Hydraulic Drive For POLYTRACK® 2.5 Modules

Machine manual
en-21031.804-E
Hydraulic drive for POLYTRACK® 2.5 modules
Code Word
Order Number
POLYSIUS Order Code (POC)

Machine manual Contents
Hydraulic drive for POLYTRACK® 2.5 modules
Contents
1 Technical data......................................................................................... 1-1
2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-1
3.2 Mode of functioning................................................................................3-12
4 Transport and assembly........................................................................4-1
4.1 Transport and storage instructions...........................................................4-1
4.2 Assembly.................................................................................................. 4-2
5 Lubrication..............................................................................................5-1
6 Preparation for the test run...................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
6.2 Filling the diaphragm accumulator............................................................6-2
6.3 Filling in the hydraulic oil..........................................................................6-3
6.4 Setting the pressures...............................................................................6-5
6.5 Flushing the piping...................................................................................6-7
6.6 Bleeding the piping.................................................................................6-10
6.7 Mounting and setting the position measuring system.............................6-11
6.8 Test run.................................................................................................. 6-12
6.9 Commissioning record............................................................................6-14
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-2
7.3 Trouble shooting.......................................................................................7-3
7.4 Repair....................................................................................................... 7-5
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers’ documentation...................................................................9-1
en-21031.804-E
Machine manual Technical data
Hydraulic drive for POLYTRACK® 2.5 modules 1
1 Technical data
NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers’
documentation.
Specification of the intended use

See machine manual of the cooler...............................................No.
Control system of the hydraulic drive

See operating instructions............................................................No.
Basic data
Year of manufacture............................................................................
Construction size of the cooler..........................................................
Construction size of the hydraulic drive............................................
Required thrust force

Grate 1 (aeration floor 1).................................. kN / transport track
Stroke frequency...............................................................2 to min-1
Stroke length................................................................50 to 220 mm
2
Tank station
Oil cooler (6) and (6a)

Coolant..................................................................................water/air
Power dissipation...........................................................................kW
Water requirement......................................................................l/min
Tank pump (10)

Type....................................................................................gear pump
Delivery rate................................................................................l/min
Pressure.........................................................................................bar
Power of the drive motor...............................................................kW
Feed oil pump (22)

Type....................................................................................gear pump
Pressure to be set at the pressure switch (29)............................bar
Pressure to be set at the pressure valve (30)..............................bar
Control oil pump (23)

Type....................................................................................gear pump
Pressure to be set at the pressure switch (37)............................bar
Pressure to be set at the pressure valve (38)..............................bar
Power of the drive motor for the pump group (22 + 23).................kW
Diaphragm accumulator (33)

Pressurising pressure..............................................................40 bar
Bladder accumulator (48)

Pressurising pressure...............................................................10 bar
Transport track drive, grate 1

Number of transport tracks.....................................................pieces
Main pump (51)

Type........................................................................axial piston pump
Pressure.........................................................................................bar
Pressure to be set (p max.) ..........................................................bar
at the pressure valves in the valve block of the pump
Pressure sensor (68)

Alarm at forward stroke pressure of............................................bar
Alarm at return stroke pressure of...............................................bar
Cylinder (80)
Type.....................................................................differential cylinder
Number..............................................................................................2
Piston diameter.............................................................................mm
Initial parameter setting at operator panel for grate drive - grate 1
Designation Operator panel text Value Unit
Maximum travel speed mm/s

of transport track
Further parameters are stated in the operating instructions Control system of

the hydraulic drive.
4

Main pump (51)

Pressure.........................................................................................bar

Cylinder (80)
Number..............................................................................................2
Maximum travel speed of mm/s

transport track


Main pump (51)

Pressure.........................................................................................bar

Cylinder (80)
Number..............................................................................................2
Maximum travel speed of mm/s

transport track

Machine manual Safety
2 Safety
NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.
Use
 The hydraulic drive is a component of the POLYTRACK® clinker

cooler.
Be sure to comply with the specification of the intended use in
section Technical data.
 Any use other than the intended use is forbidden. POLYSIUS AG
is not responsible for damage resulting from any use other
than the intended use. All other use is at the owner’s own risk.
 The intended use also includes the observance of the
instructions in the machine manual and the compliance with
the maintenance instructions.
Transport and assembly
 All transportation instructions in this machine manual refer

exclusively to transportation of the machine at the plant site.
 Only use suitable hoisting and lifting equipment which is in
serviceable order and has a sufficient load bearing capacity.
 Never work under a suspended load.
Preparation for commissioning
 Do not make any changes (software) to programmable control

systems.
Operation
 Any safety checks before or during operation depend on the

relevant national regulations. The plant management is
responsible for the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant
to safety occur, shut it down immediately.
Safety Machine manual
2 Hydraulic drive for POLYTRACK® 2.5 modules
Maintenance
 Ensure that all machines and motors whose operation might
endanger persons or equipment are switched off and
safeguarded against restarting for the entire duration of the
maintenance work.
 Ensure that all moving parts of the machine have come to a
standstill before you remove protection devices or open flaps.
 Before performing any work on the machine, make sure that
there is no danger of suffering burns when touching the
machine and that no hot material is in the machine when
inspection and service covers are opened.
 Never use gasoline or other easily inflammable substances for
cleaning the machine.
 Switch off the power supply to the electrical components
before commencing any maintenance work.
 The hydraulic system is specially designed for the supplied
machine and may, therefore, not be used for any other machine
without the express consent of POLYSIUS AG.
 Only use hydraulic oil that complies with the requirements in
section Lubrication.
 Make sure that the hydraulic piping is relieved of pressure
before disconnecting it.
 Never empty or fill the oil tank by using pumps of the hydraulic
system that are not specifically provided for that purpose.
 If you drain hydraulic oil at operating temperature, you risk
scalding yourself.
 Only use pure nitrogen and never oxygen for filling the
accumulator.
 After all maintenance work, check that there are no leaks in
connecting points and connections.
 Strictly observe the welding instructions when performing any
welding work.
 If you carry out electrical welding on any part of the machine,
never conduct the welding current through plain or antifriction
bearings, other movable connections or measuring devices.
Always directly connect the welding current return lead to the
part being welded.
Machine manual Safety
 Remount all protection devices and properly close all

inspection and service covers when maintenance work has
been finished.
Machine manual Components and mode of functioning
3 Components and mode of functioning
The hydraulic drive moves the transport tracks of the cooler. It

makes them move back and forth with a stroke length of 50 to
220 mm at a stroke frequency of between 2 and the maximum
stroke frequency per minute which is stated in the technical data.
As the stroke frequency is infinitely variable within the specified
ranges, the specific transport speed of the material to be cooled
on the grates can be adjusted to suit the functioning
requirements of the cooler.
The hydraulic drive operates according to the principle of a
closed circuit, i.e. the driven transport track is fixed by the
cylinders between two pressurised oil columns which are set in
motion by the main pump. In this connection one must distinguish
between the high pressure side - pump delivery direction - and
the low pressure side - pump suction side.
The hydraulic drive is controlled and monitored by an electronic
control system, which is described in a separate manual.
3.1 Components
NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract.
The hydraulic drive consists of the following subassemblies:

