Welcome

1
 TRAINING TOPICS
Study of Entire Hydraulic System
• Significance of every component & It’s working
• Relation and Coordination with other components

Understanding of Hydraulics Flow / Circuit Diagram (IN/OUT

Flow of oil)
Sequence and controlling of various Machinery (Pumps) by
other
Descriptive learning of Hydraulics machinery

Maintenance & Troubleshooting

A glance of operations aspects related to cooler

2
 1. Study of entire hydraulic system

• Significance of every component.

• Its working and coordination with
other components.

3
 Basic data, POLYTRACK® Clinker cooler
Construction size 8/2.5-2.5W
Number of transport tracks 8
Number of modules over cooler length 5
Number of modules over cooler width 2
Width of the aeration floor 4000 mm (4 Meters)
Length of the aeration floor 26,525 mm (26.5 M)
Area of the aeration floor (actively aerated) 104 Sq. Meter
Number of aeration floors 2
Inclination of the cooler and of the aeration floors 0°
Offset between longitudinal cooler axis and longitudinal kiln axis 630 mm
Offset of longitudinal cooler axis viewed against the direction of Right
material flow
Temperature monitoring for the transport tracks Alarm for the transport
tracks, 300 °C

4
 Mode of functioning POLYTRACK®
• To convey the material, the entire transport track
system pushes forward by a stroke length of
about 100 to 230 mm in the direction of
conveyance.
• Subsequently, the return stroke of the transport
tracks takes place in separate steps. First,
transport tracks 1 and 4 (1, 4 & 7) are moved
backwards by the stroke length,
• subsequently transport tracks 2 and 5, (2, 5 & 8)
• and finally transport track 3. (3 & 6)
• This concludes one cycle of movements. 5
 POLYTRACK® Clinker cooler with 5 transport
tracks

– M Material flow direction

– V Forward stroke
– 1. 1st return stroke
– 2. 2nd return stroke
– 3. 3rd return stroke 6
POLYTRACK® Clinker cooler with 8 transport tracks

7
 Mode of functioning POLYTRACK®
• This concludes one cycle of movements.
• In the next phase, the cycle is repeated.
• The material is transported during the forward
strokes.
• During the individual return strokes, the
frictional force between the transport tracks
and the material to be conveyed is not great
enough to convey the material backwards.

8
9
 Track Movements
• In the forward stroke all the tracks moves
together carrying the clinker with them.
• But during return stroke they moves by a
sequence so that the material don’t come
back.
• Sequence 1-4-7
2-5-8
3-6
10
Grate equipment

11
Components and mode of functioning-1
1. The hydraulic drive moves the transport tracks of
the cooler.
2. It makes them move back and forth with a stroke
length of 50 to 220 mm at a stroke frequency of
between 2 to 11 per minute….
3. As the stroke frequency is infinitely variable within
the specified ranges,
4. the specific transport speed of the material to be
cooled on the grates can be adjusted to suit the
functioning requirements of the cooler.

12
Hydraulic drive for POLYTRACK® 2.5 modules

13
Components and mode of functioning-2
1. The hydraulic drive operates according to the
principle of a closed circuit, i.e.
2. The driven transport track is fixed by the cylinders
between two pressurized oil columns which are set
in motion by the main pump.
3. In this connection one must distinguish between
the high pressure side - pump delivery direction -
and the low pressure side - pump suction side.
4. The hydraulic drive is controlled and monitored by
an electronic control system………...

14
15
16
 Denomination in the figure
A Forward stroke
B Return stroke
C Piston-travel measuring system
D Transport track
E Grate substructure
F Cylinder (80)
G Flush valve (81)
H Adjustable main pump (51)
I Proportional pressure control valve with integral
amplifier
M Electric motor
N Control system
T Oil tank

17
 2 Minutes Break

TRACK HYDRAULICS
MOVEMENT MOVEMENT

18
‘Principle of functioning’ of the Hydraulic drive-1
1. When the discs of the pump are pivoted, the created volume
flow moves one cylinder forward and the other cylinder
backward.
2. The oil of the retracting cylinder returns to the suction side
of the main pump via the hydraulic piping.
3. The size of the pivot angle of the main pump discs
determines the volume flow and thus the operating speed of
the transport track.
4. When the discs of the main pump are pivoted back in the
opposite direction via the zero position, the volume flow is
first throttled and then built up again in the opposite
direction, so that the other cylinder is now being moved
forward.
19
‘Principle of functioning’ of the Hydraulic drive-2
1. The direction and the speed of the movement to be
executed by the pistons are transmitted as a
corresponding voltage signal by the control system
to an amplifier card.
2. This card converts the input voltage into a load
independent current that activates a proportional
pressure control valve.
3. From the current loop signal, the valve generates a
proportional pressure that acts on the adjusting
device of the main pump and makes the pump pivot
accordingly.
20
‘Principle of functioning’ of the Hydraulic drive-3
1. When the discs of the main pump are pivoted from the zero
position, the transport track is accelerated to the set
operating speed.
2. After the acceleration phase, the transport track operates at
constant speed. The current of actual position of the
transport track is recorded by a travel measuring system.
3. Before the set stroke length is reached, the braking phase is
started, i.e. the main pump is pivoted back to the zero
position.
4. The transport track stops when the pump is in the zero
position.
5. The return stroke is performed identically, except that the
main pump is pivoted in the opposite direction.

21
2. Understanding of Hydraulics
flow/ circuit diagram
(In/out flow of oil).

22
The Hydraulic drive, Subassemblies

Tank station

Drive station

Cylinder unit

Accessories

Electronic control system

23
 Tank station, Basic Data
• Oil cooler (6) and (6a) • Control oil pump (23)
– Coolant water – Type gear pump
– Power dissipation 210 kW – Delivery rate 72 l/min
– Water requirement 300 l/min
– Pressure to be set at the pressure
• Tank pump (10) switch (37) 50 bar
– Type gear pump
– Pressure to be set at the pressure valve
– Delivery rate 23 l/min
(38) 70 bar
– Pressure 5 bar
–
– Power of the drive motor for the pump
Power of the drive motor 0.75
kW group (22 + 23) 37 kW
• Feed oil pump (22) • Diaphragm Accumulator (33)
• Pump 1 – Pressurizing pressure 45 bar
– Type gear pump • Bladder Accumulator (48)
– Delivery rate 362 l/min – Pressurizing pressure 10 bar
– Pressure to be set at the pressure switch
(29) 10 bar
– Pressure to be set at the pressure valve
(30) 30 bar

24
 Hydraulic drive for POLYTRACK® 2.5 Modules, Conditioning
25

29 &37 33
30 & 38

48

10
22

23
 Items shown in the drawings, Conditioning Pump (1/2)

1 Oil tank 10 Tank pump

Oil level sight glass with integral 11 Electric motor
2
thermometer
Level signal transmitter with 12 Coupling
3 integrated temperature signal
transmitter 13 Pump support

