INSTRUCTION MANUAL .

ROTARY KILN 70000817-1

Mechanical kiln drive station

Installation, operation and maintenance

In the text, reference is made to::

Ref. 1 *) Rotary kiln

General kiln instructions
Installation, operation and maintenance
Ref. 2 *) Rotary kiln plant (dry process) Safety
regulations
Ref. 3 *) General safety regulations at sites of erection
Ref. 4 *) Rotary kiln
Supporting bearing for support.
Installation
Ref. 5 *) Kiln drive station (equipment supplier manual)
Instructions for electrical equipment

*) See note Reference to instruction manuals in section 1.

VIGERSLEV ALL 77 - 2500 VALBY - DENMARK 2040 AVENUE C - PA 18017-2188 BETHLEHEM USA CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA
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Contents: Page:
1. General notes ....................................................................................................... 4
2. Construction and operating principle ...................................................................... 7
2.1 Construction .................................................................................................................... 7
2.2 Operating principle .......................................................................................................... 7
2.2.1 Planetary gear, turning device and torque arm ............................................................ 7
2.2.2 Oil cooling station for planetary gear unit..................................................................... 8
2.3 Operation of drive station ................................................................................................ 9
2.4 Alarms and interlocks...................................................................................................... 9
3. Installation .......................................................................................................... 12
3.1 Installation of baseplate for planetary gear ................................................................... 12
3.2 Installation of planetary gear ......................................................................................... 13
3.2.1 Turning of kiln ............................................................................................................ 14
3.3 Installation of oil cooling stations................................................................................... 15
3.4 Installation of electrical equipment ................................................................................ 15
3.5 Installation of guards ..................................................................................................... 16
4. Operation ............................................................................................................ 17
4.1 Trial-run......................................................................................................................... 17
4.1.1 Flushing of lubrication system.................................................................................... 17
4.1.2 Start-up of drive station .............................................................................................. 18
4.2 Normal, remote-operated start-up from central control panel....................................... 18
4.2.1 Conditions for remote-operated start-up. ................................................................... 18
4.3 Manual operation .......................................................................................................... 19
4.4 Reversing the kiln from side-heavy position to neutral position .................................... 19
5. Maintenance ....................................................................................................... 20
5.1 Lubrication..................................................................................................................... 21
5.1.1 Planetary gear ............................................................................................................ 21
5.1.2 Cardan joint shaft ....................................................................................................... 21
5.1.3 Turning arrangement ................................................................................................. 21
5.2 Cleaning ........................................................................................................................ 21
5.2.1 Planetary gear, turning arrangement ......................................................................... 21
5.2.2 Cardan joint shaft ....................................................................................................... 21
5.2.3 Oil cooling stations ..................................................................... 21
5.2.3.1 Oil filter for oil cooling stations ................................................................................ 22
5.3 Inspection and adjustment ............................................................................................ 22
5.3.1 Day-to-day inspections............................................................................................... 22
5.3.2 Weekly inspections .................................................................................................... 22
5.3.3 Pipe/hose connections ............................................................................................... 23
5.4 Checking of condition.................................................................................................... 23
5.4.1 Planetary gear ............................................................................................................ 23
5.4.2 Cardan joint shaft ....................................................................................................... 23
5.4.3 Torque arm ................................................................................................................ 23
5.4.4 Barring gear ............................................................................................................... 23
5.4.5 Overrunning coupling ................................................................................................. 23
5.4.6 Centrifugal brake........................................................................................................ 23
5.4.7 Holding brake ............................................................................................................. 24
5.5 Replacement ................................................................................................................. 24
5.5.1 Air filters ..................................................................................................................... 24
5.5.2 Oil filters ..................................................................................................................... 24
5.5.3. Planetary gear ........................................................................................................... 24
6. Appendices ......................................................................................................... 26
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Appendices:
App 1. Drive station ............................................................................................................... 29
App 2. Drive station ............................................................................................................... 31
App 3. Torque arm arrangement........................................................................................... 33
App 4. Baseplate ................................................................................................................... 35
App 5. Barring arrangement .................................................................................................. 37
App 6. Oil cooling station....................................................................................................... 39
App 7. EOC system............................................................................................................... 41
App 8. Dismantling of planetary gear .................................................................................... 43
App 9. Dismantling of planetary gear .................................................................................... 45
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NOTE !
The present instruction manual is concerned with the situations
which, according to the experience of FLS, are the most likely to
occur. An exhaustive enumeration of all conceivable situations
which may occur in connection with the installation, operation
and maintenance of the drive station cannot be provided.

