Machine manual

en-PM.FBJ.002.C

Mill feed system with gate valves for POLYCOM®

Code Word
MARWAL

Order Number
D000766

Plant Order Code (POC)

8F1.PM01
en-PM.FBJ.002.C Contents
®
Mill feed system with gate valves for POLYCOM

Contents

1 Safety ..................................................................................................... 1-1

2 Technical data ....................................................................................... 2-1
3 Components and description of functioning..................................... 3-1
3.1 Components ........................................................................................... 3-1
3.2 Description of functioning ..................................................................... 3-12
4 Transportation and assembly ............................................................. 4-1
4.1 Transportation ........................................................................................ 4-1
4.1.1 Safety instructions .................................................................................. 4-1
4.1.2 Identifying the transport units ................................................................. 4-2
4.1.3 Checking the transport units ................................................................... 4-3
4.1.4 Packaging ............................................................................................... 4-3
4.1.5 Transporting the transport units ............................................................. 4-3
4.2 Storage ................................................................................................... 4-4
4.2.1 Safety instructions .................................................................................. 4-4
4.2.2 Storage of transport units ....................................................................... 4-4
4.3 Assembly ................................................................................................ 4-5
4.3.1 Tightening torques for bolts .................................................................... 4-6
4.3.2 Safety instructions .................................................................................. 4-7
4.4 Mounting the mill feed system ................................................................ 4-8
5 Lubrication ............................................................................................ 5-1
5.1 Safety instructions .................................................................................. 5-1
6 Commissioning ..................................................................................... 6-1
6.1 Checks prior to the test run .................................................................... 6-1
6.2 Setting and adjustment ........................................................................... 6-1
7 Maintenance .......................................................................................... 7-1
7.1 Safety instructions .................................................................................. 7-1
7.2 Inspection ............................................................................................... 7-2
7.3 Servicing ................................................................................................. 7-3
7.4 Repair ..................................................................................................... 7-3
7.4.1 Prior to any maintenance work ............................................................... 7-3
7.4.2 After any maintenance work ................................................................... 7-5
8 Troubleshooting ................................................................................... 8-1
8.1 Safety instructions .................................................................................. 8-1
8.2 Faults, causes and their elimination ....................................................... 8-3
9 Spare parts ............................................................................................ 9-1
9.1 Suggestions for enquiries and orders of spare parts ............................. 9-1
10 Appendix ............................................................................................. 10-1
10.1 Technical drawings ............................................................................... 10-1
10.2 Subsuppliers' documentation ............................................................... 10-1
en-PM.FBJ.002.C Safety
®
Mill feed system with gate valves for POLYCOM 1-1

1 Safety
Use
®
● The mill feed system is a component of the overall POLYCOM high-pressure
grinding roll. Be sure to comply with the specification of the intended use, in
the section Technical data.
● 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.
● The intended use also includes observance of the machine manual and
compliance with the maintenance instructions.

Operation
● 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.
● If safety-relevant changes in the machine or its operating behaviour occur,
shut it down immediately.
● A magnetic separator and a metal detector must be installed upstream of the
® ®
mill feed system for the POLYCOM , in order to prevent the POLYCOM from
being damaged by tramp metal.
Maintenance
● Be sure to also comply with the safety instructions in the machine manuals for
®
the POLYCOM high-pressure grinding roll.
● The subsupplier's safety instructions for the load cell are to be strictly
observed.
● Before commencing any work, switch off all machines and drives whose
operation might endanger personnel and secure them against restarting.
● Do not remove or open any flaps, covers or protection devices before all parts
of the machine have come to a complete standstill.
● The plant owner must ensure that all rotating parts are protected against
accidental contact.
● Before performing any work, make absolutely sure that there is no risk of
suffering burns.
● Before performing any work on the machine and before opening any
inspection and service covers, make certain that there is no longer any hot
material inside the machine.
● Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily flammable substances for cleaning the
machine.
● Before performing any work on the machine, switch off the power supply to all
electrical components.
● The hydraulic system is specially designed for the supplied machine and may
therefore not be used for any other machine without the express consent of
thyssenkrupp Industrial Solutions.
● Make absolutely sure that the hydraulic piping is relieved of pressure before
disconnecting it.
● Never use the pumps of the hydraulic system to empty or fill the oil tank.
Safety en-PM.FBJ.002.C
®
1-2 Mill feed system with gate valves for POLYCOM

