03 Maintenence

SECTION 3 - HP PULVERIZER MAINTENANCE
TABLE OF CONTENTS

TITLE TAB NO.

GENERAL MAINTENANCE ----------------------------------------------------------------- 1
GENERAL DISASSEMBLY ----------------------------------------------------------------- 2
GENERAL REASSEMBLY ------------------------------------------------------------------- 3
COMPONENT SERVICING ------------------------------------------------------------------ 4
COMPONENT LUBRICATION AND MAINTNEANCE SCHEDULES ------------ 5

This page intentionally left blank.

i
TAB 1. GENERAL MAINTENANCE

CONTENTS
TAB 1
TITLE PAGE NO.

INTORDUCTION ------------------------------------------------------------------------------------------------ 1
GENERAL MAINTENANCE ----------------------------------------------------------------------------------- 2
INTERFERENCE FITS ----------------------------------------------------------------------------------------- 4
Heating ------------------------------------------------------------------------------------------- 4
Chilling ------------------------------------------------------------------------------------------- 4

GENERAL MAINTENANCE
ii

1
TAB 1. GENERAL MAINTENANCE

INTRODUCTION

The following tabs of the manual have been prepared to serve as a guide in
maintaining DOOSAN Pulverizers. They do not cover all possible variations in
equipment nor provide solutions for special problems which may arise. If additional
information is required, however, DOOSAN or its representatives may be contacted.

It must be recognized that no amount of written instructions can replace intelligent
thinking and reasoning by maintenance personnel and boiler operators, especially
under unpredictable conditions. It is the responsibility of the maintenance person or
operator to become completely familiar with the equipment covered in this manual,
along with the pertinent control and auxiliary equipment.

Maintenance of controls and auxiliary equipment associated with the pulverizer but
not provided by DOOSAN is the sole responsibility of the owner/operator and his
maintenance and operating personnel.

For most maintenance procedures, access to all internal wear parts can be made
through the three journal openings or the separator body and millside access doors.
To facilitate maintenance on the drive components, the gearbox assembly is
removable. This is accomplished by disconnecting the bowl assembly from the
gearbox, lifting the bowl assembly within the separator body and allowing the
gearbox to slide out from under the millside assembly. Once the gearbox is
removed from under the pulverizer, it may be disassembled in a clean environment.
If only a quick inspection of the gearbox is required, inspection doors provided in
the side of the gearbox can be used. Refer to the instructions provided by the
gearbox manufacturer.

When it is necessary to inspect, repair, or replace wear parts and drive components
of the pulverizer, the procedures described in the following sections may be used as
a guide for removal and reinstallation of individual pulverizer components.

Review the Bowl Mill Cross Section drawing E-PLVE-0528 for orientation and
location of major components. Detailed procedures covering the repair of major sub-
assemblies can be found in SECTION 5. PULVERIZER ACCESSORIES of this
manual.

GENERAL MAINTENANCE
2

GENERAL MAINTENANCE

The pulverizer is a rugged machine, designed and built for continuous operation
over an extended period, with minimal wear on the working parts. However, iron
pyrites and other abrasive substances in the coal (ex. ash composition, silica, sand)
will shorten the life of parts such as the rolls, bull ring, separator body liners, vane
wheel liners, and scrapers.

Since wear of pulverizer parts depends on many factors that vary from one
installation to another, it is difficult to prescribe a specific routine inspection and
maintenance program.

Characteristics of the coal, operating hours of individual pulverizers, availability of
pulverizers due to unit load demands, and availability of maintenance personnel
are all factors that determine the frequency and scheduling of pulverizer inspections
and maintenance. An effective program can be established only on the basis of
actual plant operating experience.

NOTE: During the initial operating period, the pulverizers
should be inspected at regular intervals not greater than 3
months apart. This interval should be maintained until sufficient
operating experience indicates otherwise. Pulverizer components
must be inspected for general condition as outlined in this manual.

It is, therefore, imperative that an accurate log be maintained on each pulverizer
from initial installation, to relate individual pulverizer running time with pulverizer
performance, plant operating schedules, unit load, outages, inspection reports, and
other associated data.

NOTE: Pulverizer wear is a function of the number of hours a
pulverizer is grinding coal, not necessarily the amount (in tons) of
coal pulverized. While operating at reduced capacities, a
pulverizer will last somewhat longer, but will grind much less
tonnage before it becomes necessary to replace parts.

WARNI NG: WHEN MAINTENANCE IS REQUIRED ON A
PULVERIZER WHILE THE UNIT IS IN OPERATION, MAKE SURE THE
PULVERIZER IS MECHANICALLY AND ELECTRICALLY ISOLATED.
FOLLOW ALL PLANT SAFETY PROCEDURES.

Pulverizer part replacement criteria cannot always be defined in advance. They must
be established on the basis of experience and judgment on the part of personnel
familiar with the pulverizer history and performance along with plant maintenance
outage schedules. The degree, location, and pattern of wear will soon become
evident and can be handled accordingly.

GENERAL MAINTENANCE

3

In some cases wear surfaces can be built up ; in other instances, replacement of the
part is more practical. The following is a list of the pulverizer parts normally subject to
wear :

1. Bull Ring and Rolls
Reduced pulverizer capacity and increased spillage are indications of excessive
wear. Contour templates, made when the equipment is new, may aid in checking
the degree and location of wear as it progresses.

2. Separator body Liners, and Vane Liner Assemblies
Some pulverizers are supplied with ceramic or other types of internal liners, their
degree of wear will vary considerably from one installation to another and
sometimes between pulverizers at the same plant. Individual liners must be
replaced when thinning and holes indicate excessive wear.

NOTE: Protective compounds use to fill liner joints and
attachment holes must be completely renewed if ther is a
possibility that liner joints and attachments will be exposed before
the next inspection. To prevent loss of liners all attachment
fasteners showing evidence of wear must be replaced.

3. Vane Wheel
Replace vane wheel segments and/or air restriction segments if excessively worn.

4. Bowl Extension Ring
The ring should be replaced when worn excessively.

5. Air Inlet Vanes
Excessive rejects will cause wear on edges of vanes. Replace or rebuild if
excessively worn.

6. Scrapers and scraper wear plates
Wear plates are most susceptible to wear and can be replaced with unworn side
upside down.

CAUTION : When maintenance is required on a pulverizer while
the unit is in operation, make sure the pulverizer is completely
isolated before entering it. Close the dampers, gates and
valves ; isolate the fire suppression system and motor circuit
breakers ; ensure that the means for operating this equipment
is suitably tagged.

Most inspection and repair work inside the pulverizer above the bowl can be
accomplished by removing one journal opening cover and on journal shaft assembly.
Work below the bowl can usually be done through the pulverizer millside access
door(s).

CAUTION : When welding on a bowl, roll or any part of the
pulverizer, the welding machine should be grounded to the
component being welded in order to prevent racing across
bearings in the gear case or journals.

GENERAL MAINTENANCE
4

7. Bearings
Unusual noise and operating temperatures consistently above normal are indications
of impending bearing failure. Bearings should be inspected at the first opportunity.

8. Gearbox
These components usually give long, trouble-free service. However, failure of other
components can accelerate their wear. Refer to manufactures instructions for
additional information.

INTERFERENCE FITS

Where components have been designed with interference fits, it is frequently
necessary to heat and/or cool the mating parts to facilitate assembly.

HEATING

Heat must be applied uniformly to the entire piece. Acetylene torches with rosebud tips
are not recommended, since heating by this method is not sufficiently uniform. Heat
can best be supplied in a commercial type oven or an oil bath. However, it is also
possible to shroud the part in an insulated enclosure and increase the part temperature
with space heaters, or stress relieving blankets. A two (2) hour minimum for heating is
recommended.

CHILLING

Components can be chilled in a commercial freezer. They may also be chilled in a dry
ice and alcohol bath, -40 or by packing in dry ice. Before submerging a part in a
chilling bath, it should be coated with a thin layer of grease. Components should be
chilled for a minimum of 3 hours. After the part is removed from the chilling process,
be sure wipe off any condensation that might have occurred.

i
TAB 2. GENERAL DISASSEMBLY

CONTENTS
TAB 2
TITLE PAGE NO.

ISOLATION OF THE PULVERIZER ------------------------------------------------------------------------ 1
JOURNAL OPENING COVER REMOVAL ---------------------------------------------------------------- 2
JOURNAL TILT OUT ------------------------------------------------------------------------------------------- 3
JOURNAL ASSEMBLY REMOVAL ------------------------------------------------------------------------ 5
JOURNAL ROLL AND SHAFT ASSEMBLY REMOVAL --------------------------------------------- 6
JOURNAL HEAD REMOVAL ---------------------------------------------------------------------------------- 8
BOWL AND BOWL HUB LIFTING -------------------------------------------------------------------------- 9
GEARBOX ASSEMBLY REMOVAL --------------------------------------------------------------------- 11

Figure.1 ----------------------------------------------------------- XHP 1103Pulverizer

GENERAL MAINTENANCE
ii

1
TAB 2. GENERAL DISASSEMBLY

ISOLATION OF THE PULVERIZER

CAUTION : Use procedures adopted by your plant, locks, tags, log
notes, etc., to ensure that gates, valves, dampers, pumps, motors and
fire suppression systems associated with an isolated pulverizer are not
inadvertently operated while a pulverizer is opened for inspection or
maintenance.

CAUTION : If the pulverizer contains coal, ensure that the gearbox drive
shaft has been blocked to prevent rotation of the bowl before entering the
pulverizer.

1. To isolate the pulverizer, close the hot air shutoff gate, the cold air shutoff gate, the
pulverizer discharge valves, the coal line gates (if provided), the vent air and seal
air shutoff valves, and the feeder discharge valve (if provided).

2. Open the pulverizer and feeder motor breakers.

3. Disconnect the pulverizer motor coupling at the gearbox.

4. Isolate, lock shut, and tag inoperative applicable fire suppression systems.

5. Ensure that pulverizer is depressureized by opening a millside access door.

GENERAL DISASSEMBLY
2

JOURNAL OPENING COVER
REMOVAL(Refer to TAB 6 )

The journal opening cover and journal spring assembly is normally removed as a unit.

1. Disconnect the seal air supply lines from the trunnion shafts and journal spring
assembly. Refer to drawings E-PLVE-0528, D-GP-9955 and SE-110-01608.
Remove the trunnion shaft air riser and plug the seal air header opening.
2. Lower the journal so the grinding rolls is resting on the bowl by removing the stop
bolt nut and fasteners.
3. Remove the key
4. Remove the stop bolt
5. Remove the O-ring

CAUTION : The journal opening cover and journal spring assembly
weighs approximately 3.79 Ton and must be adequately rigged to
ensure safe handling.

NOTE : To prevent the journal opening cover from titling and to
ensure a vertical lift it may be necessary to rig to the journal spring
assembly as well as the lifting holes in the journal opening cover

6. Center the crane directly above the journal opening. Rig the journal
opening cover for removal using the two lifting holes provided in the top edge of the
cover. Take up a slight load on the lift rigging.

7. Remove the hex head cap screws that secure the journal opening cover to the
separator body.

8. Remove the journal opening cover and move it the convenient storage area.

GENERAL DISASSEMBLY

3

JOURNAL TILT OUT

NOTE : Unless otherwise stated, refer to Fig. 1 on E-PLVE-0539
when using the following procedure.

1. Remove journal opening cover.

2. Secure the journal tilt out bracket to the separator body journal cover opening with
hex head cap screws and to the separator top lifting lug with a shaft, washers and
cotter pins. Install the safety bracket loosely to the journal cover opening with hex
head cap screws.

3. Turn the journal stop bolt to lift the grinding roll from the bull ring. Rotate the roll until
the 1-1/2 in. tapped holes on top of the journal housing are at 12 O'clock (refer to
drawing no. (D-94-1748).

4. Remove existing set screws and install lug using hex head cap screws.

5. Remove journal head cover plate and set it aside.

NOTE : If maintenance will be performed on the journal shaft assembly
then consideration should be given to pumping oil out of the bearing
housing.

6. Remove the oil fill pipe, replace the pipe plug in the journal shaft to prevent oil
leakage.

7. Attach the cable to lug and tilt out bracket as shown on Fig. 1 of E-PLVE-0539.

CAUTION : Ensure that the crane is correctly positioned for a
vertical line of pull.

CAUTION : During the next step the cable will go slack and then
tighten as the journal falls outward when its center of gravity passes
over the top of the pivot point. Always stand clear during this
operation. Do not exceed 9.0 MT of pull.

8. SLOWLY raise the cable vertically until there is a minimum distance between the tilt
- out lug connection and the active sheave (Position 2, Fig. 1, of E-PLVE-0539)

9. After the journal falls outward, SLOWLY lower the cable and tilt out lug to position 3.
The journal assembly should contact and rest on the safety bracket.

10. Install hex head cap screws and washers through the safety bracket and into the
journal head, tighten all screws per B-GP-2175 to lock the journal in the tilted

GENERAL DISASSEMBLY
4
position. This will prevent the journal from falling into or out of the mill when the tilt
rigging is removed.

11. Remove the tilt out rigging and tilt out bracket.

GENERAL DISASSEMBLY

5

JOURNAL ASSEMBLY
REMOVAL

If pulverizer repairs will be extensive or if the bowl will be removed from the gearbox, it
may be advantageous to remove the journal assemblies completely. If access to the
pulverizer is only for the purpose of inspection or minor maintenance, then removing
only the journal roll and shaft assembly may be sufficient. (Refer to J ournal Roll and
Shaft Assembly Removal, Page 6).

1. Remove the journal opening cover and spring assembly.

2. Tilt out the journal assembly.

CAUTION : The journal assembly weighs approximately 9.20 MT,
trunnion shafts weigh approximately 146 kg each. All must be
adequately rigged to ensure safe handling.

3. Remove all of the grinding roll keeper bolts and the keeper plates. Refer to Drawing
SE-GP-6646 and install the grinding roll removal lug. The hex head cap screws
should be installed through the inner bolt circle into the journal housing. Torque
fasteners (10) to 6.9 kg-m.

CAUTION : The overhead crane must support the journal assembly
at all times during the removal procedure.

