9321 18 ING 01 DOC 06 - B - B 4 - TowerMill

NIPPON EIRICH CO., LTD.
PROJECT : QUELLAVECO PROJECT

DOC. ID : TPD-022-0 INSTALLATION MANUAL / ETM-500LS TOWERMILL
ETM-500LS TowerMill
Installation Manual
Rev. Date Revision Prepared by Checked by Approved by
0 Dec. 25, 2019 1st Issue Y. Hatase J. Mangalus N. Hashiguchi
Page 1
Proprietary Information
These documents have been prepared by Nippon Eirich Co., Ltd. They are licensed for use by the
purchaser. Refined solely for the purchaser’s project under the terms and conditions of a separate
agreement and are to be held proprietary to Nippon Eirich Co., Ltd. The recipient agrees by receipt and/or
use of these documents to return them to the purchaser. Refined upon request and not to reproduce, copy,
lend or otherwise disclose or dispose of the contents, directly or indirectly, and not to use them for any
purpose other than that for which they are specifically furnished.
TowerMill Group
Nagoya Head Office

Gojinsha Meieki 3 Bldg., 3-9-37 Meieki Nishi-ku
Nagoya 451-0045 JAPAN
Tel +81-(0)52-533-2577
Fax +81-(0)52-533-2578
www.nippon-eirich.co.jp
Nippon Eirich Co., Ltd.
© Copyright 2014 Nippon Eirich Co., Ltd.
Page 2
Referenced documents and drawings
The following documents and drawings are referenced in this procedure
Document # Title of Documents / Drawings
T595001-4 General Arrangement Drawing
T595002-1 Foundation Drawing
T595003-6 P & I Diagram
T595101-3 Layout Plan Drawing
T595102-0 Anchor Bolt and Template
T595103-0 Agitator Drawing
T595104-0 Parallel Levelling Wedges
T595024-0 Screw Installation Drawing
1006223421 Outline Drawing of Main Drive Motor
G4196825 (1/2) High Speed Gear Coupling Assembly Drawing
G4196825 (2/2) Low Speed Gear Coupling Assembly Drawing
G3199661E-4 Outline Drawing of Gear Reducer
G3199662E-5 Outline & Circuit Diagram of Lubrication Unit
186232640 00 Wiring diagram for lubrication unit Terminal box-1
Note: “Final Drawing” documents/drawings shall be referred for installation works of the TowerMill.
Page 3
CONTENTS
1. General notice for transportation, unloading, installation and assembly ··································· 6

2. Scope ···················································································································· 7
3. Loading, Transportation and Unloading ············································································ 8
4. Supervision of critical assembly steps ············································································ 12
5. Concrete foundation works and checks ·········································································· 13
6. Preparation of pad····································································································· 14
7. Installation of Mill Shell assembly on Concrete foundation ·················································· 17
8. Installation of Screw assembly ····················································································· 20
9. Installation of Upper Housing assembly ········································································· 22
10. Installation of Gear Reducer ····················································································· 25
11. Installation of Main Drive Motor ···················································································· 30
12. Aligning & Assembly of H.S. Gear Couplings ·································································· 33
13. Aligning & Assembly of L.S. Gear Couplings ··································································· 37
14. Installation of Screw assembly ····················································································· 41
15. Installation of Coarse Classifier and Agitator ··································································· 44
16. Closing of Mill Shell Door ···························································································· 48
17. Installation of Lubrication Unit ······················································································ 51
18. First filling (Lubricants list) ··························································································· 53
19. Bolt and nut tightness ································································································ 54
20. Check on completion of installation ··············································································· 55
21. Record of installation condition ···················································································· 56
Appendix-1: Mill Shell assembly leveling record ······································································ 58
Appendix-2: Low Speed Gear coupling alignment record ·························································· 59
Appendix-3: High Speed Gear coupling alignment record ·························································· 60
Page 4
Attachment
1. General Arrangement Drawing T595001-4

2. Foundation Drawing T595002-1
3. P&I Diagram T595003-6
4. Layout Plan Drawing T595101-3
5. Anchor bolt & Template T595102-0
6. Agitator Drawing T595103-0
7. Parallel Levelling Wedges T595104-0
8. Screw Installation Drawing T595024-0
9. Outline Drawing of Main Drive motor 1006223421
10. High Speed Gear Coupling Assembly Drawing G4196825 (1/2)
11. Low Speed Gear Coupling Assembly Drawing G4196825 (2/2)
12. Outline Drawing of Gear Reducer G3199661E-4
13. Outline & Circuit Diagram of Lubrication unit G3199662E-5
14. Wiring diagram for lubrication unit Terminal Box 186232640 00
15. Main drive motor Manual
16. Gear Reducer & Coupling & Lubrication unit Manual
17. Agitator Manual
18. SEW Gearbox Manual for agitator
19. Sensors and Transmitter Manual
Page 5
1. General notice for transportation, unloading, installation and assembly
The job of transportation and installation of the TowerMill shall be performed by trained and qualified
personnel only. The personnel performing the unloading and installation assembly are to be trained in
advance and be familiar with this document.
Written confirmation of the receipt of these manuals, as well as the training of personnel concerning all
product documentation, shall be provided by Client and/or Purchaser to Nippon Eirich.
Following items shall be complied for the safety operation
- Before the installation operations of the TowerMill, verify that all handling equipment are capable of
and within operating safety limits for lifting and handling the mass of the equipment.
- Select suitable wire ropes, slings, shackles and etc. capable of carrying the equipment’s mass.
- Note the location of center of gravity and the mass before lifting or transporting the components.
- Do not enter the area below all hoisted equipment while cranes are under operation.
- Hoisting and lowering shall be carried out with safety under supervision by 1 (one) nominee responsible
for the job. The nominee shall determine a strict direction system and direct the workers positively with
whistle, hand-signals and etc.
- Install the firm working deck to prevent high potential accident because the installation and/or assemble
job are undertaken at high position.
- All workers shall put on safety belt and/or safety harness, safety helmet, safety shoes and etc. to
prevent any accidents.
Page 6
2. Scope
This document contains the following topics for the TowerMill
- Installation preparation for the TowerMill

- Required components/equipment for installing/erecting the TowerMill
- Assembly sequence of the TowerMill
The illustration in this document of each component and assembly shall differ from actual shapes of each
component of the TowerMill. However, the assembly procedure remains the same as described here.
Page 7
3. Loading, Transportation and Unloading
Ascertain the dimensions, mass and quantities of each component for the TowerMill such as the Mill Shell
assembly, the Screw assembly, the Upper Housing assembly, the Gear Reducer, the Main Drive Motor
and etc. before the installation activities of the TowerMill are started.
Secure both the access way for carrying each component to the site and the work space for unloading
each component from trailers for installation of the TowerMill.
2
H.S. Gear Couplings
3
L.S. Gear Couplings
Machined surface
4 for level check
8
8
6
5
Figure-1: Outline of the TowerMill assembly
Table-1 Approximate net mass and dimension for Main components
# Components Mass (kg) Dimension (mm)
1 Main Drive Motor 3,100 2,250 x 1,450 x 2,500
2 Gear Reducer 4,900 1,740 x 1,740 x 2,270
3 Lubrication Unit 650 1,800 x 1,760 x 2,170
4 Upper Housing assembly 14,250 3,300 x 4,170 x 3,390
5 Mill Shell assembly 20,690 3,610 x 5,200 x 3,600
6 Screw assembly 6,320 1,550 x 1,500 x 4,100
7 Coarse Classifier (Mill shell) 1,400 1,780 x 3,410 x 2,170
Page 8
NOTE: The Mill Shell assembly, Upper housing assembly, and Screw assembly and etc. will be
delivered to the site in a horizontal laid down condition on the trailers and/or trucks.
Therefore, two cranes at the minimum are required to erect each component at the site.
Recommended lifting positions (1/2)
1.Main Drive Motor 2. Gear Reducer
Refer to WEG Lifting Plan for more information