 Tank station
 Drive station
 Cylinder unit
 Accessories
 Electronic control system
Components and mode of functioning Machine manual
Items shown in the drawings

1 Oil tank 22 Feed oil pump
2 Oil level sight glass with 23 Control oil pump
integral thermometer
3 Level signal transmitter with 24 Pump support
integrated temperature signal
transmitter
25 Coupling
5 Heating rod 26 Electric motor
6 Oil cooler (coolant: water) 27 Pressure hose
6a Oil cooler (coolant: air) 28 Feed oil filter
7 Valve (water supply) 29 Pressure switch (feed oil) with
digital pressure indication
7a Electric motor (coolant: air) 30 Pressure limiting valve (feed oil)
8 Dirt trap 31 Pressure hose
8a Non-return valve (coolant: air) 32/5 Non-return valve
8
9 Shutoff valve 33 Diaphragm accumulator
9a Shutoff valve (coolant: air) 34 Safety valve block
10 Tank pump 35 Pressure limiting valve
11 Electric motor 36 Control oil filter
12 Coupling 37 Pressure switch (control oil)
with digital pressure indication
13 Pump support 38 Pressure limiting valve (contr.
oil press.)
14 In-line filter 39 Switch box
15 3-way valve (drain connection) 40 Minimess coupler
16 3-way valve (filling spout) 41 Drain cock
17 Non-return valve 42 Minimess hose
18 Non-return valve 43 Throttle valve
19 Non-return valve
20 Pressure hose 48 Bladder accumulator
21 Tank ventilation filter 49 Safety valve block
Supplied loose :
72 Measuring instrument case 76 Suction piping
73 Flushing filter 77 Filling and testing apparatus for
74 Non-return valve diaphragm accumulator
75 Filling hose
Figure 1
Items shown in the drawings
The hydraulic system diagram only shows one drive station.
50 Base frame
51 Main pump
52 Coupling
53 Elastic pump support
54 Electric motor
55 Stop cock (ball valve)
56 Pressure hose
57 Pressure control valve (proportional 3-way pressure
reducing valve)
with integral triggering electronics
59 Pressure hose
60 Pressure hose
61 Fixed throttle
62 Pressure hose
63 Valve block (component of the main pump)
64 Minimess coupler
65 Minimess hose
68 Pressure transducer with digital pressure indication
69 Intermediate plate
70 Switch box
80 Cylinder (differential cylinder)
81 Flush valve with base plate
ST Local/remote selector switch

Figure 2 (shows a POLYTRACK ® with 2 cylinders per transport track as an example)

Design description
Tank station
The tank station is a supporting unit consisting of an oil tank (1)
and various monitoring devices. It has the function of storing and
treating the oil.
Oil tank (1)

The oil tank is equipped with a welded-on oil sump and an oil
drain valve, as well as with all necessary connecting pieces and
fastening devices for all additional equipment.
The oil tank is divided into compartments by an internal partition
that separates the suction side from the return side. This permits
settlement and deaeration of the oil before it is sucked into the
pump again. Any suspended particles in the oil are deposited in
the settling compartment. Each compartment is equipped with an
inspection and cleanout port.
Oil level monitoring

The oil level is monitored by means of an optical and an electrical
indicator. The optical indicator consists of an oil level sight glass
(2), through which the oil level can be observed. The electrical
monitoring equipment consists of a level signal transmitter (3)
with integrated temperature signal transmitter.
Oil temperature monitoring

The oil temperature is monitored by means of an optical and an
electrical indicator. The optical indicator is a thermometer which
is integrated into the oil level sight glass (2). The electrical
indicator consists of a temperature signal transmitter that is
integrated into the level signal transmitter (3).
Oil heating
The oil is heated up by heating rods (5) in the oil tank (1). The
surface temperature of the heating rods remains low enough so
that even if the oil is not being circulated no local overheating of
the oil can occur.
The oil heating system is not necessary in countries in which the
ambient temperatures do not fall below approx. 20 °C.
Oil cooling
The oil cooler (6 or 6a) is installed in the feed oil and control oil
return piping from the drive stations to the oil tank (1). The
standard cooling medium is water, while air is used in special
cases.
The water supply is controlled by a solenoid valve (7). Upstream

of this valve (7) there is a dirt trap (8). The water supply can - e.g.
in case of repair work - be closed by means of the manually
operated shutoff valve (9). During normal operation, the oil
cooling is automatically switched on and off depending on the oil
temperature.
Tank pump (10)

A tank pump is mounted on the oil tank (1) for filling and
emptying it. The tank pump is also used to circulate the oil in the
tank during the heating-up phase and during emergency cooling.
The 3-way valves (15 and 16) enable the respective function.
Oil filter
The in-line filter (14) is equipped with an electrical and an optical
clogging indicator. This in-line filter cleans the oil as it is filled
into the hydraulic system.
Pump group for feed oil and control oil

The feed oil pump (22) and the control oil pump (23) are flanged
together and are driven by an electric motor (26).
The pump group is mounted on or under the oil tank (1). It
centrally supplies all drive stations with feed oil and control oil.
The feed oil pump supplies oil to the main circuit of the drive
station, thus compensating for any oil losses due to leaks and
ensuring a continuous exchange of oil.
The control oil pump supplies oil to the control circuit, i.e. the
pressure control valve (57) and the pump adjusting unit of the
main pump (51).
Diaphragm accumulator (33)

The diaphragm accumulator has the function of keeping the
pressure in the control oil circuit more or less constant during
the pivoting of the discs of the main pump (51). It must be
pressurised to the pressure stated in the section Technical data.
Safety valve block (34)

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

The filter units for the feed oil and control oil circuit are designed
as double in-line filters. They are monitored by an electrical and
an optical clogging indicator.
A 3-way valve is used to switch over to the filter cartridge which
is not in operation while the drive is running, so that a clogged
filter cartridge can be exchanged without difficulty during
operation.
Pressure switches (29 and 37)