5 Heating rod 14 In-line filter

6 Oil cooler (coolant: water) 15 3-way valve (drain connection)
6a Oil cooler (coolant: air)
16 3-way valve (filling spout)
7 Valve (water supply)
17 Non-return valve
7a Electric motor (coolant: air)
18 Non-return valve
8 Dirt trap
8a Non-return valve (coolant: air) 19 Non-return valve

9 Shutoff valve 20 Pressure hose

9a Shutoff valve (coolant: air) 21 Tank ventilation filter

26
 Items shown in the drawings, Conditioning Pump (2/2)

22 Feed oil pump

23 Control oil pump 36 Control oil filter

24 Pump support Pressure switch (control oil) with

37
digital pressure indication
25 Coupling Pressure limiting valve (contr. oil
38
press.)
26 Electric motor
39 Switch box
27 Pressure hose
28 Feed oil filter 40 Minimess coupler
Pressure switch (feed oil) with
29 41 Drain cock
digital pressure indication
30 Pressure limiting valve (feed oil) 42 Minimess hose
31 Pressure hose
43 Throttle valve
32/58 Non-return valve
48 Bladder accumulator
33 Diaphragm accumulator
34 Safety valve block 49 Safety valve block
35 Pressure limiting valve 27
 Loose, Oil Filling Kit

Filling hose
72 Measuring instrument case 75

Suction piping
73 filter 76

Filling and testing

74 Non-return valve 77 apparatus for
diaphragm
accumulator

28
Next, Main Drive Circuit

29
Transport track drive, Grate 1 (Basic Data)
• Number of transport tracks .......................................................................... 8 pieces
• Main pump (51)
– Type.............................................................................................. axial piston pump
– Delivery rate ............................................................................................... 105 l/min
– Pressure ....................................................................................................... 250 bar
– Power of the drive motor ................................................................................ 45 kW
– Pressure to be set (p max.) ......................................................................... 250 bar
– at the pressure valves in the valve block of the pump
• Pressure sensor (68)
– Alarm at forward stroke pressure of ............................................................. 200 bar
– Alarm at return stroke pressure of ................................................................ 200 bar
• Cylinder (80)
– Type............................................................................................ differential cylinder
– Number ................................................................................................................... 2
– Piston diameter ...................................................................................... 80 / 56 mm

• Initial parameter setting at operator panel for grate drive - Grate 1

Maximum travel speed of transport track (VF_Max ) 195 mm/s
30
 Transport track drive, Grate 2 (Basic Data)
• Number of transport tracks .......................................................................... 8 pieces
• Main pump (51)
– Type.............................................................................................. axial piston pump
– Delivery rate ............................................................................................... 105 l/min
– Pressure ....................................................................................................... 250 bar
– Power of the drive motor ................................................................................ 55 kW
– Pressure to be set (p max.) ......................................................................... 250 bar
– at the pressure valves in the valve block of the pump
• Pressure sensor (68)
– Alarm at forward stroke pressure of ............................................................. 200 bar
– Alarm at return stroke pressure of ................................................................ 200 bar
• Cylinder (80)
– Type............................................................................................ differential cylinder
– Number ................................................................................................................... 2
– Piston diameter ...................................................................................... 80 / 56 mm
• Initial parameter setting at operator panel for grate drive - Grate 2
Maximum travel speed of transport track (VF_Max ) 195 mm/s

31
 Main Drive
81
81

80 80
68

57

63

51

32
 Main Drive
Items shown in the drawings
(The hydraulic system diagram only shows one drive station)

50 Base frame 61 Fixed throttle

51 Main pump 62 Pressure hose
52 Coupling 63 Valve block (component of the
53 Elastic pump support main pump)
54 Electric motor 64 Minimess coupler
55 Stop cock (ball valve) 65 Minimess hose
56 Pressure hose 68 Pressure transducer with digital
57 Pressure control valve pressure indication
(proportional 3-way pressure 69 Intermediate plate
reducing valve) with integral 70 Switch box
triggering electronics 80 Cylinder (differential cylinder)
59 Pressure hose 81 Flush valve with base plate
60 Pressure hose ST Local/remote selector switch
33
4. Descriptive learning of
Hydraulics machinery.

34
 Hydraulic system for Transport track drive

•Supplier : POLBECH /Bosch Rexroth

•No. of pumps: 16 (2 Grates x 8 Tracks)
•Type Of Pump : Axial Piston pump
•No. of Hydraulic Cylinder: 32
(2 Grates x 8 Tracks x 2 Forward & Reverse)
•Type of cylinder: Differential ??
•Diameter of piston(mm): 80/56
•Oil tank volume: 2500
•Oil grade : VG-46
35
 Transport track Drive
Axial piston pump, Variable Flow
Specification:

 Delivery rate : 105 liters per

minute
 Pressure : 250 bar
 Power of the motor: 45kw /
55kw
 Alarm at forward / reverse is
set at 200 bar
36
 Transport Track
Required Thrust force
• Grate-1 : 120 kN/Transport track
• Grate-2 : 120 kN/Transport track
• Stroke Frequency : 2 to11 per min
• Stroke length : 50 to 220 mm

37
 Hydraulic drive for
POLYTRACK® 2.5 modules

Description,
Operation, Function

38
 Design description (2-Stations)
1. Tank station
– The tank station is a supporting unit consisting of an oil tank
(1) and various monitoring devices. It has the function of
storing and treating the oil.
2. Drive station
– The drive station has the function of producing the
necessary volume flow at the necessary pressure for moving
the pistons of the cylinder unit.
– All components of the drive station are installed on a
common base frame (50) that is mounted on vibration
dampers.
– Wherever necessary, flexible pressure hoses are used as
connecting elements, e.g. to compensate for vibrations and
to enable the quick exchange of a complete drive station. 39
 (1) Tank station, Components
• Oil tank (1)
• Oil level monitoring
• Oil temperature monitoring
• Oil heating
– heating rods (5) in the oil tank (1)
• Oil cooling oil cooler (6 or
6a)
• Tank pump (10)
• Oil filter
• Pump group for feed oil
and control oil
– The feed oil pump (22) and the
control oil pump (23)
• Diaphragm accumulator (33)
– The diaphragm accumulator has the
function of keeping the pressure in
the control oil circuit more or less
constant during the pivoting of the
discs of the main pump (51).
• Safety valve block (34)
• Control oil and feed oil filters (28
and 36)
• Pressure switches (29 and 37)
• Pressure valves (30 and 38)
• Switch boxes (39 and 70)
• Bladder accumulator (48)
• Safety valve block (49)
40
 (2) Drive station, Components

• Main pump (51)

• Valve block (63)
• Pressure control valve (57)
• Pressure transducer with digital pressure
indication (68)
• Cylinder (80)
• Flush valve (81)