3.Lubrication Unit 4. Upper Housing assembly
Support
.
Chains or ropes to be used on the lifting eyes The drive shaft support shall be removed before
lifting the whole upper housing
Page 9
Recommended lifting positions (2/2)
5. Mill Shell assembly 6. Screw assembly
7. Coarse Classifier
.
Page 10
Remove the rust inhibitive coating (primer) from each flange surface with solvent (mineral oil, etc.) before
assembling each component. Rust inhibitive coating is applied on the machined surfaces as shown in
Figure-2.
Main Drive Motor

Gear Coupling Gear Reducer
(High Speed side)
Gear Reducer
Upper Housing assembly
Gear Coupling
(Low Speed side)
Upper Housing assembly

Mill Shell assembly
Drive Shaft
Screw Shaft
Figure-2: Location of rust inhibitive coating
Page 11
4. Supervision of critical assembly steps
It is highly recommended that an engineering supervisor shall direct the installation of one unit of the
TowerMill until the completion of all the installation activities.
The outline of installation procedures are as follows:
1) Field check before installation works

2) Condition check of the concrete foundation
3) Installation of Mill Shell assembly
4) Installation of Screw assembly into Mill Shell assembly
5) Installation of Upper Housing assembly onto Mill Shell assembly
6) Installation of coarse classifier onto mill shell overflow port
7) Level adjustment on machined flange surface of Upper Housing assembly
8) Installation of Gear Reducer
9) Installation of Main Drive Motor
10) Aligning & assembling Low Speed Gear couplings
11) Aligning and assembling High Speed Gear couplings
12) Assembling Screw assembly & Drive Shaft
13) Connection of the slurry pipings into and from the TowerMill
14) Field check after all installation works finished
Page 12
5. Concrete foundation works and checks
Refer to the following drawings for the Concrete foundation works.
- Plan the installation procedure of the anchor bolts by referring “Foundation Drawing Template
Installation procedure” in advance.
- Construct the Concrete foundation by following the drawings on the “Foundation Requirements”.
- The foundation check for the TowerMill is carried out in accordance with the documents above.
- Confirm the following items of each anchor bolt before installation of the TowerMill.
- Position of anchor bolts
- Size of anchor bolts
- Height of anchor bolts that appear above the foundation surface
- Draw the longitudinal center lines, the lateral center lines and the installation reference lines on the
foundations.
- Conformance to industry standards, best practices and the mill manufacturer’s specifications are
essential to the reliability and production quality of the mills. Any deviations from these specifications
will limit the manufacturer’s liability and possibly the warranty conditions of the contract.
Page 13
6. Preparation of pad
Refer to the following drawings for making pad.
The following items shall be prepared for making pad in advance.
Prepared
Items Description Qty. Supplied
at work site
Pad Liner 85 x 240 x 22 mm 24 X -
Forms for padding Lot - X
Forms for grouting Lot - X
Padding mortar Non-shrinking mortar Lot - X
Grouting mortar Lot - X
Chisel and hammer for chipping concrete - - X
Level vial or Y-level - - X
Page 14
Padding procedure
1) Set 2 (two) pad liners on both sides of anchor bolts shown in the Figure-3.
2) Chip the surface of Concrete foundation.
3) Keep the surface of the Concrete foundation wet by watering 24 hours prior to the padding.
4) Place forms for padding on the Concrete foundation.
5) Put padding mortar (non-shrinking mortar) into the forms for padding.
6) Sink pad liners by tapping with a plastic hammer.
7) Measure the height of each pad liner with level vial respectively. The tolerance of the level shall be
1 mm/m.
NOTE: Top surface of pad liners shall be max 28 mm below the base-plate of Mill Shell
assembly.
8) Remove the forms for the pad gently after confirming the above accuracy.
9) Round each corner of padding.
10) Make cutting grooves on the surface.
Page 15
Figure-3: Concrete foundation detail
Page 16
7. Installation of Mill Shell assembly on Concrete foundation
Refer to the following drawings for the installation works of Mill Shell assembly.
The following items shall be prepared for installation works of Mill Shell assembly in advance
Prepared
at work site
Taper Liner 200x75x8/20 mm 48 X -
Square Washer 125x125x25 mm 12 X -
Plain Washer 42 12 X -
Hex-nut M42 24 X -
Recycle Inlet 1 X -
Temperature sensor TR13-ACB1AFSX320DE 1 X -
Offset wrench or spanner M20, M30 and M42 - - X
Solvent, rust remover and etc. Lot - X
Page 17
Mill Shell assembly Installation procedure
1) Set 2 (two) Taper Liners respectively on both each side of Anchor bolts as shown in Figure-3.
2) Ascertain the orientation of the Mill Shell assembly by comparing the position of components such
as Recycle Nozzle, the chute covers of the Ball Discharge and other equipment with the “General
Arrangement Drawing”.
3) Ensure the enough space for installation:
the installation works of swiveling the components, lifting the components, lowering the components,
placing the components on the ground and etc.
4) Prepare the shackles and/or tools with both the proper size and the proper shape and the wire
ropes sustainable against the load to hoist each component.
NOTE: The total mass of Mill Shell assembly is approximately 19,000 kg.
5) Clean off the Concrete foundation surface and installed both taper liners and pad liners. No dust,
rust, defects and other obstacles shall be found on the Concrete foundation surface.
6) Clean the bottom surface of the base-plate of the Mill Shell assembly that attaches to the
foundation.
7) No dust, rust and defects shall be found on the bottom surface of Mill Shell assembly base-plate.
8) Set shackles and wire ropes on lifting lugs of the Mill Shell assembly.
9) Hoist the Mill Shell assembly slowly with 2 (two) heavy duty machines such as the cranes, UNIC
cranes, etc.
10) Place the Mill Shell assembly on the Concrete foundation with care so as not to damage each
anchor bolt.
11) Release the shackles and wire ropes from the lifting lugs of the Mill Shell assembly.
12) Put the following items on each anchor bolt.
- 1 (one) piece of Square Washer (125 x 125 x 25 mm)
- 1 (one) piece of Plain Washer (size 42)
- 2 (two) pieces of Hex-nuts (M42)
NOTE: For details of the parts above-mentioned, refer to “Anchor bolt & Template”.
Page 18
13) Fasten all Hex-nuts (M42) temporarily.
NOTE: Do not fully fasten yet all Hex-nuts (M42) firmly at this stage. All Hex-nuts (M42)
shall be fastened firmly after the Upper Housing assembly installed on the Mill
Shell assembly and the level-checks finished.
14) Clean the top flange surface of the Mill Shell assembly with solvent.
Figure-4: Installation of the Mill Shell assembly on the Concrete foundation
WARNING
Confirm that all eye-bolts (M20 and M30) and nuts (M20 and M30) on the Mill Shell
Door and the Ball Discharge Cover are fastened firmly BEFORE lifting, slinging and/or
unloading the Mill Shell assembly.
In the case that any loosened bolts & nuts were found, those bolts & nuts shall be
fastened firmly and surely.
No operations of lifting, slinging and/or unloading the Mill Shell assembly are
permitted until all eye-bolts and nuts are confirmed to be fastened rigidly.
Page 19
8. Installation of Screw assembly
Refer to the following drawings for the installation works of Screw assembly.
T595024 Screw Installation Drawing
The following items shall be prepared for installation works of Screw assembly in advance
Prepared
at work site
Screw band with Hex-bolts and
(used in screw hanging) 1 set X -
Hex-nuts
Hex-bolt M48 x 350L 4 X -
Hex-bolt M48 x 280L 8 X -
Hex nuts M48 24 X -