4. Make sure that the scribe line on the lug faces into the center of the mill. Install a
wire rope through the removal lug and attach to an overhead crane [10 MT
minimum capacity]. The wire rope sling must clear the classifier door opening when
loaded.

CAUTION : The crane must provide support for the journal assembly
during the entire removal procedure.

5. Attach the sling to an overhead crane positioned above the center of the door
opening. Take up slack.

NOTE : The sling and/or crane cable must not contact the separator
body when the journal assembly is being lifted out of the separator
body opening.

6. Remove the safety bolts from the journal head.

7. Remove the cap screws from the trunnion shaft end caps, the use jacking bolts in
the threaded holes to remove the trunnion shafts from the journal head.

8. When the trunnion shafts clear the journal head, swing the journal assembly clear of
the classifier body.

GENERAL DISASSEMBLY
6
9. Move the assembly to convenient work area.

10. Inspect the trunnion shaft bushings.

11. Store the trunnion shafts until required for reassembly.

JOURNAL ROLL AND SHAFT
ASSEMBLY REMOVAL

If repairs are required on the journal shaft assembly only, or less access to the
separator body is required, it may be easier to remove the journal roll and shaft
assemblies and leave the journal heads in place. The procedure and equipment
arrangement are explained in the following text.

NOTE : For the following procedures, refer to drawings D-94-1747
and D-94-1748 unless otherwise stated.

1. Remove the journal opening cover and spring assembly.

2. Remove the journal head cover plate and the journal oil fill plug and pipe assembly.
Remove the pipe plug from the assembly and replace the plug in the end of the
journal shaft assembly.

NOTE : If maintenance is to be performed upon the journal shaft
assembly then consideration should be given to pumping
approximately 49 liter of oil out of the bearing housing at this time.
Refer to "J ournal Oil Removal Procedures",.Maintenance Tab 4
COMPONENT SERVICING

3. Install journal head safety brackets and perform the J ournal Tilt Out procedure.

CAUTION : The journal roll and shaft assembly weighs
approximately 5.8 MT and must be adequately rigged to ensure safe
handling.

4. Remove all of the grinding roll keeper bolts and the keeper plates. Refer to Drawing
SE-GP-6646 and install the grinding roll removal lug (Item 5). The hex head cap
screws should be installed through the inner bolt circle into the journal housing.
Torque fasteners (Item 10) to 6.9 kg-m.

CAUTION : The overhead crane must support the journal assembly
at all times during the removal procedure.

5. Make sure that the scribe line on the lug faces into the center of the mill. Install a
wire rope through the removal lug and attach to an overhead crane [7.5 MT
minimum capacity]. The wire rope sling must clear the classifier door opening when
loaded.

GENERAL DISASSEMBLY

7

6. Attach the sling to and overhead crane positioned above the center of the door
opening. Take up slack.

NOTE : The chain sling and crane cable must not contact the
separator body when the journal roll and shaft assembly is lifted out
of the separator body journal opening.

7. Remove the journal skirt.

NOTE : Some journals are equipped with journal head liners. If
supplied, they must be removed at this time. The journal head liners
are custom fit during assembly and some liners may not be
interchangeable. It is imperative that each liner be identified and
marked so that it can be reinstalled in the SAME position from which
it was removed.

8. Remove the journal shaft flange bolts.

9. Lift the journal roll and shaft assembly clear of the journal head and swing assembly
out of the separator body journal opening. Move it to a convenient work area.

GENERAL DISASSEMBLY
8

JOURNAL HEAD REMOVAL

If, after the journal roll and shaft has been removed, it is necessary to remove the
journal head the following procedures may be used.

NOTE : Refer to drawing D-PLVD-0823.

CAUTION : The journal head weighs approximately 2.6 MT, trunnion
shafts weigh approximately 146 kg each and must be adequately
rigged to ensure safe handling.

1. Install two(2) 1-1/4 in. eyebolts in the head flange 180apart.

2. Install a chain shackle in each eyebolt and attach a chain sling.

3. Attach the chain sling to an overhead crane positioned above the center of the
journal opening. Take up slack.

CAUTION : The crane must provide support for the journal head
during the entire removal procedure.

4. Remove the safety bolts from the journal head.

5. Remove the cap screws from the trunnion shaft end caps and use jacking bolts to
remove the trunnion shafts from the journal head.

6. When the trunnion shafts clear the journal head, swing the head clear of the
classifier body.

7. Move the journal head to a convenient work or storage area.

8. Inspect the trunnion shaft bushings.

9. Store the trunnion shafts until required for reassembly.

GENERAL DISASSEMBLY

9

BOWL AND BOWL HUB
LIFTING

In order to access the gearbox for major maintenance, it must be removed from under
the mill. The bowl and bowl hub assembly must be lifted clear of the gearbox to do this.

NOTE : Refer to drawing SC-GP-8255 and SE-110-01595.

1. Remove the three journal opening covers.

2. Tilt out all journal assemblies.

3. Remove all journal assemblies.

4. Open the millside access doors.

NOTE : Before disassembly, verify that each piece is identified and
match marked.

5. Remove the scraper assemblies and move them to the outer edge of the millside.

6. Disassemble the components of the bowl hub air seal ring and bowl hub liners. Use
care not to damage the lower surface of the air seal ring.

7. Disassemble the air seal packing gland and packing. Transfer parts to clean, safe
storage area.

8. Remove the bolt protection piece and cap plates.

9. Start the lubrication oil system and turn the bowl by hand until one of the 1 in. hex
socket head cap screws (located in the bowl extension ring) is positioned at the
center line of each journal opening. Refer to drawing SD-110-01596.

10. Remove that cap screw and adjacent cap screws on each side, for a total of three
at each opening.

11. Install bowl hoist clevis and bowl hoisting frame hook at each journal opening.
Refer it drawing SC-GP-8255.

12. Disassemble the bolts that secure the vane wheel segments to the bowl hub and
remove the vane wheel segment. Mark each segment as it is removed so that it
can be installed in the same location.

13. Remove torque nuts and then remove all 8 studs from the hub.

CAUTION : The bowl hub, vane wheel and bowl assembly weighs
approximately 17.98 MT and must be adequately rigged to ensure
safe handling.

GENERAL DISASSEMBLY
10

14. Attach three chain blocks or come-alongs [each with a 15 MT minimum capacity] to
the tilt-out lug and the bowl hoisting clevis (refer to drawing SC-GP-8155).

15. Lift the bowl, bowl hub assembly approximately 50 mm. Stabilize the bowl hub
assembly with screw jacks or cribbing.

16. Remove the gearbox.

GENERAL DISASSEMBLY

11

GEARBOX ASSEMBLY
REMOVAL

NOTE : Reference drawings E-PLVE-0528 ans SC-GP-8255.

1. Remove three (3) journal opening covers and journal spring assemblies.

2. Remove the Three (3) journal assemblies.

3. Lift the bowl and bowl hub assembly as described above.

4. Isolate the lubrication system and disconnect the oil lines from the gearbox. Cap or
cover all openings to keep the system clean.

5. Disconnect the wiring from the bearing thermocouples, and from the other
monitoring equipment on the gearbox. Mark and secure the wiring.

6. If not previously done, remove the coupling guard and disconnect the drive coupling.

7. Remove fasteners securing the pyrite hopper to millside, pyrite valves and pyrite
hoppers.

8. Remove the hex head cap screws that secure the gearbox to its sole plate. Also
remove the dowel pins that align the gearbox.

9. Place the gearbox removal rails on cribbing or a steel frame built up from the floor.
Ensure that top of the rails are flush with the gearbox sole plate, then attach to the
sole plate, see drawing SC-110-1359.

10. Slide the gearbox onto the rails.

CAUTION : The gearbox weighs approximately 17.0 MT and must
be adequately rigged to ensure safe handling.

11. Once the gearbox is out from under the pulverizer, it may be moved to a
maintenance area for disassembly.

12. If a replacement gearbox will not be installed immediately, build a steel or wood
crib capable of supporting the weight of the bowl and bowl assembly under the
bowl hub. The height of the crib should be set so that when the bowl and bowl hub
assembly is placed on it, the assembly will be at approximately the same height it
was before disassembly.

13. Lower the bowl and bowl hub assembly onto the cribbing. Stabilize the bowl hub
assembly with screw jacks or cribbing, If necessary, remove the lift rigging to
provide access to the interior of the pulverizer.

Refer to the manufacturer's instructions for further information about the gearbox.

GENERAL DISASSEMBLY
12

Figure.1 XHP 1103Pulverizer

i
TAB 3. GENERAL REASSEMBLY

CONTENTS
TAB 3
TITLE PAGE NO.

GEARBOX ASSEMBLY INSTALLATION ----------------------------------------------------------------- 1
BOWL HUB TO GEARBOX ASSEMBLY ----------------------------------------------------------------- 3
AIR SEAL INSTALLATION AND CLEARANCE ---------------------------------------------------------- 4
SECURING GEARBOX TO SOLE PLATE --------------------------------------------------------------- 5
SCRAPER AND GUARD ASSEMBLY --------------------------------------------------------------------- 5
BOWL HUB INSTALLATION ------------------------------------------------------------------------- 6
PULVERIZER LUBRICATION SYSTEM REASSEMBLY -------------------------------------------- 6
JOURNAL HEAD ASSEMBLY INSTALLATION -------------------------------------------------------- 7
JOURNAL ROLL AND SHAFT ASSEMBLY INSTALLATION ---------------------------------- 9
JOURNAL OPENING COVER AND SPRING ASSEMBLY --------------------------------------- 10
SEAL AIR -------------------------------------------------------------------------------------------------------- 12
PULVERIZER MOTOR --------------------------------------------------------------------------------------- 12
PREPARATION FOR A RETURN TO SERVICE ------------------------------------------------------ 13

GENERAL MAINTENANCE
ii

1
TAB 3. GENERAL REASSEMBLY

GEARBOX ASSEMBLY
INSTALLATION

The gearbox assembly is installed by sliding it into position under the assembled
pulverizer. Special fixtures should be provided to assist in this procedure.

NOTE: Refer to drawings T04019-PV-A003, E-PLVE-0528, SD-110-
01594, C-GP-7389, and SC-110-1359 unless stated otherwise. For
the gearbox and lube system preparation and handling procedures,
refer to instructions in the gearbox manufacturers instruction manual.

1. Attach the gearbox removal rails to the sole plate. Place the rails on cribbing as
required to level them with the top of the gearbox sole plate.

WARNING: THE PULVERIZER GEARBOX WEIGHS
APPROXIMATELY 17 MT AND MUST BE ADEQUATELY RIGGED
TO ENSURE SAFE HANDLING.

NOTE: Prior to installing the gearbox under the pulverizer, check
that two dowel pins are installed in the gearbox output adapter. Use
Loctite RC 680 and install the pins so that they protrude 15.2 mm,
0.4 mm.

NOTE: If the same gearbox is being reinstalled on the same sole
plate, and if perfect alignment of the original holes can be achieved,
the same size dowel pins may be used. However, it is permissible
(and possibly easier) to re-drill and ream the holes at the old location
and install 6.3 mm larger diameter dowel pins.

If a new or different gearbox assembly is installed under a pulverizer, it will be
necessary to drill new dowel pin holes in the gearbox mounting flange and the sole
plate. These must be located at least 15.24 cm away from the original dowel pin (or
existing) holes and diametrically opposed.

NOTE: If a new or different gearbox is installed, perform step 2; if re-
installing the same gearbox, skip to step 3.

2. As necessary, drill two 34 mm pilot holes 180 apart in the gearbox bottom flange.
Pilot holes should be at least 152.4 mm away from existing holes and diametrically
opposed.

GENERAL REASSEMBLY
2

NOTE: The gearbox must be positioned adjacent to the pulverizer
foundation, oriented with the input drive shaft facing toward the
motor location.

3. Assure that the gearbox removal rails are clean, apply a light film of grease, and set
the gearbox assembly on the fixture.
4. Lift the bowl, bowl hub assembly as required to clear the gearbox.

a. If previously removed, reinstall a bowl hoist clevis at each journal opening. Refer
to drawing SC-GP-8255.

b. Rig three 10 MT minimum capacity each chain block or come alongs to the bowl
hub assembly hoist clevis.

WARNING: THE BOWL, BOWL HUB, AND VANE WHEEL
ASSEMBLY WEIGHS APPROXIMATELY 17.9 MT AND MUST BE
ADEQUATELY RIGGED TO ENSURE SAFE HANDLING.

c. Lift the bowl as required to clear the gearbox.

5. Remove the bowl hub assembly support cribbing.
6. Slide the gearbox assembly into position under the millside. Check that the gearbox
bolt holes line up with the tapped holes in the sole plate and the old dowel pin (if to
be reused).
7. Install the washers and cap screws which secure the gearbox to the gearbox sole
plate (hand tight with Fel-Pro C5-A anti-seize compound or equal).
8. Remove the gearbox removal rails.
9. Install the gearbox millside adjustment blocks on the sole plate.
Refer to drawing C-GP-7389

GENERAL REASSEMBLY

3

BOWL HUB TO
GEARBOX ASSEMBLY

1. Ensure that the mating surfaces of the bowl hub and the gearbox adapter are
clean.

NOTE: Apply anti-seize compound to all threads and torque all
fasteners per B-GP-2175 unless otherwise specified.

CAUTION: Ensure that the upper reservoir of the gearbox is full of oil
to the level indicated on its sight glass before turning the gearbox
shaft.

2. The input shaft of the gearbox may be turned by hand to get the dowel pins in the
output adapter to line up with the dowel pin holes in the bowl hub.
3. When aligned, lower the bowl hub assembly onto the gearbox assembly. Be sure
that the pins are properly engaged and that the hub is firmly seated on the gearbox
output adapter.
4. Clean the threads of the eight 2" studs that secure the bowl hub to the gearbox.
5. Apply Loctite 277 to lower 76 mm of thread opposite stud hex. head.
6. Install studs so that thread engagement into the output plate is 101.6 mm, +1.5
mm, - 0.0 mm.
7. Clean the top of the bowl hub flange and apply anti-seize compound to the
protruding end of the studs.