The pressure switches monitor the pressure level in the feed oil
and control oil circuit. The switching points are set to the values
stated in the section Technical data.
Pressure valves (30 and 38)

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

A switch box (39 or 70) is mounted on the oil tank (1) and on each
drive station. All electrical equipment belonging to the tank and
the drive stations, except for the electric motors (11, 26 and 54),
are wired to terminals in the switch box.
Bladder accumulator (48)

The bladder accumulator has the function of keeping the
pressure in the feed oil circuit more or less constant during the
pivoting of the discs of the main pump (51). It must be
pressurised to the pressure stated in the section Technical data.
Safety valve block (49)

The safety valve block installed upstream of the bladder
accumulator (48) is a simple way of relieving the pressure on the
oil side of the bladder accumulator during repair work. The
installed pressure valve protects the bladder accumulator against
impermissibly high pressures.
Drive station
The drive station has the function of producing the necessary

volume flow at the necessary pressure for moving the pistons of
the cylinder unit. All components of the drive station are installed
on a common base frame (50) that is mounted on vibration
dampers.
Wherever necessary, flexible pressure hoses are used as
connecting elements, e.g. to compensate for vibrations and to
enable the quick exchange of a complete drive station.
Main pump (51)

The main pump is a reversible axial piston pump. The swash plate
of the axial piston pump is swivelled by an adjusting cylinder. The
pilot control of the pump adjusting unit is performed
hydraulically.
Valve block (63)

The valve block controls the feeding and discharging of oil into
and out of the main circuit. An integral non-return valve
combination assures these functions during the pumping and at
the zero position of the main pump. Two adjustable pressure
valves are installed for limiting the pressure in the main pump.
The valve block is mounted on the housing of the main pump.
Pressure control valve (57) [proportional 3-way pressure reducing
valve]
with integral control electronics
The pressure reducing valve contains two proportional solenoids
for the two pivoting directions of the main pump (51). It
transforms the individual signal from the electronic controller
into a proportional pressure for adjusting the pump. The pressure
reducing valve is mounted directly on the main pump (51).
Pressure transducer with digital pressure indication (68)

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

opposite directions, which are attached by means of shackle
toggles at the piston rod end to the transport track and at the
cylinder bottom end to the grate substructure. The cylinder
chambers at the cylinder bottom end and the piston rod
compartments are connected to the pressure piping A and B of
the main pump (51). These compartments are interconnected by
flushing pipes that are closed by a flush valve (81). All pressure
piping connections of the cylinders can be closed with ball valves
so that the cylinders can be dismounted.
Figure 3
A = forward stroke
B = return stroke
C = position measuring system
D = transport track
E = grate substructure
F = flushing pipe
Cylinder (80)
The cylinders are commercially standard differential cylinders
with shackle toggle fastenings and radial plain bearings at both
ends.
Flush valve (81)

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

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

automatically. The functional sequences are electronically
controlled and monitored.
For commissioning and maintenance purposes, all the functions
can also be operated manually.
This section only describes the movement of one transport track,
but this description applies for all the transport tracks. The
interaction of all transport tracks, which is necessary for the
transport of the material being cooled, is described in the
separate manual for the control system and for the cooler.
Main circuit
The pistons of the cylinder unit are moved by the main pump (51)
via the main circuit.
When the discs of the main pump (51) are pivoted, the created
volume flow moves the piston of the cylinder (80) forward. The
load due to the machine causes a corresponding high pressure to
build up in the feed pipeline. The oil which is displaced by the
opposite cylinder flows back to the suction side of the main pump
via the return piping. There is a low pressure in this piping. The
size of the disc pivot angle determines the volume flow and thus
the speed of the pistons.
When the discs of the main pump (51) are pivoted back via the
zero position in the opposite direction, the volume flow is initially
throttled and then built up again in the opposite direction. At the
same time, the high pressure and low pressure sides, i.e.
pressure and suction sides of the main pump are reversed. The
pistons are thereby moved backwards.
The feed and return piping of the main circuit are both protected
by pressure limiting valves in the valve block (63). In the event of
an overload, the corresponding pressure limiting valve causes a
short-circuit of oil to the low pressure side.
The unavoidable oil losses due to leaks in the main circuit are
compensated by the feed circuit. In addition, the surplus oil due
to the input from the feed circuit is discharged from the main
circuit into the oil tank to be cooled and filtered.
The constant flow of oil delivered by the feed oil pump (22)
passes through the feed oil filter (28) and into the valve block
(63). Here, the feed valves feed the oil into the corresponding low
pressure side of the main circuit The difference between the
quantities of feed oil and leak oil is discharged via a discharge
valve in the low pressure side. The downstream pressure limiting
valve (30) ensures a minimum pressure in the feed oil circuit and
in the respective low pressure side of the main circuit.
Control circuit
The control circuit supplies the adjusting unit of the main pump
(51) with the required control oil. The oil delivered by the control
oil pump (23) passes through the control oil filter (36) to the
pressure control valve (57) and to the pump adjusting unit. The
excess oil flows back to the oil tank via the pressure limiting
valve (38). The pressure set on the pressure limiting valve
assures reliable control of the main pump.
Operation
Working cycle
One working cycle consists of a forward stroke and a return
stroke of the transport track. It always starts with the forward
stroke from the back final position and ends with the return
stroke into the rear end position.
The control system sends the pressure control valve (57) a signal
defining the direction and speed of the movement to be
performed by the pistons. The pressure control valve converts the
signal into a proportional pressure which acts on the adjusting
device of the main pump (51) and makes the pump’s discs pivot
accordingly.
Coming from the zero position, the main pump (51) constantly
increases the volume flow, so that the transport track, which
follows a ramp function, is accelerated to the operating speed.
The movement of the track is controlled over the entire stroke
distance by means of the installed position measuring system.
Towards the stroke end, the discs of the pump are pivoted back
following a ramp function and the braking phase of the transport
track movement is initiated.
When the pump is in zero position, the transport track stops in
the end position of the set stroke distance.
The return stroke is performed identically, except that the discs
of the main pump (51) are pivoted in the opposite direction.
Flushing cycle
To ensure an exchange of oil in the long pipes between the drive
station and the cylinder unit during the manufacturing process, a
flushing cycle is started at regular intervals.
For the flushing process, the transport track is moved into the
mechanical return stroke end position and the flush valve (81) is
opened.
The flushing time is permanently set to 10 seconds in the
electronic control system.
The flushing intervals can be freely selected on the operator
panel. The standard time for one interval is 30 minutes.
A flushing cycle is performed before each start of continuous
operation.
Monitoring devices
During operation, the following functions are continuously
monitored and any faults are shown as text on the display of the
operator panel and in the master control system.
See the operating instructions
Control system for POLYTRACK® hydraulic drive.
Filter clogging indicator