Flange key for screw-
Sunk Key 1 X -
drive shaft
Hydraulic Jack 1 X
M20x75 (screw band
Hex Socket Head Bolt 4 X -
bolts)
Spanners / Wrench M48, M20 size lot
Ratchet lever hoist 5 - X
Shackles 10 - X
Page 20
Screw assembly Installation procedure
1) Place the hydraulic jack on center of the Mill Shell assembly bottom.
2) Mount the Band on the neck of the Screw assembly as shown in Screw Installation Drawing
(T595024)
3) Set shackles to the holes on the lifting lug of the Band and on the lifting lug of the Mill Shell assembly.
4) Remove the rust inhibitive coating using solvent from the flange surface end of the Screw assembly
connecting to the Drive Shaft.
5) Confirm that no rust, dust, foreign matters and etc. are found on the cleansed portions above.
6) In the case that any defects found on the cleansed portions, remove the defects surely.
7) Set the lift crane used for lifting, and attach the wire ropes and 2 sets of shackles to the M48 eye-
bolts and nuts to the flange surface of the Screw assembly. The other set of shackles and lifting
rope/crane shall be attached to the arm side attached to the screw.
8) Loosen the end plate at the other end of the screw transport and remove all the bolts/nuts installed
preventing the screw from moving with respect to the screw transport.
9) Hoist the Screw assembly slowly with cranes begin lifting horizontally the screw and have it
lifted/separated from the screw transport.
10) When the screw assembly is separated already, lower the screw near the ground and tighten again
the screw end plate previously loosened.
11) Continue lifting the whole screw and beging horizontal to vertical orientation lifting with 2 cranes
12) Release the wirerope hooked on the lifting arm/jig when the screw is vertically positioned already.
13) Disattach the arm from the screw.
14) Lift the screw the Screw assembly and insert it in the mill shell and have it sitted above the hydraulic
jack.
15) Apply hooks of ratchet lever hoist to the shackles tied down to the rib on the Mill Shell assembly.
16) Apply other hooks of ratchet lever hoist to the shackles tied down to the rib on the Band.
17) Tension each chain of ratchet lever hoist.
NOTE-1: Confirm that the distance between flange surface of the Screw assembly and
the top face of the Mill Shell flange shall be around 920 mm.
NOTE-2: The Screw assembly (vertical axis) should be perpendicular to the base-plate of
the Mill Shell assembly when all the chains of ratchet lever hoists are on
tensioned condition.
18) Confirm that all chains of ratchet lever hoist have enough tension to allow the Screw assembly to
stand perpendicular.
19) Release the wires hooked on the eye-bolts and remove the two eyebolts finally. Follow the
procedure in T596024 for installation of the screw agitator blade during upper housing installation.
Page 21
9. Installation of Upper Housing assembly
Refer to the following documents for Installation works of Upper Housing assembly.
The following items shall be prepared for installation works of Upper Housing assembly in advance.
Prepared
at work site
Hex-bolt M30 x130L 30 X -
Hex-nut M30 30 X -
Vibration sensor CMSS2100 (SKF) 1 X -
Temperature sensor TR11-ACACDSX330DA 1 X -
Level switch FTL31-AA1V3AAVCJ-I7 1 X -
Shackle 6 - X
Level vial Precision: 0.05 mm/m 1 - X
Spanner M30 Min. 2 - X
Page 22
Upper Housing Assembly Installation procedure
1) Remove the upper housing support frame used for transportation.

2) Remove the rust inhibitive coating using solvent from (1) both flange-surfaces of the Upper
Housing assembly, (2) the flange surface end of the Drive Shaft connecting to the Screw
assembly and (3) the lower side of the L.S. Gear Couplings installed on the end of the Drive Shaft
assembly.
4) In the case that any defects were found on the cleansed portions,make sure to remove the
defects.
5) Set shackles and wire ropes on lifting lugs of the Upper Housing assembly.
6) Hoist the Upper Housing assembly slowly with 2 (two) heavy duty machines such as the cranes,
(UNIC cranes, etc.) considering the capacity of each.
7) Confirm the orientation of the Upper Housing assembly by comparing the reference drawings
before placing the Upper Housing assembly onto the Mill Shell assembly. The upper housing
access doors should be with the same direction as the mill shell door.
8) Place the Upper Housing assembly on the flange surface of the Mill Shell assembly.
9) Install thirty pieces (30pcs) of Hex-bolts (M30x130L) with Plain Washers through the through-
holes on the mating flange surface of between the Mill Shell assembly and the lower portion of the
Upper Housing assembly from the bottom side of the flange surface of the Mill Shell assembly.
10) Set Plain Washers and Hex-nuts onto the installed Hex-bolts above. Bolts heads should be
coming from the lower side with nuts above(upper housing flange side)
11) Tighten all the thirty (30) pieces of Hex-bolts & Hex-nuts diagonally, evenly and firmly.
NOTE-1: All workers shall put the safety goods such as the safety belts, the safety
harnesses, the safety helmets and etc. while they are engaged in these activities
above.
NOTE-2: Pay the closest attention so as not to drop the items such as Hex-bolts
(M30x130), and tools etc. during these activities above.
12) Place the level vial on the top face of the Upper Housing assembly as shown in Figure-5: Location
of the level vial and check level diagonally.
Level tolerance: 0.1 mm/m
NOTE: Adjust the level by tapping the taper liners beneath the base-plate of the Mill
Shell assembly.
13) Confirm the level on the flange surface of the Upper Housing assembly with level vial.
14) Spot-weld between (1) the upper taper liners and the lower taper liners and (2) the lower taper
liners and the pad liners as shown in Figure-3 after the level-checks are finished.
15) Tighten all the Hex-nuts (M42) for the anchor bolts diagonally, evenly and firmly.
NOTE-1: Conduct finishing works at the top of each Concrete foundation by pouring the
grout after all the level-checks have been finished.
NOTE-2: The covers for the manholes inside of the Upper Housing assembly (lower
section) shall be placed precisely.
Page 23
16) Loosen 6 (six) pieces of Lock-bolts (M42x120L) on the Bushing Box.

NOTE-1: Do not remove the Lock-bolts from the Bushing Box.
NOTE-2: The distance between the surface of the Bushing Box and the tip of the Lock-
bolt shall be approximately 10 mm
17) Install all other items on the ports of the bearing box (sensors, level switch etc)
Level vial
Mass of the Upper Housing assembly: 15,000 kg
Figure-5: Location of the level vial
support
Figure-6: Upper housing (with coupling brace and lower transport frame)
Page 24
10. Installation of Gear Reducer
Refer to the following documents for Installation works of Gear Reducer.
G3199661E-4 Outline Drawing of Gear Reducer
The following items shall be prepared for installation works of Gear Reducer in advance.
Prepared
at work site
Hex-bolt M36x150L 24 X -
Hex-nut M36 24 X -
Spring Washer 36 24 X -
Temperature sensor TR10-ACA1CDTE3A0DK 1 X -
Vibration sensor CMSS2100 (SKF) 1 X -
Hex-bolt M24 4 X
Offset wrench or spanner M24 & M36 Min 2 - X
Ratchet wrench M36 - - X