Consequently, if a situation should arise, the occurrence of

which is not foreseen in the instruction manual, and which the
operator is/or feels unable to handle, we would recommend that
FLS is contacted without undue delay for advice on appropriate
action.

1. GENERAL NOTES

This instruction manual describes the relevant procedures for

the installation, preparation, operation and maintenance of the
mechanical drive station for friction-based operation of rotary
kiln.

The drive station consists of two planetary gears with a built-

on turning arrangement. The planetary gears are connected to
the main motors by means of cardan joint shafts. The turning
arrangement is made up of an overrunning coupling, turning
gear, holding brake and a hydraulic coupling.

The drive station is designed for handling any conceivable

operating conditions, involving also the capability of turning
the kiln on emergency power supply in event of mains failure.

One planetary gear must be mounted at a very early stage so

that it will be possible to turn the kiln mechanically in
connection with the execution of erection and welding
operations through the gear unit by means of the turning
arrangement.
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References to instruction manuals

In the text of this instruction manual, reference is made to an
instruction manual reference No. where this is deemed to be
relevant.
The titles of all instruction manuals referred to are listed on the
front page of this instruction manual, with indication of the
number referred to.
Reference to other instruction manual numbers is done via the
General kiln instruction manual, ref. 1 in which relevant
instruction manual numbers can be identified on the basis of the
title of the relevant manual.

REQUIREMENT:
Machine to be used only for the purpose for which it has been
designed.

MANDATORY!
The directions outlined in instruction manual No.
32031 "General safety regulations at erection site"
must be strictly observed at the site of erection. This
instruction manual must be scrutinized by the client,
the erection contractor and FLS representatives
before erection work is started.

MANDATORY!:
The erection/maintenance activities described in the
following sections must only be carried out by skilled
machine specialists or subject to the supervision of
such specialists.
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MANDATORY!:
In connection with arc welding and when operations
involving blowtorching with gouge are carried out, the
return cable must always be attached to the object
subjected to welding, as close as possible to the area
of welding.
The return cable must never be attached in a way
which will cause the return current to be passed
through parts not connected to the object being
welded, for example: moving parts, bearings,
electrical installations or any other parts.
A return current through a bearing may give rise to
welding scars which will cause severe damage to
bearing.
A return current through electrical installations may
cause serious damage to protective earth lines
(extremely hazardous condition!) or electronic
equipment.

Where ERECTION CHECK is specifically called for in the

erection manual, this means that the FLS erection supervisor
must inspect and approve the parts mounted before permission
to proceed with the erection work can be given.
 70000817-1 7

2. CONSTRUCTION AND OPERATING PRINCIPLE

2.1 Construction
The drive station is designed so that friction-based rotation of
the kiln is attained via the two supporting rollers on support
No. 2.

The torque applied for the operation of the two supporting

rollers is exactly the same. This is ensured by means of the
electrical control system for the main motors.

Each supporting roller (26) is equipped with a planetary gear

(07), an overrunning coupling (13), a turning gear (12),
centrifugal brake (14), holding brake (15), hydraulic coupling
(16) and a turning motor (19).

Each planetary gear will incorporate an oil cooling station (28)

to ensure input of cooled and filtered lubricating oil to the gear
units.

2.2 Operating principle

The operating principle of the mechanical drive station is
described below.

2.2.1 Planetary gear, turning arrangement & torque arm

The two planetary gear units must be mounted on the
supporting roller journals on support 2. The planetary gears
are provided with a velocity sensor, PT100-temperature
sensor (10), air filter (08) and inlet and outlet for cooling oil.