NOTE: Clean the internal threads of the torque nuts, check that
all jack bolts supplied with the nuts have been removed, cleaned and
lubricated with an approved lubricant to ensure proper jackbolt
performance upon re-installation. Install jack bolts in the tension nut so
they are flush with the bottom of the nut.

NOTE: For torquing procedures refer to the SUPERBOLT

Multi-J ackbolt Tensioner instructions with the vendor equipment.

8. Install the hardened washers supplied with the torque nuts.
9. Install and snug the torque nuts by hand; the nut body should contact the
hardened washer.
10. Remove the chain hoists and bowl hub hoisting fixtures.
11.Tension the studs (tighten the torque nuts). Refer to Note 6 on drawing E-
PLVE-0528.
12. Check the upper air seal clearance before doweling the gearbox to the sole plate.

GENERAL REASSEMBLY
4

AIR SEAL INSTALLATION
AND CLEARANCE

NOTE: The following steps refer to drawings SD-110-01597 and
E-PLVE-0528.


CAUTION: Ensure that the upper oil reservoir of the gearbox h
as been filled with the recommended oil, to the centerIine of th
e gauge glass before turning the gearbox input shaft (by hand)
during air seal setting.

1. Use the drive adjustment blocks and center the gearbox and bowl hub assem
bly to the millside within 0.010" (0.254 mm). For this initial setting, measure fr
om the packing ring bore in the millside to the outside diameter of the bowl
hub.

2. Install the rings of pecking and the packing gland. Install and torque fasteners.

3. Install the gearbox thermocouples (if previously removed).

4. Install the sections of expanded metal screen to the millside guard supports. A
ssemble with nuts, washers, and cap screws.

5. Reconnect all thermocouples, oil lines, and instrument wiring.

6. Check coupling alignment.

GENERAL REASSEMBLY

5

SECURING THE GEARBOX
TO SOLE PLATE

NOTE: Refer to drawing E-PLVE-0528 unless otherwise stated.


Secure the gearbox to the sole plate only after the coupling alignment has been set and
confirmed.

1. Remove the bolts which hold the gearbox to the sole plate. Coat each bolt with anti-
seize compound, then install and torque.
2. Mount a drilling rig above each of the dowel pin holes in the gearbox mounting
Flange.
3. Drill and ream to oversize for new dowel pins or using the 34 mm diameter holes in
the gearbox flange as pilots, drill and ream two holes into the sole plate, 38.1 mm, -
0.026 mm ~-0.0038 mm to a depth of 139.7 mm.
4. Lubricate the dowel pins with Molykote GN-Paste, or an equivalent, and press fit the
dowel pins into the reamed holes.
5. Remove the gearbox adjustment blocks and retain for use on next gearbox
installation.
6. Verify coupling alignment, secure the coupling, and install the coupling guard.

SCRAPER AND GUARD
ASSEMBLY

NOTE: The following steps refer to drawings E-PLVE-0528 and SD-
110-01597 unless otherwise stated.

NOTE: Apply thread locking sealant to all threads and torque all

1. Install the two scraper assemblies on the bowl hub.
2. Set the clearance between scraper wear plate and millside bottom plates to 9.7
mm, 6.3 mm.

CAUTION: Ensure that the upper reservoir of the gear box is full of
oil to the level indicated on its sight glass before turning the
gearbox shaft.

3. Rotate the bowl and recheck the gap, along the radius, in at least eight places,
once for each millside bottom plate. Check the gaps at the highest point on each
wear plate.

GENERAL REASSEMBLY
6

BOWL HUB INSTALLATION


NOTE: Apply anti-seize compound to all fasteners and torque all

1. Wrap bowl hub insulation, around the bowl hub.

2. Re-install the bowl hub liners using bolts and plain washers through the clips at the
top of the liners.

3. Torque all bolts.

PULVERIZER
LUBRICATION SYSTEM
REASSEMBLY

NOTE: Refer to gearbox and lube oil system manufacturers
instruction manual for details.


1. Connect the wiring to the gearbox thrust bearing thermocouples.

2. Remove the caps and covers that were applied to keep the system clean from the
oil supply and return piping and gearbox.

3. Clean and assemble the flanges.

4. Fill the oil tank to operating level with the recommended oil.

5. Start the lube system pump to fill the oil supply and return lines, the thrust bearing
reservoir, and the gearbox. Check for system leaks.

6. Refill the oil tank reservoir to operating level.

7. Place the lubrication system back into service.

GENERAL REASSEMBLY

7

JOURNAL HEAD ASSEMBLY
INSTALLATION

NOTE: Refer to drawings E-PLVE-0528, D-94-1747, D-94-1748, and
C-GP-7711 unless otherwise stated.


WARNING: J OURNAL HEAD LIFTING EYEBOLTS MUST BE
DROP FORGED STEEL SHOULDER PATTERN AND RATED FOR
3.0 MT WORKING LOAD CAPACITY.

WARNING: THE J OURNAL HEAD WEIGHS APPROXIMATELY 2.5
MT AND MUST BE ADEQUATELY RIGGED TO ENSURE SAFE
HANDLING.

1. With the journal head assembly laying flange side up, remove the trunnion shafts
and install two 1-1/4" lifting eye bolts 180 apart in the head flange.
2. Install a chain shackle in each eyebolt and attach a chain sling. Rig the chain sling
to an overhead crane. Take up the slack.

WARNING: TRUNNION SHAFTS WEIGH APPROXIMATELY 146
KG EACH AND MUST BE ADEQUATELY RIGGED TO ENSURE
SAFE HANDLING.

3. Place a trunnion shaft near each side of the journal opening.
4. Lift the head and remove the journal head cover plate.
5. Position the journal head in the separator body journal opening and align with the
trunnion shaft openings.
6. Slide a 366cm or longer "all thread" rod through the separator body trunnion shaft
openings and the journal head.
7. Coat the surfaces of the trunnion shafts liberally with anti-seize compound.

NOTE: If alignment is perfect, trunnion shafts may slide into position
without performing steps 13 through 15.

8. Lift each shaft and slide it over the all thread rod and into its separator body opening.
Start the end of each trunnion shaft into the journal bushing retainers.
9. Remove the pipe plug from the seal air opening in the trunnion shaft end plate.

GENERAL REASSEMBLY
8

CAUTION: Maintain alignment of all components during the next few
steps to prevent components from binding.

10. Slide a backing plate on each end of the all thread rod. Thread two hex nuts on
one end of the all thread rod and one heavy duty hex nut on the other end.
11. Securely lock the two hex nuts together at one end of the all thread rod and tighten
the nut on the other end.
12. Use an air impact wrench on the double nutted end of the rod. Use a wrench, as
necessary, to hold the single heavy hex nut. Then slowly turn the rod to tighten
the heavy hex nut and pull the trunnion shafts into place.
13. When trunnion shafts are fully inserted, align the bolt holes and secure the
trunnion shaft end plates to the trunnion shafts and separator body with Iubricated,
hex head cap screws. Torque the bolts per drawing B-GP-2175.
14. Disconnect the rigging and remove the eyebolts.
15. Install the journal roll and shaft assembly.

GENERAL REASSEMBLY

9

JOURNAL ROLL AND SHAFT
ASSEMBLY INSTALLATION

NOTE: Refer to drawings E-PLVE-0528, D-94-1747, D-94-1748, D-
PLVD-0823, E-PLVE-0539, D-110-01604 and SC-GP-6646 unless
otherwise stated.


WARNINGS: THE J OURNAL ROLL AND SHAFT ASSEMBLY
WEIGHS APPROXIMATELY 5.8 MT AND MUST BE ADEQUATELY
RIGGED TO ENSURE SAFE HANDLING.

1. Move the journal roll and shaft assembly adjacent to the mill.

2. Remove the grinding roll keeper bolts and keeper plates. Install the grinding roll
removal lug. Torque all fasteners.

WARNING: THE OVERHEAD CRANE MUST SUPPORT THE
J OURNAL SHAFT ASSEMBLY AT ALL TIMES DURING THE
INSTALLATION PROCEDURE.

NOTE: The slings and crane cable must not contact the separator
body when the journal roll and shaft assembly is lifted into position.

3. Clean the mating surfaces of the journal head assembly and the journal shaft flange.

NOTE: To ensure correct assembly, one hole in the shaft flange is
offset 0.50" (12.7 mm).

4. Set the journal roll and shaft assembly in position on the journal head assembly.
Rotate shaft to align the holes in the journal shaft flange with the tapped holes in
the journal head.
5. Apply thread locking compound and install hex socket head cap screws. Tighten
fasteners in the sequence shown on drawing D-94-1747, Section "A-A."
6. Install the journal head skirt and torque fasteners per drawing B-G P-2175.

NOTE: J ournals are equipped with journal head liners. As some
liners may not be interchangeable, it is imperative that each liner be
identified and marked so that it can be re-installed on the same
journal.

7. Re-install the journal head liner assembly and torque fasteners per drawing B-BP-
2175.

GENERAL REASSEMBLY
10

8. Remove the grinding roll removal lug. Reinstall the grinding roll keeper plates and
bolts. Torque the fasteners.

9. Tilt in the journal assembly to return the roll to the bowl

WARNING: STAND CLEAR OF THE J OURNAL DURING THE TILT-
OUT PROCEDURE. AS THE J OURNAL APPROACHES TOP DEAD
CENTER, THE J OURNAL WILL TEND TO FALL OUT OF THE
PULVERIZER SINCE THE CENTER OF GRAVITY IS PASSING
THROUGH THE TOP OF ROTATION

JOURNAL OPENING COVER
AND SPRING INSTALLATION

NOTE: Refer to drawings E-PLVE-0528, D-GP-9955, D-GP-8580 ,
E-GP-8101 and B-GP-3960 unless otherwise stated.

fasteners per B-GP-2175 unless otherwise specified

WARNING; THE J OURNAL OPENING COVER ASSEMBLY
WEIGHS APPROXIMATELY 2.6 MT AND MUST BE ADEQUATELY
RIGGED TO ENSURE SAFE HANDLING. USE LIFTING HOLES
PROVIDED.

1. Loosen the spring position adjusting stud nuts and studs.
2. Retract the spring assembly until only 2.54 cm of the assembly is protruding from
the inside of the journal opening cover. Snug the inner nuts on the studs to maintain
the position of the spring assembly.
3. Rig to lift the journal opening cover using the top lifting holes.
4. Ensure that the journal stop bolt is through the journal door. The flat edges of the
stop bolt should be in the operating position, parallel to the sides of the cover. The
stop bolt keyway should be facing approximately 45 from the top of the cover.
5. The nut should be threaded onto the stop bolt until the stop bolt keeper plate can
just be installed and engage the keyway (stop bolt in the full inward position). Hand
tighten the cap screws into the stop bolt nut and keeper plate.
6. Clean the mating surfaces of the journal opening frame and journal opening cover
and coat them with Felt-Pro C5-A anti-seize compound or equal.
7. Hoist the journal cover and spring assembly into position away from the separator
body, but aligned with the journal opening. Position the cover so the "mushroom
head" of the stop bolt is higher than the slot in the journal head arm. Carefully
move the cover inward, then downward, to engage the stop bolt in the journal head
slot.
8. Align the cover bolt holes with the journal opening bolt holes and install all journal
cover bolts. Torque per drawing B-GP-2175.

GENERAL REASSEMBLY

11

9. Remove the keeper plate socket cap screws and stop bolt nut/washer cap screws.
Retract the stop bolt using the stop bolt nut until the "mushroom head" is fully
seated in the journal head slot.
10. Install the stop bolt keeper plate bolts hand tight. Final stop bolt setting will be
made later when ring-to-roll clearance is set.
11. Check the journal spring compression; refer to Pulverizer Component Servicing,
"J ournal Spring Preloading Procedure for instructions.

NOTE: Steps 12 and 13 can only be performed when the pulverizer
is operational.

12. Set the roll-to-bowl ring clearance. Refer to Pulverizer Component Servicing for
procedures.
13. Adjust the journal spring to journal head clearance. Refer to Pulverizer Component
Servicing, J ournal Spring Position for procedures.
14. Reconnect the seal air system piping.

GENERAL REASSEMBLY
12

SEAL AIR

NOTE: Refer to drawings E-PLVE-0528 and SE-110-01608 unless
otherwise stated.

NOTE: Apply pipe thread sealant to all threaded joints at assembly.


1. Replace the seal air piping removed in the disassembly procedures.
2. Replace the male portion of a 2-1/2" pipe nipple on the trunnion shaft end plate at
each journal and a pipe plug in the other end plate. Ensure that the male portion of
the 2-1/2" pipe nipple on the rigid piping meets the female portion at the trunnion
shafts.
3. If removed, replace the male portion of a 1-1/2" pipe nipple at the top of each
journal spring housing. Ensure that the male portion of the 1-1/2" pipe nipple on the
rigid piping meets the female portion of 1 -1/2 90 elbow. Tighten all fittings.

PULVERIZER MOTOR

If the pulverizer motor was removed, or a new motor is installed, use the following
procedure as a guide for installation.

The pulverizer motor may be in place on its sole plate. When the gearbox has been
secured on its sole plate and air seal clearances have been set, the installation of the
pulverizer motor and coupling can be completed.

NOTE: Refer to motor and coupling manufacturer's instructions for
mounting and alignment recommendations.

GENERAL REASSEMBLY

13

PREPARATION FOR
A RETURN TO SERVICE

1. Check motor rotation. (This must be performed before the motor/gearbox coupling
is assembled.)
2. Assemble the motor/gearbox coupling.
3. Install the coupling guard.
4. Clean out the pulverizer. Remove tools, lights, etc.
5. Close and secure doors and inspection plates.
6. Install the miliside inspection door insulation covers.

NOTE: For steps 7 and 8, reference procedures in "Pulverizer
Component Servicing."

7. Ensure that the roll to-ring clearance has been adjusted.
8. Ensure that the clearance between the journal spring and journal head has been
adjusted.
9. Start up and test the lubrication oil system. Repair leaks and add oil as necessary.
10. Use plant procedures to remove the pulverizer from isolation. Remove the tags,
unlock switches, close the pulverizer motor breaker, etc.
11. Use plant procedures to remove the feeder from isolation. Remove tags, unlock
switches, close the feeder motor breaker, etc.
12. Open the hot air shin off gate, the cold air shut off gate, the mill discharge valves,
the Coal pipe gates, the vent air and seal air shut off valves, and the feeder
discharge valves (if provided).
13. Check that the pulverizer fire suppression system is operative.
14. Return the pulverizer to service. Refer to the Pulverizer Operating Procedures for
additional information.