Dial gauge (Inside knife-edge
- - X
caliper and/or nominal caliper)
Solvent, rust remover and etc. 1 Lot - X
Page 25
Gear Reducer Installation procedure
1) Set shackles and wire ropes on the lifting eyes/holes of the Gear Reducer.
2) Remove the fixing bolts and the nuts that are settling the Gear Reducer on the transportation
frame.
3) Remove the rust inhibitive coating with solvent from (1) both flange-surfaces of the Gear Reducer,
(2) the upper side of L.S. Gear Couplings and (3) the lower side of the H.S. Gear Couplings.
5) In the case that any defects were found on the cleansed portions, remove the defects surely.
6) Hoist the Gear Reducer slowly.
7) Confirm the orientation of the Gear Reducer by comparing the reference drawings before placing
the Gear Reducer onto the Upper Housing assembly.
8) Loosen 4 (four) pieces of the Adjusting push-bolts (M24 x140L) on the mounting flange of the
Upper Housing assembly BEFORE placing the Gear Reducer onto the Upper Housing assembly.
9) Place the Gear Reducer on the flange surface of the Upper Housing assembly.
Note-1: Before fully fastening the bolts of the reducer to the upper housing, alignment with
the L.S Coupling lower part and upper part is necessary (sub steps 9.1 to 9.3)
9.1) Prepare the LS Coupling (Upper and lower half) for alignment.
NCCH-560
LS Coupling
Figure-7: L.S. Coupling
Page 26
9.2) Have the surfaces of the LS coupling (upper and lower half) exposed so that a dial gauge
with magnet base can be installed on both sides. (A laser alignment tool is also a good
alternative to use whenever available) See illustration below.
9.3) Follow the required angularity, distance, alignment (Figure-10)
10) Measure the following values between the upper side Coupling center and the lower side
Coupling center respectively. Adjust as necessary the gear reducer centering through the four
adjustment bolts between the upper housing and gear reducer.
Angularity Distance Eccentricity
＋ 1.5 mm
B-C≦0.34 mm D = 28 mm A≦ 0.21mm
－ 1.5 mm
Figure-10: L.S. Gear Couplings(NCCH-560) / Allowable tolerances of Angularity & Distance
NOTE-1: In the case that both measured values and/or either measured values do not
satisfy the allowable tolerances above, the adjustment operations shall be
carried out by inserting and/or taking out the shim-plates between the mounting
flange of the Upper Housing assembly and the lower flange of the Gear
Reducer.
NOTE-2: Record the all activities such as measuring operations, the measured values
and etc.
Page 27
11) Lastly, close the sleeves of the L.S. Coupling by lowering the upper sleeve and lifting the lower
sleeve(covers) using the support plates/bolts using spanners and wrenches. Closed the gap
between the sleeves until the two surfaces meet each other, then fasten all the set of bolts and nuts
together. Remove the support and fixed plates and bolts. .
12) Install/tighten twenty four (24) pieces of Hex-bolts (M36x150) with Plain Washers through the
through-holes on the mating flange surface of between the Upper Housing assembly and the Gear
Reducer from the bottom side surface of the Upper Housing assembly.
13) Set Plain Washers and Hex-nuts onto the installed Hex-bolts above.
14) Fasten the Hex-bolts and the Hex-nuts temporarily, not firmly.
NOTE-1: All workers shall put the safety goods such as the safety belts, the safety
harnesses, the safety helmets and etc. while they are engaged in these activities
above.
15) Install the related sensors (vibrationx1pc and temperature sensorx1pc) in accordance with
“Outline Drawing of Gear Reducer”.
NOTE-1: Lower half of H.S. Gear Coupling has been installed on the input shaft of the
Gear Reducer.
NOTE-2: Upper half of L.S. Gear Coupling has been installed on the output shaft of the
Gear Reducer.
Page 28
Figure-12: Installation of the Gear Reducer
Page 29
11. Installation of Main Drive Motor
Refer to the following documents for Installation works of Main Drive Motor.
10006223421 Outline Drawing of Main Drive Motor
The following items shall be prepared for installation works of Main Drive Motor in advance.
Prepared
at work site
Hex-bolt M24x75L 8 X -
Offset wrench or spanner M20 & M24 - - X
Ratchet wrench M24 - - X
Inside knife-edge caliper and/or

- - X
nominal caliper
Page 30
Main Drive Motor Installation procedure
1) Remove the rust inhibitive coating from (1) the mounting flange surface of the Main Drive Motor
and (2) the upper side of H.S. Gear Couplings installed on the output shaft of the Main Drive
Motor.
3) In the case that any defects were found on the cleansed portions, remove the defects surely.
4) Set shackles and wire ropes on through-holes of the Main Drive Motor.
5) Hoist the Main Drive Motor slowly.
6) Confirm the orientation of the Main Drive Motor by comparing the reference drawings before
placing the Main Drive Motor onto the Gear Reducer.
7) Place the Main Drive Motor on the flange surface of the Gear Reducer.
8) Measure the following values between the upper side Coupling center and the lower side
Coupling center respectively
Angularity Distance Eccentricity
＋ 0.75 mm
B-C≦0.14 mm D = 12 mm A≦ 0.07mm
－ 0.75 mm
Figure-13: H.S. Gear Couplings(NSV-242) / Allowable tolerances of Angularity & Distance
NOTE-1: In the case that both measured values and/or either measured values do not
satisfy the allowable tolerances above, the adjustment operations shall be carried
out by inserting and/or taking out the shim-plates between the upper mounting
flange of the Gear Reducer and the mounting flange of the Main Drive Motor.
NOTE-2: Record the all activities such as measuring operations, the measured values and
etc.
9) Install eight (8) pieces of Hex-bolts (M24x85) through the through-holes on the mating flange
surface of between the Gear Reducer and the Main Drive Motor from the bottom side surface of
the Gear Reducer.
10) Fasten the Hex-bolts temporarily. Proceed first with HS Coupling alignment.
Page 31
Figure-14: Installation of the Main Drive Motor with H.S. Gear Couplings
Page 32
12. Aligning & Assembly of H.S. Gear Couplings
Refer to the following documents for Aligning & Assembly of H.S. Gear Couplings.
TPD-021-0 Lubrication List
The following items shall be prepared for aligning work of High Speed Gear Couplings in advance.
Prepared
at work site
Reamer-bolt M10 12 X -
Reamer bolt Hex-nut M10 12 X -
O-ring (mounted) 1 X -
(in between
Center plate / o-ring 1 set X -
upper,lower half)
precision 0.01 mm
Dial gauge - - X
with magnetic stand
Offset wrench or spanner M10 - - X
Torque wrench M10 - - X
Page 33
H.S. Gear Couplings Aligning & Assembly procedure
1) Lift the upper Coupling case carefully and hang it above the teeth of the upper side of the
Coupling center with the annealing wires.
NOTE-1: Tie wires between the through-holes of the upper Coupling case and any
hooking points inside of the Gear Reducer.
NOTE-2: Prepare the wooden plates, the rubber-sheets and/or the waste-clothes on the
upper case of the Gear Reducer for placing the lower Coupling case on the Gear
Reducer during the alignment checks.
2) Clean the surface of both the upper Coupling center and the lower Coupling center (with external
gear teeth).
5) Measure and check the distance and the angularity between the lower Coupling center and the
upper Coupling center again.
6) Set the Dial-gauge with the magnetic stand on the upper Coupling center.
7) Apply the spindle of the dial-gauge onto the vertical machined-surface of the lower Coupling
center to measure the eccentricity of the H.S. Gear Couplings.
8) Turn the output shaft of the Main Drive Motor by rotating the cooling fan manually.
NOTE-1: Record the measured eccentricity values of the Coupling centers with 4 (four)
points at a minimum.
9) Tighten the eight (8) pieces of Hex-bolts (M20) between the Gear Reducer and the Main Drive
Motor diagonally, evenly and firmly.
10) Remove the Dial-gauge with the magnetic stand from the upper Coupling center.
Page 34
③ ① ⑤
⑥
④ ⑨
⑧
②
⑦
NSV 242
Figure-15: Outline of the Gear Reducer and alignment of the H.S. Gear Couplings
1 Motor 6 Coupling center (Upper side)
2 Gear Reducer 7 Gear Reducer shaft
3 Coupling (Upper side) 8 Coupling center (Lower side)
4 Coupling (Lower side) 9 Dial gauge
5 Motor shaft
11) Record all the measured values such as the eccentricity, the angularity and the distance of the
H.S. Gear Couplings. These recorded values shall be filed for the future maintenance and/or the
overhaul operations.
12) Apply sufficient grease (“Ref. TPD-021-0 Lubrication List) to the internal gear teeth and the
external gear teeth of both sides of the H.S. Gear Couplings.
13) The indication quantities of the grease are as follows:
- Upper side approximately 0.104 kg (0.120 L)
- Lower side approximately 0.127 kg (0.147 L)
14) Insert the O-ring into each ditch on the lower Coupling case respectively.
15) Insert the Center plate with spherical convex prominence between the upper Coupling center and
the lower Coupling center.
NOTE: The direction of the spherical convex prominence on the “Center plate” shall be
downward. Wrong installation direction of the Plate shall cause the critical
damages to the TowerMill.
16) Lift the lower Coupling case.