41
Hydraulic drive for POLYTRACK® 2.5 modules

42
Cylinder unit

43
 Cylinder unit, Functioning
• The cylinder unit consists of two cylinders (80) working in
opposite directions, which are attached by means of
shackle toggles at the piston rod end to the transport track
and at the cylinder bottom end to the grate substructure.
• The cylinder chambers at the cylinder bottom end and the
piston rod compartments are connected to the pressure
piping A and B of the main pump (51).
• These compartments are interconnected by flushing pipes
that are closed by a flush valve (81).
• All pressure piping connections of the cylinders can be
closed with ball valves so that the cylinders can be
dismounted.
44
 Electronic control system
• The hydraulic drive is electronically controlled and
monitored
• This control system is installed in a separate cabinet.
• The signals needed for controlling the movement are
transmitted by the position measuring system
mounted at the transport tracks.
[LVDT System Operation, (POSITIONAL SENSORS, Linear Variable
Differential Transformers (LVDTs)
• All drive-specific parameters are input digitally into
the control system via an operator panel.
• Any faults are displayed as text in the display of the
operator panel.
45
Conditioning Circuit 46
Conditioning Circuit 47
 48
Accumulators
Oil Filling & Emptying

10

49
 Tank station

The tank station is a supporting unit

consisting of an oil tank (1) and
various monitoring devices.

It has the function of storing and

treating the oil.

50
 Oil tank (1)
• The oil tank is equipped with a welded on oil sump
and an oil drain valve, as well as with all necessary
connecting pieces and fastening devices for all
additional equipment.
• The oil tank is divided into compartments by an
internal partition that separates the suction side from
the return side.
• This permits settlement and de-aeration of the oil
before it is sucked into the pump again. Any
suspended particles in the oil are deposited in the
settling compartment.
• Each compartment is equipped with an inspection and
cleanout port. 51
 Oil level monitoring
• The oil level is monitored by means of an
optical and an electrical indicator. The
optical indicator consists of an oil level
sight glass (2), through which the oil level
can be observed.
• The electrical monitoring equipment
consists of a level signal transmitter (3)
with integrated temperature signal
transmitter.
52
 Oil temperature monitoring
• The oil temperature is monitored by means
of an optical and an electrical indicator.
• The optical indicator is a thermometer
which is integrated into the oil level sight
glass (2).
• The electrical indicator consists of a
temperature signal transmitter that is
integrated into the level signal transmitter
(3).
53
 Oil heating
• The oil is heated up by heating rods (5) in the
oil tank (1).
• The surface temperature of the heating rods
remains low enough so that even if the oil is
not being circulated no local overheating of
the oil can occur.
• The oil heating system is not necessary in
countries in which the ambient temperatures
do not fall below approx. 20 °C.

54
 Oil cooling
• The oil cooler (6 or 6a) is installed in the feed oil
and control oil return piping from the drive
stations to the oil tank (1). The standard cooling
medium is water, while air is used in special cases.
• The water supply is controlled by a solenoid valve
(7). Upstream of this valve (7) there is a dirt trap
(8). The water supply can e.g. in case of repair
work be closed by means of the manually
operated shutoff valve (9).
• During normal operation, the oil cooling is
automatically switched on and off depending on
the oil temperature.
55
 Tank pump (10)
• A tank pump is mounted on the oil tank
(1) for filling and emptying it.
• The tank pump is also used to circulate
the oil in the tank during the heating up
phase and during emergency cooling.
• The 3-way valves (15 and 16) enable the
respective function.

56
 Oil filter
• The inline filter (14) is equipped with an
electrical and an optical clogging
indicator.
• This inline filter cleans the oil as it is
filled into the hydraulic system.

57
 Pump group for feed oil and control oil
• The feed oil pump (22) and the control oil pump (23)
are flanged together and are driven by an electric
motor (26).
• The pump group is mounted on or under the oil tank
(1). It centrally supplies all drive stations with feed oil
and control oil.
• The feed oil pump supplies oil to the main circuit of the
drive station, thus compensating for any oil losses due
to leaks and ensuring a continuous exchange of oil.
• The control oil pump supplies oil to the control circuit,
i.e. the pressure control valve (57) and the pump
adjusting unit of the main pump (51).

58
 Diaphragm accumulator (33)
• The diaphragm accumulator has the function
of keeping the pressure in the control oil
circuit more or less constant during the
pivoting of the discs of the main pump (51).

• It must be pressurized to the pressure stated in

the section Technical data.

59
 Safety valve block (34)
• The safety valve block installed upstream
of the diaphragm accumulator (33) is a
simple way of relieving the pressure on
the oil side of the diaphragm
accumulator during maintenance work.
• The fixed setting of the pressure valve
(35) protects the oil side of the
diaphragm accumulator from
impermissible overpressure.
60
Control oil and feed oil filters (28 and 36)

• The filter units for the feed oil and control

oil circuit are designed as double inline
filters. They are monitored by an electrical
and an optical clogging indicator.
• A 3-way valve is used to switch over to the
filter cartridge which is not in operation
while the drive is running, so that a
clogged filter cartridge can be exchanged
without difficulty during operation.
61
 Pressure switches (29 and 37)
• The pressure switches monitor the
pressure level in the feed oil and control
oil circuit.
• The switching points are set to the values
stated in the section Technical data.

62
 Pressure valves (30 and 38)
• The pressure valve (30) pressurizes the feed oil
circuit to the pressure specified in the section
Technical data.
• This ensures that there is always sufficient pressure
and a sufficient volume of oil at the suction side of
the main pump (51).
• The pressure valve (38) pressurizes the control oil
circuit to the pressure specified in the section
Technical data.
• This ensures that there is always sufficient pressure
available for adjusting the main pump (51).
63
 Switch boxes (39 and 70)

• A switch box (39 or 70) is mounted

on the oil tank (1) and on each drive
station.
• All electrical equipment belonging
to the tank and the drive stations,
except for the electric motors (11,
26 and 54), are wired to terminals in
the switch box.
64
 Bladder accumulator (48)
• The bladder accumulator has the function of
keeping the pressure in the feed oil circuit
more or less constant during the pivoting of
the discs of the main pump (51).

• It must be pressurized to the pressure stated

in the section Technical data.