● If you drain hydraulic oil at operating temperature, you risk scalding yourself.
● Before performing any work on the machine, make absolutely sure that all
piping is depressurised.
● Before carrying out work on the central lubrication system with pneumatically
operated grease pump, you must disconnect the grease pump from the
compressed-air supply system.
● Close the shut-off devices for lubricant supply after you have shut down the
®
POLYCOM high-pressure grinding roll.
● Make absolutely sure that the piping of the central lubrication system is
relieved of pressure.
● Only use 24-volt lamps to illuminate the interior of machines.
● Observe the welding instructions.
● Never set up welding current sources in confined spaces with electrically
conductive walls.
● When performing electric arc welding or cutting work, use insulating mats to
ensure that personnel cannot come into contact with electrically conductive
parts.
● If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
● After finishing all work, check all joints and connections for leaks.
● After finishing all work, make absolutely sure that nobody remains inside the
plant section. Properly close inspection and service covers. Remount all
protection devices.
● Make absolutely sure that all warning signs are complete and distinctly legible.
Mount new warning signs if necessary.
en-PM.FBJ.002.C Technical data
®
Mill feed system with gate valves for POLYCOM 2-1

2 Technical data
Specification of the intended use
See the machine manual for the No. PM.CPT.001
®
High-pressure grinding roll POLYCOM

Bin
Bin, moveable yes

Empty weight 12400 kg

Lining composite plate

Dimensions 2944 x 2842 x 4083 mm

3
Filling volume at a filling ratio of 75% 14.3 m

Storage time 43 s

Load cells
Quantity 2

Type PR 6201 / 34 D1

Rated load per load cell 30 t

Fixed bearing
Quantity 2

Type PR 6101 / 54 N

Filling level monitor

Max. filling level monitor yes

Type CT-201 G

Overflow no
Technical data en-PM.FBJ.002.C
®
2-2 Mill feed system with gate valves for POLYCOM

Drive (2.12) for adjustable infeed guide plate

Type of drive manual

Type -

Spindle-type lifting device (2.14)

Type SHE 5

Quantity 4

Effective stroke 600 mm

Hydraulic drive for gate valve (2.25)

See machine manual No. PM.HYS.002

Proximity switch (2.32)

Type XS1-M30MA250

Assembly dimension
Clearance "A" between track wheel 15 mm
(1.4) and running rail

Fig. 1
en-PM.FBJ.002.C Components and description of functioning
®
Mill feed system with gate valves for POLYCOM 3-1

3 Components and description of functioning

3.1 Components

Some details of the drawings in this manual may not be identical to the drawings
of the actually delivered machine.
Components and description of functioning en-PM.FBJ.002.C
®
3-2 Mill feed system with gate valves for POLYCOM

Overview

Fig. 2
en-PM.FBJ.002.C Components and description of functioning
®
Mill feed system with gate valves for POLYCOM 3-3

No. Denomination Description

1.0 Bin

2.0 Adjustable feed shaft

Components and description of functioning en-PM.FBJ.002.C
®
3-4 Mill feed system with gate valves for POLYCOM

Bin (1.0)

Fig. 3
en-PM.FBJ.002.C Components and description of functioning
®
Mill feed system with gate valves for POLYCOM 3-5

