintenance costs. The roll unit can easily be separated from the reduction
gear box for maintenance and service.

7.2 Primary gear box

The primary gear requires very little maintenance and should operate
quietly and trouble-free during many years with the following care:

The reduction gear boxes are placed on the fabricated steel frame and
connected to the main drive shafts through bevel gears, all with the same
fixed ratio. The second stage in the reduction gear box has individual ratio
determined with regard to the rolling speed and location in the block.

The primary gear box and the block frame are provided with foundation
bolts, adjustable nuts and spherical washers to facilitate levelling to the
foundation at erection.

The power transmission to the roll unit is of a unique design as it is made

direct to the roll shafts from the reduction gear boxes over torsionally rigid,
self-aligning gear couplings. This simplifies the design of the roll shafts as
they are plain shafts without gears which means easy replacement and low
maintenance costs. The roll unit can easily be separated from the reduction
gear box for maintenance and service.

34
7.2 Primary gear box

The primary gear requires very little maintenance and should operate
quietly and trouble-free during many years with the following care:

• Lubricating oil which is supplied from the oil central serving the block,
must be applied according to the recommendations. The pressure
should be set by adjusting the pressure gauge at the gear box to 1.5
bar.

• Check the oil flow inside the gear box from time to time through the
inspection windows.

• Check the V-seal arrangement on the input and output shafts regularly.

• During normal conditions bearing lifetime in the area of 40 000 hours

should be able to obtain.

Note: If for some reason the primary gear has to be opened,special care
must be taken with bolts and parting surfaces. See order specification for
assembly drawing with instruction.

7.3 Reduction gear boxes

7.3.1 Gear box removal

• Remove the roll unit according to section No. 4.2.

• Disconnect the drive shafts according to section No. 8.

• Disconnect the lubricating oil pipes.

• Remove the four bolts between the gear box and the block frame.

Note: The gear boxes are aligned to the frame at the workshop assembly
and locking pieces are welded to assure the correct position if the unit is
removed.

7.3.2 Disassembly

Disassembly must take place in a clean area away from the rolling mill
floor, preferably in the preparation shop for roll units.

• Necessary order specifications and assembly drawings shall be

available.

• Dismount the gear coupling hubs on the bevel gear shaft by using the
SKF oil injection method.

• Remove the covers at the input and output shafts.

35
 • Put the gear box on one side supported with wooden blocks.

• The gear box housing is vertically parted. Remove the bolts the two
parts and the housing is free to be separated.

• Use eye-bolts when the housing is lifted apart. Be careful not to

damage the mating surfaces or the gears.

7.3.3 Bearing examination

Bearing QJ 320 N2M on pinion.

Axial play between bearing and cover shall be preloaded 0.00 – 0.05 mm,
when the parts are assembled.

Bearing NU 2311 ECML + QJ211 on P-815 output shafts, axially preloaded

0.01-0.02 mm

Bearing NU 2217 ECML + QJ215 on P-820 output shafts, axially preloaded

0.01-0.02 mm

Bearing NU2212 ECML + 7212 ACD on P-815 high speed shafts, axially
preloaded 0.02-0.05 mm

7.3.4 Bevel gear check

• Backlash at assembly is 0.25 – 0.33 mm.

• Measure the axial play by using a digital clock and pressing the pinion
against the QJ-bearing.

• If the axial play is found to exceed 0.2 mm the spacers between the QJ-
bearing and the cylindrical roller bearing must be checked.

Note: The thickness of the spacers must be 10 mm with tolerance 0/+0.1

mm.

• Check that the pin which prevents the outer ring of the QJ-bearing from
rotating has not broken.

• If the bearings have been removed and cleaned by solvent they must
be oiled or greased immediately to prevent corrosion.

36
37
8. COUPLINGS

The couplings within the finishing block are all of the gear type.

8.1 Drive shaft couplings

The coupling hub is mounted to the bevel gear shaft with an intermediate
tapered sleeve. The SKF oil injection method must be used for mounting
and dismantling of the hub.

Dismounting of the shaft coupling is carried out by separating the outer

gearings and flanges from each by removing the bolts.

To fit the tapered sleeve onto the shaft neck, it must be heated to
approximately 100°C. When a tapered sleeve has to be removed, just heat
quickly a thin stripe axially along the sleeve whereupon the sleeve can be
taken off by hand.

38
8.2 Roll Unit Couplings

These couplings are mounted to the gearbox output shafts and the
rollshafts with tapered sleeves.

The sleeves are fitted to the shafts in the same way as above.

The hubs must be heated to 250-275°C when they are to be mounted onto
the shafts. For dismantling, the oil injection method has to be used.

Roll Unit P-815

Gearcoupling, dismounting procedure

1. Remove the 8 screws (M12) between Safety Hub (pos. 5) and gearshaft
hub
2. Dismount the Locking Ring FK7
3. Pull out the Spacer Ring, (pos. 4)
4. Move the outer Sleeve, (pos. 2), towards the roll shaft
5. Take out the Safety Hub, (pos. 5 & 3), and Spacer ring from the unit
6. Take out the Sleeve from the unit

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8.3 Safety Device

The P-815 Roll Units are provided with Safety Device to protect the
gearboxes from accidental overload due to rolling defects. The Safety Ring
connected to the gearbox hub is made with a groove, and will brake in case
of overload. Two sizes of Safety Rings are available and installed in
different stands in the block:

1. Shear torque 3000, beginning & intermediate stands.

2. Shear torque 2000, finishing stands.

Replacing a safety coupling:

• Shut off the lubricating system.