An EOC system (Electronic Operating Control system) (17),

see Appendix 7, is fitted to the hydraulic coupling. The system
consists of a proximity sensor which will determine whether
the speed of the hydraulic coupling has dropped below a
predetermined limit. This system will trigger an electrical
alarm before the hydraulic coupling (16) runs hot, leading to
outflow of oil. See instruction manual from equipment
supplier.

The planetary gears have separate oil cooling stations which

supply cooled and filtered oil when turning of kiln is taking
place and during normal operation.
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The planetary gears are held in place to enable them to

transmit the torque to the supporting roller shafts via a double
torque arm arrangement (05). This arrangement will ensure
that torsion is transmitted only to the supporting roller shafts,
see Appendix 3.

The torque arms (05) are supported by spherical plain

bearings allowing the planetary gear to follow the movements
of the supporting roller, vertically as well as horizontally.

2.2.2 Oil cooling station for planetary gear

For enhancing the service life of the planetary gears, the oil
from the units must be cooled and subjected to filtration. This
is done in separate oil cooling stations (28). Each of the oil
cooling stations has two pumps. One pump must be running
while the second pump is on standby during normal operation.
In front of the pumps there is a three-way valve (29) which
must normally be in a position which will allow the suction line
for both pumps (30) to be open. In case of faulty pump or
motor, the suction line for the pump involved will be shut off.

When the kiln is in normal operation, the cooling stations must

ensure continuous cooling and filtration of the gear oil. This
will ensure a long service life of gear unit.

The pump station is equipped with double oil filters (32), a

temperature-controlled oil/water cooler (33), and a flow
monitor (36).

The oil cooler is designed for ensuring an operating

temperature in the gear unit of 60-70 C.

Max. operating temperature in gear unit is: 90 C.

The control system is designed so that prior operation of the

oil cooling stations is a prerequisite for starting the kiln.
However, it will be possible to turn the kiln without oil
circulation.

The gear units cannot be drained of oil, so this will ensure

that lubrication in the units is maintained, even if the oil
cooling stations are off-line. It will be possible to turn the kiln
without problems, but the normal operating speed of kiln will
not be attainable due to the excessive amount of heat
generated in the planetary gears.
 70000817-1 9

2.3 Operation of drive station

The operation of the rotary kiln can be subdivided into four
different scenarios which the drive station and its associated
control system must be capable of handling:

1. Normal operation of the kiln.

2. Turning of the kiln.

3. Turning of the kiln on emergency power supply.

4. Reversing the kiln from side-heavy position to neutral

position.

The electronic control system incorporates a number of

programs which will automatically monitor the operation of the
kiln in the different situations. Reference is made to the
electrical instruction manual.

2.4 Alarms and interlocks

Oil filter (32):

An alarm will be tripped in case of a too high differential

pressure across the oil filter during a period of more than 30
seconds.

Gear unit temperature:

The PT100 sensor (10) will trip an alarm if the oil

temperature in gear units is higher than 80C

The PT100 sensor (10) will trip an alarm and cut out the
main motors of the kiln in case of a temperature exceeding
90C. The oil cooling station will continue to cool down the oil
in the gear unit.

Flow controller (36)

The flow controller has two levels with the following functions:

Oil flow <80% of pump capacity will cause alarm tripping

Oil flow <70% of pump capacity will entail shutdown of pump

and starting of standby pump
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Oil cooling station (28)

The oil cooling stations must, as a minimum, be in operation

when the kiln is operated at the rated operating speed. The
pumps must be operated in manner ensuring intermittent
operation. This can either be done by switching the pumps for
every 8 hours of operation, or by pump switching in
connection with every group start-up.

If an alarm is tripped because of inadequate oil flow, the

operation must be switched to the standby pump.

Planetary gear unit (07)

Max. gear unit temperature: 90C. The kiln is shut down if this
temperature limit is exceeded. However, it will be possible to
turn the kiln during the cooling-down period of kiln.

The main motor of kiln must only be restarted if the gear unit
temperature is below 75C.

Turning arrangement

The EOC (Electronic Operating Control-system) (17), for

hydraulic coupling (17) will release a pulse signal as long as
the temperature does not exceed 125C in the hydraulic
coupling. Absence of signal will cause both turning motors to
be cut out.