No. Denomination Description

1.1 Middle bin section

1.2 Support frame

1.3 Bracket for track wheel

1.4 Track wheel

1.5 Filling nozzle

1.6 Bin suspension

1.7 Expansion joint

1.8 Lower bin section

1.9 Bin outlet

1.10 Inspection door

1.11 Load cell

1.12 Fixed bearing

1.13 Filling level monitor

1.14 Expansion joint

1.15 Eyebolt

1.16 Wear protection Bin suspension

1.17 Wear protection Middle bin section

1.18 Wear protection Lower bin section and door

A Clearance Between track wheel and running rail, see the section
Technical data
Components and description of functioning en-PM.FBJ.002.C
®
3-6 Mill feed system with gate valves for POLYCOM

Adjustable feed shaft (2.0)

Fig. 4
en-PM.FBJ.002.C Components and description of functioning
®
Mill feed system with gate valves for POLYCOM 3-7

No. Denomination Description

2.1 Sidewall

2.2 Wear protection Sidewall

2.3 Inspection door

2.4 Spacer

2.5 Protective cover

2.6 Sealing frame

2.7 Transport aid

2.10 Adjustable infeed guide

plate

2.20 Position indicator

2.25 Gate valve

2.32 Proximity switch

2.33 Seal For hydraulic cylinder

Components and description of functioning en-PM.FBJ.002.C
®
3-8 Mill feed system with gate valves for POLYCOM

Adjustable infeed guide plate (2.10) located in the adjustable feed shaft (2.0)

Fig. 5
en-PM.FBJ.002.C Components and description of functioning
®
Mill feed system with gate valves for POLYCOM 3-9

No. Denomination Description

2.1 Sidewall

2.11 Wear protection

2.12 Drive

2.13 Drive shaft With coupling

2.14 Spindle-type lifting device

2.15 Threaded spindle

2.16 Bellows

2.17 Protective pipe For threaded spindle

2.18 Intermediate shaft With couplings

2.19 Lifting spindle crossbeam

2.20 Position indicator

2.35 Guide rail With guide blocks

2.36 Guide bar

Components and description of functioning en-PM.FBJ.002.C
®
3-10 Mill feed system with gate valves for POLYCOM

Gate valve (2.25) located in the adjustable feed shaft (2.0)

Fig. 6
en-PM.FBJ.002.C Components and description of functioning
®
Mill feed system with gate valves for POLYCOM 3-11

No. Denomination Description

2.1 Sidewall

2.26 Wear protection

2.28 Bellows

2.29 Swivel pin

2.30 Shackle toggle joint

2.31 Tie-bar For hydraulic cylinder

2.35.2 Guide rail With guide blocks

2.36.2 Guide bar

H Hydraulic cylinder
Components and description of functioning en-PM.FBJ.002.C
®
3-12 Mill feed system with gate valves for POLYCOM

3.2 Description of functioning

®
By means of the mill feed system installed above the POLYCOM , a number of
process-technological prerequisites for achieving an optimal grinding process can
be realised.
Depending on the grinding method, the volume is defined for a determined
storage time. The respective bin content, and thus the bin's filling level as well,
can be determined by means of one load cell or several load cells, or limited by
means of an overflow. If the filling level is limited by an overflow, the load cell is
omitted. To achieve an optimal homogenisation of the current consumption of
®
both POLYCOM drive motors for the different grinding methods, the shaft width
can be adjusted. By adjusting the shaft width, the running smoothness can also
be improved.
To be able to prevent the bin from overflowing when using a load cell or to
compensate for different bulk densities, the upper bin section is fitted with a filling
level monitoring system.

A magnetic separator and a metal detector must be installed upstream of the

® ®
mill feed system for the POLYCOM , in order to prevent the POLYCOM from
being damaged by tramp metal.