17) Install twelve pieces of Reamer-bolts (M10) into the mating flange surface of between the upper
Coupling case and the lower Coupling case from the bottom side surface of the lower Coupling
case.
Page 35
18) Set Spring Washers and Hex-nuts onto the installed Reamer-bolts above.
19) Tigthen the Reamer-bolts with the torque wrenches diagonally, evenly and firmly.
Page 36
13. Aligning & Assembly of L.S. Gear
Refer to the following documents for Aligning & Assembly of L.S. Gear Couplings.
TPD-021-0 Lubrication List
The following items shall be prepared for aligning work of Low Speed Gear Couplings in advance.
Prepared
at work site
Reamer-bolt M20 20 X -
Hex-nut M20 20 X -
To be installed in
O-ring / center plate between upper half and 1 set X -
lower half coupling
hanging the
Annealing wire 1 lot - X
upper Coupling case
precision 0.01 mm
Dial gauge 1 - X
with magnetic stand
Offset wrench or spanner M20, M24, M36 - - X
Torque wrench M20, M36 - - X
Page 37
L.S. Gear Couplings Aligning & Assembly procedure
1) For smooth alignment check activities, remove the cooling fan cover of the Main Drive Motor.
2) Ask/prepare one (1) worker on the top of the Main Drive Motor for rotating the cooling fan
manually.
NOTE-1: The worker on the top of the Main Drive Motor shall rotate the cooling fan
manually whenever asked by the site manager (the qualified personnel or the
supervisor).
NOTE-2: The worker on the top of the Main Drive Motor shall put on the safety goods
such as the safety belt, the safety harness, the safety helment and etc. surely.
NOTE-3: The other worker(s) shall stay on the maitenance floor (the same height of the
upper flange of the Upper Housing assembly) and keep sharp eyes on the
worker on the top of the Main Drive Motor so that the worker does not fall down.
NOTE-4: Prepare the wooden plates, the rubber-sheets and/or the waste-clothes on the
upper case of the Bearing Box for placing the lower Coupling case on the
Bearing Box during the alignment checks.
3) Clean the surface of both the upper Coupling center and the lower Coupling center (with external
gear teeth).
6) Measure and check the distance and the angularity between the lower Coupling center and the
upper Coupling center.
7) Set the Dial-gauge with the magnetic stand on the upper Coupling center (see Figure 16 on next
page)
8) Apply the spindle of the dial-gauge onto the vertical machined-surface of the lower Coupling
center to measure the eccentricity of the L.S. Gear Couplings.
9) Turn the output shaft of the Gear Reducer by rotating the cooling fan manually.
NOTE-1: The site manager, a qualified personnel and/or the supervisor shall suggest the
worker on the top of the Main Drive Motor to continue to rotate the cooling fan
manually until the Dial gauge circuits around the lower Coupling center.
NOTE-2: Record the measured eccentricity values of the Coupling centers with 4 (four)
points at a minimum.
10) Fasten and/or loosen 4 (four) pieces of the Adjusting push-bolts (M24x140) on the base-plate of
the Upper Housing assembly by referring the measured values above.
11) Continue to measure the eccentricity by adjusting the installed position of the Gear Reducer with
the Adjusting push-bolts until the eccentricity values satisfy the allowable values as shown in エ
ラー! 参照元が見つかりません。10.
12) Fasten 4 (four) pieces of Lock nuts on the Adjusting push-bolts so as not to be loosened AFTER
the eccentricity of the Coupling center is confirmed to satisfy the allowable values.
13) Tighten the 12 (twelve) pieces of Hex-bolts (M48x195) & Hex-nuts (M48) between the Upper
Housing assembly and the Gear Reducer diagonally, evenly and firmly.
14) Remove the Dial-gauge with the magnetic stand from the upper Coupling center.
Page 38
NCCH 560
Figure-16: Outline of the Gear Reducer and alignment of the L.S. Gear Couplings
1 Gear Reducer 9 Coupling case (Lower side)
2 Upper Housing assembly 10 Coupling center (Upper side)
3 Hex-bolt (M36x150) 11 Coupling center (Lower side)
4 Hex-nut (M48), PW 12 Reamer-bolt (M20), Hex-nut
5 Adjusting push-bolt (M24x140) 13 Dial gauge
6 Lock nut (M24) 14 Center plate
7 Drive Shaft for Screw 15 O-ring
8 Coupling case (Upper side)
** Legend PW = Plain Washer,
Page 39
15) Record all the measured values such as the eccentricity, the angularity and the distance of the
L.S. Gear Couplings.These recorded values shall be filed for the future maintenance and/or the
overhaul operations (Figure-10).
16) Apply sufficient grease to the internal and the external gear teeth of both sides of the L.S. Gear
Couplings uniformly.
17) The indicated quantities of the grease/oil lubricant are as follows for NCCH 560 LS coupling:
(Ref. TPD-021-0 Lubrication List)
- Upper side coupling : 2.03 kg (2.247 L)
- Lower side coupling : 1.91 kg (2.118 L)
18) Insert the O-ring in the coupling gap
19) Insert the center support platesand which between the upper Coupling center and the lower
Coupling center
20) Release the tied wires on the upper Coupling case.
21) Lift the lower Coupling case.
22) Install twenty (20) pieces of Reamer-bolts (M20) into the mating flange surface of between the
upper Coupling case and the lower Coupling case from the bottom side surface of the lower
Coupling case.
23) Set Spring Washers and Hex-nuts onto the installed Reamer-bolts above.
24) Tigthen all the Reamer-bolts with the torque wrenches diagonally, evenly and firmly.
Page 40
14. Installation of Screw assembly
Refer to the following documents for Installation works of Screw assembly.
T595024 Screw Installation Drawing
The following items shall be prepared for installation works of Screw assembly in advance.
Prepared
at work site
Hex-bolt M48 x 280 L 8 X -
Hex-bolt M48 x 350 L 4 X -
Hex-nut M48 24 X -
Spring Washer 48 12 X -
Screw stirring blade 1 set X -
Hydraulic jack 1 X -
Jack base 1 X -
Band w/ M20 bolts/nut set 1 set X -
Ratchet lever hoist - - X

Single-end ring slogging
M48 - - X
spanner
Spanner / wrench M20, M48 - - X
Hammer - - X
Page 41
Screw assembly Installation procedure
1) Ascertain that 6 (six) pieces of Lock-bolts (M42x120L) on the Bushing Box are loosened before
turning the Drive shaft.
2) Match the direction of the keyway on the Drive Shaft to the direction of the sunk key by turning the
cooling fan of the Main Drive Motor manually.
3) Operate the hydraulic jack slowly to push up the Screw assembly.
NOTE: Pay the closest attention so as not to damage the flange surface of the Drive Shaft
or the edges of the keyway on the drive shaft by the sunk key during the operation
of hydraulic jack.
4) Install first the eight piece of pieces of Hex-bolts (M48x208L) through the through-holes on the
mating flange surface of between the Screw assembly and the Drive Shaft from the bottom side of
the flange surface of the Screw assembly. Refer to T596024 for the arrangement of bolts and the
figure below. Note that the first 8 bolts shall be used for flange to flange direct bolting and not for
the stirring blade of the screw.
5) Next install the remaining 4 pcs of M48x350L bolts sandwiching the two sets of stirring blade plates.
35 kg
Figure 17 : Screw stirring blade installation

6) Set Spring Washers and Hex-nuts onto the installed Hex-bolts above.
7) Tighten all the 12 (twelve) pieces of Hex-bolts and & Hex-nuts with M48 Single-end ring slogging
spanner by hammering M48 Single-end ring slogging spanner diagonally, evenly and firmly.
NOTE: Be sure that 2 (two) workers shall be engaged upon operation for tightening
M56 size bolts and nuts.
Page 42
8) Loosen the tension of all chains for ratchet lever hoists.