If turning motor is needed for turning the kiln, a delay of max.

2 seconds for the starting of one turning motor may be applied
relative to the second turning motor. The holding brake must
be released 3 seconds after a starting signal has been sent to
the first turning motor.

The holding brake must be maintained in lifted position as

long as the turning motor is being used. In connection with
stoppage, the power to turning motors and the holding brake
must be cut off simultaneously. The bridge coupling in the
holding brake will ensure that the holding brake is cut in with
appropriate time delay.

The turning motor (19) must be connected to the emergency

power supply.

The holding brake (15) must be connected to the emergency

power supply.
 70000817-1 11

When starting the kiln on the main motors, this can be done in
any of the two methods described below:

1. While the kiln is operated on the turning motors, the main

motors are started in flying start mode. Once the kiln
speed exceeds the turning speed, the voltage supply to
turning motors and holding brake can be cut out. The
overrunning coupling between turning gear and main
gear unit will ensure freewheeling.

2. Following shutdown, it will be possible to restart the kiln

directly by means of the main motors, without in any way
involving the holding brake. The overrunning coupling
between turning gear and main gear unit will ensure
freewheeling.

When the kiln is reversed from side-heavy position, the

holding brake must be maintained in lifted position during a
period of minimum 2 minutes or until the kiln has reached its
neutral position and with kiln at standstill. The kiln must not be
restarted until these requirements are met.
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3. INSTALLATION
The installation of the planetary gear with turning arrangement
must not take place UNTIL the kiln has been set up and all
required welding operations have been carried out.

However, one planetary gear unit must be installed at such an

early stage that it can be used to turn the kiln in connection
with alignment and welding procedures, see sub-section 3.2.1
and Appendix 5

3.1 Mountng of baseplate for planetary gear

The baseplates (01) for the torque arm arrangements must be
mounted in the position indicated on the kiln position drawing.
It would be advantageous to postpone the alignment of the
baseplates (01) until the alignment of the bedplate (02) has
been carried out. See Appendix 4.

The centrelines and cross lines used for positioning and

aligning the bedplate (02) are used to determine the position
of the baseplates (02) in the horizontal plane.

The horizontal line of sight which is used to position the

bedplate is the baseline for determining the height H of the
baseplates which is indicated on the position drawing.

Where appropriate, a concrete block-up must be executed on

the base foundation, established in-situ in wooden frames,
see Appendix 4. A shim must be embedded in the block-up
structure, and it must have the height and inclination needed
to ensure that a fine alignment of the bedplate can be made
within a tolerance range of 10 mm.

The baseplates (01) must be adjusted in the correct position

relative to the bedplate (02) in the longitudinal direction of the
kiln, see position drawing.

The next step involves adjustment of the baseplates (01) in

sideways and vertical direction and at the angle of inclination
specified on the position drawing. The baseplates must be
aligned using a levelling instrument and spirit level.

ERECTION CHECK

Following the alignment of the baseplates (01), the foundation

bolts (03) must be loosely tightened.
 70000817-1 13

The baseplates (01) must be embedded up to the level

indicated on the arrangement drawing. Embedment of the
baseplates is executed by means of non-shrink concrete. The
embedment must not extend all the way to the top of the
baseplate since space must be provided for accommodating
the bolts for fixation of the torque arm arrangement.

After the embedment has hardened, the foundation bolts (03)

must be tightened to extent indicated on the arrangement
drawing.

3.2 Installation of planetary gear

When the kiln erection process has advanced to the stage
where the kiln has been set up and welded, it will be time for
mounting the planetary gears (07) with built-on turning
arrangement.

Rust-proofing Tectyl must be removed from the supporting

roller journal (26).

Tectyl must be removed from the drilled point at the clamp

coupling (23) on the planetary gear. The planetary gear must
be lifted using the provided lifting holes, and the unit is
mounted on the supporting roller journal as shown on the
arrangement drawing.

All the bolts on the clamp coupling (23) must be tightened to

the specified torque level. The bolts (24) must be tensioned in
sequence, n1, n2, n3, ...nn, see Fig. 1 so that the operation
proceeds from bolt to bolt in clockwise or anti-clockwise
direction until the specified torque level has been attained.
This will require that all bolts are tightened in several
operations. Consequently, crosswise tightening MUST NEVER
be applied.
14 70000817-1

Fig. 1.