The mill feed material is fed into the bin, whose content is limited by means of an
overflow or controlled by means of a load cell (1.11). The maximum filling level is
controlled by means of a filling level monitoring system (1.13). The bin is fitted
with track wheels (1.4) and is thus movable.
Inside the adjustable feed shaft, the shaft width can be freely adjusted by means
of the two adjustable infeed guide plates (2.10). There is thus the possibility of
influencing the position of the stream of mill feed material in relation to the
grinding rolls. The adjustment takes place by means of the drive (2.12). The
adjustable infeed guide plates may be adjusted only when the bin is empty. The
positions of the adjustable infeed guide plates can be read from the position
indicators (2.20). In addition, the adjustable feed shaft is provided with
hydraulically actuated gate valves (2.25).
The gate valves allow closing of the mill feed system and starting the
® ®
POLYCOM without emptying the bin. During operation of the POLYCOM , the
gate valves are covered by the adjustable infeed guide plates.

After having started closing of the gate valves, the push-back of the floating roll
is also started with a time delay.

The end positions of the gate valves are monitored by the proximity switches
(2.32).
The mode of functioning of the hydraulic drive of the gate valves is described in
®
the machine manual of the Hydraulic system for the POLYCOM .
®
If the POLYCOM is equipped for larger wear displacement distances (rolls with
roll bodies made of chilled casting), the feed material guide and the adjustable
feed shaft must be shifted in the direction of the fixed roll as wear progresses.
The feed material guide's mode of functioning is described in the machine
®
manual Feed material guide for POLYCOM .
For repair work on the high-pressure grinding roll, the bin (1.0) can be moved to
the side and the adjustable feed shaft including the feed material guide can be
®
lifted out of the POLYCOM . At the adjustable feed shaft, transport aids (2.7) are
provided as anchorage points for the hoisting gear.
en-PM.FBJ.002.C Components and description of functioning
®
Mill feed system with gate valves for POLYCOM 3-13

The optimal position of the adjustable infeed guide plates is calculated during
commissioning by a specialist from thyssenkrupp Industrial Solutions. As shown
in the following figure, the adjustable infeed guide plates can be set symmetrically
or asymmetrically in relation to the roll gap.

Fig. 7
en-PM.FBJ.002.C Transportation and assembly
®
Mill feed system with gate valves for POLYCOM 4-1

4 Transportation and assembly

4.1 Transportation

4.1.1 Safety instructions

WARNING
Suspended loads
During lifting operations, loads might swing out or fall down. This could
lead to life-threatening injuries.
I. Wear personal protective equipment.
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 so that it is
located directly above the centre of gravity of the load.
III. Carefully lift the load and observe whether it tips or not. If necessary,
adjust the attachment.
Transportation and assembly en-PM.FBJ.002.C
®
4-2 Mill feed system with gate valves for POLYCOM

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 designated lifting points.
III. Do not remove packaging until shortly before assembly.

4.1.2 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
en-PM.FBJ.002.C Transportation and assembly
®
Mill feed system with gate valves for POLYCOM 4-3

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

4.1.3 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.

4.1.4 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.

4.1.5 Transporting the transport units

Transport the transport units under the following conditions:
● Be sure to observe the safety symbols and instructions on the transport units.
● Cranes and fork-lift trucks must be designed for the weight of the transport
units.
● Handle the transport units carefully when unloading them, when they are
delivered and when transporting them on site.
● Transport the transport units using suitable lifting machinery.
● Only use the designated lifting points.
● Do not remove packaging until assembly begins.
● Before transporting, remove the piping or oil pumps from gear units and close
all pipe sockets and openings with weather-proof and impact-proof sealing
covers to prevent ingress of tramp material.
Transportation and assembly en-PM.FBJ.002.C
®
4-4 Mill feed system with gate valves for POLYCOM

4.2 Storage

4.2.1 Safety instructions

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.

4.2.2 Storage of transport units

Store the transport units under the following conditions:
● Protect against moisture, soiling and damage.
● Protect against direct sunlight.
● 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.
en-PM.FBJ.002.C Transportation and assembly
®
Mill feed system with gate valves for POLYCOM 4-5

4.3 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.
Transportation and assembly en-PM.FBJ.002.C
®
4-6 Mill feed system with gate valves for POLYCOM

4.3.1 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
en-PM.FBJ.002.C Transportation and assembly
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Mill feed system with gate valves for POLYCOM 4-7

4.3.2 Safety instructions

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.