65
 Safety valve block (49)
• The safety valve block installed
upstream of the bladder accumulator
(48) is a simple way of relieving the
pressure on the oil side of the bladder
accumulator during repair work.
• The installed pressure valve protects
the bladder accumulator against
impermissibly high pressures.
66
Day-2, DRIVE STATION, Main

67
DRIVE STATION

Main

68
Main Drive

69
 Ref. Hyd. Drive Manual
Main Drive
81
81

80 80
68

57 57

63

51
 Items shown in the drawings
50 Base frame
51 Main pump
52 Coupling
53 Elastic pump support
54 Electric motor
55 Stop cock (ball valve)
56 Pressure hose
57 Pressure control valve
(proportional 3-way pressure
reducing valve) with integral
triggering electronics
59 Pressure hose
60 Pressure hose
61 Fixed throttle
62 Pressure hose
63 Valve block (component of the
main pump)
64 Minimess coupler
65 Minimess hose
68 Pressure transducer with digital
pressure indication
69 Intermediate plate
70 Switch box
80 Cylinder (differential cylinder)
81 Flush valve with base plate
ST Local/remote selector switch
71
 Drive station
• The drive station has the function of producing
the necessary volume flow at the necessary
pressure for moving the pistons of the cylinder
unit.
• All components of the drive station are installed
on a common base frame (50) that is mounted on
vibration dampers.
• Wherever necessary, flexible pressure hoses are
used as connecting elements, e.g. to compensate
for vibrations and to enable the quick exchange of
a complete drive station.
72
 Main pump (51)

The main pump is a reversible axial piston

pump. The swash plate of the axial piston
pump is swiveled by an adjusting cylinder.

The pilot control of the pump adjusting

unit is performed hydraulically.

73
74
75
76
77
 PUMP, Functional description, 1
1. Torque and rotational speed are applied to the drive shaft
(1) by a Motor
2. The drive shaft is connected by splines to the cylinder (8) to
set this in motion.
3. With every revolution, the pistons (9) in the cylinder bores
execute one stroke whose magnitude depends on the
setting of the swash plate (11).
4. The pistons hold the slipper pads (10) onto the glide surface
of the swash plate with the retaining plate (2) and guide
them along.

78
 PUMP, Functional description-2
1. The swash plate setting during a rotation causes each piston
to move over the bottom and top dead centers and back to
its initial position. Here, hydraulic fluid is fed in and drained
out through the two control slots in the control plate (4)
according to the stroke displacement.
2. On the high-pressure side (5) the hydraulic fluid is pushed
out of the cylinder chamber and into the hydraulic system
by the pistons.
3. At the same time, hydraulic fluid flows into the growing
piston chamber on the low-pressure side (7). In a closed
circuit, supported by the return and boost pressure.

79
80
81
 PUMP, CONTROL
1. The swivel angle of the swash plate (11) is sleeplessly
variable.
2. Controlling the swivel angle of the swash plate changes the
piston stroke and therefore the displacement.
3. Adjusting the swash plate through the neutral position will
change the direction of flow (making reversing operation
possible).
4. The swivel angle is controlled hydraulically by the stroke
piston (3). The swash plate is mounted in swivel bearings for
easy motion and the neutral position is spring-centered.
5. Increasing the swivel angle increases the displacement;
reducing the angle results in a corresponding reduction in
displacement.
83
4/3 Solenoid Valve

84
 Valve block (63)
• The valve block controls the feeding and
discharging of oil into and out of the main
circuit.
• An integral non-return valve combination
assures these functions during the pumping
and at the zero position of the main pump.
• Two adjustable pressure valves are installed
for limiting the pressure in the main pump.
The valve block is mounted on the housing of
the main pump.
85
Pressure control valve (57) with integral control
electronics [proportional 3way pressure reducing valve]

• The pressure reducing valve contains two

proportional solenoids for the two pivoting
directions of the main pump (51).
• It transforms the individual signal from the
electronic controller into a proportional
pressure for adjusting the pump.
• The pressure reducing valve is mounted
directly on the main pump (51).

86
Pressure transducer with digital pressure
indication (68)
• The pressure transducer measures the
necessary pressure for the forward stroke of the
transport track during operation and transmits
the measured value to the control room.
• If 80 % of the maximum pressure is reached, an
alarm is triggered so that action can be taken in
time before the transport track stops moving at
the maximum pressure.
• The pressure transducer has a digital display for
optical pressure indication.

87
 Cylinder unit
• The cylinder unit consists of two cylinders (80)
working in opposite directions, which are attached by
means of shackle toggles at the piston rod end to the
transport track and at the cylinder bottom end to the
grate substructure.
• The cylinder chambers at the cylinder bottom end and
the piston rod compartments are connected to the
pressure piping A and B of the main pump (51).
• These compartments are interconnected by flushing
pipes that are closed by a flush valve (81).
• All pressure piping connections of the cylinders can be
closed with ball valves so that the cylinders can be
dismounted.

88
 Cylinder (80)

• The cylinders are commercially

standard differential cylinders with
shackle toggle fastenings and radial
plain bearings at both ends.

89
 Flush valve (81)
• The flush valve enables the exchange of oil in
the pipelines between the main pump and the
cylinders.
• At periodic intervals, the transport tracks are
moved into the return stroke end position and
the flush valve is opened so that the oil can be
circulated and thus exchanged.
• At the flush valve there is a ball valve that is
only opened for bridging the flush valve in
order to flush the piping during commissioning.
90
 Accessories
• The following parts are kept separately:
– suction piping (76),
– flushing filter (73) with mounted non-return valve (74),
– measuring instrument case (72),
– filling hoses (75),
– filling and testing device for the diaphragm accumulator
(77) and bladder accumulator (48),
• These parts are required for the commissioning and for
maintenance purposes.
• Fixing elements for the position measuring system for
controlling the transport tracks.

91
 Electronic control system
• The hydraulic drive is electronically controlled and
monitored; this control system is installed in a
separate cabinet.
• The signals needed for controlling the movement are
transmitted by the position measuring system
mounted at the transport tracks.
• All drive specific parameters are input digitally into
the control system via an operator panel.
• Any faults are displayed as text in the display of the
operator panel.
• The functioning and use of the control system are
described in a separate operating instruction.

92
Main Circuit

Function

93
 3.2 Mode of functioning
• During the manufacturing process, the
hydraulic drive operates automatically. The
functional sequences are electronically
controlled and monitored.
• For commissioning and maintenance purposes,
all the functions can also be operated manually.
– This section only describes the movement of one transport track,
but this description applies for all the transport tracks.
– The interaction of all transport tracks, which is necessary for the
transport of the material being cooled, is described in the
separate manual for the control system and for the cooler.

94
 Main circuit-1
1. The pistons of the cylinder unit are moved by the
main pump (51) via the main circuit.
2. When the discs of the main pump (51) are pivoted, the
created volume flow moves the piston of the cylinder
(80) forward.
3. The load due to the machine causes a corresponding
high pressure to build up in the feed pipeline. The oil
which is displaced by the opposite cylinder flows back
to the suction side of the main pump via the return
piping.
4. There is a low pressure in this piping. The size of the
disc pivot angle determines the volume flow and thus
the speed of the pistons.
95
 Main circuit-2
5. When the discs of the main pump (51) are pivoted back via the
zero position in the opposite direction, the volume flow is
initially throttled and then built up again in the opposite
direction. At the same time, the high pressure and low pressure
sides, i.e. pressure and suction sides of the main pump are
reversed. The pistons are thereby moved backwards.
6. The feed and return piping of the main circuit are both protected
by pressure limiting valves in the valve block (63). In the event of
an overload, the corresponding pressure limiting valve causes a
short circuit of oil to the low pressure side.
7. The unavoidable oil losses due to leaks in the main circuit are
compensated by the feed circuit. In addition, the surplus oil due
to the input from the feed circuit is discharged from the main
circuit into the oil tank to be cooled and filtered.