Tensioning of clamp coupling.

Measures are needed to prevent skewing from occurring when

tensioning of the clamping rings is done. Further precautions
in connection with the clamp coupling and gear units are listed
in the instruction manual from the equipment supplier, ref. 5.

ERECTION CHECK

The torque arm arrangement (05) must be mounted on the

baseplate. Do not forget shim (06) between the supporting
plate for the torque arm arrangement and baseplate (01). On
completion of adjustment procedures, the bolts must be
tensioned to the specified torque level. The fixing screws on
the torque arm arrangement used for transportation purposes
must be dismantled.

3.2.1 Turning of kiln

In connection with the alignment and welding of the kiln,
deployment of the drive station for turning the kiln would be
advantageous.

One gear unit is equipped with a fixed coupling (18) between

turning gear (12) and turning motor (19). This gear unit must
be mounted first, and it can be used to turn the kiln - see
Appendix 5. The gear unit should be mounted in relation to
direction of kiln rotation as indicated in Appendix 5.
 70000817-1 15

To ensure sufficient friction between the one supporting roller

and the kiln tyre, the surfaces of the supporting rollers and
kiln tyre must be cleaned very carefully, accompanied by
simultaneous removal of any tectyl rust-proofing compound.

Before any rotation of kiln is initiated, it must be checked that

oil has been supplied to the supporting bearings of the kiln,
see instruction manual ref. 4.

Oil must also be charged to the planetary gear. The oil level in
gear unit must reach up to the oil level glass. Clean oil must
be filled through a filter having a mesh size of 25 m at the oil
filler socket (09), see Appendix 2.

Further precautions to be observed concerning the

preservative oil in the gear units are described in the
equipment suppliers manual, ref. 5.

When kiln welding operations have been completed, the fixed

coupling (18) must be dismantled and the hydraulic coupling
(16) must be mounted. See arrangement drawing and the
equipment suppliers instruction manual, ref. 5.

ERECTION CHECK

3.3 Installation of oil cooling stations

Installation of oil cooling stations must be carried out as
indicated on the arrangement drawings. The hose connections
between the planetary gear and the oil cooling stations must
also be mounted. Before the hoses are fitted to the planetary
gear unit, scavenging of the lubrication system must be
carried out. This is done by inter-connecting the supply line
hoses and the return line hoses.

The oil cooling stations must be located immediately below or

as close to the planetary gears as possible. This is very
important to ensure a free oil flow from gear unit to pumps.

3.4 Installation of electrical equipment

A PT100-sensor (10) for temperature monitoring must be
mounted in the planetary gear (07), as shown on the
arrangement drawing.

The proximity sensor (11) mounted on one gear unit is used

for monitoring the kiln speed through a counter, e.g. four
signals for every cardan joint shaft revolution.
16 70000817-1

The proximity sensor which is mounted on another gear unit

under the kiln and it is used for resetting the counters for
kiln speed and kiln angle one signal for every kiln rotation.

The third proximity sensor is mounted under the kiln and it is

used for resetting the counters for kiln speed and kiln angle
one signal for every kiln rotation.

The EOC system (Electronic Operating Control system) (17)

is fitted to the hydraulic coupling, see Appendix 7.

3.5 Installation of guards

The guards included in the supply for the cardan joint shaft,
the guard for coupling between support bearing housing and
planetary gear as well as the guard included in gear unit
supply for the hydraulic coupling must be fitted as shown on
the arrangement drawings.

It is essential to make sure that the guards have been fitted

prior to commencement of kiln operation. If the guards have
been dismantled in connection with maintenance work, it is
essential to ensure that they are refitted prior to start-up.
 70000817-1 17

4. Operation
Testing of the drive station can be done after both planetary
gear units, main motors and oil cooling stations have been
mounted.

4.1 Trial run

Before a refractory lining can be installed in the kiln, a no-load
trial-run of drive station and kiln must be performed. This trial-
run is carried out from the local control panel even if the
central control system has not been connected.