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.
Transportation and assembly en-PM.FBJ.002.C
®
4-8 Mill feed system with gate valves for POLYCOM

4.4 Mounting the mill feed system

Required personnel
● Assembly personnel
Prerequisites
● The high-pressure grinding roll has been mounted.

Be sure to comply with the assembly instructions in the drawing (see page 10-1,
Technical drawings).

Step 1: Align the top frame of the feed material guide on the upper chord plates and
fasten the feed material guide plates to the top frame.

Be sure to comply with the mounting instructions for the feed material guide, in
the separate machine manual (see machine manual for the feed material guide).

Step 2: Align and bolt the completely preassembled adjustable feed shaft (2.0) onto
the top frame.
Step 3: Preassemble the bin (1.0) in an assembly scaffold:
3.1 Bolt together the support frame (1.2), the bin suspension (1.6), the middle
bin section (1.1), the lower bin section (1.8) and the bin outlet (1.9) incl.
expansion joint (1.14).
Step 4: Install the wear protection (1.16, 1.17 and 1.18).
Step 5: Install auxiliary mounting supports (provisional support) for the load cell
(1.11) and the fixed bearing (1.12).

Be sure to comply with the instructions in the subsupplier's documentation

regarding installation of the load cell (1.11).

Step 6: Install the preassembled bin (1.0) in the building structure, then align it
relative to the adjustable feed shaft (2.0) and set it down on the auxiliary
mounting supports.
en-PM.FBJ.002.C Transportation and assembly
®
Mill feed system with gate valves for POLYCOM 4-9

Step 7: Mount the track wheels (1.4).

Upon completion of the installation, the track wheels (1.4) must not come into
contact with the running rails, as otherwise the functioning of the load cell would
be affected. Adjust clearance "A" using shims (see page 2-2).

Fig. 8

Step 8: Mount the filler neck (1.5) and the expansion joint (1.7).
Step 9: Install the hydraulic piping according to the piping diagram.
Step 10: Replace the auxiliary mounting supports with the load cell (1.11) and the
fixed bearing (1.12), and align.

Be sure to comply with the instructions in the subsupplier's documentation

regarding installation of the load cell (1.11).

Step 11: Install the filling level monitoring system (1.13) and the earth cable.
en-PM.FBJ.002.C Lubrication
®
Mill feed system with gate valves for POLYCOM 5-1

5 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.

5.1 Safety instructions

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

CAUTION
Improper handling of lubricants
Lubricants such as greases and oils can contain toxic substances. If
lubricants are released into the natural environment, they may harm
humans, animals and plants.
I. Ensure that the environment is not polluted when 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.FBJ.002.C
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5-2 Mill feed system with gate valves for POLYCOM

Lubrication chart

Fig. 9: Lubrication points

en-PM.FBJ.002.C Lubrication
®
Mill feed system with gate valves for POLYCOM 5-3

Lubrication points Quantity (L, kg) per Lubrication intervals

lubrication point (weeks)

No. Qty. Designation Lubricant Initial Topping Topping First Further

ref. no. filling up up change changes

1 4 Spindle-type lifting device [1] ● [1] [1] [1] [1] [1]

2 4 Threaded spindle [2] [1]

Explanation of the icons

● Initially filled

○ Not initially filled

Explanation of the numerals in square brackets

[1] See the subsupplier's documentation COLUMBUS McKINNON.

[2] Remove the protective covers before lubricating.

en-PM.FBJ.002.C Commissioning
®
Mill feed system with gate valves for POLYCOM 6-1

6 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.