96
 Main circuit-3
8. The constant flow of oil delivered by the feed oil pump
(22) passes through the feed oil filter (28) and into
the valve block (63).
9. Here, the feed valves feed the oil into the
corresponding low pressure side of the main circuit .
10.The difference between the quantities of feed oil and
leak oil is discharged via a discharge valve in the low
pressure side.
11.The downstream pressure limiting valve (30), in Cond.
Cqt. ensures a minimum pressure in the feed oil
circuit and in the respective low pressure side of the
main circuit.
97
 Control circuit
• The control circuit supplies the adjusting unit of the
main pump (51) with the required control oil.
• The oil delivered by the control oil pump (23) passes
through the control oil filter (36) to the pressure
control valve (57) and to the pump adjusting unit.
• The excess oil flows back to the oil tank via the
pressure limiting valve (38).
• The pressure set on the pressure limiting valve
assures reliable control of the main pump.

98
3. Sequence and controlling of
various Machinery (pumps) by
other.

99
Operation

100
 Working cycle-1
1. One working cycle consists of a forward stroke and a return stroke of
the transport track. It always starts with the forward stroke from the
back final position and ends with the return stroke into the rear end
position.
2. The control system sends the pressure control valve (57) a signal
defining the direction and speed of the movement to be performed by
the pistons.
3. The pressure control valve converts the signal into a proportional
pressure which acts on the adjusting device of the main pump (51)
and makes the pump’s discs pivot accordingly.
4. Coming from the zero position, the main pump (51) constantly
increases the volume flow, so that the transport track, which follows a
ramp function, is accelerated to the operating speed.
101
 Working cycle-2
5. The movement of the track is controlled over the entire stroke
distance by means of the installed position measuring system.
6. Towards the stroke end, the discs of the pump are pivoted back
following a ramp function and the braking phase of the transport
track movement is initiated.
7. When the pump is in zero position, the transport track stops in
the end position of the set stroke distance.
8. The return stroke is performed identically, except that the discs
of the main pump (51) are pivoted in the opposite direction.

102
 Flushing cycle
• To ensure an exchange of oil in the long pipes between the
drive station and the cylinder unit during the
manufacturing process, a flushing cycle is started at
regular intervals.
• For the flushing process, the transport track is moved into
the mechanical return stroke end position and the flush
valve (81) is opened.
• The flushing time is permanently set to 10 seconds in the
electronic control system.
• The flushing intervals can be freely selected on the
operator panel. The standard time for one interval is 30
minutes.
• A flushing cycle is performed before each start of
continuous operation.

103
 Monitoring devices

• During operation, the following

functions are continuously
monitored and any faults are shown
as text on the display of the operator
panel and in the master control
system.
• See the operating instructions Control system for
POLYTRACK® hydraulic drive.

104
 Filter clogging indicator
• The feed oil filter (28) and the control
oil filter (36) are monitored by an
electrical and an optical filter clogging
indicator.
• If the filter clogging indicator
responds, change over to the second
filter cartridge manually and replace
the clogged up filter cartridge.
105
106
 Monitoring and safety functions

• Monitoring functions
– Monitoring the change of pressure fluid level
– Monitoring via a level indicator
– Monitoring via level indicator and temperature switch (if
fitted)
– Controlling and monitoring the pressure fluid temperature
(if fitted)
– Monitoring the filter
– Protecting against un-permissible operating pressures
• Safety valves must not be altered by the user of the system. The
set value must be 10 % or at least 20 bar above the permissible
system operating pressure (for details see circuit).
107
 Pressure fluid
(Mineral oil based hydraulic oil to DIN 51524 part 2)

• Temperature Recommended for

continuous operation +25 ... +55 °C
– Permissible min./max. 0 ... +80 °C
• Viscosity Recommended for continuous
operation 20 ... 100 mm²/s
– max. permissible 12 ... 500 mm²/s

108
 Pressure fluid
• The viscosity classifications to ISO-VG are
based on a reference temperature of 40 °C,
e.g. ISO-VG 46 relates to 46 mm²/s at 40 °C.
• A maximum oil reservoir temperature of 55 °C
is recommended for mineral oil, as an increase
in the operating temperature results in an
accelerated ageing of the oil and a reduction
in the service life of seals and hoses.

109
Viscosity temperature diagram

110
5. Maintenance & Troubleshooting

111
 Maintenance, Inspection
No. Work to be performed Frequency
Weekly
1 Check the piping system for leaks (Attention: Do not re-use leak
oil)
2 Check for leaks in the drive stations Weekly
3 Check the cylinders (80) for leaks Weekly
Check the cylinders (80) for normal movement (reversal,
4 stroke length) Weekly

5 Check the piston rods for scoring Weekly

Check the pumps (22, 23 and 51) for abnormal running
6 noises Weekly

7 Check the oil level in the oil tank (1) Weekly

8 Check the control oil pressure Weekly
9 Check the feed oil pressure Weekly
In accordance with the
Check the initial nitrogen filling pressure of the manufacturer’s instructions
10 diaphragm accumulator (33) and of the bladder (accumulator are relieved of
accumulator (48) pressure on the oil side)
11 Check the max. pressure limitation Annually
112
 Maintenance, Servicing
SN Work to be performed Frequency
1 Clean the unit Every 26 weeks (6-monthly)

Change the filter cartridges of the oil filters According to the display of the electrical
2 (28 and 36) and optical monitoring system

Take an oil sample and have it analyzed by

the oil supplier. (Take the sample at the
pressure connection of the pump) Every 26 weeks (after the first
3 It must have at least purity class 9 acc. to NAS 1638 or 6 commissioning:
acc. to SAE, ASTM, AIA or 18/15 acc. to ISO 4406. first sample after 1000 operating hours)
The test results must be documented and made
available to POLYSIUS AG.