It is a foregone conclusion that the thrust device has been

fitted so that the kiln can be maintained in its axial position.

Before rotation of kiln is initiated, it must be checked that the

kiln supporting bearings are filled with oil, see instruction
manual ref. 4.

It is essential to check that equipment from kiln welding

operations etc. have been removed from the kiln shell, and
that no working operations are in progress at the inlet and
outlet sealing or elsewhere on the kiln shell.

ERECTION CHECK

4.1.1 Flushing of lubrication system

It is essential to ensure compliance with the directions of the
equipment supplier outlined in instruction manual ref. 5 with
regard to oil filling procedures and any flushing procedure to
remove residues of preservative oil in the gear unit and the oil
cooling system.

Fresh oil must be charged to the planetary gear units. The oil
is supplied to the gear unit at the filler socket (09) through a
filter max. mesh width 25 m. Gear units to be filled with oil
until the oil level extends to the middle of the oil level glass.

The pump housing must be filled with oil; reference is made to

the equipment suppliers instruction manual, ref. 5.

Jog-start the oil pumps (30) to check the direction of rotation,

see Appendix 6. The pumps may sustain serious damage if
the direction of rotation is not correct.
18 70000817-1

Check that the water cooling system (36) has been installed in
correct manner.

ERECTION CHECK

The pump station must be started and the system must be

flushed during a period of minimum 4 hours with short-
circuited hoses.

On termination of flushing procedure, the hoses must be

attached to the planetary gear.

Further information is provided in the equipment suppliers

instruction manual, ref. 5.

4.1.2 Start-up of drive station .

Kiln to be started on slow turning speed.

Rotation of kiln to be done on slow turning speed so that

speed-related signals from the gear units can be checked.

Main motors must be put into operation.

Rotation of kiln to be done on operating speed so that speed-

related signals from gear units can be checked.

4.2 Normal, remote-controlled starting from central

control panel
4.2.1 Preconditions for remote-controlled starting
The preconditions for starting the kiln from central control
panel are as follows:

1. There must not be any interlocking alarms relating to the

monitoring of temperatures, levels etc..

2. The electrical control panel has been switched for

operation from the control centre.

Once compliance with these conditions has been ensured, the

drive stations will be ready for remote-controlled starting.
 70000817-1 19

4.3 Manual operation

When starting command has been given from the central

control room to local control unit, the kiln can be rotated from
the local electrical control cabinet at a turning speed of 0.2
rpm.

4.4 Reversing of kiln from side-heavy position to

neutral position
The holding brakes (15) can be lifted so that the kiln is
reversed from side-heavy position to neutral position where
the kiln charge will be in bottom position. The centrifugal
brakes (14) will ensure a controlled return movement of the
kiln at a low speed.
20 70000817-1

5. Maintenance
Inspection and maintenance of planetary gear and turning
arrangement to be carried out in accordance with the
directions provided by the equipment suppliers. Therefore,
only a brief description is given in this manual. Detailed
descriptions and guidelines are given in the manual from the
equipment suppliers.

Preventive maintenance, survey:

Pos Text 1. 2. 3. 4. 5.
7 Planetary gear 2A D A T
25 Seal S
8 Air filter 2A
5 Torque arm 2A A
20 Cardan joint shaft A 2A A

Turning arrangement 2A D A
13 Overrunning coupling T
12 Turning gear T
14 Centrifugal brake T
15 Holding brake T
16 Hydraulic coupling T

Pipe/hose connections 2A M

28 Oil cooling station for 2A D A

planetary gear
32 Oil filter T S D T

D = per 8-hour A number in front of

operation the letter indicates
S = weekly the frequency of
M = monthly procedure.
A = yearly For example, 2M =
T = see text in twice a month.
instruction manual

.
 70000817-1 21

5.1 Lubrication
Oil products corresponding to the applied FLS symbols for
lubricants can be found in the FLS Key to Lubricants 36501
forwarded on separate basis.

5.1.1 Planetary gear

Shaft seals to be grease-lubricated until fresh grease
protrudes at the shaft.

Feed grease through the grease nipple ( 25).