6.1 Checks prior to the test run

● Can the adjustable infeed guide plates (2.10) and the gate valves (2.25) be
adjusted easily over the entire adjustment range?
● Is there a gap of at least 20 mm between the grinding rolls and the closed
gate valves?
● Have bin inlet (1.6) and bin outlet (1.9) been installed properly and are they
free of spurious forces caused by unintended stressed contact with other parts?
● Has the load cell (1.11) been installed properly and in accordance with the
subsupplier's instructions?
● Has the movability of the load cell been ensured?
● Have all the monitoring devices been checked for proper functioning?
● Have all protection devices been mounted properly?
● Has the hydraulic drive of the gate valves (2.25) been bled of air and is it
ready for operation?
● Has the clearance "A" between the track wheels (1.4) and the running rail
been set?

6.2 Setting and adjustment

● Adjust the load cell (1.11) in accordance with the manufacturer's instructions
(see the subsupplier's documentation).
● The adjustable infeed guide plates (2.10) are preset by a specialist from
thyssenkrupp Industrial Solutions during first commissioning.
en-PM.FBJ.002.C Maintenance
®
Mill feed system with gate valves for POLYCOM 7-1

7 Maintenance
7.1 Safety instructions
WARNING
Hot surfaces
Components in contact with the material may heat up during operation, as
may bearings and motors. Skin contact with hot surfaces may cause
severe burns.
Always wear personal protective equipment and heat-resistant protective
clothing when working in the vicinity of hot surfaces.

WARNING
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.

WARNING
Moving components
If you reach past moving components, parts of your body may be pulled in
and crushed or severed.
I. Operate the high-pressure grinding roll only with properly mounted
protection devices.
II. Before commencing any work, switch off the machine and secure it
against restarting.
III. Wait until the high-pressure grinding roll has swung to a complete stop
and secure it against turning.
IV. Pay attention to the after-running time. Do not open any protection
devices or inspection doors until all components have come to a
complete standstill.
V. After performing any work, mount all protection devices. Close the
inspection doors properly.
Maintenance en-PM.FBJ.002.C
®
7-2 Mill feed system with gate valves for POLYCOM

WARNING
Incrustations falling down inside the mill
In the interior, adhering incrustations of material may come loose, fall
down and cause injuries. There is also a danger of being buried alive.
I. Wear personal protective equipment.
II. Before entering the interior of the mill and the inlet, check it for
incrustations.
III. Eliminate incrustations from the walking surfaces and grab handles
first, before entering the interior.
IV. Check the incrustations for adequate load-bearing capacity.
V. Before entering the interior, suitably cover such incrustations as are
present.

7.2 Inspection
No. Work to be performed Frequency Remarks

1 Check the wear protection (2.11 and Every 3 months For this purpose, the bin
2.26) for wear needs to be empty

2 Check the couplings and the Monthly

spindle-type hoisting units (2.14) for
proper functioning

3 Inspect the expansion joints (1.7 and Monthly

1.14) for serviceability

4 Check the inspection door for leaks Monthly

5 Check the bin's internal surface for Every 3 months For this purpose, the bin
wear needs to be empty

6 Inspection work on the weigher See

subsupplier's
instructions.

7 Inspection work on the drives of the See

adjustable infeed guide plates (2.10) subsupplier's
and of the gate valves (2.25) instructions.

8 Check the bellows (2.16 and 2.28) Monthly

9 Check the proximity switch (2.32) for Monthly

proper functioning
en-PM.FBJ.002.C Maintenance
®
Mill feed system with gate valves for POLYCOM 7-3

7.3 Servicing
No. Work to be performed Frequency Remarks

1 Replace the As required For this purpose, the bin

● wear protection (1.16) needs to be empty

● wear protection (1.17)

● wear protection (1.18)

2 Replace the wear protection (2.11 or As required

2.26)

3 Clean and relubricate the threaded As required

spindles (2.15)

4 Maintenance work on the weigher See

subsupplier's
instructions.