GENERAL REASSEMBLY
14

i
TAB 4. COMPONENT SERVICING

CONTENTS
TAB 4
TITLE PAGE NO.

Bull Ring Segment Replacement ---------------------------------------------------------------------- 1
Vane Wheel Servicing ----------------------------------------------------------------------------------- 3
Liner Installation Using Weld Plugs -------------------------------------------------------------- 4
Equipment Required ------------------------------------------------------------------------------------------ 4
Welding Specification - Manual Insert Gas Welding (MIG) ------------------------------------------ 4
Welding Specification - Stick Weld, Manual Metal Arc Process ---------------------------------- 4
Application of Weld Plugs ----------------------------------------------------------------------------------- 4
Installation of Tiles and Liners - General --------------------------------------------------------------- 5
Trouble Shooting - Large Gaps Between Tile ------------------------------------------------------- 6
Trouble Shooting - Tile is Cracking -------------------------------------------------------------------- 6
Trouble Shooting - Welds Not Fusing ------------------------------------------------------------------ 6
Li ner Repl acement ---------------------------------------------------------------------------------------- 7
General -------------------------------------------------------------------------------------------------------- 7
Separator Body Liners -------------------------------------------------------------------------------------- 7
Journal Lubrication ------------------------------------------------------------------------------------ 7
J ournal Assembly ----------------------------------------------------------------------------------- 7
J ournal Stop Bolt ------------------------------------------------------------------------------------- 9
J ournal Trunnion Shafts ------------------------------------------------------------------------------ 9
Major Adjustment -------------------------------------------------------------------------------------------------------------------- 10
J ournal Spring Assembly Preload Procedure -------------------------------------------------------- 10
Ring to Roll Gap ------------------------------------------------------------------------------------------- 11
Spring Assembly to J ournal Head Gap ------------------------------------------------ 13
Component Mai ntenance ----------------------------------------------------------------------------- 14
J ournal Opening Cover Removal and Installation --------------------------------------------- 14
J ournal Oil Replacement ------------------------------------------------------------------- 15
J ournal Oil Seal Replacement ----------------------------------------------------------------------- 16
J ournal Bearing End Play Checking --------------------------------------------------------------- 18
J ournal Bearing Replacement------------------------------------------------------------------------- 19
J ournal Shaft Assembly Removal ------------------------------------------------------- 19
J ournal Shaft Assembly Disassembly ------------------------------------------------------- 20
J ournal Shaft Assembly Reassembly ------------------------------------------------------- 21
J ournal Shaft Assembly Reinstallation -------------------------------------------------- 24
Gri ndi ng Rol l Repl acement --------------------------------------------------------------------- 26
Trunnion Bushing and Seal Replacement --------------------------------------------------------- 28
Journal Spri ng Assembl y Rebui l d--------------------------------------------------------------- 29
Spring Assembly Disassembly ------------------------------------------------------------------ 29
Spring Assembly Reassembly --------------------------------------------------------------------- 30

COMPONENT SERVICING
ii

1
TAB 4. COMPONENT SERVICING

Bull Ring Segment Replacement

NOTE: The following steps refer to drawings SD-110-01596 and D-

NOTE: Apply anti-seize compound to all fasteners and torque all
fasteners per drawing B-GP-2175 unless otherwise noted.

1. Isolate the pulverizer.
3. Open the separator body access doors.
4. To provide access to the bowl, remove at least one journal opening cover and journal
roll and shaft assembly as described in General Disassembly.
5. Unbolt and lower the vane wheel segments into the millside.

NOTE: The two hex socket set screws installed in each bowl
extension ring segment. These can be used as jacking bolts during
the removal process. Cut or break tack welds on end shims as needed.

6. Unbolt and remove the bowl extension ring segments.
7. Remove the old bull ring segments.
8. If undamaged, leave the bull ring clamping ring in place. If damaged, unbolt and
remove the bull ring clamping ring.
9. Clean all interior surfaces of the bowl.
10. Replace any damaged components.

NOTE: If the bull ring clamping ring was not removed, skip steps 11
through 14.

11. Install one of the bull ring clamping ring segments.
a. Apply Loctite 271 to the hex socket head cap screws for that segment.
b.Insert the hex socket head cap screws and washers and torque each screw to 34.5
kg-m (338 Nm), one half of the value specified on SD-110-01596
c. Torque the cap screws again to the full value, 69 kg-m (676 Nm).

12. Repeat step 11 until all of the bull ring clamping ring segments are fastened in place.
13. In the same order that, the screws were torqued in step 11, repeat the torquing
procedure to verify that the socket head cap screws are torqued to the specified
value, 69 kg-m (678 Nm).

NOTE: Bull ring segments are numbered for sequential installation.
Segment 1 is keyed to the bowl.

If ribbed segments are used, they should be spaced at approximately
equal angular increments. Ensure that no two ribbed segments are
spaced exactly 120 apart.

COMPONENT SERVICING
2

14. Arrange the bull ring segments on the bowl in numbered sequence starting with the
keyed segment number 1 and proceeding clockwise.
15. Push the segments downward into the bowl as far as possible against the clamping
ring and firmly butt them against each other.

NOTE: Bull ring segment shims should be inserted at points equally
spaced around the perimeter of the bowl with no more than one shim
between segments. DO NOT install shims adjacent to a ribbed
segment. Total shim thickness in a complete ring should not exceed
25.4 mm.

16. Bull ring segment shims may be added or removed to make a tight fit. Drive
segments counterclockwise to ensure contact before gauging and fitting the final
shim.
17. Upper surfaces of adjacent bull ring segments should match within 1.5 mm. Mis-
match around the entire perimeter of the bowl must not exceed 3.0 mm.

NOTE: If original bowl extension ring segments are reused, any shims
or weld material left on them must be removed prior to re-installation.

18. Position the bowl extension ring segments on the bowl. When they are properly
seated, (metal-to-metal contact) a 0.038 mm feeler gauge should not fit between the
bowl extension ring segments and bowl at the bowl outside diameter. Additionally,
none of the bull ring segments should touch the bowl extension ring.
19. Install and torque the hex socket head cap screws for a bowl extension ring segment.
a. Apply Loctite 271 to the screws.
b. Install the hex socket head cap screws and washers and torque to 34.5 kg-m (338
Nm), one half of the value specified on drawing SD-110-01596.
c. Torque the cap screws again to the full value 69 kg-m (676 Nm)
20. Repeat step 19, a to c until all of the bowl extension ring segments are fastened in
place. Check clearance per step 18.
21. In the same order that the screws were torqued in step 19 c, repeat the torquing
procedure to verify the socket head cap screws are torqued to the specified value,
69 kg-m (676 Nm).
22. Replace the hex socket head set screws, after applying anti-seize lubricant. Screws
should be flush to two turns below the surface of the bowl extension ring. Stake the
at two places for each screw.
23. Starting with any one bull ring segment, measure the gap between the center of the
bull ring segment and the bowl extension ring.
24. Select bull ring segment end shims so that the thickness of the shim pack will be
0.00 to 0.38 mm less than the measured gap. Use the minimum number of shims
possible.
25. Drive the shims into the gap between the center of the bull ring segment and the
bowl extension ring.

CAUTION: During all welding procedures, ground each component
individually as close as possible to the point of weld to prevent damage
to any bearings.

26. Bend the shims back until they contact the bowl extension ring. Tack weld them in
place. Refer to drawing D-66-754.
27. Replace the vane wheel segments.

COMPONENT SERVICING

3
28. Use anti-seize lubricant and install and torque the bolts attaching the segments to
the bowl extension ring to 41.5 kg-m (407 Nm). Torque all other bolts per drawing
B-GP-2175. Tack weld washers and bolts to the support lugs after installation.

CAUTION: Before turning the gearbox input shaft by hand, ensure
that the upper oil reservoir of the gearbox has been filled with the
recommended oil to the centerline of the gauge glass.

29. Reinstall the journal roll and shaft assemblies and journal opening covers.

Vane Wheel Servicing

110-01596, unless otherwise stated.

1. To provide access to the bowl, remove a journal opening cover and tilt out all journal
assemblies.
3. Inspect the body liner segment, air restriction segment, and vane wheel segments.
4. Remove and replace body liner segment and air restriction ring segment as necessary.
If new vane wheel segments will not be installed, new wing tips may be installed by
welding them to the wheel vanes.
5. Replace worn vane wheel segments as follows:
a. Break tack welds and remove cap screws and washers from vane wheel support
lugs.
b. Remove the bolt protection piece by carefully grinding or burning out.
c. Unbolt and remove worn vane wheel segments.
d. Fit a new vane wheel segment and install and hand tighten the hex head cap
screws and plain washers holding the segment to the bowl extension ring. Do not
torque the screws at this time.
e. Apply anti-seize lubricant to the hex head cap screws then attach the vane wheel
support lugs to the bowl with the screws and plain washers.
f. Position and weld the support lugs to the vane wheel segments. Torque he support
lug cap screws per B-GP-2175 then tack weld the Washers and screws to the
support lugs.
g. Remove the vane wheel segment cap screws, apply anti-seize lubricant, reinstall
and torque them to 41.5 kg-m (407 Nm).

CAUTION: Before turning the gearbox input shaft by hand, ensure
that the upper oil reservoir of the gearbox has been filled with the
recommended oil to the centerline of the gauge glass.

6. Reweld the bolt protection piece removed in step 5.b. Maintain the gap of 5 mm
between body liner segment and vane wheel segment shown on drawing E-PLVE-
0528. Ensure that the gearbox hydrodynamic bearing is properly lubricated then
manually turn the gearbox input shaft to rotate the bowl. Re-check gap at 45
intervals.
7. Tilt in the journal assemblies and reinstall the journal opening covers.

COMPONENT SERVICING
4

Liner Installation Using Weld Plugs

The following procedures cover installation of liners that cannot be directly welded to the
pulverizer

NOTE: The pulverizers at your installation may not have all liner
variations covered in these instructions.

Equipment Required
The following equipment and materials will be required:
1. MIG or Electric Arc Welder.
2. Masonry saw (Clipper trademark SM 300 or equivalent) for ceramic liners.
3. Diamond blade (Selker Bay State M-1 Bar 500 mm diameter, 2150 RPM or
equivalent) for ceramic liners.
4. Solvent (if required) such as toluene, zylene, or acetone.
5. Weld Plugs.

NOTE: Item 6 and 7 are sent complete from shop in a single unit
container.

6. RTV Adhesive Sealant.
7. Duromar HAR Filler.

Other fill materials such at Moldit D, Nordback, or Devcon Martek may be required to fill
voids between and adjacent to installed tiles. See notes on reference drawings.

Welding Specification - Manual Insert Gas Welding (MIG)
1. Follow standards of the American Welding Society (AWS).
2. Wire rod size: 0.045" diameter.
3. Wire type: AWS-ASTM E605-E or similar.
4. Voltage requirement: 20 to 24 volts.
5. Amperage requirements 180 to 230 amps.
6. Gas rate: 10 CFH.

Welding Specification - Stick Weld, Manual Metal Arc Process
1. Follow standards of the American Welding Society.
2. Electrode: 3/32" or 1/8" diameter E-6011, E-6012 or E-6013; 3/32" diameter E-7014 or
E-7018.
3. Amperage-set near maximum amperage recommended by the electrode manufacturer.

Application of Weld Plugs

Procedures excerpted from drawing B-GP-3843.

WARNING: DURING ALL WELDING PROCEDURES, GROUND
EACH COMPONENT INDIVIDUALLY AS CLOSE AS POSSIBLE TO
THE POINT OF WELD. IF THE WELD IS ON A PART WHICH
ROTATES, GROUND THE WELDING EQUIPMENT TO THE
ROTATING PART TO PREVENT DAMAGE TO ANY BEARINGS.

COMPONENT SERVICING

5
NOTE: Hold a short arc to float molten flux to the top of the weld. Fill
weld plug 1/3 to 1/2 full. Do not overfill.

The following welding procedures are taken verbatim from Section 4.21, 'Plug Welds' of
the American Welding Society Structural Welding Code D 1.1. These procedures should
be adhered to during the installation of any weld plugs.

1. "For welds to be made in the flat position, each shall be deposited around the root of
the joint and then deposited along a spiral path to the center of the hole, fusing and
depositing a layer of weld metal in the root and bottom of the joint. The arc is then
carried to the periphery of the hole and the procedure is repeated, fusing and
depositing successive layers to fill the hole to the required depth. The slag covering
the weld metal should be kept molten until the weld is finished. If the arc is broken or
the slag is allowed to cool, the slag must be completely removed before restarting
the weld.
2. "For welds to be made in the vertical position, the arc is started at the root of the joint
at the lower side of the hole and is carried upward, fusing into the face of the inner
plate and to the side of the hole. The arc is stopped at the top of the hole, the slag is
cleaned off, and the process is repeated on the opposite side of the hole. After
cleaning slag from the weld other layers should be similarly deposited to fill the hole
to the required depth."
3. "For welds to be made in the overhead position, the procedure is the same as for the
flat position, except that the slag should be allowed to cool and should be completely
removed after depositing each successive bead until the hole is filled to the required
depth."

Installation of Tiles and Liners - General

1. Clean the metal surfaces thoroughly. The surface must be free of dirt, dust, oil, rust, or
scale. Clean with solvent. Sandblast or grind if required.
2. Scribe lines to be used as guides to assure proper layout of tiles.
3. The application of the tile should begin with the bottom or lower course. Proper
alignment at this stage is critical. Misalignment here will be compounded as additional
courses of tile are added.
4. Trial fit the tiles; note location of excessive gaps between tiles and mating parts.
Trim tile as required to ensure a snug fit.