Grease quality: FLS Mat. 7425

Grease quantity/nipple: 25 cm 3.

Planetary gear (07):

Charge clean oil through the filter hopper, 25m, at planetary

gear (07).

Gear unit lubricating oil: See equipment suppliers instruction

manual, ref. 5.

Oil volume: See equipment suppliers instruction manual, ref.

5.

5.1.2 Cardan joint shaft

Lubrication of cardan joint shaft (20) to be effected in
accordance with the directions given in the equipment
suppliers instruction manual, ref. 5.

5.1.3 Turning arrangement

The turning arrangement (12) and the planetary gear (07)
have a shared oil sump.

5.2 Cleaning
5.2.1 Planetary gear, turning arrangement
Dirt and impurities must be removed on and around the
planetary gear (07) and the turning arrangement (12).

5.2.2 Cardan joint shaft

Dirt and impurities must be removed on and around (20).

22 70000817-1

5.2.2 Oil cooling stations

Dirt and impurities must be removed on and around the oil

cooling stations (28).

5.2.2.1 Oil filter for oil cooling stations

If the filter (35) is clogged, it will be possible to clean
exercising due caution - the filter element. For procedure, see
equipment suppliers instruction manual, ref. 5.

5.3 Inspection and adjustment

5.3.1 Day-to-day checks
The following activities must be carried out for the planetary
gear and oil cooling stations for planetary gear.

Check the planetary gear units for any leaks

Check the screwed connections in pump station for leaks

Check hoses

Check oil filters

Check for any signs of leakage at pump station

Re-tighten joins in case of leakage

Check oil temperature and water thermostat

5.3.2 Weekly checks

The following activities must be carried out for the planetary
gear and oil cooling stations for planetary gear.

Clean planetary gear units and oil cooling stations.

Check filters for any indication of contaminated filters. The oil

cooling stations are provided with duplex filters, and,
therefore, filter cartridge replacement can be done with the
kiln in operation by switching to the second filter.

Check the function of the oil coolers by physically touching

the oil and water pipes and check the oil temperature.
 70000817-1 23

5.3.3 Pipe/hose connections

Impurities and contaminants must be removed on and around
pipes and hoses. By ensuring that pipes and hoses are kept
clean, it will be easy to identify any leakage in the system.

5.4 Checking of condition

5.4.1 Planetary gear
The oil in the planetary gear units (07) must be replaced as
specified in the equipment suppliers instruction manual. The
planetary gear (07) has an oil sump which it shares with the
turning gear (12) and the overrunning coupling (13).

See also the equipment suppliers instruction manual, ref. 5.

5.4.2 Cardan joint shaft

Check the bolts in the flanges on the cardan joint shaft (20) as
directed in the equipment suppliers instruction manual, ref. 5.

Check the clearance in cross joints and longitudinal

displacement as specified in the equipment suppliers
instruction manual, ref. 5.

5.4.3 Torque arm

The torque arms (05) are maintenance-free. Still, a check is
needed to ensure that all rubber seals are properly fitted at
the spherical plain bearings in the structure.

5.4.4 Turning gear

Turning gear (12). See the equipment suppliers instruction
manual, ref. 5.

5.4.5 Overrunning coupling

Overrunning coupling (13). See the equipment suppliers
instruction manual, ref. 5.

5.4.6 Centrifugal brake

Centrifugal brake (14). See the equipment suppliers
instruction manual, ref. 5.
24 70000817-1

5.4.7 Holding brake

The holding brake (15) is maintenance-free. See the
equipment suppliers instruction manual, ref. 5.

5.5 Replacement
5.5.1 Air filters
The air filters of the planetary gear units (08) must be
replaced twice a year.

5.5.2 Oil filters

The oil filter (35) is a duplex filter in which the filter unit in one
filter can be replaced during operation while the oil is filtered
through the second filter. Detach the filter case and replace
the filter element. Fixation of filter must be ensured, and the
filter must be checked for any signs of leakage when the unit
is in operation.

The filter elements can be cleaned in response to an alarm

from the electrical monitoring system. See equipment
suppliers instruction manual, ref. 5.

5.5.3. Planetary gear

If the planetary gear is to be dismantled from the support
roller shaft, the following procedure can be used.