9) Release the shackles from the lifting lugs of Mill Shell assembly.
NOTE-1: All workers themselves shall pay the closest attention so as not to drop down.
NOTE-2: Never throw the released hook of the ratchet lever hoist so as not to damage the
inside of Mill Shell assembly or Screw assembly.
10) Release the other shackles from the lugs of the Screw Band.
11) Remove the Band.
NOTE-1: Be sure that at least 2 (two) workers shall engage to dismantle the Band from
the Screw assembly.
NOTE-2: Pulling on the safety belts, all workers themselves shall pay the closest
attention so as not to drop down.
NOTE-3: Pay the closest attention so as not to drop off the dismantled the Band inside
the Mill Shell assembly.
12) All workers shall leave from the inside Mill Shell assembly.
13) Release pressure of hydraulic jack slowly.
Page 43
15 Installation of Coarse Classifier and Agitator
Refer to the following documents for Installation works of Coarse classifier and agitator.
T595103 Agiator Drawing
The following items shall be prepared for installation works of Coarse classifier and agitator in advance.
Prepared
at work site
Hex Bolts,nuts set M20 32 set X -
Hex Bolts,nuts, plain washers, spring
M20 4 sets X -
washers set
Coarse classifier Support arm L = 740mm (angle) 2 sets X -
Coarse classifier cover 1020 x 330 x 110 2 sets X -

2.2 kW drive (WEG-
Agitator (Motor-Gearbox-Agitator body 1 set X -
SEW)
Shaft L=1775mm,
blade 400mm dia
Agitator Shaft (with 2 blades, set bolts) 1 set X -
Set bolts
M12x30L(2pcs)
Dessicant type air breather (with pipe
DAB-2 1 set X -
extension for gearbox)
Agitator base plate 620mm dia. , (35kg) 2 sets X -
Agitator base plate Hex bolts / nuts /
M20x90L 12 sets X -
Plain Washers / Spring Washers
Agitator base plate Plain Washers /
M20 16 sets X -
Spring Washers
Agitator Hex Bolts M20x50L 4 pcs X -
Agitator Plain washer, Spring washer M20 16 sets X -
Socket wrench / spanners M12, M20 lot - X
Solvent, rust-remover lot - X
Page 44
Coarse Classifier installation into Mill Shell:
1) Prepare all lifting tools (shackles, eyebolts, wire ropes, overhead crane or chain block).
2) Pre-install the support arm of the coarse classifier onto the coarse classifier, but lightly tightening
the bolts/nut set to it.
3) Set up the lifting tools so as to carry the whole coarse classifier.
4) Lift the coarse classifier like the way shown in Figure 18 below
5) Install all thirty two (32) sets of M20x80L size hex bolts/nuts in between the flange of the coarse
classifer and mill shell overflow port. Note that the bolt heads shall be coming from mill shell
side overflow port, while nuts shall be located on the coarse classifer side.
a-detail
Coarse classifier
Support arm
Figure 18 : Assembling of coarse classifer and agitator into Mill Shell
Page 45
6) After having the coarse classifer installed into the mill shell via the port to port connections
through bolts, next is to fix the support arm on both mill shell side and coarse classifier(to
tightened level).
7) Use the four (4) pieces of M20x65L hex bolts together with the plain and spring washers (6 sets
total).
8) Balance and tighten firmly all the the connecting bolts between mill shell and coarse classifer.
9) Remove all the lifting ropes and shackels when the whole coarse classifer has been secured
and tightened.
NOTE-1: Make sure to clean all mating surface always using the solvent remover and
rugs
NOTE-2: Always observe precation on heavy items that might fall while working. Use
safety harness, ladders, when necessary.
Installation of Agitator to Coarse Classifier:
Refer to Figure 19, for the next procedure steps on how to install the agitator body on top of the coarse
classifer.
10) Install the agitator blades(impeller) (2 sets) onto the agitator shaft by tightening the set bolts
(M12x30L) attached to the blade hubs.
11) Install the shaft onto the agitator main body by inserting the shaft and tightening the set bolts
M10x25L (4 sets)
12) Remove the prebolted Agitator base plate on top coarse classifier. There are two half circle
plates, only one need to be removed so that the blades and agitator shaft can be inserted inside
the coarse classifer.
13) Lift the whole agitator unit carefully up and have the shaft/impeller side get inside the coarse
classifier opening.
14) Have the agitator base flange sit on the top of the pre-installed half base plate and bolt the
two(2) sets of M20x50L bolts/PW/SW sets alotted for the installation of the agitator to the base
plate.
Do not tighen yet the bolts fully, tighten them just enough to have the agitator unit temporarily
installed.
15) Bring back the previously remove agitator base plate half (step No. 12), and have it installed in
between the agitator and the coarse classifer body to close now the opening.
16) Install the same remaining bolts sets to secure fully the agitator. These are the same M20x50L
bolts/PW/SW sets (2sets).
17) Make sure that the agitator shaft is centered in between the base plate halves’ hole (circle shape
when completed) so as to prevent the agitator shaft from touching the base plate during
rotation/operation.
18) Tighten firnly all the bolts and make final adjustments when necessary.
19) Remove the old air vent (with pipings) of the agitator gear reducer and replace it witht the
dessicant type air breather. Refer to Figure 20 for the illustration of the old vent and new vent
with air breather
Install it onto the gear reducer part of the Agitator and use a seal tape to seal the pipings.
Note: Make sure the oil inside of the gear reducer does not leak. Also have the agitator
positioned so that the orientation of the air breather will be on the highest side (opposite of the
incline, towards the center)
Page 46
Figure 19 : Coarse classifier and Agitator installation arrangement
Reducer air vent (old) Reducer with dessicant air breather
Figure 20 : Agitator gear reducer air breather
Page 47
16 Closing of Mill Shell Door
Refer to the following drawings for closing of Mill Shell Door.
The following items shall be prepared for closing of Mill Shell Door in advance.
Prepared
at work site
Eye-bolt M30x 130 2 X -
Hex-nut & PW M30 2 X
Hydraulic pump for Jack 1 X -
Hydraulic Hose for Jack 1 X -
Offset wrench or spanner M30 - X
Page 48
Mill Shell Door Closing procedure
1) Connect the mating flange surface of between the Mill Shell assembly and the Mill Shell Door.
2) Install 1 (one) piece of Hex-bolt (M30x130) through the through-holes on the mating flange in the
hinge area of the door and mill shell.
3) Set Plain Washer and Hex-nut onto the installed Hex-bolt above.
4) Fasten the Hex-bolt and the Hex-nut.
NOTE-1: Initial setting of the gap between the Mill Shell assembly and the Mill Shell Door
shall be approximately 35 mm. During the factory test, this was already preset at
35mm. Make sure that the same measurement can be observed during on site
installation.
NOTE-2: Keep the gap between the Mill Shell assembly and the Mill Shell Door.
NOTE-3: Don’t remove the Stopper-bolts from the flange of the Mill Shall assembly.
5) Install the next piece of Hex-bolts (M30x130) through the through-holes on the mating flange
surface of between the the Mill Shell assembly and the Mill Shell Door from the flange surface of
the Mill Shell assembly in the position 2 and 3 in Figure-16.
6) Set Plain Washers and Hex-nuts onto the installed Hex-bolts above.
7) Continue the procedures: total 6 (six) sets of the Hex-bolts & Hex-nuts in the position 4 to 6 in
Figure-16.
8) Set eye-bolts with Plains Washer and Hex-nuts in sequence 7 to 10 in Figure-16.
9) Fasten the Hex-nuts (M30) evenly.
Page 49
5
Bolts & Nuts
4
M30 A
6 Gap
A Initial setting: 35 mm
Eye-bolt
M30 x 175
Stopper-bolt
Initial setting: 12 mm
10
2
Bolts & Nuts 1
M30 3
Mill Shell assembly flange
Mill Shell Door flange