Re-lubricate the spherical plain bearing of

4 Annually / 6-Monthly
the hydraulic cylinder
Top up the diaphragm accumulator with
5 As required
nitrogen
113
 Trouble shooting-1
Fault Cause Elimination

Check whether pressure is available;

The transport track is jammed
restore free movement of the grate

The maximum pressure limiting valve

Set, repair or replace the maximum
[in the valve block (63)] is not building
pressure limiting valve
up any pressure

The pressure control valve (57) is not

Check the electronic control system
The cylinders activated
(80) do not
move Check the control oil pressure; check the
The pressure control valve (57) is not
pressure control valve and replace it if
working
necessary

The discs of the main pump (51) do not Check the adjusting unit of the main pump
pivot and if necessary replace the main pump

The position measuring system is not Check the position measuring system and
working replace if necessary
114
 Trouble shooting-2

Fault Cause Elimination

Air locks in the

Bleed the system
piping
The cylinders (80)
move erratically
The pressure control Check the pressure
valve (57) is not valve and replace it if
working properly necessary

115
 Trouble shooting-3
Fault Cause Elimination

Check the cooling water

Cooling water failure or
circuit, clean the dirt trap
insufficient cooling water
(8)

Oil cooler (6) defective. Either no

The oil gets too Check and repair the oil
water or no oil passing through
hot cooler
the cooler

Sludge sediments from the

cooling water are preventing the Clean out the oil cooler
heat transfer (insulating effect)
116
 Trouble shooting-4
Fault Cause Elimination

Properly set the pressure

The pressure valve (38) is
valve or replace it if
wrongly set or is faulty
necessary

No control oil
Check the control oil
pressure or The control oil pump (23) is
pump and replace it if
inadequate control faulty
necessary
oil pressure

Check the setting and

The pressure switch (37) is set
replace the pressure
too high or is faulty
switch if necessary

117
 Trouble shooting-5
Fault Cause Elimination

Properly set the

The pressure valve (30) is
pressure valve or
wrongly set or is faulty
replace it if necessary

No feed oil pressure Check the feed oil pump

The feed oil pump (22) is
or inadequate feed and replace it if
faulty
oil pressure necessary

Check the setting and

The pressure switch (29) is
replace the pressure
set too high or is faulty
switch if necessary

118
 Trouble shooting-6

Fault Cause Elimination

The pumps (22 and 23)

Check the suction piping
are sucking in an oil/air
for leaks and seal it
mixture
The pumps (22, 23 and There are air locks in the
51) make noticeable main circuit, so that the
Bleed the piping system
banging noises or a very main pump (51) is sucking
loud permanent noise in an oil/air mixture

The oil level in the oil tank Top up the oil; check the
(1) is too low float switch (3)

119
 Trouble shooting-7
Fault Cause Elimination

In the case of the feed oil filter (28) and

the control oil filter (36), switch over
The clogging The filter cartridge
the duplex filter and then replace the
indicator of an oil of the indicated oil
filter cartridge.
filter responds filter is clogged up
In no case is it possible to clean the
filter cartridge!

Oil level min. or The oil level in the

Top up the oil; check the system for
oil level min. min. oil tank (1) is too
leaks and eliminate these.
is indicated low
120
121
 Maintenance Safety-1
1. Switch off the power supply to the electrical components before
commencing any maintenance work.
2. And safeguarded against restarting for the entire duration of the
maintenance work.
3. Ensure that all moving parts of the machine have come to a standstill
before you remove protection devices or open flaps.
4. PLEASE see that no danger of suffering burns when touching the
machine and that no hot material is in the machine when inspection and
service covers are opened.
5. Never use gasoline or other easily inflammable substances for cleaning
the machine.
6. Only use hydraulic oil that complies with the requirements.
7. Make sure that the hydraulic piping is relieved of pressure before
disconnecting it.

122
 Maintenance Safety-2
1. Never empty or fill the oil tank by using pumps of the hydraulic system
(Use only Pump No. 10)
2. If you drain hydraulic oil at operating temperature, you risk scalding
(hot) yourself.
3. Only use pure nitrogen and never oxygen for filling the accumulator.
4. Check for no leaks in connecting points and connections, after all
maintenance work are completed.
5. Strictly observe the welding instructions when performing any welding
work.
1. If you carry out electrical welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other movable connections or
measuring devices. Always directly connect the welding current return lead to the part
being welded.
6. Remount all protection devices and properly close all inspection and
service covers when maintenance work has been finished.

123
 Q&A
LET US DISCUSS

Fault causes and their effect on

Hydraulic Systems

124
 An overview of the effects of a fault
A. Excessive noise
– Pump, Hoses, Pipes
B. Insufficient force/torque (pressure) at the drives
C. Uneven drive movements (pressure and/or flow oscillations)
D. The drive does not move or is too slow (none or too little
flow)
E. The drive does not stop or overruns
F. The pump switches on and off loads too frequently
G. Switching shocks when valves are switched
H. The operating/pressure fluid temperature is too high
I. Contaminated pressure fluid
• ????
125
 Excessive noises-1
Fault Fault Cause
 Coupling: Incorrectly aligned, loose, defective
Mechanical drive  Pump or motor fixing loose
component  Defective pump or motor
 Wrong direction of rotation

Unfavorable suction conditions due to:

 Air breather clogged or too small
 The suction line isolator valve is not fully open
Suction conditions  Suction line is blocked, too small , too many bends
 Located 1000 m above seal level
 Suction line is not air-tight, air is being sucked in

1. Incorrect direction of rotation or the speed is too high

2. The suction and pressure lines exchanged
Pump 3. Defective pump seals/pump
4. Oscillating control system

1. Pipe mounts missing or loose

Pressure lines 2. Incorrectly fitted (e.g. not free of tension)
3. 3. Flow noises due to the cross-section being too small
 Switching shocks, due long return lines and/or too high flow
Return lines velocities. The oil column is not pre-loaded
1. Flow noises and oscillation due to incorrect valve selection,
unfavorable characteristic curve or the flow is too high
Pressure valves 2. Valve oscillations causes other controller to oscillate

126
 Excessive noises-2
Fault Fault Cause
Flow valves  Flow control valve pressure compensator oscillation
Isolator valves 1. Vibration caused by control pressure fluctuations with
pilot operated check valves
2. Performance limits have been exceeded (flow too high)
Directional valves 1. Valve rattles, defective solenoid or the voltage is too low

Pressure fluid  Fluid level is too low

 The viscosity is too high (temperature is too low, oil with
an unsuitable viscosity
 grade)
 The pressure fluid foams (too much air in the fluid)
 1 to 3 results in, dependent on the combinations, suction
problems = pump noise,
 flow noises, switching shocks

Drive (cylinder/motor)  Wear on the running surfaces

127
 Insufficient power/torque (pressure) at the drives- B

Fault source Fauly Cause

1. Defective pump 2. Pump flow too low or with variable pumps the de-
Pump
swash pressure is set too low, 3. The controller is defective
Pressure lines or
The pipe resistance is too high (length, cross-section, pipe bends)
Return Lines
1. The operating pressure is set too low, 2. The valve seat is
contaminated, damaged or worn, 3. The safety valves are set too close
Pressure valves
to the operating pressure relief valve (d > 20 bar), so that flow can pass
to tank
Incorrect switched position (e.g. zero pressure circulation, the valve
Directional valves
does not switch or the spool jams)
1. The viscosity is too low > leakage is too high, The viscosity is too high >
Pressure fluid
flow resistance is too high

1. Internal leakage (e.g. worn cylinder seals) 2. Friction is too high (in the
Drive
cylinder, e.g. due to side loading at the piston rod or seal
(cylinder/motor)
elements)

128
 Uneven drive movements-C
Fault source Fault cause
Pump Fluctuating flows, with variable displacement pumps, caused by:
1. Defective pump, controller
2. Unsuitable pilot control valve
3. Influences from the system acting io the controller

Flow valves 1. Changes to the flow rates at the throttle valves due to
pressure changes , 2. Fluctuations at the pressure compensator
when the natural frequency of the drive is low

Pressure fluid Entrapped air in the pressure fluid

Drive 1. Hydraulic motor speed below minimum limit, 2. Stick-Slip-
(cylinder/ Effect (jerky movement) with cylinder (the lower the stick
motor) friction the lower the cylinder speed can be)

???