The kiln must be reversed to neutral position, i.e. with

the kiln charge at the bottom.

The voltage supply to the motor must be cut off at the

MCC unit.

Dismantle the cardan joint shaft (20) between gear unit

and main motor

Dismantle electrical connections to planetary gear and

turning arrangement

Dismantle vertical connectors for torque arm

Dismantle oil pipes

The clamp coupling at the supporting roller shaft must

be relaxed
 70000817-1 25

The gear unit must be strapped as indicated in

Appendices 8 and 9. Two wire winches or chain pulleys
must be mounted as indicated in Appendices 8 and 9.

The gear unit must be pulled off the supporting roller

shaft very carefully. If there are oil channels in the
tubular shaft of the planetary gear, oil can
advantageously be pumped into the area between
supporting roller shaft and the tubular shaft in order to
facilitate the erection procedure.

An alternative to the aforementioned procedures is a method

which involves lowering of the supporting roller and gear unit
as an assembled unit. Prior to such action, investigations are
needed to determine the point of gravity for the total
arrangement of supporting roller and planetary gear.

For remounting of gear unit, it would be advantageous if,

when the gear unit is lifted up, it is lifted in manner ensuring a
predetermined rate of inclination corresponding to the
inclination of the kiln. This will facilitate the mounting on the
supporting roller shaft. The same procedure as mentioned
above, but in opposite sequence, and as mentioned in section
3 in this manual, must be used.
26 70000817-1

6. APPENDICES

01 Baseplate
02 Bedplate
03 Foundation bolt
04 Embedment concrete
05 Torque arm arrangement
06 Shim
07 Planetary gear
08 Air filter
09 Oil filler socket
10 PT100-temperature sensor
11 Proximity sensor
12 Turning gear
13 Overrunning coupling
14 Centrifugal brake
15 Holding brake
16 Hydraulic coupling
17 EOC system
18 Fixed coupling
19 Turning motor
20 Cardan joint shaft
21 Grease nipple
22 Main motor
23 Clamp coupling
24 Screw
25 Grease nipple
26 Supporting roller shaft
27 Supporting bearing
28 Oil cooling station
29 Three-way valve
30 Pump
31 Terminal box
32 Oil filter
33 Oil cooler
34 Thermometer
35 Pressure gauge
36 Flow control
 70000817-1 27

Blank page
28 70000817-1

05 Torque arm arrangement

07 Planetary gear

12 Turning gear

13 Overrunning coupling

14 Centrifugal brake

15 Holding brake

16 Hydraulic coupling

19 Turning motor

20 Cardan joint shaft

22 Main motor

23 Clamp coupling

26 Supporting roller shaft

27 Supporting bearing

28 Oil cooling station

 70000817-1 29

Appendix 1. Drive station

30 70000817-1

06 Shim

07 Planetary gear

08 Air filter

09 Oil filler socket

10 PT100-temperature sensor

20 Cardan joint shaft

21 Grease nipple
 70000817-1 31

Appendix 2. Drive station

32 70000817-1

05 Torque arm arrangement

07 Planetary gear
 70000817-1 33

Appendix 3. Torque arm arrangement

34 70000817-1

01 Baseplate

02 Bedplate

03 Foundation bolt

04 Embedment concrete
 70000817-1 35

Appendix 4. Baseplate
36 70000817-1

12 Turning gear

18 Fixed coupling

19 Turning motor
 70000817-1 37

Appendix 5. Turning arrangement

38 70000817-1

28 Oil cooling station

29 Three-way valve

30 Pump

31 Terminal box

32 Oil filter

33 Oil cooler

34 Thermometer

35 Pressure gauge

36 Flow control
 70000817-1 39

Appendix 6. Oil cooling station

40 70000817-1

11 Proximity sensor

16 Hydraulic coupling

17 EOC system

25 Grease nipple
 70000817-1 41

Appendix 7. EOC system

42 70000817-1

Blank page
 70000817-1 43

Appendix 8. Dismantling of planetary gear

44 70000817-1

Blank page
 70000817-1 45

Appendix 9. Dismantling of planetary gear