NOTE: The purpose of the adhesive sealant cement is to secure the
tile to the steel, and to provide a solid back-up by filling the void
between the tile and steel. Too much cement will make the weld plug
welding difficult (or impossible) and reduce the cohesive properties of
the product.
5. Using the adhesive sealant cartridge in a caulking gun, apply a thin coat (bead) of
adhesive e to the back of the ceramic tile. Use a thicker coating in areas observed
with excessive gaps Do not apply the adhesive near the weld plug hole. The eventual
weld must not be contaminated with t e adhesive.
6. After the first course of tile is in place and properly aligned, weld plugs should be
inserted and welded. Use the recommended welding procedure.

CAUTION: During all welding procedures, ground each component
individually as close as possible to the point of weld. The welds should
be made as quickly as possible so that a minimum amount of heat is

COMPONENT SERVICING
6
transferred to the liners. Excessive heat will cause the liners to crack.

7. Continue the attachment of successive courses of tiles. Maintain a check on
alignment with scribed lines. Close adherence to the piece mix in each course count
is essential to minimize openings between tiles. Each piece of tile has a number 1 or
2 embossed on the wear surface. Any special cut pieces are also marked for
identification. Welding of metal plugs other than the first course as described in step 6
can be done after all the tiles have been cemented in place.
8. It may be necessary to cut the last piece of tile in each course.
9. If the closing tile/liner is ceramic, a masonry saw and diamond blade will be required.

10. Open joints should not exceed 1/16" and should be filled with the adhesive sealant
(silicone) cement, such as RTV Sealer, troweled flush with the surface of the liner.

NOTE: RTV Sealer and Duromar HAR requires approximately 24
hours to cure completely, however, both set up rapidly (approximately
1/2 hour).

11. Fill the weld plug holes with Duromar HAR and trowel flush with the surface of the
liner.

Trouble Shooting - Large Gaps Between Tile

Possible cause and remedies are as follows:
1. Improper piece mix - check drawing for proper count and mix.
2. Improper alignment - check scribed alignment lines and correct as required.
3. First (bottom) course has been installed improperly - check against the print provided.
4. Improperly fabricated liners - check print provided.

Trouble Shooting - Tile is Cracking

Possible cause and remedies are as follows:
1. Too much heat - use smaller diameter welding rod. Decrease weld puddle and fill.

Trouble Shooting - Welds Not Fusing

Possible cause and remedies are as follows
1. Area contaminated - burn cement away by heating above 371 C.
2. Surface scale - clean by grinding or sandblasting

COMPONENT SERVICING

7

Liner Replacement

General

NOTE: Refer to the specific segment for reference illustrations and
drawings.

Individual tiles and liners held in place with weld plugs can be replaced as follows:
1. Remove the damaged or worn tile/liner.
2. Clean the metal seating surface, grind off the old weld plugs.
3. Fit the new tile/liner in the area voided by the original. Maintain a clearance of 3 mm
between liners
4. Secure the new liner with adhesive and weld plugs. See "Application of Weld Plugs."
5. After all damaged liners have been replaced, fill the weld plug holes with Duromar
HAR and the spaces between the liners with RTV Sealer. Trowel all surfaces flush.

CAUTION: Protrusions or sharp breaks between liners can cause
eddies and coal/airflow disturbances which will accelerate to wear on
the adjoining tiles.

Separator Body Liners

NOTE: The following steps refer to drawing SE-110-01598, unless
otherwise stated.

1. To provide access to the liners, remove the journal opening covers and tilt out the
journal assemblies.

NOTE: Individual liners can be replaced per Liner Replacement. If it
becomes necessary to install or replace an entire liners, use the steps
below.

2. Install the bottom row of liners starting at the right end. Maintain 105.6 mm, +0.0 mm,
- 3.0 mm clearance from the bottom flange of separator body and allow 3 mm
between the liners. At the left end, the liners should be trimmed to overhang the left
end liner. Install weld plugs and weld.
3. Fill all the weld plug holes with Duromar HAR filler and trowel flush.
4. Fill all the gaps between liners with RTV Sealer.
5. Close up the pulverizer by tilting in the journals and replacing the journal opening
covers as described in the General Reassembly Procedures.

Journal Lubrication

Journal Assembly
Each of the three journal assemblies has a self-contained oil bath lubrication system.
Refer to Figure 1. The journals are shipped completely filled with the recommended
lubricant in order to protect the bearings and internal surfaces.
Prior to operation, the oil level in each installed journal must be adjusted to its proper
level for operation. Determine the proper level by using the oil dip stick, measuring
from the bottom of the oil reservoir. If the customer will use a different brand of oil for

COMPONENT SERVICING
8
replacement or make up, replace the oil with customer-supplied lubricant prior to
start up.

NOTE: The journal oil level must be checked periodically (at least
once every 6 months).

CAUTION: Do not overfill the journal assembly oil reservoir. Too
much oil may damage the oil seals.

Notes:
1. A lubricant is acceptable only if the acceptance criteria of the most recent
AGMA Standard for Industrial Enclosed Gear Drives (250.0 X) and the
above specifications are met.
2. EP additives such as molybdenum disulfide, borate, lead napthanates,
chlorides, sulfurized esters, etc., are not recommended.
3. Absolutely no water-based or water-containing lubricants are
recommended for service anywhere in the pulverizer.
4. Change oil in new or rebuilt journals after 400 hours of pulverizer
operation. Thereafter, oil changes should be scheduled every 6 months or
when oil analysis shows signs of breakdown. Drain the oil while warm.
At each oil change, flush the journal assembly oil prior to refilling to the
proper oil level.
5. Toward the end of an oil change interval, an oil analysis by a qualified
laboratory is recommended. Test results will indicate the remaining
lubricant service life.
6. If a pulverizer fire occurs, journal oil should be changed or analyzed by a
qualified laboratory for degradation before returning the pulverizer to
service.
7. Do not mix oil brands or grades.

Fi gure 1

COMPONENT SERVICING

9

Journal Stop Bolt

Lubricant : Heat resistant multipurpose NLGI#2 extreme pressure Lithium based grease with
a 375F minimum drop point, Molykote #33, Dow Corning #33 or Mobilith
#AW2.
Fitting : Grease fitting on the end of each (3) stop bolt
Frequency : Grease initially and after every adjustment

Fi gure 2

Journal Trunnion Shafts

Lubricant: Heat resistant multipurpose NLGI#2 extreme pressure Lithium based
grease with a 375F minimum drop point, Molykote #33, Dow Corning
#33 or Mobilith #AW2.
Fitting: Grease fitting on the end of each (6) trunnion shaft
Frequency: Grease initially and every 6 months

Fi gure 3

COMPONENT SERVICING
10

Major Adjustments

Journal Spring Assembly Preload Procedure

WARNING: THE PULVERIZER MUST BE MECHANICALLY AND
ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND HOT
AIR GATES MUST BE CLOSED AND THE PULVERIZER MOTOR BREAKER
MUST BE OPEN BEFORE RE-MOVAL OF THE INSPECTION HOLE
COVER. ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED.

NOTE: The following steps refer to drawings D-GP-8580 and E-GP-
8101, unless otherwise stated. This procedure can be performed in the
maintenance shop or with the spring assembly mounted on the pulverizer.

NOTE: The HP 1103 pulverizer spring rate is 5,357 kg/cm and the
commissioning preload is 13608 kg or 2.54cm of spring deflection.
Preload may vary depending on final pulverizer adjustments.

NOTE: The J ournal Spring Assembly Preload Tools referred to in this
procedue are supplied by Doosan.

1. The journal spring assembly should be completely assembled
except for the spring stud extension cap, spring stud key, and
connecting fasteners.
2. Measure the extension of the six positioning studs per dimension
"A" on drawing E-GP-8101. All six studs should be extended
from the spring housing cover the same amount to within 0.06".
If this condition does not exist, the studs should be adjusted to
achieve this requirement.
3. Mount the hydraulic cylinder onto the preload fixture using
fasteners.
4. Install the spring preload fixture onto the journal spring assembly.

NOTE: The fixture should be installed providing access to the cotter
pin. It may be necessary to rotate the preload stud or the preload
fixture.

5. Using the hand pump, extend the hydraulic cylinder until it is
approximately 12.7 mm from full retraction.
6. Remove the cotter pin.
7. Install the preload stud, threading it onto the journal pressure
spring stud until it bottoms out. Install the stud washer and hex
nut.

WARNING: TO PREVENT POSSIBLE INJ UYRY OR DAMAGE TO
EQUIPMENT, DO NOT STAND OR WORK IN LINE WITH THE SPRING
ADJ USTING STUD WHILE HYDRAULIC PRESSURE IS BEING APPLIED.

COMPONENT SERVICING

11
8. Preload the spring by pressurizing the hydraulic cylinder to 2,350 psi, +
100 psi (from table of drawing E-GP-81 01 -p/n GP-8101-A.) The pressure
is based on an effective hydraulic cylinder area for (P/N GP-369-A) of
12.73 sq. in. . Note if during commissioning a different spring preload is
used then the pressure would need to be adjusted : [pressure {PSI}=
preload {Ibs}/ 12.73 {in
2
(hydraulic cylinder area)}].
9. Use the locknut wrench to advance the adjustment castle nut until
it contacts the spring stud adapter. If the slots in the castle nut do
not align with the cotter pin hole in the journal spring preload stud, back
off the nut, a quarter turn maximum, until the slot aligns with the hole.
10. Relieve the hydraulic cylinder pressure.
11. Check the preload by reapplying the hydraulic pressure and
recording the pressure at which the nut begins to move away from the
spring stud adapter. The nut should begin to move within +150 psi
of the set value (2,350 psi). A dial indicator can be used to
monitor this movement. If no movement is detected, repeat steps
8 and 9.
12. Release the hydraulic pressure and remove the preload
adjusting stud, hydraulic cylinder and preload fixture.
13. Install the cotter pin and spring housing cover.
14. Set the roll-to-ring clearance. (Refer to detailed procedure)
15. Set journal spring to journal head clearance. (Refer to detailed
procedure)

Ring to Roll Gap

The following procedure uses the journal stop bolt to set the roll-to-ring clearance and must
be performed before the journal spring assembly to journal head clearance is set.

ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD
AND HOT AIR GATES MUST BE CLOSED AND THE
PULVERIZER MOTOR BREAKER MUST BE OPEN BEFORE
REMOVAL OF THE INSPECTION HOLE COVER. ALL PLANT
SAFETY PROCEDURES MUST BE OBSERVED.

NOTES:
1 . The following steps refer to drawing E-PLVE-0528.
2. Apply anti-seize compound to all fasteners and torque all fasteners
per drawing B-GP-2175 unless otherwise noted.
3. The pulverizer must be 100% operational before this procedure can be
done.

NOTE: The HP 1103 pulverizer commissioning ring to roll gap is four flats.
This value may vary depending on final pulverizer adjustments.

1. Open at least one pulverizer separator body access door and clean the
bowl. Vacuum out any residual coal from the bowl.
2. Back out the journal spring adjusting studs 25.4 mm (refer Dwg D-GP-8580) in
order to provide additional clearance between the journal spring assembly
and the journal head.
3.Working with one journal at a time, remove the stop bolt nut fasteners
and retract the stop bolt nut until the journal roll rests on the bowl.

COMPONENT SERVICING
12

NOTE: To ensure that the stop bolt does not rotate during this
process, be sure that the key and stop bolt keeper plate remain in
position.

4. Mark the back face of the roll at the contact point between the bowl
and roll. Label this point "1 ".
5. Raise the roll by turning the stop bolt nut 2 flats
6. Find the high spot on the roll by turning the roll through one full
revolution. If the roll turns through one complete revolution, skip to
Step 8.
7. If the roll cannot be turned through one full revolution, mark the
contact point with the bowl and label "2" and repeat Step 5.
Continue this procedure (5, 6, 7, etc.) until the highest point is
found on the roll.
8. After the roll can be turned through one full revolution, turn the roll
so that the high point of the roll (highest number) is at the 6 o'clock
position.
9. Turn the stop bolt nut two complete revolutions inward in order to
raise the roll away from the bowl.
10. Repeat Steps 3 through 9 for the remaining journals.
11. Once journal adjustments are complete, remove any foreign
material from the bowl area and close the separator body access
doors.
12. Place the pulverizer lube oil system in operation and start the
pulverizer. If any roll is still in contact with the bowl, raise the roll
slightly.
13. Working with one roll at a time, lower the roll (via the stop bolt nut)
until till the first indication of contact with the bowl. Stop at first
indication of contact.
14. Immediately raise the roll via the stop bolt nut four flats (one
revolution with 4 threads per inch thread) of the stop bolt nut.
15. Repeat Steps 13 through 14 for the remaining journals. Stop and
isolate the pulverizer.
16. Secure the stop bolt nut by installing the four fasteners between the
nut and stop bolt keeper plate. If the holes in the nut and keeper
plate do not line up, turn the stop bolt nut clockwise (raise the roll
slightly) so that they can be installed.
17. If not previously done, set journal spring compression. (Refer to
detailed procedure)
18. Set journal spring assembly to journal head clearance. (Refer to
detailed procedure)
19. Close the separator body access doors.

COMPONENT SERVICING

13

Spri ng Assembl y to Journal Head Gap

ELECTRICALLY ISOLATED. THE COAL PIPE GATES AND COLD AND
HOT AIR GATES MUST BE CLOSED AND THE PULVERIZER MOTOR
BREAKER MUST BE OPEN BEFORE REMOVAL OF THE
INSPECTION HOLE COVER. ALL PLANT SAFETY PROCEDURES
MUST BE OBSERVED.

CAUTION: This procedure is used to prevent the spring from
exerting pressure on the stop bolt. This step is performed only after
the springs have been preloaded and the roll-to-ring clearance has
been set.

NOTES:
1. The following steps refer to drawings D-GP-8580, and E-GP-
8101.
2. Apply anti-seize compound to all fasteners and torque all

NOTE: The HP 1103 pulverizer commissioning spring assembly to
journal head gap is 0.0625"(1.6mm). This value may vary
depending on final pulverizer adjustments.