129
 Uneven drive movements- C
Fault Fault Cause
Pump Fluctuating flows, with variable displacement pumps,
caused by:
1. Defective pump, controller
2. Unsuitable pilot control valve
3. Influences from the system acting io the controller
Flow valves 1. Changes to the flow rates at the throttle valves due to
pressure changes
2. Fluctuations at the pressure compensator when the
natural frequency of the drive is low
Pressure fluid  Entrapped air in the pressure fluid
Drive 1. Hydraulic motor speed below minimum limit
(cylinder/motor) 2. Stick-Slip-Effect (jerky movement) with cylinder (the
lower the stick friction the lower the cylinder speed can
be)
Others 1. Insufficient load holding on the return side of the drive
2. The system has not been fully bled

130
 The drive does not move or is too slow- D

Fault Fault Cause

Pump, Pressure Valve, Previous Reasons
Flow Valves, Directional
Control Valve, Drive
(cylinder/motor)
Others The start conditions have not been
met. Electrical control lines (plugs)
disconnected, signal elements (e.g.
pressure switches are incorrectly set
or defective) or limit switches are
not being reached

131
 The drive does not stop or follows on / Over-run- E
Fault Fault Cause
Isolator valves 1. Do not close or are too slow due to back pressures
2. The valve seat is contaminated or defective

Directional valves 1. Switching time adjustment is too slow

2. The drive creeps due to the internal leakage of the
valve (design constrictions).

Drives  Internal leakage, e.g. due to worn out cylinder seals

(cylinder/motor)

Others 1. The system has not been adequately bled

2. The electrical signal processing from the contact
switch to the adjustment element is defective or too
slow
3. The valve spool jams (e.g. due to contamination)

132
 Pump on or off load switching too frequent- F

Fault Fault Cause

Force = The operating pressure should be maintained, without
Drive accumulators, when the pump is switched off.
(cylinder/mo The compression volumes (e.g. the volume within the drive and
tor) pipes/hoses) is in relation to the system leakage too low.

For systems with accumulators:

1. The oil demands from the actuator and/or leakage is too
high
2. The oil volume is not or only partially available:
a. Isolator valve to the accumulator is closed
Others b. Bladder (membrane) defective
c. Gas pre-charge, operating and set pressures (e.g.
pressure switches do not meet the requirements)

133
 Repair Tips
1. Locate and eliminate malfunction and damage (Fault localisation)
a. A precondition for system repairs is successful, i.e. systematic fault search.
b. This requires in any case detailed knowledge of the structure and the operating principle of the
individual components as well as of the entire system.

2. The required documentation should be available and easily accessible.

3. The most important measuring instruments (Thermometer, Electrical
Multimeter, Industrial Stethoscope, Stop Watch, RPM counter, etc.)
should also be available in the vicinity of the system, especially in the
case of large systems.
4. Fault correction (Cleaning, Inspection, Replacement, Repair, Function
Test)
5. When carrying out any work, observe strictest cleanliness.
6. Before loosening fittings, clean the surrounding area.

134
6. A glance of operations
aspects related to cooler
135
136
LAY OUT, COOL
ROLL CRUSHER

137
138
 Subassemblies
• Grate Equipment (1.0)
• Longitudinal Girder with
Bearing Assembly (2.0)
• Grate substructure (3.0)
• Lower Housing section (4.0)
• Upper Housing section (5.0)
• Exhaust Air Connection (5.1)
• Air Blast Unit (6.0)
• Doors & Inspection (9.0)
• Thermocouples (10.0)
• Drive Unit (14.0)
• Roll Crusher (20.0)
• Fans (21.0)
• Refractory lining (22.0)
139
AIR FLOW

140
FAN ARRANGEMENT

141
LAYOUT

142
 Aeration of the POLYTRACK® clinker cooler
Static
Compart Flow rate pressure
Fan no. ment no. [m3/h] [mbar]

Aeration of upper housing

section 7896 7
V1 1 59000 100
V2 2 54000 100
V3 3 52500 90
V4 4 50500 80
V5 5 49000 75
V6 6 47000 65
V7 7 45500 60
V8 8 85500 50
V9 9 78500 40
Components and mode of functioning
1. The hydraulic drive moves the transport tracks of the
cooler.
2. It makes them move back and forth with a stroke length
of 50 to 220 mm
3. And at a stroke frequency of between 2 and the
maximum stroke frequency per minute of 11 (technical
data)
4. As the stroke frequency is infinitely variable within the
specified ranges, the specific transport speed of the
material to be cooled on the grates can be adjusted to
suit the functioning requirements of the cooler.

144
Components and mode of functioning

5. The hydraulic drive operates according to the

principle of a closed circuit, i.e. the driven transport
track is fixed by the cylinders between two
pressurized oil columns which are set in motion by
the main pump.
6. In this connection one must distinguish between
the high pressure side - pump delivery direction -
and the low pressure side - pump suction side.
7. The hydraulic drive is controlled and monitored by
an electronic control system, which is described in
a separate manual.

145
 Function-a
1. The transport tracks are driven hydraulically.
Cylinders mounted at the ends of the transport
tracks move the respective transport tracks in the
direction of conveyance.
2. The forward and return stroke movements of the
cylinders is controlled by a pivoted axial piston
pump.
3. A separate axial piston pump is allocated to each
transport track so that the transport tracks can be
moved independently of each other.