7 A-A
Figure-21: Closing of the Mil Shell Door
Page 50
17. Installation of Lubrication Unit
Refer to the following drawings for the installation works of Lubrication Unit.
G3199662E-5 Outline & Circuit Diagram of Lubrication Unit
The following items shall be prepared for installation works of Lubrication Unit in advance.
Prepared
at work site
JIS 10K 32A /
Flexible Metal Hose 1 set X -
L=1750mm
JIS 10K 40A /
Flexible Metal Hose 1set X -
L=1750mm
Hex-bolt M12 8 - X
Hex nut and washer M12 8 sets - X
Offset wrench or spanner M12 lot - X
Seal tape - lot - X
Pipe wrench - - X
Shackle - - X
Sling-belt and/or chains - - X
Page 51
Lubrication Unit Installation procedure
1) Install Flexible Metal Hoses on each connection (gear reducer in/out to lubrication unit in/out
ports.
NOTE: Apply the “seal-tape” on the threaded portions of the “male-connection” on the
Gear Reducer BEFORE connecting Union Joints.
NOTE: Depending on the layout plan of the customer, a firm base for the lubrication
unit may be necessary. (e.g. channels or metal frame)
2) Set shackles and wire ropes or chains on the lifting eye bolts of the Lubrication Unit.
3) Hoist the Lubrication Unit slowly.
4) Place the Lubrication Unit on the floor with care so as not to damage it.
5) Position it above the holes of the matching base and insert the bolts and nuts set for installation.
6) Tighten the hex bolt and nuts sets
7) Release the shackles and wire ropes from the lifting lugs of the Lubrication Unit.
8) Connect flexible hoses on the Lubrication Unit and gear reducer side with the pipe wrenches.
9) Make sure to open all valves on the lubricant piping of the Lubrication Unit.
10) Confirm that the “Change handle” of the Duplex filter is at the “OPERATION” position.
11) Close the draining valves.
Page 52
18. First filling (Lubricants list)
Prepare lubricants for assembling each component in accordance with the table below.
# Items Oil grade Quantity
Bearing Box
MOBIL 600XP150
1 in Upper Housing approximately 50 liters
or ISO VG150
assembly
2※ Gear Reducer with ISO VG150 or

approximately 145 L
Lubrication Unit Mobil 600XP150
Shell Alvania GL00
Upper side : approx 0.104 kg (0.120 L)
H.S. Gear Couplings or EP Grease No.1
3 Lower side : approx 0.127 kg (0.147 L)
(NSV242) / Mobilux EP No. 1
or equiv.
Shell Alvania GL00
L.S. Gear Couplings or EP Grease No.1 Upper side : approx. 2.03 kg (2.247 L)
4
(NCCH 560) / Mobilux EP No. 1 Lower side : approx. 1.91 kg (2.118 L)
or equiv.
NOTE(※): For filling procedures, refer to the “TowerMill operation manual”.
Page 53
19. Bolt and nut tightness
Items Bolt size Tightening Torque
Main Drive Motor - Gear Reducer M20 (75L) 228 N-m

Gear Reducer- Upper Housing
M36 (150L) 1368 N-m
assembly
Upper Housing - Mill Shell assembly M30 (140L) 783 N-m
Drive Shaft - Screw assembly M48 (350L, 280L) 3,281 N-m
H.S. Gear coupling M10 (reamer bolts) 53.3 N-m
L.S. Gear coupling M20 (reamer bolts) 427 N-m
LS Coupling case cover - case M10 27 N-m
Page 54
20. Check on completion of installation
Check the following items physically and visually:
- All components are installed in accordance with the relevant drawings.

- All nuts for the Anchor Bolts such as the TowerMill and other ancillary components are tightened evenly
and firmly.
- All bolts and nuts for connecting the components such as between “the Mill Shell assemlby and the
Upper Housing assemlby”, “the Upper Housing assembly and the Gear Reducer”, “the Drive Shat and
the Screw assembly” and etc. are tightened evenly and firmly.
- 6 (six) pieces of the Lock-bolt on the Bushing Box are loosened enough that the Drive Shaft rotates
smoothly. However, do not remove the Lock-bolts.
- All flange connections for the grinding and slurry systems are tightened evenly and firmly.
- No defects and/or no faults are found on the rubber-lining for the inside of the Mill Shell assembly, the
Screw assembly and etc.
- No garbage and/or no mislaid items (tools, devices) inside of the assembled TowerMill components
such as the inside of the Mill Shell assembly, the inside of the Upper Housing assemlby and etc.
- The motor fan cover for the Main Drive Motor is installed on its own proper position.
- The covers for the Lubrication Units, the manhole covers for the Upper Housing assembly and etc. are
installed precisely.
- All electrical instruments are installed on their proper positions precisely.
- The grease and the lubricant oil for the first filling are applied to each component.
Page 55
21. Record of installation condition
The site-manager is requested to remain the following items at a minimum as the “Records of the
installation conditions” for the future maintenance activities
Check Person
Item Condition
date in charge
Loose them approximately
Bushing Box 6 pieces of Lock-bolts
10 mm for Drive shaft's free
Upper Housing Check its condition & Full
Leveling
assembly the inspection sheet
Check its condition & Full
Eccentricity
the inspection sheet
Angular
H.S. Gear the inspection sheet
coupling Check its condition & Full
Distance
Lubricant First filling

Eccentricity
Angular
L.S. Gear the inspection sheet
coupling Check its condition & Full
Distance
Connect them between

Flexible hose-inlet Lubrication Unit and Gear
Lubrication Reducer
Unit Connect them between
Flexible hose-outlet Lubrication Unit and Gear
Reducer
Temperature Sensor Equip it to Gear Reducer

Gear Reducer
Mill Shell
Rubber lining Check its condition
assembly
Check condition of each
Fixing bolts and nuts
equipment
All equipment
All opening covers and Check condition of each
doors equipment
Page 56
APPENDIX
INSTALLATION DATA SHEET
Page 57
Appendix-1: Mill Shell assembly leveling record
Page 58
Appendix-2: Low Speed Gear coupling alignment record
Page 59
Appendix-3: High Speed Gear coupling alignment record
Page 60
Final Drawing
Final Drawing
Final Drawing
Final Drawing
Final Drawing
Final Drawing
１２３４５６７８９
T595024
ＤＷＧ．ＮＯ．
ＡＡ
SCREW INSTALLATION PROCEDURES
1. Before starting the installation of the screw, mount the screw “BAND” on the screw just
below the flange as shown in “detail A”.
Pay close attention so as not to damage the screw’s rubber lining.
2. Place the jack base, and hydraulic jack inside the mill shell, at the center of the base plate.
Make sure that the hydraulic jack is at its lowest position (zero stroke) before starting putting
the screw inside the mill shell
3. Have the screw lifted by the crane (from the screw transport originally carrying it,
Ｂ and conduct horizontal to vertical orientation change). Ｂ
Lift and put the screw inside the mill shell by inserting it from the top shell flange opening then
have the bottom part (end cap) to sit above the hydraulic jack.
Note: At this period, DO NOT release yet the wire ropes carrying the screw.
4. Set the rachet lever hoist (5 sets) and tension each chain so that the screw shall be sitting
straight perpendicular with respect to the mill shell base plate.
Note: Confirm that the center of the screw flange is at the center of the mill shell upper flange
and the distance from the machined flange is around 920mm.
This is the clearance needed so that around 20mm gap shall be present when the time
to lower the upper housing with drive shaft flange is inserted inside the mill shell.
As much as possible, have the screw flange keyway pointing to the mill shell door.
C 5. When it is time to install the upper housing(with drive shaft on it), match the screw keyway
CHECK THE CENTER ※ direction with that of the drive shaft keyway so the two shall match and be on the same
ＣＣ
direction upon bolting the two flanges. Adjustment of the keyway direction can be done by
※ ※ rotating the LS Coupling side of the drive shaft.
6. Raise the hydraulic jack by using the hydraulic manual pump supplied with the parts.
RATCHET DRIVE SHAFT
LEVER HOIST Pay attention so as not to damage the edge of the keyway or flange surface.
7. Insert the first 8 pcs of flange bolts with M48 x L280mm in the arrangement shown in View C.
These are 3pcs in the door side, 3 pcs in the overflow side, and 2 pcs 90degrees with respect
※
to the first two sides.
VIEW C 8. Next, insert the remaining flange bolts with size M48 x L350mm by sandwiching
AROUND 920
the agitator blade plates (2pcs) first and then inserting the 2 bolts per agitator blade plate.
900
※ Insert the first 8 pcs of flange This is shown in second View D.Tighten all bolts firmly.
bolts with M48 x L280mm 9. When all the flange bolts have been installed already, loosen the ratchet hoist and
( Bolt heads lower side ) disassemble them together with the screw band and take out the hydraulic jack and base
Ｄ BAND Ｄ
A MILL SHELL out of the mill shell.
( JACK UP )
( CLEARANCE )
AGITATING BLADE
DETAIL - A
Ｄ
SCREW JACK ( STROKE 0 mm )
ＥＥ
TOTAL STROKE 50 mm ※ ※
※ ※
32 140∼146
VIEW D
Next,insert 4 pcs of flange
※ Next,insert 4 pcs of flange bolts with M48 x L350mm
bolts with M48 x L350mm
( Bolt heads lower side )
32
JACK BASE PLATE ORIGINAL DWG.