1. Open the separator body access door(s). Vacuum out any residual coal
from the bowl.
2. Verify that nothing is wedged under the grinding rolls by turning each by
hand. If they do not turn, either the ring to roll gap is not correctly set or
there is residual material under the roll.
3. Using two opposite spring adjusting studs, move the spring assembly into
the mill until there is a 1.6mm gap between the spring stud face and the
journal head as shown on drawing E-GP-8101. A 1.6mm shim should be
used to ensure that this gap is maintained.
4. Adjust all 6 spring adjusting studs so that they make contact with the spring
stud adapter. Verify that all 6 studs are positioned correctly by measuring
the stud length extending from the spring housing cover. The stud length
extending should be the same within 1.6mm.
5. Remove the 1.6mm shim and verify the gap.
6. Torque the spring position adjusting nuts per drawing B-GP-2175.
7. Set the spring position on the other two journals.
8. Close the separator body access door(s).

COMPONENT SERVICING
14

Component Maintenance

Journal Openi ng Cover Removal and Instal l ati on

HOT AIR GATES MUST BE CLOSED AND THE PULVER-IZER MOTOR
MUST BE OBSERVED.

NOTES:
1. The following steps refer to drawing E-PLVE-0528.

Removal

2. Remove the seal air piping from the spring assembly.
3. On the back end of the spring assembly, there are eight studs. Back
them out 25.4mm in order to provide additional clearance between
journal spring assembly and journal head . This clearance is
required during the reinstallation process.
4. Lower the journal so the grinding rolls is resting on the bowl by
removing the stop bolt nut and fasteners.
5. Remove the key.
6. Remove the stop bolt .
7. Remove the O-Ring.
8. Rig the journal opening cover thru the two holes in the top. A choker
around the end of the spring assembly with come-along up to the
crane hook for balance may be used. Take up the slack on the
crane.
9. Remove the fasteners and cover.

Install ati on

1. Grease the frame of the separator body with Molykote #33 or
Mobilith #AW2.
2. Rig the journal opening cover. Thru the two holes in the top. A
choker around the end of the spring assembly with come-along up
to the crane hook for balance may be used. Install the journal
opening cover with fasteners.
3. Grease the O-Ring with Molykote #33 or Mobilith #AW2 and install
it in the groove.
4. Install the journal stop bolt. Be sure not to damage the O-Ring which
is in the cover with the threads of the stop bolt.
5. Install the key.
6. Apply anti-seize compound (Fel-Pro #C5A or Molykote #41) to the
threads of the stop bolt.
7. Apply Molykote #33 or Mobilith #AW2 to the face of the stop bolt

COMPONENT SERVICING

15
nut.
8. Install the stop bolt nut.
9. Reset the ring to roll gap. (Refer to detailed procedure)
10. Reset the spring assembly to journal head gap. (Refer to detailed
procedure)

Journal Oi l Replacement

HOT AIR GATES MUST BE CLOSED AND THE PULVER-IZER MOTOR
BREAKER MUST BE OPEN BEFORE REMOVAL OF THE INSPECTION
HOLE COVER. ALL PLANT SAFETY PROCEDURES MUST BE
OBSERVED.

NOTES:
1. It is recommended that the oil in journals be changed with the
journal warm. This will facilitate draining and removal of
contaminates.
2. Refer to J ournal Lubrication System section of this manual for oil
specifications and service recommendations.
3. The journal must be in its normal installed position to perform
the following procedure.
4. The area around the oil fill pipe acts as an air plenum for the
journal oil seal and bearing seal air system. Failure to keep
this area clean will reduce the life of the oil seal and
subsequently cause early failure of the journal bearing(s).
5. The following steps refer to drawing D-GP-9955, D-94-1748
and D-PLVD-0823 unless otherwise noted

2. Remove the journal opening cover inspection hole cover and gasket item
on Dwg D-GP-9955.
3. Remove the journal head cover plate items on Dwg D-PLVD-0823
4. Remove the 1-1/4" pipe plug from the oil fill pipe Dwg D-94-1748.
5. Oil may be siphoned from a journal through the oil fill plug in order to
adjust oil level or continue with the following procedure to drain a journal.

WARNING: EXERCISE CAUTION WHEN THE DRAIN PLUG IS FIRST
REMOVED, WARM OIL COULD BE DISCHARGED IF THE J OURNAL
OIL LEVEL IS HIGHER THAN RECOMMENDED.

6. Rotate the grinding roll three revolutions by hand to mix the oil and stop it
with the drain plug at its highest possible position, near the top of the roll.
This will be above the normal oil level.
7. Assemble a section of flexible hose to a 1" pipe nipple. Provide an oil
receiver, bucket or large pan, with a capacity of more than 13 gallons (50
liter) in the pulverizer bowl.
8. Remove the 1" drain plug, be ready to insert and secure the pipe nipple and
hose.
9. Ensure that the hose end is directed into the oil receiver then rotate the roll
to place the drain at the lowest position.

COMPONENT SERVICING
16
10. When oil is completely drained, rotate the roll
1
/4 turn clockwise.
11. Add to the journal thru the 1" pipe nipple, one quart (approx. 1 liter) of
journal oil, see Pulverizer Lubricants section for oil specification.
12. Ensure that the hose end is directed into the oil receiver then rotate the roll
to place the drain at the lowest position.
13. When completely drained, remove the hose and nipple and replace the
drain plug.
14. Refill the journal with new oil. Refer to Pulverizer Lubrication section for the
oil specification and quantity.
15. Install the 1-1/4" pipe plug in the oil fill pipe.
16. Clean the mating surfaces of the journal head and cover plate, apply RTV
sealer, and install the plate.
17. Install the journal opening cover inspection hole cover and gasket.

Journal Oil Seal Replacement

AND HOT AIR GATES MUST BE CLOSED AND THE PULVER-IZER
MOTOR BREAKER MUST BE OPEN BEFORE REMOVAL OF THE
MUST BE OBSERVED.

NOTES:
1. It is recommended that the oil in journals be changed when
the oil seals are changed.
2. Refer to J ournal Lubrication System section of this manual for
oil specifications and service recommendations.
3. This procedure is based upon having the journal in its normal
installed position. If additional workspace is required, tilt out
the journal and replace the seals with the journal in the
vertical position.
4. The area around the oil fill pipe and oil seal keepers act as an
air plenum for the journal oil seal and bearing seal air.
Failure to keep these areas clean will reduce the life of the oil
seal and subsequently cause early failure of the journal
bearing(s).
5. The following steps refer to drawing D-94-1747 unless
otherwise noted

J ournal oil seals should be replaced during a J ournal Bearing Replacement
procedure, however, if there is evidence of oil leakage, the oil seals can be replaced
without removing the journal assembly from the pulverizer.

1. Drain the oil from the journal using the J ournal Assembly Oil
Replacement Procedure, steps 1 thru 13.
2. Remove the journal head liner assembly. Set it down on the bowl.
3. Remove the journal skirt assembly.

COMPONENT SERVICING

17

NOTES:
1. The following steps refer to drawing D-94-1748 unless otherwise
noted
per drawing B-GP-21 75 unless otherwise noted.

4. Remove the oil seal keeper .
5. Remove the oil seal access cover.
6. Cut the three oil seals and remove them from the upper journal housing
cover.
7. Rotate the journal and inspect the seal wear ring. If excessively scored,
replacement should be considered.
8. Coat the upper journal housing cover oil seal bore with a small amount of
Molykote 33 or Mobilith #AW2 grease.
9. Pack the new oil seals with Molykote 33 or Mobilith #AW2 grease. Slide
the first seal into the journal housing cover with the lip facing the journal
roll. Be sure to glue the ends of the seal together using the procedure and
adhesive supplied with the oil seal.
10. Slide the second and third oil seals into the journal housing cover with
the lip facing out. Be sure to glue the ends of the seal together using the
procedure and adhesive supplied with the oil seal. Also be sure to pack
the region around the seals with Molykote 33 or Mobilith #AW2 grease.
11. Ensure by inspecting through an access cover that oil seal splits are
staggered (at least 60 apart) and match end to end without overlap.
12. Apply Loctite Sealant 515 to the oil seal access covers and replace them.
Lubricate and torque the access cover fasteners per B-GP-2175.
13. Replace the seal keeper. Install and torque the bolts per B-GP-2175.

NOTES:
1. The following steps refer to drawing D-94-1747 unless
otherwise noted
per drawing B-GP-2175 unless otherwise noted.

14. Replace the journal skirt. Install and torque the bolts per B-GP-
2175.
15. Replace the journal head liner assembly.
16. Complete the remaining steps of the J ournal Assembly Oil
Replacement Procedure, steps 14 thru 18.

COMPONENT SERVICING
18

Journal bearing end play checking

J ournal bearing end play should be checked at two to three year intervals or anytime an
oil sample analysis shows evidence of metal contamination (manganese, nickel,
chromium).

NOTE: Refer to drawings D-94-1748 and C-GP-7711 unless otherwise
noted.

NOTE: J ournal bearing end play can be checked with the journal
assembly in the tilt-out position or the journal roll and shaft assembly
can be removed and placed on a temporary foundation.

1. Remove the journal opening cover and tilt out the journal assembly.
2. Ensure that the journal is secured to the tilt out bracket.
3. Remove the lower journal housing cover.
4. Remove two keeper bolts 180 apart and install eyebolts to the full depth
of the full depth of the threads. Ensure that the shoulders of the eyebolts
are flush with the roll keeper plate surface.
5. Install a chain shackle in each eyebolt and attach a chain sling. The sling
when loaded must clear the journal opening and allow the roll to be
rotated.
6. Rig a chain fall to an 'overhead crane centered above the journal
opening. Attach a sling, and load cell.
7. Mount a dial indicator on the journal housing with the indicator needle
resting on a machined face of the bearing inner race.
8. Rotate the roll several times to be sure that the bearings are properly
seated. Zero the indicator and mark the location of the indicator needle
on the housing.
9. Use the chain fall to apply a load of 6.44 MT. ("Lift Load with Roll",
tabulated on P/N GP-7711-B on drawing C-GP-7711) to the journal
housing roll assembly.
10. Rotate the roll several times to be sure the bearings are properly
seated. Realign the indicator needle with the mark on the journal
housing and record then reading.
11. Lower the roll until there is no load on the load cell. Rotate the housing
several time to seat the bearings. Line up the indicator needle with the
mark on the housing. If the reading is within 0.013 mm the original zero
setting, the measurement is considered accurate.
12. Repeat steps 8 through 11 until two accurate measurements are
obtained.
13. Average the readings and compare the results to the maximum
allowable in the table.
14. If the measured end lay is less than the maximum allowable 0.13mm
then the journal may be returned to service for the next six month
interval.
15. If the measured end pay is greater than the maximum allowable
0.13mm, then the bearing internal clearance must be reset. Refer to
the J ournal Shaft Disassembly Procedure.

NOTE: If the bearing end play was out of specification and will be
reset, it should be set to the specification 0.03 to 0.08mm loose.

COMPONENT SERVICING

19

16. If the bearing end-play was acceptable, tilt in the journal assembly.
17. Check and re-establish the journal oil level, 343 to 394 mm measured
on the oil dip stick.
18. Re-install the journal opening cover.

Journal Bearing Replacement

MUST BE OBSERVED.

NOTES:
1. The following steps refer to drawing, D-94-1747.
3. It is not necessary to remove the grinding roll from the journal
hosing to replace the journal bearings. If the roll is worn and
needs replacement, it can be replaced as per the procedure in
another section of this manual.

This procedure is best performed if the journal shaft assembly is removed from
the mill and taken to a maintenance shop. This procedure can be performed
with the journal shaft assembly still attached to the journal head, which is still
in the mill. If it is done on the mill, cleanliness and accuracy of the bearing set-
up may be compromised.

Journal Shaft Assembly Removal

2. Remove the journal opening cover.
3. Drain the oil from the journal assembly using the procedure in the section of
this manual titled J ournal Assembly Oil Replacement.
4. Remove the oil fill pipe and fittings. Plug the oil fill port in the journal shaft
with the pipe plug
5. Tilt out the journal. (Refer to detailed procedure and fixture supplied by
Doosan) Be sure that the safety lug is properly installed and secured to the
journal assembly and separator body frame.
6. Remove the journal head liner assembly.
7. Remove the journal skirt assembly.

NOTES: The following steps refer to drawing D-94-1748 unless
otherwise noted. Apply anti-seize compound to all fasteners and
torque all fasteners per drawing B-GP-2175 unless otherwise noted.

8. Remove the grinding roll keeper and grinding roll key.
9. Install the grinding roll removal lug supplied by Doosan; ensure that the

COMPONENT SERVICING
20
bolts thread into the journal housing, not the grinding roll. Refer to
drawing E-GP-6646. The scribe line on the removal lug must face into the
center of the mill. Torque the bolts to 6.9 kg-m.

10. Install a wire rope sling through the grinding roll removal lug.

NOTE: The sling and crane cable must not contact the journal
opening frame when the journal assembly is lifted.

11 . Attach the rope sling to the overhead crane positioned above the center of
the grinding roll. Take up the slack.
12. After removing the fasteners holding the journal shaft assembly to the
journal head, Dwg D-94-1747 item 25, lift the journal shaft assembly off
the journal head and take it to a maintenance facility.

Journal Shaft Assembly Disassembly

NOTE: Fabricate a foundation plate and mount it on the floor in a
maintenance area. This foundation plate (supporting platform) will
be used for journal shaft disassembly as well as journal bearing
endplay checking. It must be capable of withstanding a lift load of
6,441 kg without movement. The plate should be at least three
inches thick, have a thru center hole which is 435mm in diameter
and have equally spaced holes 1.250"-7 UNC tap on 508mm
DBC. The plate should be at least 914mm OD or square. A rim
around the plate to retain oil is recommended. Refer to Dwg C-GP-
7711 (flanged shaft design)

1. Secure the shaft assembly to the foundation plate.
2. Unbolt and remove the lower journal housing cover. Discard the O-Ring.
3. Unbolt the oil seal keepers and remove them.
4. Remove and discard the three oil seals. As the seals are removed, some
residual oil may spill; be prepared for clean up.
5. Unbolt and remove the two journal housing liners.
6. Unbolt the upper journal housing cover and let it slide down to rest on the
seal wear ring. When the O-ring seal loosens, some residual oil may spill;
be prepared for clean up. Discard the O-Ring.
7. Continue disassembly of the journal shaft by unbolting and removing the
journal bearing keeper, cap screw lock plate, and bearing keeper shims.