The feed oil filter (28) and the control oil filter (36) are monitored
by an electrical and an optical filter clogging indicator. If the filter
clogging indicator responds, change over to the second filter
cartridge manually and replace the clogged up filter cartridge.
NOTE
The changeover must be completed within 2 hours as, otherwise,
the drive is automatically shut down
Machine manual Transport and assembly
4 Transport and assembly
4.1 Transport and storage instructions
The hydraulic drive unit is delivered ready for installation in

subassemblies and several loose-supplied parts. It must be
ensured that suitable lifting equipment is employed for lifting the
parts from the transport vehicles and transferring them to the
storage area.
The ready-mounted subassemblies are:

 the tank station
 the drive station
 the electronic control system.
Parts delivered individually are:

 cylinders (80)
 flush valve (81) with base plate
 accessories
 piping.
The oil tank (1) has an internal zinc dust priming coat; the
cylinders (80) and the main pumps (51) are filled with slushing oil.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against moisture, soiling and
damage. Never place the parts directly on the ground.
Make absolutely sure that motors, couplings, gear units and
measurement and control equipment are stored in well-ventilated
rooms and protected against moisture.
Transport and assembly Machine manual
4.2 Assembly
General notes
The following assembly instructions do not detail the individual
steps for assembling the machine units but rather give an
overview of the work to be performed.
Changes in the planning of the plant during the processing of the
contract may lead to deviations from these assembly
instructions.
NOTE
It is a prerequisite of our warranty that final assembly and
assembly inspection are undertaken by an assembly specialist
from POLYSIUS AG.
We recommend that the assembly work is supervised from start

to finish by an assembly specialist from POLYSIUS AG.
Careful selection of the tools and appliances as well as the
assembly personnel to be employed is important for the correct
performance of the work.
CAUTION
If you carry out electrical welding on any part of the machine,
never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring
devices, in order to prevent damage to these parts.
Always directly connect the welding current return lead to the
part being welded.
Sequence of assembly
The hydraulic drive must be installed according to the unit
drawing in the location specified in the general arrangement
drawing.
The piping between the drive station and the cooler grate must
be executed in accordance with the drawing ”Hydraulic piping for
POLYTRACK® and the hydraulic system diagram. Make absolutely
sure that the instructions and specifications of the drawing are
precisely complied with.
Ensure absolute cleanliness, especially during final assembly of

the hydraulic piping.
The hydraulic piping must be free from metal chips and dirt
particles. Before installing the pipes flush them with a suitable
cleaning liquid and blow out with clean compressed air.
Transport and assembly Machine manual
Mounting the cylinders

Make absolutely sure that when the transport tracks are moved,
the mechanical stop, which limits the stroke length, is within the
range of the cylinder that causes the stroke.
Proceed in the following work steps:
 Bolt the fork bearing blocks V (B) onto the longitudinal girder
(A). When the bolts are finger-tight, push the blocks in the
thrust direction of the cylinders until there is no play between
the holes and the bolts. Then fully tighten the bolts with the
stipulated torque.
 Bolt the fork bearing blocks H (C) onto the grate substructure
(F).
 Install the first cylinder between the bearing blocks.
 Move the transport track until the piston rod is completely
extended and the piston makes contact with the cylinder head
(E).
 Install the second cylinder with the piston rod completely
retracted. When doing so, check whether the piston rod for
connection to the second shackle toggle joint has to be
extended by 10 mm. This means that the piston of this cylinder
should be located 10 mm before the stop at the cylinder
bottom. If this is not the case, add or remove packing plates
(D) under the fork bearing blocks H.
Figure 4
A = longitudinal girder
B = fork bearing block V
C = fork bearing block H
D = packing plate
E = stop
F = grate substructure
Machine manual Lubrication
5 Lubrication
NOTE
The POLYSIUS table of lubricants with the lubricant reference
numbers is contained in the supplement Important notes on the
documentation. The supplement is contained in this folder or at
the beginning of the overall documentation. Each lubricant has a
unique reference number to which the lubrication instructions in
this section relate. The table gives a complete list of all suppliers
and products approved by POLYSIUS AG.
It is the responsibility of the lubricant supplier to select
appropriate lubricants corresponding to the lubricant reference
numbers. POLYSIUS AG accepts no liability for the correctness of
these data.
If you wish to use a lubricant that is not included in the Table of
lubricants, you have to first obtain the express permission of
POLYSIUS AG.
The supplement Important notes on the documentation also
contains the generally valid Notes on lubrication.
CAUTION
Ensure that the environment is not polluted when lubricants are
stored, used and disposed of and carefully observe the relevant
national legislation for the protection of the environment when
handling lubricants.
Lubrication chart
Lubrication points Quantity (ltr, kg) Lubrication intervals

per lubrication (weeks)
point
No. Qty. Designation Lubricant Initial Topping Topping First Further

ref. no. filling up up change change
s
1 Oil tank 4 as [1] [2]

required
2 Spherical plain 55 0.005 0.005 annually

bearing of the
Lubrication Machine manual
hydraulic cylinder
3 Electric motor In accordance with the manufacturer’s instructions
The different makes of lubricant corresponding to the lubricant reference numbers are shown in the
Table of lubricants in the supplement Important notes on the documentation. The supplement is
contained in this folder or at the beginning of the overall documentation.
Explanation of the numbers

[1] Oil change according to result of oil analysis - First oil analyses must be carried out 1000 operating
hours after first
commissioning.
[2] Oil change according to result of oil analysis - Oil analyses must be carried out every 26 weeks.
Machine manual Lubrication
Instructions for changing the oil