□200 x t32
THIRD ANGLE
Ｆ B PROJECTION
ＤＡＴＥＳＣＡＬＥ
Ｆ
ＴＹＰＥＮＡＭＥ
2019.08.30 Non
DETAIL - B ETM - 500LS TOWERMILL
TITLE
t32 ＡＰＰＲＯＶＥＤＢＹＣＨＥＣＫＥＤＢＹ DESIGN ＤＲＡＷＮ
ＢＹＢＹ
H. Ishikawa J. Mangalus K.Nishio SCREW INSTALLATION DRAWING

□200 DWG. SIZE ＤＷＧ．ＮＯ．
B T595024
１２３４５６７８９
Final Drawing
Final Drawing
Final Drawing
Final Drawing
Final Drawing
制御盤回路図
Control Panel Wiring Diagram
納入先
Customer Anlgo American Peru, SA 殿
装置名
M a c h i n e N a m e ETM-500LS Terminal Box-1
機番
Machine No. 990202
製番
Order No. 186232640
図番
Drawing No. 186232640 00
承認審査作成
A PPR OV ED CH EC KE D D ESI GN ED
TAKAHASHI TAKAHASHI SHIRAKAWA

002
Drawing index
頁名称 /CONTENTS 頁 /PAGE
Cover 1
Drawing index 2
Box outside details 3
Inside details 4
Parts List 5
機械名／ Machine Name 機番／ Machine No. 承　認検　図設　計縮　尺

APPROVED CHECKED DESIGNED SCALE
ETM-500LS Terminal Box-1 990202
TAKAHASHI TAKAHASHI SHIRAKAWA
客先名／ Customer 頁名称／ Page Name
Anlgo American Peru, SA Drawing index 製番／ Order No. 図番／ Drawing No. 頁／ PAGE
186232640 186232640 00 002 002 005
400 120
300
正面図/Front view 右側面図/Right side view
機械名／ Machine Name 承認検図設計縮尺頁名称／ TITLE

ETM-500LS Terminal Box-1 APPROVED CHECKED DESIGNED SCALE
Box outside details
客先名／ ORDER NEME PAGE
Anlgo American Peru, SA TAKAHASHI TAKAHASHI SHIRAKAWA 1/3 製番／ Order No. 図番／ Drawing No.
No. ＮＯＴＥＤＡＴＥ CHKD APVD 186232640 186232640 00 003 003 005
配線表/Wiring table
機器ｺﾈｸﾀNo. 端子台No.
Device Connector No. Terminal block No.
1(+) 1
385 温度計1 2(4-20mA) 2
Thermometer1
3(-)COM 3
4(NO) 4
1(+) 5
温度計2 2(4-20mA) 6
Thermometer2
3(-)COM 7
W40×H80 4(NO)
1(+)
8
9
圧力計1 2(4-20mA) 10
Pressure gauge1
3(-)COM 11
TB
275
4(NO) 12
1(+) 13
圧力計2 2(4-20mA) 14
Pressure gauge2
3(-)COM 15
W40×H80 4(NO)
1(+)
16
17
圧力計3 2(4-20mA) 18
Pressure gauge3
3(-)COM 19
4(NO) 20
NC 21
流量計1 COM 22
Flowmeter1
中板部品配置図/Placement of middle part parts NO 23
24
予備 25
Spare
26
27
28
29

Inside details
Anlgo American Peru, SA TAKAHASHI TAKAHASHI SHIRAKAWA 1/3 製番／ Order No. 図番／ Drawing No.
Symbol Name Type Maker Remarks Symbol Name Type Maker Remarks
Terminal box 1 1530.010 RITTAL NEMA4X
Mounting plate 1 1568.700 RITTAL
Mounting bracket 1 1594.000 RITTAL
Cover Hinge 1 1592.010 RITTAL
TB Terminl block 29 BN15LW IDEC
End plate 2 BNE15W IDEC
Bracket 2 BNL6 IDEC

Parts List
Anlgo American Peru, SA TAKAHASHI TAKAHASHI SHIRAKAWA F/ 製番／ Order No. 図番／ Drawing No.

9321 18 ING 01 DOC 06 - B - B 4 - TowerMill

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9321 18 ING 01 DOC 06 - B - B 4 - TowerMill

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NIPPON EIRICH CO., LTD.

PROJECT : QUELLAVECO PROJECT

Rev. Date Revision Prepared by Checked by Approved by

0 Dec. 25, 2019 1st Issue Y. Hatase J. Mangalus N. Hashiguchi

Nagoya Head Office

Referenced documents and drawings

The following documents and drawings are referenced in this procedure

Document # Title of Documents / Drawings

T595001-4 General Arrangement Drawing

T595002-1 Foundation Drawing

T595003-6 P & I Diagram

T595101-3 Layout Plan Drawing

T595102-0 Anchor Bolt and Template

T595103-0 Agitator Drawing

T595104-0 Parallel Levelling Wedges

T595024-0 Screw Installation Drawing

1006223421 Outline Drawing of Main Drive Motor

G4196825 (1/2) High Speed Gear Coupling Assembly Drawing

G4196825 (2/2) Low Speed Gear Coupling Assembly Drawing

G3199661E-4 Outline Drawing of Gear Reducer

G3199662E-5 Outline & Circuit Diagram of Lubrication Unit

186232640 00 Wiring diagram for lubrication unit Terminal box-1

1. General notice for transportation, unloading, installation and assembly ··································· 6

1. General Arrangement Drawing T595001-4

1. General notice for transportation, unloading, installation and assembly

Following items shall be complied for the safety operation

This document contains the following topics for the TowerMill

- Installation preparation for the TowerMill

3. Loading, Transportation and Unloading

Figure-1: Outline of the TowerMill assembly

Table-1 Approximate net mass and dimension for Main components

# Components Mass (kg) Dimension (mm)

1 Main Drive Motor 3,100 2,250 x 1,450 x 2,500

2 Gear Reducer 4,900 1,740 x 1,740 x 2,270

3 Lubrication Unit 650 1,800 x 1,760 x 2,170

4 Upper Housing assembly 14,250 3,300 x 4,170 x 3,390

5 Mill Shell assembly 20,690 3,610 x 5,200 x 3,600

6 Screw assembly 6,320 1,550 x 1,500 x 4,100

7 Coarse Classifier (Mill shell) 1,400 1,780 x 3,410 x 2,170

Recommended lifting positions (1/2)

1.Main Drive Motor 2. Gear Reducer

Refer to WEG Lifting Plan for more information

Recommended lifting positions (2/2)

5. Mill Shell assembly 6. Screw assembly

Main Drive Motor

Upper Housing assembly

Figure-2: Location of rust inhibitive coating

4. Supervision of critical assembly steps

The outline of installation procedures are as follows:

1) Field check before installation works

5. Concrete foundation works and checks

Refer to the following drawings for the Concrete foundation works.

Document # Title of Documents / Drawings

T595002-1 Foundation Drawing

T595102-0 Anchor Bolt and Template

T595104-0 Parallel Levelling Wedges

Refer to the following drawings for making pad.

Document # Title of Documents / Drawings

T595002-1 Foundation Drawing

T595102-0 Anchor Bolt and Template

T595104-0 Parallel Levelling Wedges

The following items shall be prepared for making pad in advance.

Forms for padding Lot - X