• Remove the inspection cover on one side of the roll unit.
• Remove the safety ring from the gear box hub and lift out the coupling.
• Separate the broken flange from the gear ring.
• Fit a new safety ring. Check that correct torque is applied (marked on
the ring).
• Use Loctite to secure the bolts when the coupling is assembled.
Tightening torque for the bolts shall be 120 Nm.
Note: We recommend that both safety rings always are replaced when
a breakage has occured.

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8.4 P-820

Gearcoupling, dismounting procedure

7. Remove the Roll Unit from the Gearbox

8. Dismount the Locking Ring FK7
9. Pull out the Spacer Ring, (pos. 3)
10. Take out the Sleeve, (pos. 2)
11. Put a safety washer with screw at the gearshaft end (with sufficient gap)
12. Apply oil injection to the gearhub, until the same is released from the tapered sleeve
13. Dismount and take out the remaining parts

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9. COOLING WATER PIPES

The finishing block is equipped with the following cooling water facilities:

• Roll ring cooling.

• Interstand cooling. (Option)

• Roller guide cooling.

Carbide ring breakage and wear can both directly be related to the
effectiveness of the roll cooling.

A cooling pipe with nozzles is installed for each roll ring. For a roll unit the
water requirements will be as follows:

Minimum pressure 5 bar

Flow 270 – 280 l/min

It is very important that the nozzles are maintained in a proper way and
checked periodically for clogging.

Interstand cooling is performed by use of combined exit guides and cooling

nozzles. The grade of cooling is selected and depending on the rolling
programme.

Cooling water to the roller guides is connected to the roll ring cooling device
and automatically switched on when the block is running.

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10. ROLL SHAFT SEALS

The roll shaft seal arrangement consists of inner seal flinger (D), cover (E)
with V-seals (B+C) and outer seal flinger (A). The V-rings are stationary
seals in the cover seat. There is a groove in the seat, which is matching the
seal shape and keeping the seals fixed. The V-seal working against flinger
(D) is the oil seal, located at the inside of the roll unit. The other V-seal is
the water seal, working together with flinger (A).

The flingers are provided with Wo-Ni coated surfaces for wear resistance,
and improved lifetime of the V-seals.

Periodic inspection must be carried out as follows:

• Replace the outer seal (B) at every roll ring change, and check the
surface condition of the flinger (A).
• In case of wear, or damage, the ring must be replaced immediately.
• Defects on the flinger ring, or the V-seal, will result in water leakage,
into the block, and contamination of the lubricating oil, which can be a
serious problem.
• Examine the V-seal “off-line”. If it is found OK, it can be put into
service again.
• The inner V-seal, and ring (C+D) should normally be checked every
third month. Look for oil leakage out through the seals.

B E C

A D

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11. LUBRICATION

11.1 General

The finishing block is lubricated by circulated oil supplied by a lubricating

central. The same oil is used to lubricate gears, as well as bearings and the
pressure is regulated accordingly.

The lubricating central comprises the following main items:

• Reservoir tank provided with parallel plates, heaters and ventilator.

• System pumps, in most cases two pumps with one kept stand-by.

• Dual filter arrangement.

• Heat exchanger for cooling of lubricating oil.

• Pressure tank (oil/air balanced) supplying the block during emergency

stop in case of power failure.

• Separator unit to clean the oil from water and solid particles.

See separate manual and function description regarding the lubricating

central.

12. OPERATING PRACTICE

12.1 Safety systems

The finishing block is provided with the following safety systems:

• Block cover has two limit switches for indication of open and closed
position. An interlocking prevents start of the block when cover is in
open position.

• Cooling water supply is provided with a pressure switch. An interlocking

prevents the block to be running without cooling water.

• There are temperature sensors in the roll units (see section No. 4.3.5)
to protect the block from overload/overheating during rolling.

• The couplings between the roll units and gear boxes are provided with
shearing elements for overload protection (see section No. 8.2.1).

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 • The lubricating system is equipped with control and alarm functions for
oil level, temperature and pressure.

• Cobble indication is achived by time control between entry and exit of

the block, tensioned nylon wire with limit switch which will be actuated
in case of a cobble and a limit switch mounted to the cobble box located
in the block. All the cobble indicatings are connected to the electrical
control system which will stop the block in this event.

Cobble indicators:

12.2 Starting sequences

The start order to the block shall be given from the main control desk in the
mill. Prior to the block starting, the oil lubricating system must be in
operation. There are interlockings connected between the block and the
lubricating system. When the start button is pressed the cooling water and
the air/oil lubrication will automatically be switched on. After a certain time
delay of ≈ 5 sec, the block motors will start. The time delay is due to the
interlocking by the pressure switch in the cooling water supply.

12.3 Stopping times

The following stopping times shall be expected for the block:

Normal stop 30 sec.

Emergency stop 5-8 sec.

Power failure stop (disc break or battery back-up) 5-8 sec.

The cooling water supply will be automatically switched off after a delay of
≈ 30 sec. When the block motors are stopped.

The air/oil lubricating system for roller guides will be stopped after a delay
of 15 minutes after stop of the block.

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