 Pump out the old hydraulic oil using the filling pump (10). To do
so, connect the suction piping (76) to the 3-way valve (15) and
turn the 3-way valve into the illustrated position.
Figure 5
Start the filling pump (10) and pump the oil into a suitable
collecting container. Drain the residual oil in the oil tank (1)
using the drain plug in the bottom of the tank.
 Drain the piping by opening it at the lowest points. These are
normally at the hoses before the cylinders (80) and the main
pumps (51).
It is important to empty all the piping because if old, spent oil
is mixed with new oil, it leads to a premature ageing of the
fresh oil.
 Open the oil tank (1) and clean it.
 After reclosing all openings, fill the system with oil. See
section Preparation for test run under point 6.3.
 Start the feed and control pumps (22 and 23) and the main
pump (51) without pivoting the discs of the main pump (51).
 Using the local inching switch, pivot the discs of the main
pump (51) at intervals in feed direction ”B” (return stroke) with
minimum speed. This fills the piping.
 As soon as the piping has been filled, start the flushing
program with the local switch in order to bleed the system of
air.
(Also see points 6.5 and 6.6 in section Preparation for test run)
 When the oil has reached the operating temperature, you must
check the oil level again and top up with oil to the maximum oil
level if necessary.
Lubrication Machine manual
NOTE
In the case that the POLYTRACK® is equipped with a roll crusher,
you must bleed the suction piping of the pumps of roll crusher’s
hydraulic drive after filling the oil tank (see machine manual of
the hydraulic drive of the roll crusher).
Machine manual Preparation for the test run
6 Preparation for the test run

NOTE
I It is a prerequisite of our warranty that the first test run is
carried out in the presence of and according to the instructions of
specialists from POLYSIUS AG.
6.1 Checks prior to the test run
After completing the assembly work and prior to the first test run,
check all parts of the plant according to the list below. Make
absolutely sure that any material remnants, tools and assembly
aids have been completely removed.
 Has the oil tank (1) been cleaned?
It must be completely free of dirt particles and loose rust! It
must be absolutely dry! For cleaning purposes only use lint-
free cloths, never use cotton waste!
 Was all piping cleaned before installation?
 Has all the piping been correctly installed in accordance with
the circuit diagram?
 Have all the monitoring devices been correctly connected and
are they functioning correctly?
 Have all the electric motors (11, 26 and 54) been correctly
connected and has their direction of rotation been checked?
NOTE
To check this run them only briefly (inching operation)!
The correct direction of rotation is marked on the pumps with an
arrow!
 Has the correct hydraulic oil been provided?

 Have filters with the correct fineness been installed?
 Is the initial parameter setting on the operator panel correct?
(See section Technical data )
 Has the oil cooler been checked for proper functioning and has
sufficient cooling water been provided?
Preparation for the test run Machine manual
NOTE
Prior to the first commissioning, the housing of the feed oil
pump (22) and of the control oil pump (23) must be filled with oil
via their suction or pressure connection. This increases the
operating reliability and prevents wear under unfavourable
installation conditions.
During the first commissioning, drain off the foamy oil by carefully
opening the pressure side flange or the pressure piping (if
necessary, mount a splash guard) while the oil is in absolutely
pressureless circulation. Wait until the emerging oil is free from
bubbles before you refasten the flange with the stipulated bolt
tightening torque.
6.2 Filling the diaphragm accumulator
DANGER
The diaphragm accumulator will explode if you fill it with oxygen.
Your life is in danger.
Always and exclusively use pure nitrogen for filling the piston
accumulators.
You must pressurise the diaphragm accumulator (33) and the

bladder accumulator (48) by filling with nitrogen to the pressure
specified in the section Technical data. For this purpose, use the
supplied filling and testing device (77).
Be absolutely sure to precisely comply with the operating
instructions of the manufacturer for the filling process!
6.3 Filling in the hydraulic oil
CAUTION
During the filling process take care that the suction opening of
the suction pipe is permanently immersed in the oil, in order to
prevent air from being sucked in and the tank pump (10) from
running dry!
Be sure to stop the tank pump before removing the suction pipe
from the oil barrel!
Filling the oil tank:

 Connect the suction piping (76) to the 3-way valve (16) and
insert the pipe that is attached to the suction piping through
the bunghole in the oil barrel.
 Turn the 3-way valves (15 and 16) into the illustrated position.
Figure 6
 Start the tank pump (10). The hydraulic oil is sucked in through
the suction piping (76) and pumped via the 3-way valve (15),
the in-line filter (14) and the oil cooler (6) into the oil tank. Fill
the oil tank up to the upper edge of the oil level sight glass (2).
 Turn the 3-way valves (15 and 16) into the illustrated position.
Figure 7
Filling the piping:

 Detach the pressure hoses from all the differential cylinders
(80) and connect them with one another as shown in the
following Figure, so that the cylinders are uncoupled from the
system.
Figure 8
 Close all the stop cocks (55) in the pressure piping A and B of
the main pumps.
 Open the ball valves at the flush valves (81).
 Dismount the pressure hose (20).
 With the aid of the filling hoses (75), make the connection from
point ”E” to ”G” and from point ”D” to ”F”.
 Start the tank pump (10).
 As soon as the piping is full, stop the tank pump (10).
 You have to repeat this procedure for every transport track
drive.
 When all the piping is full, dismount the filling hoses (75) and
remount the pressure hose (20).
 After all the piping has been filled, you must top up the oil in
the oil tank until it has again reached a level of 3 cm below the
upper edge of the optical oil level indicator (2).
 Reset the local/remote selector switch of the tank pump (10) to
the position ”CENTRAL”.
The filling process is thus concluded.
NOTE
During the oil tank filling process, you must check the electrical
oil level indicator for proper functioning.
When the oil tank (1) is empty, it must indicate the fault ”oil level
min. min.”. As the oil level rises, the indication must change to ”oil
level min.” and must completely disappear when the oil tank is
full.
NOTE
In the case that the POLYTRACK® is equipped with a roll crusher,
you must bleed the suction piping of the pumps of roll crusher’s
hydraulic drive after filling the oil tank (see machine manual of
the hydraulic drive of the roll crusher).
6.4 Setting the pressures
CAUTION
The hydraulic pipes are subjected to a high system pressure.
If oil spurts out, it may injure you or cause a fire.
First depressurise the hydraulic system and only then retighten
leaky connections and pipe unions.
Tank station
 Set the pressure switches (29 and 37) to the value specified in
the section Technical data.
 Undo the counternuts of the pressure setting elements of the
pressure valves (30 and 38). Unscrew the pressure setting
elements by a few turns until the compression springs are
largely, but not completely relieved.
 Start the feed oil and control oil pumps (22 and 23) locally.
 Screw in the pressure setting element of the pressure valve
(38) slowly until the control oil pressure reaches the value
specified in the section Technical data. During the setting
procedure monitor the pressure by means of the digital
pressure indication of the pressure switch (37). After
concluding the setting, secure the pressure valve by tightening
the counternut!
 Screw in the pressure setting element of the pressure valve
(30) slowly until the feed oil pressure reaches the value
specified in the section Technical data. During the setting
procedure monitor the pressure by means of the digital
pressure indication of the pressure switch (29). After
concluding the setting, secure the pressure valve by tightening
the counternut!
NOTE
Normally, this setting to the values specified in the section
Technical data is already carried out during the test run at the
manufacturer’s workshop.
Drive station
 By disconnecting the leak oil piping at the main pump (51),
ascertain whether the pump casing is filled with oil. If there is
no oil in the casing, you must fill it up with oil through this
connection opening.
 Set both pressure valves in the valve block (63) for the
maximum pressure limit at the main pump (51). Unscrew the
pressure setting elements of both pressure valves by a few
turns, so that the compression springs are largely, but not
completely relieved.
 Close both stop cocks (55).
 Start the main pump (51). At the same time, the feed oil and
control oil pumps (22 and 23) must be running.
 Pivot the discs of the main pump (51) by approx. 10%. You can
pivot the discs of the main pump (51) by carefully pressing in
the emergency operation button of the pressure control valve
(57) or better by activating it with the electrical control.
Both stop cocks (55) must meanwhile remain closed!
 With the discs of the main pump pivoted, screw in the pressure
setting element of the first pressure valve until the pressure
value specified in the section Technical data is reached. During
the setting procedure monitor the pressure by means of the
digital pressure indication of the pressure measuring
transducer (68). After concluding the setting, secure the
pressure valve by tightening the counternut!
 Repeat the same procedure for the second pressure valve with
the discs of the main pump (51) pivoted in the opposite
direction.
You have to set the pressure valves in the valve block (63) for
every drive station in accordance with the number of transport
tracks.
When the hydraulic oil reaches operating temperature (approx.
50 °C), and the drive has been in operation for several hours,
you must again check all the set pressures and correct them if
necessary.
NOTE
Normally, this setting to the values specified in the section
Technical data is already carried out during the test run at the
manufacturer’s workshop.
6.5 Flushing the piping
Flushing the piping in delivery direction (B) [return stroke]