NOTE: The inner race of the upper and lower journal bearings was
a line to line / loose fit at original installation on the journal shaft.

8. Using a suitable puller, remove the inner race of the lower journal bearing
from the journal shaft.
9. Attach lifting equipment, eyebolts and sling, to the journal housing. Lift the
journal housing off the journal shaft. The upper and lower bearing outer
races will remain inside the journal housing.
10. Using a suitable puller, remove the inner race of the upper bearing and
spacer from the journal shaft.
11. Lift off the upper journal housing cover .
12. Using a suitable puller, remove the seal wear ring from the journal shaft.

COMPONENT SERVICING

21

NOTE: The outer races of the upper and lower journal
bearings are a tight fit at original installation in the
journal housing.

13. Use a suitable puller to remove the upper and lower bearing cup
assemblies from the journal housing.
14. Clean and inspect all components to determine required replacements.

Journal Shaft Assembly Reassembly

NOTE: Do not use split oil seals when rebuilding a journal
assembly. Use only solid oil seals.

1. Slide over the shaft the three solid oil seals and set them down on the
flange. Be sure that the two closest to the large flange have the lips
pointing towards the flange and the one farthest away from the
flange has the lip pointing away from the flange. See Figure 4

Figure 4

2. Heat the new oil seal wear ring (10) to 250
F(121) and slide it into

position on the journal shaft (5). The oil seal wear ring must be firmly
seated against the shaft step before it cools.
3. Apply Loctite Sealant 515 to the oil seal access cover (20) and mount
the oil seal access cover to the upper journal housing cover (15).

4. Set the upper journal housing cover (15) down over the journal shaft
(5) and block it up so that the end of the journal housing cover (15)
is at the same elevation as the end of the oil seal wear ring (10).
See Figure 5.

COMPONENT SERVICING
22

Fi gur e 5

5. Grease the O-Ring with Molykote #33 and set in the upper journal housing
cover grove.
6. Slide the journal bearing spacer over the journal shaft with the chamfer side
against the shoulder.
7. Slide the inner race assembly for the upper bearing onto the journal shaft. It
should rest firmly against the bearing spacer.

NOTE: It may be necessary to heat the bearing cone assembly
prior to installation. Do not exceed 200F (93).

8. Chill the two tapered roller bearing outer races down to at least -60F(-
51). Install both races in the journal housing and clamp them in place
until the housing and race temperatures reach equilibrium.

CAUTION: To prevent damage to the bearing, exercise care when
positioning the bearing cup on the rollers.

9. Lower the journal housing assembly onto the journal shaft.

NOTE: It may be necessary to heat the bearing cone assembly
prior to installation. Do not exceed 200
F (93).

10. Install the inner race assembly of the lower tapered roller bearing on the
journal shaft.
11. Attach the bearing keeper to the end of the journal shaft. Hand tighten the
bolts.
12. When the component temperatures are equal, rotate the journal housing at
least five times in each direction to seat the bearing rollers.
13. Remove the bearing keeper and use a depth micrometer to measure the
gap between the end of the shaft and the edge of the lower bearing cone.

COMPONENT SERVICING

23
14. Assemble a shim set 0.00 ~0.05mm more than the measured gap.
15. Install the shims, bearing keeper, and the lock plate, and torque the
fasteners per B-GP-2175.

NOTE: The following steps refer to drawings C-GP-7711, unless
otherwise stated.

16. Install two eyebolts 180 apart on the bearing housing (holes are 1-8
UNC), attach chain shackles and a chain sling. (Note the lift load to be
14,200 lbs(6,441 kgf).
17. Center a crane over the roll and shaft assembly and attach a chain fall,
shackle, sling and load cell.
18. Install three dial indicators onto the bearing keeper plate. Rest the
indicator needles on the machined surface of the journal housing.
19. Rotate the roll several times to be sure that the bearings are properly
seated. Zero the indicators.
20. Number and mark the location of each indicator on the journal housing.
21. Rotate the journal housing five times and return to original indicator
positions. If all indicator readings do not return to zero, repeat step.

NOTE: If fixtures other than eyebolts, shackles, and chain slings are
used in this procedure, add twice their weight to the recommended
lift loads.

22. Using the chain fall, apply a lift load of 14,200 lb(6,441 kgf) ("Lift Load with
Roll", tabulated as P/N GP-771 1-B on drawing C-GP-771 1) to the journal
housing assembly. (Apply a lift load of 10,300 lb(4,672 kgf) if the roll has
been removed.)
23. Rotate the housing several times to be sure the bearings are properly
seated. Align the indicators at their original positions, record the indicator
readings, and average them.
24. Release the load on the journal housing assembly and rotate the housing
several times to seat the bearings. Line up the indicators with their
original marks. All indicator readings must return to zero.
25. Repeat steps 19 through 24 five times and calculate the average of the
averages. This average should be between 0.03mm and 0.08mm, the
recommended initial endplay for new bearings. If the averaged readings
are out of specification, add or subtract shims as necessary and repeat the
bearing endplay check, steps 11 through 15. When the measured endplay
falls within the indicated range, remove the equipment used for checking,
and proceed with the journal shaft reassembly.
26. Grease the lower journal housing cover O-ring with Molykote 33 or
Mobilith #AW2 grease. Install the O-ring and the lower journal housing
cover.
27. Replace pipe plugs in the lower journal housing cover using pipe sealant.
Lubricate and replace set screws in tapped holes; stake four places.

NOTE: If the roll was removed, install a new roll per the "Grinding
Roll Renewal" procedures.

28. Remove the journal shaft from the foundation plate and turn the journal
assembly over so that the lower journal housing cover is sitting on the
floor. Verify that the O-ring is properly positioned between the upper
journal housing and housing cover.

COMPONENT SERVICING
24
29. Fasten the upper journal housing cover to the journal housing.
30. Add to the journal assembly the journal oil thru the port in the end of the
journal shaft. See the section titled Pulverizer Lubrication for additional
detailed information.
31. Coat the journal housing cover upper seal bore with a small amount of
Molykote 33 or Mobilith #AW2 grease.
32. Pack the oil seals with Molykote 33 or Mobilith #AW2 grease.
33. Slide the first seal into the bore with the lip facing into the bore. Slide the
second and third oil seals into the bore with the lip facing out.
34. Install the oil seal keeper.
35. Position and fasten both halves of the journal housing liner to the journal
housing. Install the remaining bolts through the journal housing cover into
the journal housing.
36. Install the grinding roll key.

Journal Shaft Assembly Reinstallation

37. Turn the journal shaft assembly over (weight is 12500 lbs(5.8 MT).) so that
the large flange is down and install the grinding roll removal lug, ensure
that the bolts thread into the journal housing, not the grinding roll. Refer to
drawing E-GP-6646.

NOTE: There is an offset hole in the bolt pattern, which fastens the
journal shaft assembly to the journal head. Be sure that the offset
holes are aligned.

38. Set the journal shaft assembly down on the journal head. Be sure to align
the offset bolt hole.
39. Using a hydraulic torque wrench, pump and drive and torquing pattern
shown in Figure 6, torque the fasteners to 235 kg-m using a three step
sequence of 1.38 kg-m, 138 kg-m and 235 kg-m.
40. Remove the roll removal lug and install the roll keeper plates.
41. Install the journal skirt.
42. Install the journal head liner assembly.
43. Tilt in the journal assembly.
44. Remove the access cover on the back side of the journal head.
45. Remove the pipe plug in the end of the journal shaft and check the oil
level. Add or subtract oil as necessary. See the Pulverizer Lubrication
section of this manual for additional information. Reinstall the oil fill pipe
and fittings and reinstall the access cover.
46. Reinstall the journal opening cover. (Refer to detailed procedure)
47. Reset the ring to roll gap. (Refer to detailed procedure)
48. Reset the spring assembly to journal head gap. (Refer to detailed
procedure)

COMPONENT SERVICING

25

Figure 6

COMPONENT SERVICING
26

Grinding Roll Replacement

AND HOT AIR GATES MUST BE CLOSED AND THE PULVERIZER
MOTOR BREAKER MUST BE OPEN BEFORE REMOVAL OF THE
MUST BE OBSERVED.

NOTES:
1. The following steps refer to drawing D-94-1748, and SE-GP-
6646

This procedure can be performed with the journal assembly in the tilt-out position on
the pulverizer, or the journal roll and shaft assembly can be removed to a convenient
work area.
2. Remove the journal opening covers (Refer to detailed procedure)
3. Tilt out the journal. Be sure that the safety lug is properly installed and
secured to the journal assembly and separator body frame.
4. Remove the grinding roll keeper and grinding roll key refer to Dwg D-94-
1748.
5. Install the grinding roll removal lug, ensure that the bolts thread into the
grinding roll, not the journal housing. Refer to drawing E-GP-6646. The
scribe line on the removal lug must face into the center of the mill. Torque
the bolts to 6.9 kg-m.
6. Install a wire rope sling through the grinding roll removal lug.

NOTE: The sling and crane cable must not contact the journal
opening frame when the journal roll is lifted.

7. Attach the rope sling to the overhead crane positioned above the center of
the grinding roll. Take up the slack.

WARNI NG: THE GRINDING ROLL SHOULD NOT BE HEATED
ABOVE 300F(148). CIRCUMFERENTIAL TEMPERATURE
GRADIENTS SHOULD BE MINIMIZED.

NOTE: The entire roll must be heated evenly all the way through to
permit its removal. Use a contact pyrometer or similar device to
measure the temperature of the grinding roll surface. Temperature
variations around the perimeter of the roll must not exceed
10F(5).

8. Heat the grinding roll with a stress relieving blanket or similar device;
monitor the temperature.

NOTE: As the roll expands due to heating, it should lift off the
journal housing.

COMPONENT SERVICING

27

9. As the temperature of the roll approaches 200F(93), apply a slight load
on the rigging. Maintain a constant heat for approximately 45 to 60
additional minutes to insure that the roll is heated throughout.
10. Once the roll breaks free and lifts clear of the housing, move it away from
the pulverizer to a suitable area to cool.

NOTE: Allow the journal bearing housing to cool before installing a
new roll.

NOTES:
1. If schedule permits, the journal bearing end play should be
checked at this time. Refer to the J ournal Bearing Replacement
Procedure for information.
2. If schedule permits, the journal oil and seals should be replaced.
See the appropriate sections of this manual for the procedures.

11. Clean the mating surfaces of the journal housing and the bore of the new
roll.
12. Install the grinding roll removal lug on the new roll.

NOTE: The entire roll must be evenly heated throughout to allow
installation. Use a contact pyrometer or similar device to measure
the surface temperature. Temperatures around the perimeter of the
roll must vary by less than 10F(5).

13. Install the grinding roll key and torque the hex socket head screws to 42.8
kg-m.
14. Use a stress relieving blanket or similar device to heat the new grinding
roll. Monitor the roll temperature; it should not exceed 200F(93)..
15. Lift the roll and carefully lower it onto the journal housing. Ensure that the
keyway on the roll is in line with the key on the journal housing.
16. Verify that the back face of the roll seats completely on the housing.
17. Remove the wire rope sling and grinding roll removal lug. Immediately
install the grinding roll keeper plates and keeper bolts. Torque the keeper
bolts to 42.8 kg-m.
18. Allow the roll and journal housing to cool to near ambient.

NOTE: If the journal roll and shaft assembly was removed to a
maintenance area for this procedure, it may be reinstalled on the
journal head at this time.

19. Tilt in the journal as per the J ournal Tilt-out Procedure.
20. Check and re-establish the journal oil level. See the section on Pulverizer
Lubrication for details.
21. Install the journal opening covers. (Refer to detailed procedure)
23. Set the ring to roll gap. (Refer to detailed procedure)
24. Adjust the spring assembly to journal head gap. (Refer to detailed
procedure)

COMPONENT SERVICING
28

Trunnion Bushing and Seal Replacement

BREAKER MUST BE OPEN BEFORE OPENING THE ACCESS DOORS.
ALL PLANT SAFETY PROCEDURES MUST BE OBSERVED.

NOTES:
1. The following steps refer to drawing, D-94-1747

1. Using the journal shaft assembly removal procedure found in another
section of this manual, remove the journal shaft assembly.

NOTES:
1. The following steps refer to drawing D-PLVD-0823 unless
otherwise noted.

2. With the journal head in the tilted out position, install three equally spaced
eye bolts into the holes that were securing the journal shaft assembly to the
journal head. Using the maintenance crane, lift up slightly on the journal
head to take its weight off the trunnion bushings. Be sure that the crane
chain / cable is not dragging on the face of the journal opening frame.
3. Remove the trunnion end plates.
4. Pull out the trunnion shafts, and remove and dispose of the O-Rings.
5. Lift the journal head out of the mill and place it on the floor on timbers.
6. Remove the two trunnion bushing retainers and remove and dispose of the
0-Rings.
7. Remove the trunnion bushings .
8. After cleaning the bore of the journal head and bore and OD of the
trunnion bushings, install them into the journal head with anti-seize
compound on the OD of the bushing.
9. Install the trunnion bushing retainers.
10. Lubricate and install the O-Rings with molykote #33 or Mobilith #AW2 in
the trunnion bushing retainer.
11. After cleaning the trunnion shafts, lubricate and install the O-Rings .
12. Set the journal head back in position in the mill. Be sure to install the
retaining bracket under the journal head.
13. Lubricate the OD of the trunnion shafts with molykote #33 or Mobilith
#AW2 and reinstall them. Be sure that the end of the shaft with the pipe
plug in it is installed inboard.
14. Install the trunnion end plates. Be sure that the grease fitting in the trunnion
end plate lines up with the grease hole in the trunnion shaft.
15. Grease the trunnion assembly.
16. Reinstall the journal shaft assembly using the journal shaft assembly
reinstallation procedure found in an earlier section of this manual.

COMPONENT SERVICING

29

Journal Spring Assembly Rebuild

MUST BE OBSERVED.

NOTES:
1 . The following steps refer to drawing D-GP-8580, and E-GP-
8101.
3. Before reassembling of the journal spring, clean and coat
internals with Molykote Metal Protector. Take care not to coat
mating surfaces, threads, plated or bearing surfaces.