7.4 Repair

7.4.1 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.
● Ensure that there is adequate space to perform the work.
● Keep the work area clean and tidy. Components or tools that are loosely lying
on top of each other or lying around on the floor are potential causes of
accidents.
● Switch off the machine and secure it against restarting.
● Allow the machine to cool down to ambient temperature.
● Stop the material feed.
● Close all hot-gas routes.
● Close the shut-off devices.

Dismounting the hydraulic cylinder (A)

● Put the gate valve (2.25) in the "OPEN" position.
● Close the ball valves in the hydraulic piping.
● Disconnect the hydraulic piping on the piston side of the cylinder.
● Remove the seal (2.33).
● Dismount the face-side protective cover (2.5).
● Fix the gate valve in the "OPEN" position.
● Remove the connecting pin between the shackle toggle joint (2.30) and the
gate valve.
● Undo the holder for the swivel pin (2.29) at the tie-bar (2.31).
● Dismount the hydraulic cylinder.
Maintenance en-PM.FBJ.002.C
®
7-4 Mill feed system with gate valves for POLYCOM

Dismounting a gate valve (2.25)

● Dismount the proximity switches (2.32) with holder.
● Dismount the tie-bar (2.31)
● Pull the gate valve out of the guide rails (2.35.2).
Replacement of the wear protection (2.26)
● After mounting the gate valves, check the gap between the wear protection
(2.26) and the wear plates of the feed material guide, also see the machine
manual for the Feed material guide.
There must be a gap of at least 5 mm.

Dismounting an adjustable infeed guide plate (2.10)

● Dismount the gate valve.
● Fix the adjustable infeed guide plate into position.
● Remove the wear protection (2.11).
● Dismount the drive (2.12) together with the drive shaft (2.13).
● Remove the connecting pin between the adjustable infeed guide plate (2.10)
and the threaded spindle (2.15).
● Dismount the lifting spindle crossbeam (2.19) together with the spindle-type
lifting device and the intermediate shaft (2.18) as one unit.
● Pull the adjustable infeed guide plate out of the guide rails (2.35.1).
● In order to replace the bellows (2.16), the threaded spindle (2.15) has to be
unscrewed from the spindle-type lifting device (2.14).
Replacement of the wear protection (2.11)
● After mounting the adjustable infeed guide plates, check the gap between the
wear protection (2.11) and the wear protection (2.2) and the wear plates of the
feed material guide.
There must be a gap of at least 5 mm.

Dismounting the bin (1.0)

● Disconnect the bin outlet (1.9) and the expansion joint (1.14) from the lower
bin section (1.8) and set down on the adjustable feed shaft (2.0).
● Loosen and fold down the eyebolts (1.15).
● The bin (1.0) will lower and the track wheels (1.4) will be in contact with the
running rail.
● With the aid of the track wheels (1.4) and the running rails, move the bin (1.0)
to the side.
en-PM.FBJ.002.C Maintenance
®
Mill feed system with gate valves for POLYCOM 7-5

Dismounting the adjustable feed shaft (2.0)

● Put the gate valve (2.25) and the adjustable infeed guide plate (2.10) in the
"OPEN" position and fix into position.
● Close the ball valves in the hydraulic piping.
● Disconnect the hydraulic hoses between the roll frame and the feed material
guide. Protect the joints against soiling.
● Undo the bolted connection between the feed material guide and the roll
frame, and then remove the connecting bolt.
● Disconnect and remove the support of the guide plates.
● Lift the adjustable feed shaft including the feed material guide out of the
®
POLYCOM by means of hoisting gear and transport aids (2.7).

7.4.2 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 6-1).
● 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 doors previously opened.
● Close the inspection covers, service covers and inspection doors properly.
en-PM.FBJ.002.C Troubleshooting
®
Mill feed system with gate valves for POLYCOM 8-1

8 Troubleshooting
8.1 Safety instructions
WARNING
Hot surfaces
Components in contact with the material may heat up during operation, as
may bearings and motors. Skin contact with hot surfaces may cause
severe burns.
Always wear personal protective equipment and heat-resistant protective
clothing when working in the vicinity of hot surfaces.