 Close the stop cock (55) before connection ”A” of the main
pump (51).
 Install the supplied flushing filter (73) with mounted non-return
valve (74) between ”G” and ”A”.
The non-return valve (74) must be so installed between the
main pump and the flushing filter that the main pump can only
suck in oil through the flushing filter.
Figure 9
 The cylinders (80) remain uncoupled from the piping system,

as described under point 6.3.
 Open the stop cock (55) before connection "B" of the main
pump, and also open the stop cocks at the first bridged
cylinder (80) of the transport track.
 The ball valves at the flush valves (81) must remain open, as
described under point 6.3.
 Starting the flushing process in delivery direction (B)
 Start the feed oil and control oil pumps (22 and 23) locally.
 Start the main pump locally.
 Preselect the pivot angle of the main pump on the operator

panel with the parameter ”Y-MAX”.
 Set the local/remote selector switch (ST) to the position

”FLUSH”.
 Start the flushing in delivery direction (B) with the inching

switch key ”BACK”.
In piping ”B” there must now be a pressure of approx. 50 to
80 bar and in piping ”A” there must now be the correct feed
oil pressure. These pressures are measured directly at the
main pump and you can read them at the digital pressure
indications of the pressure measuring transducers (68).
However, if the measurements show a pressure pmax. in
piping ”A” and the feed oil pressure in piping ”B”, the wrong
flushing direction has been accidentally selected. The main
pump is then pumping against the non-return valve (74).
 During the flushing process be sure to constantly check the
clogging indicator of the flushing filter (73). If the clogging
indicator responds, you must change the filter cartridge.
NOTE
For this purpose, you must interrupt the flushing process and
switch off all the pumps. Change the filter cartridge in
accordance with the manufacturer’s instructions.
If the flushing process is started with cold oil, the clogging

indicator might respond, even though the filter cartridge is
still clean. In this case, you must stop the main pump (51)
briefly as soon as the oil has warmed up somewhat, so that
the clogging indicator no longer responds. When you start the
flushing process again, the clogging indicator must not
respond again.
 After a flushing period of 1-2 hours, open the ball valves at the
second bridged cylinder (80) and close the stop cocks at the
first bridged cylinder (80). Continue the flushing process for a
further 1-2 hours.
 Ending the flushing process in delivery direction (B)
 After a flushing period of 2-4 hours, end the flushing process

by switching the local/remote selector switch (ST) to ”OFF”.
 If an oil contamination analyser is installed, you can end the

flushing process as soon as the oil contamination values do
not decrease any further.
 Switch off the feed oil and control oil pumps, as well as the
main pump.
 Dismount the flushing filter (73).

Flushing the piping in delivery direction (A) [forward stroke]

 Carry out the flushing in delivery direction (A) analogously to
the flushing in delivery direction (B), but connect the flushing
filter (73) between the connections ”F” and ”B” of the main
pump (51).
 After ending the flushing process in delivery direction ”A”,
remove the flushing filter (73). Close the stop cocks at the
cylinders, in order to prevent unnecessary loss of oil and
connect the pressure hoses between the cylinders and the
piping.
 Close the ball valves at the flush valves (81) and dismount the
grips.
 Open all the ball valves in the main piping system.
 Start the feed oil and control oil pumps (22 and 23).
 The feed oil pump (22) delivers oil into the piping system and
builds up the feed oil pressure.
 Set the local/remote selector switch (ST) to the position
”FLUSH”.
 Using the local inching switches, start the flushing process in
delivery directions ”B” and ”A” for about 15 minutes each.
After completion of the flushing program, the piping flushing
process is concluded.
You must carry out the piping flushing process for all further drive
stations, in accordance with the number of transport tracks.
6.6 Bleeding the piping
Air bleed valves and Minimess couplers are installed in the piping
system leading from the main pump (51) to the cylinders (80), as
well as in the connecting piping between the cylinders. These are
installed at the highest points in the respective piping.
To ensure proper functioning of the hydraulic drive, the piping
system must be free from air locks.
 Open the air bleed valves while the feed oil and control oil
pumps (22 and 23) and the main pump (51) are operating but
the transport tracks are stopped and connect a measurement
hose to the Minimess couplers.
You must bleed the oil until it comes out free from bubbles and
without air locks.
 You have to repeat this procedure another 2 to 3 times after
the transport tracks have been tested in continuous operation
for some time.
6.7 Mounting and setting the position measuring system
The position measuring system consists of a sensor (14.10)

and a magnet (14.13)
The measuring range of the position measuring system is 300
mm.
 Install the sensor with its cable connection facing in the
direction of the cooler inlet.
 Install the magnet
NOTE
Only use brass screws for fastening the magnets.
 Make sure that the dimension ”X” for the distance between the
magnet and the sensor is approx. 10 mm. In longitudinal
direction the magnet must move over the total stroke range
along the centre of the sensor.
Figure 10
 Bring the transport track into its return stroke end position.
A value between 20 and 50 mm should be indicated by the
position measuring system.
 If the value is outside these limits, shift the sensor in
longitudinal direction and newly position it.
The stroke length is always measured from the return stroke end
position of the transport track.
Setting the stroke length via the operator panel of the control
cabinet is described in the operating instructions Control system
of the hydraulic drive.
6.8 Test run
After you have completed the work in accordance with point 6.1
to point 6.7, the hydraulic drive is ready for the test run.
NOTE
Detailed information about the use of the operator panel is
contained in the operating instructions Control system of the
hydraulic drive.
You must set the parameters for the transport track control
system on the operator panel in the control cabinet (see
operating instructions Control system of the hydraulic drive).
Test run in continuous operation