This procedure is best performed if the spring assembly is removed from the
mill to a maintenance shop. This procedure can be performed with the spring
assembly still assembled to the mill. However, cleanliness and accuracy of the
bearing set-up may be compromised.

Spring Assembly Disassembly
2. Uncouple the pipe nipple at the spring housing and remove the seal air
piping at the spring assembly.
3. Release the tension on the spring position adjusting stud nuts and retract the
spring position adjusting studs at least 2.0".
4. Remove the spring stud extension cap.

WARNI NG: IT IS ADVISABLE TO RELEASE THE SPRING PRESSURE
BEFORE THE ASSEMBLY IS REMOVED FROM THE J OURNAL
OPENING COVER. USE EQUIPMENT SUPPLIED FOR J OURNAL
SPRING PRELOAD. REFER TO DRAWING E-GP-8101.

5. Bolt the hydraulic cylinder to the spring preload fixture.
6. Remove the spring stud cotter pin and thread the preload adjusting
stud into the journal pressure spring preload stud to the full depth of the
preload stud threads.
7. Attach the preload fixture to the spring assembly; be sure to align a side
opening of the fixture with the cotter pin hole in the spring preload stud.
8. Using the hand pump, extend the hydraulic cylinder until it is within 1/2" of
full extension.
9. Install the flat washer and lock nut, and hand tighten with a wrench. The
nut must thread completely onto the adjusting stud.

NOTE: The HP 1103 pulverizer spring rate is 5,357kg/cm and
the commissioning preload is 13,608 kg. Preload may vary
depending on final pulverizer adjustments.

10. Use the hydraulic pump and extend the hydraulic cylinder to apply pressure

COMPONENT SERVICING
30
to the spring.
11. Pump the hydraulic cylinder pump until the pressure gauge exceeds "P",
165.2 kg/cm
2
(2,350 psi )(from the table on drawing GP-8101, P/N GP-
8101-A) and the spring adjusting castle nut is free.
12. Remove the spring stud cotter pin and back off the spring adjusting castle
nut 2.0".
13. Slowly release the hydraulic pressure on the cylinder. The spring adjusting
castle nut should be loose after the hydraulic pressure is released. If-not,
repeat the process until the spring stud lock nut is fully loosened.
14. Remove the spring preload adjusting fixture.
15. Provide support to the spring assembly and rig for removal.
16. Remove the eight cap screws holding the spring assembly to the door.
17. Using the overhead crane, apply some lift, and slide the spring housing
out of the journal opening cover. Move the spring assembly to a work area.
18. With spring assembly on its side (shop floor or bench), remove the spring
air seal cap and the spring orifice plate. Inspect the orifice plate for wear.
19. Using a fixture or cribbing, stand the spring assembly on the inboard face
of the spring housing flange.
20. Remove spring housing cover.
21. Install an eyebolt into the end of the spring stud and lift the spring stud,
spring adjusting nut, spring stud adapters, and the journal pressure spring
out of the spring housing.
22. Sequentially, remove the adjusting nut , spring stud adapter, spring, and
the second spring stud adapter from the spring stud .
23. Remove the retaining ring and the spring stud bearing .
24. Remove the spring stud bearing from the spring hosing cover.
25. Clean and inspect all components to determine required replacements.

Spring Assembly Reassembly

26. Stand the spring housing on end so the inboard end of the housing is up.
Chill and insert a spring stud bearing into the spring housing. Lock in
place with the retaining ring.
27. Flip the spring housing 180 so that the outboard end is now up. Use a
fixture or cribbing to support the spring housing (by the flange) 6.0" above
the floor.
28. Chill and insert the second spring stud bearing into the spring housing
cover.
29. Assemble onto the spring preload stud; the spring stud adapter, the spring ,
the second spring stud adapter, the spring housing cover and the spring
stud adjusting nut.
30. Install an eyebolt in the end of the spring preload stud. Carefully lift the
assembly and lower it into the spring housing. Take care when guiding the
preload stud through the lower bronze bushing.
31. Install the spring housing cover cap screws, lubricate, and torque per
drawing B-GP-21 75.
32. Turn the spring housing on its side, and install the spring orifice plate and
spring air seal cap. Torque the socket head cap screws per drawing B-GP-
21 75.
33. When ready to mount the spring assembly in the journal opening cover,
coat the bore of the journal opening cover and mating faces with Molykote
#33 grease.
34. Rig to lift the spring assembly. Lift and guide the spring assembly into the
journal cover. Locate the spring assembly and install the eight cap screws.

COMPONENT SERVICING

31
Torque the cap screws per drawing B-GP-2175.
35. Set journal spring compression. (Refer to detailed procedure)
36. Set the roll-to-ring clearance. (Refer to detailed procedure)
37. Set journal spring to journal head clearance. (Refer to detailed procedure)
38. Reinstall the seal air piping and spring stud extension cap.

COMPONENT SERVICING
32

i
TAB 5. COMPONENT LUBRICATION AND MAINTENANCE
SCHEDULES

CONTENTS
TAB 5
TITLE PAGE NO.

1. PULVERIZER MAINTENANCE SCHEDULES ---------------------------------------------- 1
2. PULVERIZER LUBRICATION SCHEDULES --------------------------------------------- 3
GENERAL MAINTENANCE
ii


1
1. PULVERIZER MAINTNEANCE MAINTENANCE SCHEDULE

ITEM REFERENCE ONCE/SHIFT 3 MONTHS 6 MONTHS 12 MONTHS OTHER
Lubrication System
Check oil storage tank level Level gauge
Check oil storage tank temperature 30 to 60 C
Check oil supply temperature 35 to 60 C
Check oil supply pressure 0.9 kgf/cm Min.
Check oil supply flow 173 Liter/min Min.
Check cooling water supply temperature 44C Max.
Check oil filter differential pressure 2 Bar Max.
Check oil filter clean indicator Indicator
Check for oil leaks Visual
Change oil
Change oil filter Or as required
Oil Analysis
Planetary Gearbox
Check upper housing oil level Level Gauge
Check for oil leaks Visual
Check gearbox general condition Visual
Check for any abnormal noise or vibration
Clean / regrease input shaft labyrinth seal
Pyrites Rejects Collection
Check inlet gate normally open Visual
Check for normal reject flow Visual
Check hopper reject level Visual
Pulverizer Body (All Housing External)
Check pressure tap purge air flow (3 points) Gauge Column
Check general condition Visual
Check for any abnormal noise or vibration
Coal Discharge Gate Valves
Check / adjust body packing

2
ITEM REFERENCE ONCE/SHIFT 3 MONTHS 6 MONTHS 12 MONTHS OTHER
Grinding Elements
Check roll journal bearing oil level Dip Stick
Change roll journal oil
Oil Analysis
Check roll journal spring compression Procedure
Check clearance spring to journal head arm Procedure
Check / reset ring to roll clearance Procedure
Replace grindingrolls >5,500 Hours
Re place grindingroll bearings 10 Years
Overhaul roll journal springs 10 Years
Replace bull ring segments
>5,500 Hours
Pulverizer Internals

Inspect millside inlet duct screen
Check / adjust pyrite scrapers

Inspect vane wheel support brackets Procedure
Inspect bowl hub insulation covers
Inspect millside pressure taps
Check bull ring segments wear condition
Check vane wheel wear condition
Check separator body liners
Check inner cone ceramic tile condition
Inspect separator body pressure tap
Check mill outlet thermowells for wear
Inspect / clean water spray nozzles
Check grinding roll wear condition
Check/ adjust deflector blades
Inspect journal and journal head liners
Inspect journal spring stud orifice plate

Gener al

Check / retorque gearbox mounting bolts
Check drive coupling alignment
Check / recalibrate all instruments

2. PLVERIZER LUBRICATION SCHEDULES

1. A LUBRICANT IS ACCEPTABLE ONLY IF THE ACCEPTANCE CRITERIA OF THE MOST RECENT AGMA STANDARD
FOR INDUSTRIAL ENCLOSED GEAR DRIVES #250.OX AND THE ABOVE SPECIFICATIONS ARE MET.

2. EP ADDITIVES SUCH AS MOLYBDENUM DISULFIDE, BORATES, LEAD NAPTHANATES, CHLORIDES, SULFURIZED
ESTERS, ETC. ARE NOT RECOMMENDED. CONSULT EQUIPMENT MANUFACTURER FOR EXCEPTIONS NOT
LISTED.

3. ABSOLUTELY NO WATER BASED OR WATER CONTAINING LUBRICANTS ARE RECOMMENDED FOR SERVICE
ANYWHERE IN THE PULVERIZER.

4. DRAIN THE GEAR CASE J UST AFTER THE EQUIPMENT HAS BEEN SHUT DOWN, WHILE LUBRICANT IS WARM. THIS
AIDS IN A MORE COMPLETE REMOVAL OF THE DETERIORATED OIL AND ACCOMPANYING CONTAMINANTS.

5. CHANGE OIL IN NEW OR REBUILT J OURNALS AFTER 400 TO 1000 HOURS OF PULVERIZER OPERATION. DRAIN THE OIL
WHILE IT IS WARM. EACH OIL CHANGE, FLUSH THE ASSEMBLY WITH NEW J OURNAL OIL PRIOR TO REFILLING IT TO
THE PROPER OPERATING LEVEL.

6. TOWARD THE END OF A CHANGE INTERVAL, AN OIL ANALYSIS BY A QUALIFIED INDEPENDENT LAB IS RECOMMENDED.
TEST RESULTS WILL INDICATE THE REMAINING LUBRICANT SERVICE LIFE AND THE GENERAL CONDITION OF
BEARINGS AND GEARS.

7. IF A PULVERIZER FIRE OCCURS. J OURNAL OIL SHOULD BE CHANGED OR ANALYZED BY A QUALIFIED INDEPENDENT LAB
FOR DEGRADATION BEFORE PUTTING THE PULVERIZER BACK INTO SERVICE.

8. MOBIL OIL LUBRICANTS LISTED, CUSTOMER TO SUPPLY AND RECORD IF DIFFERENT.

9. DO NOT MIX OIL BRANDS OR GRADES.

10. OIL TO BE APPROVED BY GEAR BOX ASSEMBLY VENDOR
LUBRICANT SPECIFICATIONS
1,3
QUANTITY OF LUBRICANT REQUIRED
VISCOSITY HP PULVERIZER SIZE
CTS SSU
LUBRICANT
SERVICE
AGMA
NUMBER
ISO
VISCOSITY
GRADE
40C 100C 100'F 212F
POUR
POINT
F
EP TYPE
ADDITIVE
TYPE OF
FITTING
963-1103
CHANGE
6
FREQUENCY
OF
OBSERVATION
REMARKS
LITERS / (GALLONS) APPROXIMATE. REFER
TO GEAR BOX MANUFACTERS INSTRUCTIONS
FOR SPECIFIC RECOMMENDATIONS
6EP,1 320
268-
352
21.8
26.4
1505-
1840
108
129
+10
MAX.
SULFUR
PHOSPHORUS
2
PULVERIZER
PLANETARY
GEAR BOX
ASSEMBLY
10

NAME OF CUSTOMER'S LUBRICANT
8,9
MOBIL GEAR #632
OIL. TANK
RESERVOIR
FILL PIPE
1030 (265)
9 TO12
MONTHS
4,6,9
ONCE DAILY
CHECK GAUGES,
UNES AND
HEADERS
SHIPPED WITH PRESERVATIVE OIL FLUSH
AND FILL WITH OPERATING OIL BEFORE
START-UP. SEE MANUFACTURERS INSTRIJ CIIONS
CHECK TEMPERATURE, PRESSURE, FILTER FLOWS
AND OIL LEVEL DAILY. MAKE INITIAL OIL CHANGE
AFTER 1000 HOURS OF OPERATION
OIL FOR STORAGE, LITERS/(GALLONS) APROXIMATE
86.5(23)
OIL FOR OPERATION LITERS (GALLONS)
APPROXIMATE
49(13)
COLD (21C/70F) OIL LEVEL ,MILLIMETERS
343 TO 394
HOT (82C/180F) OIL LEVEL, MILLIMETERS
8 EP 1 680
612-
748
32.1-
41.1
3261-
3988
155-
191
+20
MAX
SULFUR
PHOSPIN DRUS 9
JOURNALS
NAME OF CUSTOMERS LUBRICANT MOBILGEAR
8,9
MOBILGEAR #636
RESERVOIR
CAP ON
J OURNAL
SHAFT
394 TO 445
9 TO 12
MONTHS
4,6,9
CHECK WHEN
ACCESSIBLE;
AT LEAST
EVERY 3
MONTHS
AT ASSEMBLY EACH J OURNAL IS FILLED WITH
AN OIL SUITABLE FOR SERVICE. CHECK THAT
THE ASSEMBLY REMAINS FULL DURING STORAGE

TO PREVENT POSSIBLE DAMAGE TO THE J OURNAL
OIL SEALS, REMOVE OIL TO THE RECOMMENDED
COLD 21C(70F) LEVEL PRIOR TO START-UP OF
THE PULVERIZER. CONFIRM THE OIL LEVEL IN
THE INSTALLED POSITION
USE A HEAT RESISTING MULTI-PUROPOSE NGLI 82 EXTREME PRESSURE
LITHIUM GREASE WITH A 375F MINIMUM DROPPING POINT
CLASSSIFIER
VANE SHAFT
AND GEAR BOX
LABYRINTH
SEALS
NAME OF CUSTOMER'S LUBRICANT MOSILUX
8,9
MOBILGEAR #EP2
GREASE
FITTINGS
OUTPUT SEALS - AT INITIAL ASSEMBLY AND DURING REBUILDS
INPUT SHAFT SEALS - AT INITIAL ASSEMBLY AND EVERY 2 MONTHS
WIPE ALL GREASE FITTINGS BEFORE AND
AFTER GREASING

03 Maintenence

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

03 Maintenence

Hochgeladen von

Copyright:

Verfügbare Formate

SECTION 3 - HP PULVERIZER MAINTENANCE

F(121) and slide it into

Das könnte Ihnen auch gefallen