WARNING
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.

WARNING
Moving components
If you reach past moving components, parts of your body may be pulled in
and crushed or severed.
I. Operate the high-pressure grinding roll only with properly mounted
protection devices.
II. Before commencing any work, switch off the machine and secure it
against restarting.
III. Wait until the high-pressure grinding roll has swung to a complete stop
and secure it against turning.
IV. Pay attention to the after-running time. Do not open any protection
devices or inspection doors until all components have come to a
complete standstill.
V. After performing any work, mount all protection devices. Close the
inspection doors properly.
Troubleshooting en-PM.FBJ.002.C
®
8-2 Mill feed system with gate valves for POLYCOM

WARNING
Incrustations falling down inside the mill
In the interior, adhering incrustations of material may come loose, fall
down and cause injuries. There is also a danger of being buried alive.
I. Wear personal protective equipment.
II. Before entering the interior of the mill and the inlet, check it for
incrustations.
III. Eliminate incrustations from the walking surfaces and grab handles
first, before entering the interior.
IV. Check the incrustations for adequate load-bearing capacity.
V. Before entering the interior, suitably cover such incrustations as are
present.
en-PM.FBJ.002.C Troubleshooting
®
Mill feed system with gate valves for POLYCOM 8-3

8.2 Faults, causes and their elimination

® ®
The mill feed system for the POLYCOM is interlocked with the POLYCOM
high-pressure grinding roll. During operation, the maximum filling level of the bin
is monitored.

Fault Cause Elimination

The maximum filling level has
been reached.
Indication:
Filling level monitor
The bin outlet is jammed by
tramp material or lumps of
material.
NOTICE
Stop the high-pressure
grinding roll!
Open the adjustable infeed
guide plates and gate valves
so that the tramp material can
be removed.

False load cell measurement The bin inlet or the bin outlet Disassembly and cleaning of
signal. is blocked because of a the expansion joints at the bin
Indication: frictional connection. inlet and the bin outlet.

Measured value does not The weigher is defective. Repair or replace the weigher.
correspond to the actual filling
level.

The shaft width cannot be The adjustable infeed guide Clean the guide bars and the
adjusted. plates (2.10) are jammed. guide rails.

The wear protection (2.11) is ● Check the clearances

rubbing against the guide between the wear
plates. protection and the guide
plates.
● Readjust the guide plates.

The drive is defective. Repair the drive.

The gate valves (2.25) cannot The gate valves are jammed Clean the guide bars and the
be actuated guide rails.

The hydraulic drive is faulty Repair the hydraulic system.

Proximity switch (2.32) Reset or replace the proximity

defective or not properly set switch.

Leaky supply piping Eliminate the leaks.

Additional information about faults, their causes and their elimination is provided
in the subsuppliers' documentation and the machine manual for the Hydraulic
system.
Troubleshooting en-PM.FBJ.002.C
®
8-4 Mill feed system with gate valves for POLYCOM

It is a prerequisite for our warranty that the first test run is carried out in the
presence of specialists from thyssenkrupp Industrial Solutions and in
accordance with their instructions.
en-PM.FBJ.002.C Spare parts
®
Mill feed system with gate valves for POLYCOM 9-1

9 Spare parts
9.1 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.FBJ.002.C Appendix
®
Mill feed system with gate valves for POLYCOM 10-1

10 Appendix
10.1 Technical drawings
For drawing numbers, please refer to the table of contents of this folder.

10.2 Subsuppliers' documentation

Designation Subsupplier

Weigher MINEBA

Spindle-type lifting device COLUMBUS McKINNON

Filling level monitor CONVEYOR COMPONENTS

Proximity switch SCHNEIDER ELECTRIC