 Set a stroke frequency of approx. 8 per minute at a stroke
length of 200 mm and start the hydraulic drive for continuous
operation.
Be sure to check the piping at regular intervals for leaks and
the pumps for unusual running noises.
 After normal operating temperature has been reached, check
all the functions, monitoring devices and interlocks.
 Monitor the oil temperatures and test for proper functioning of
the oil cooler (6), (Cooler on at ”t ≥ 55 °C”, cooler off at ”t ≤ 53
°C”).
Provoke the fault message ”Oil temperature ≥ 57 °C” and the
cutting-out temperature ”t ≥ 60 °C” by shutting off the cooling
water by means of the shutoff valve (9) while the drive is
running.
 To cool down the oil, the tank pump is automatically started.
After cooling down to ”t < 57 °C”, the cooler drive must be
available again.
 You can for switching off due to ”Oil level min. min.” by
disconnecting the cable at the switch box (39) of the oil tank
(1).
 Check the oil pressures in the feed oil circuit and the control
oil circuit.
The oil pressures for the feed oil circuit and the control oil
circuit are monitored by the pressure switches (29 and 37).
Check the proper functioning by setting a slightly higher
pressure than that of the feed oil circuit and, respectively, the
control oil circuit. The drive must then shut down and the fault
must be indicated.
Then you must reset the pressure switches (29 and 37) in
accordance with the specifications in the section Technical

data.
 Check the clogging indicator of the oil filters (28 and 36) by
pulling out the cubic plug. First, a corresponding message
must be transmitted, and after 2 hours the drive must shut
down.
The electrical clogging indicator of the in-line filter (14) only

triggers a message.
When you have checked all the functions, perform continuous
operation for at least 8 hours at a stroke frequency of 8 per
minute. If no fault occurs during this period of operation, the test
run is concluded.
You must then fill in and sign the commissioning record provided
at the end of this section.
Upon completion of the test run, be sure to retighten all the
screwed connections of the piping system, even if they are not
leaky. Only perform the retightening when the system has been
depressurised.
6.9 Commissioning record

Activities Checked:
Checking the piping for tightness everything OK:

yes/no
Oil type used
Set pressures: Feed oil circuit [bar]
Control circuit [bar]
Interlocks checked: Float type switch
(3)
Filter clogging
indicator (14)
Filter clogging
indicator (28)
Filter clogging
indicator (36)
Oil temperature of
different
switching points
Pressure switch
(29)
Pressure switch
(37)
Transport track
Total flushing period [hours]
Max. pressure ”A” [bar]
Max. pressure ”B” [bar]
Place:.......................................... . Date:...................................................
...................................................
Assembly:..................................... Commissioning:.................................
......................................................
Comment:
Place:.......................................... . Date:...................................................
...................................................
Assembly:..................................... Commissioning:.................................
......................................................
Machine manual Maintenance
7 Maintenance
7.1 Inspection
DANGER
The entire cooler is hot.
You may suffer very severe burns!
Wear the proper protective clothing.
No. Work to be performed Frequency Comments
1 Check the piping system for leaks weekly Attention:

Do not reuse
leak oil
2 Check for leaks in the drive stations weekly
3 Check the cylinders (80) for leaks weekly
4 Check the cylinders (80) for normal weekly

movement (reversal, stroke length)
5 Check the piston rods for scoring weekly
6 Check the pumps (22, 23 and 51) for weekly

abnormal running noises
7 Check the oil level in the oil tank (1) weekly
8 Check the control oil pressure weekly
9 Check the feed oil pressure weekly
10 Check the initial nitrogen filling In accordance

pressure of the diaphragm with the
accumulator (33) and of the bladder manufacturer’s
accumulator (48). instructions
When doing so, make sure that the
diaphragm accumulator and the
bladder accumulator are relieved of
pressure on the oil side.
Maintenance Machine manual
11 Check the max. pressure limitation annually

7.2 Servicing
DANGER
The diaphragm accumulator can explode if you fill it with oxygen.
Your life is in danger.
Always use only pure nitrogen to fill the diaphragm accumulator.
No. Work to be performed Frequency Comments
1 Clean the unit every 26

weeks
2 Change the filter cartridges of the according to of the electrical and
oil filters (28 and 36) the display optical monitoring
system
3 Take an oil sample and have it every 26 after the first

analysed by the oil supplier. (Take weeks commissioning:
the sample at the pressure first sample after
connection of the pump) 1000 operating
It must have at least purity class 9 hours
acc. to NAS 1638 or 6 acc. to SAE,
ASTM, AIA or 18/15 acc. to ISO
4406.
The test results must be
documented and made available to
POLYSIUS AG.
4 Relubricate the spherical plain annually
bearing of the hydraulic cylinder
5 Top up the diaphragm accumulator as required
with nitrogen
CAUTION
When the hydraulic drive unit is shut down in the case of danger
of freezing, the water must be discharged from the oil cooler.
7.3 Trouble shooting
If any faults occur, determine the cause with the aid of the
hydraulic system diagram and by exact checking of the entire
system and eliminate the fault.
The most important functions of the hydraulic drive are
electrically monitored during operation. If there are problems
with these functions, an alarm is triggered and/or the hydraulic
drive is stopped. Any faults are displayed as text in the display of
the operator panel.
Fault Cause Elimination
The cylinders (80) The transport track is Check whether pressure is

do not move jammed available;
restore free movement of the
grate
The maximum pressure Set, repair or replace the
limiting valve [in the maximum pressure limiting
valve block (63)] is not valve
building up any pressure
The pressure control Check the electronic control
valve (57) is not system
activated
The pressure control Check the control oil pressure;
valve (57) is not working check the pressure control
valve and replace it if
necessary
The discs of the main Check the adjusting unit of