146
 Function-b
4. The conveying speed of the material can be set within a wide
range. The speed depends on the cycle time of the forward
and backward movement of the transport tracks and on the
adjustable stroke length.
5. As the stroke length is separately adjustable for each
transport track, any transport profile can be set for the
material to be conveyed.
6. The outer transport tracks, for instance, can be set to 150
mm stroke length and the transport track in the centre to
200 mm.
7. In this way, the clinker distribution and the bed depth can be
adjusted over the width of the cooler to suit the discharge
conditions of the kiln.
147
 Function-c
8. The moving longitudinal girders, to which the transport
tracks are fastened, are seated in sliding bearings inside the
cooling air compartment underneath the aeration floor.
9. Two bearing blocks are installed at each bearing point to
guide the longitudinal girders in the vertical and horizontal
directions.
10. A plastic fabric laminate with embedded dry lubricant
particles is used as bearing material. No additional
lubrication is necessary.
11. The moving mounting plates between the transport tracks
and the static aeration floor are sealed by means of
horizontal sliding seals. The sliding surfaces are of machined
hard facing.
148
 Function-d
12. The lower static part of the pair of seals is pressed by springs
against the upper part, which moves in longitudinal direction
of the cooler. This ensures safe sealing even in the case of
deformation and settlement.
13. The front of the transport tracks at the beginning of the
cooler is sealed by gap seals. The cooling air pressure
prevents clinker from entering the cooling air compartment.
14. Special aeration units distribute the cooling air into the
clinker bed. Labyrinths prevent the clinker from entering the
cooling air compartment.
15. The air outlet zone and the floor of the aeration unit is
protected against wear by a static bed of clinker.

149
ROLL CRUSHER

150
 Basic data, Roll Crusher: 8/4
1. Required torque
a. Crusher roll I 20000 Nm
b. Crusher roll II 20000 Nm
c. Crusher roll III 20000 Nm
d. Crusher roll IV 20000 Nm

2. Speeds
a. Crusher roll I 4 min-1
b. Crusher roll II 4 min-1
c. Crusher roll III 4 min-1
d. Crusher roll IV 4 min-1

3. Tank station
a. Oil reservoir, heating rods, oil coolers, filling pumps with motor and
in-line filters are included in the hydraulic drive of the REPOL® /
POLYTRACK®.

151
 The hydraulic drive, ROLL CRUSHER

Comprises the following sub-assemblies:

– Tank station,
– drive station (Pump, Valves, etc.)
– Hydraulic Motor with Planetary Gear
system,
– Accessories
– Electronic control
152
 Drive system, crusher roll I
Main pump (251)
Design .......................................................................................... axial piston pump
Delivery rate ................................................................................................. 24 l/min
Admissible pump pressure ........................................................................... 230 bar

Electric motor (254)

Rating ............................................................................................................. 15 kW
Speed ...................................................................................................... 1450 min-1
Type of construction .................................................................................. B35-160L

Hydraulic motor (301)

Design .......................................................................................... axial piston motor
Weight .............................................................................................................. 18 kg
Absorption volume ...................................................................................... 63 cm3/U
Torque constant .........................................................................................1 Nm/bar
Pressure difference ...................................................................................... 220 bar

Planetary gear system (300)

Weight ............................................................................................................ 324 kg
Output torque ........................................................................................... 20000 Nm
Output speed ................................................................................................. 4 min-1
Transmission .............................................................................................. 92.12 : 1
Tightening torque for shrunk-on disk ............................................................ 250 Nm

Pressures to be adjusted 153

at the pressure limiting valve (267) .............................................................. 250 bar
 ROLL CRUSHER, Mode of functioning-1
1. For the hydraulic drive of the roll crusher, the tank station of the REPOL®
/ POLYTRACK® drive is used.
2. In addition, the components according to items 46 and 47 are mounted. In
order to level out vibrations, flexible pressure hoses are installed at all
necessary points in the connecting lines.
3. The drive stations are designed for producing the required volumetric flow
required to operate the hydraulic motors using the respective pressure.
4. The main pumps are the axial piston pumps in swash disk construction.
The main pumps have already been set to the volume flow rate required
for the roll speed (adjustment of the swash disks).
5. The oil flowing back through the tank pipe ”T“ is cleaned by the return
flow filter (46) and conveyed into the tank.
6. By means of the pressure limiting valves (267), every drive train is secured
against overloading.

154
 ROLL CRUSHER, Mode of functioning-2
1. The direction of rotation of the hydraulic motors is controlled by
electromagnetically actuated directional control valves (260).
2. At the first and last crusher roll, only one solenoid is actuated. If the
directional control valve (260) is in centre position, all connections limited
with each other (P-T and A-B). This is the so-called “floating mid-position“.
3. The drive stations for the reversible rolls have an additional pressure
switch (262). When a certain maximum drive moment and the resulting
pressure is reached, the pressure switch (262) triggers a change in the
direction of rotation of the roll.
4. After expiry of the preset time, the original direction of rotation is
resumed. If a preset number of changes in the direction of rotation is
exceeded, an alarm is triggered and the roll crusher is automatically
switched off.

155
 ROLL CRUSHER, Mode of Functioning

(1) Normal Operation (2) Off-normal Operation

”Reversing“
Operating mode

156
ROLL CRUSHER, Mode of functioning 1

1) Normal operation
– Under normal operating conditions, the rolls are
moved at constant speed and in one direction of
rotation.
– 1 ,2 ,3 4
– CW, ACW, CW, ACW

157
ROLL CRUSHER, Mode of functioning 2
2) Off-normal operation (”Reversing“ operating mode)
– If material gets stuck in the crushing gap, the admissible maximum
pressure at the pressure switch (262) is exceeded.
– The signal transmitted from the pressure switch causes a reversal of the
direction of rotation of the blocked roll.
– After a short period of time, the original direction of rotation is
automatically resumed.
– If, within a preset period of time, several changes of the direction of
rotation are performed without eliminating the disturbance, the roll
crusher is shut down.

158
 Items relating to the drive system of the first roll

250 Supporting structure Delivered as individual

251 Main pump components:
252 Coupling
• 300 Planetary gear system
253 Pump support
254 Electric motor • 301 Hydraulic motor
256 Base plate Components of the hydraulic
260 Directional control valve pipe
263 Pressure hose • MK Min. measuring coupler
265 Pressure hose
266 Min. measuring coupler
• KA Stop cock
267 Pressure limiting valve • KB Stop cock
278 Stop cock • SK Quick-acting coupling
280 Pressure gauge
281 Pressure hose
159
first and last crusher roll

301

267

251

160
 Items relating to the drive system of the reversible rolls

250 Supporting structure Delivered as individual

251 Main pump
components:
252 Coupling
253 Pump support • 300 Planetary gear
254 Electric motor system
256 Base plate • 301 Hydraulic motor
260 Directional control valve
262 Pressure switch Components of the hydraulic
263 Pressure hose pipe
265 Pressure hose • MK Min. measuring coupler
266 Min. measuring coupler
267 Pressure limiting valve
• KA Stop cock
278 Stop cock • KB Stop cock
280 Pressure gauge • SK Quick-acting coupling
281 Pressure hose
161
 reversible rolls with pressure switch (262)

301
Additional
pressure switch 262

267

251

162
 ROLL CRUSHER DRIVE

HYDRAULIC PUMP OR MOTOR?

301

163
164
165
166
167
168