pump (51) do not pivot the main pump and if
necessary replace the main
pump
The position measuring Check the position measuring
system is not working system and replace if
necessary
The cylinders (80) Air locks in the piping Bleed the system
move erratically
The pressure control Check the pressure valve and
valve (57) is not working replace it if necessary
properly
The oil gets too hot Cooling water failure or Check the cooling water
insufficient cooling circuit, clean the dirt trap (8)
water
Oil cooler (6) defective. Check and repair the oil
Either no water or no oil cooler
passing through the
cooler
Sludge sediments from Clean out the oil cooler (6)
the cooling water are
preventing the heat
transfer
(insulating effect)
Fault Cause Elimination
No control oil The pressure valve (38) Properly set the pressure
pressure or is wrongly set or is valve or replace it if
inadequate control faulty necessary
oil pressure
The control oil pump Check the control oil pump
(23) is faulty and replace it if necessary
The pressure switch Check the setting and replace
(37) is set too high or is the pressure switch if
faulty necessary
No feed oil The pressure valve (30) Properly set the pressure
pressure or is wrongly set or is valve or replace it if
inadequate feed oil faulty necessary
pressure
The feed oil pump (22) is Check the feed oil pump and
faulty replace it if necessary
The pressure switch Check the setting and
(29) is set too high or is replace the pressure switch if
faulty necessary
The pumps (22, 23 The pumps (22 and 23) Check the suction piping for
and 51) make are sucking in an oil/air leaks and seal it
noticeable banging mixture
noises or a very
There are air locks in Bleed the piping system
loud permanent
the main circuit, so that
noise
the main pump (51) is
sucking in an oil/air
mixture
The oil level in the oil Top up the oil; check the float
tank (1) is too low switch (3)
The clogging The filter cartridge of In the case of the feed oil
indicator of an oil the indicated oil filter is filter (28) and the control oil
filter responds clogged up filter (36), switch over the
duplex filter and then replace
the filter cartridge.
In no case is it possible to
clean the filter cartridge!
Oil level min. or oil The oil level in the oil Top up the oil; check the
level min. min. is tank (1) is too low system for leaks and
indicated eliminate these.
If any faults occur which are not described above, consult the
additional information about faults, their causes and their
elimination in the subsuppliers’ documentation.
7.4 Repair
Before beginning any repair work, switch off the power supply to
all electrical components.
DANGER
The entire cooler is hot.
You may suffer very severe burns!
Wear the proper protective clothing.
All parts of the system that are pressurised (piping) have to be

relieved of pressure.
Ensure absolute cleanliness at all times during the repair work in
order to prevent dirt from entering the bearings, the drives, the
hydraulic system or other sensitive parts of the machine or plant.
Do not remove or open any covers or protection devices before all
rotating parts have stopped.
If damage is observed during checks, you must repair the
damaged parts or replace them with new parts.
CAUTION
The hydraulic piping is subjected to a high system pressure.
If oil spurts out, it may injure you or cause a fire.
Depressurise the hydraulic system and tighten the leaky
connections and pipe unions.
When dismounting components of the hydraulic system, ensure

that the oil loss is kept as low as possible. If stop cocks are
installed before and after the point to be repaired, close them to
minimise the oil loss.
Catch the oil that unavoidably runs out in a clean container. If the
quantity is significant, you can return it to the oil tank (1) via the
in-line filter (14).
When disassembling individual components be sure to comply
with the manufacturer’s instructions.
After every repair during which air enters the hydraulic system,
you must bleed and flush the system. (Also see points 6.5 and 6.6
in section Preparation for test run).
CAUTION
After you have completed the repair work you must check the
machine/plant again in accordance with the section Preparation
for test run.

Tools and auxiliary devices
No special tools are required for repair work on the machine.

However, you may need torque wrenches of a bigger size than
normal.
Whether or not you need auxiliary equipment, such as scaffolds
or hoists, depends on the conditions in your plant.
Machine manual Spare parts
8 Spare parts
NOTE
A spare parts list for the hydraulic drive is contained in the
manufacturer’s documentation.
Machine manual Appendix
9 Appendix
9.1 Technical drawings
Designation Drawing no.
Hydraulic drive for POLYTRACK®
Hydraulic accessories
Hydraulic piping for POLYTRACK®
Cylinder
9.2 Subsuppliers’ documentation
Hydraulic drive

Hydraulic Drive For POLYTRACK® 2.5 Modules

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Machine manual

Hydraulic drive for POLYTRACK® 2.5 modules

POLYSIUS Order Code (POC)

Specification of the intended use

Control system of the hydraulic drive

Required thrust force

Oil cooler (6) and (6a)

Tank pump (10)

Feed oil pump (22)

Control oil pump (23)

Diaphragm accumulator (33)

Bladder accumulator (48)

Transport track drive, grate 1

Main pump (51)

Pressure sensor (68)

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

Designation Operator panel text Value Unit

Maximum travel speed mm/s

Further parameters are stated in the operating instructions Control system of

Transport track drive, grate 2

Main pump (51)

Pressure sensor (68)

Initial parameter setting at operator panel for grate drive - grate 2

Designation Operator panel text Value Unit

Maximum travel speed of mm/s

Further parameters are stated in the operating instructions Control system of

Transport track drive, grate 3

Main pump (51)

Pressure sensor (68)

Initial parameter setting at operator panel for grate drive - grate 3

Designation Operator panel text Value Unit

Maximum travel speed of mm/s

Further parameters are stated in the operating instructions Control system of

 The hydraulic drive is a component of the POLYTRACK® clinker

Transport and assembly

 All transportation instructions in this machine manual refer

Preparation for commissioning

 Do not make any changes (software) to programmable control

 Any safety checks before or during operation depend on the

 Remount all protection devices and properly close all

3 Components and mode of functioning

The hydraulic drive moves the transport tracks of the cooler. It

The hydraulic drive consists of the following subassemblies:

Items shown in the drawings

Items shown in the drawings

The hydraulic system diagram only shows one drive station.

80 Cylinder (differential cylinder)

81 Flush valve with base plate

ST Local/remote selector switch

Figure 2 (shows a POLYTRACK ® with 2 cylinders per transport track as an example)

Oil tank (1)

Oil level monitoring

Oil temperature monitoring

The water supply is controlled by a solenoid valve (7). Upstream

Tank pump (10)

Pump group for feed oil and control oil

Diaphragm accumulator (33)

Safety valve block (34)

Control oil and feed oil filters (28 and 36)

Pressure switches (29 and 37)

Pressure valves (30 and 38)

Switch boxes (39 and 70)

Bladder accumulator (48)