Hydraulic Dismounting System For QUADROPOL® QM

Machine manual
en-QM.DMD.002.A
Hydraulic dismounting system for QUADROPOL ® QM²
Code word
Order number
POLYSIUS Order Code (POC)

Machine manual Contents
®
Hydraulic dismounting system for QUADROPOL QM²
Contents
1 Safety 1-1
2 Technical data 2-1
3 Components and mode of functioning 3-1
3.1 Components 3-1
3.2 Mode of functioning3-4
4 Transport and assembly 4-1
4.1 Transport and storage instructions 4-1
4.2 Assembly 4-1
5 Lubrication 5-1
6 Commissioning 6-1
6.1 Checks prior to the test run 6-1
6.2 Test run of the hydraulic system 6-2
7 Operation 7-1
8 Maintenance 8-1
8.1 Safety instructions 8-1
8.2 Inspection 8-2
8.3 Servicing 8-2
8.4 Repair 8-3
9 Trouble shooting 9-1
10 Spare parts10-1
11 Appendix 11-1
11.1 Subsuppliers' documentation 11-1
en-QM.DMD.002.A
Machine manual Safety
®
Hydraulic dismounting system for QUADROPOL QM² 1
1 Safety
IMPORTANT
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.
Use
● The hydraulic dismounting system for the QUADROPOL ® QM² is a component

of the QUADROPOL® QM² roller mill.
Be sure to comply with the specifications on the intended use in the 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 observance of the instructions in the machine
manual and 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 gear and load-carrying equipment which is in
serviceable order, has been checked and has a sufficient load-bearing
capacity. Select the attachment points correctly in compliance with the
relevant regulations and rules of engineering.
● Never work under a suspended load.
● Cordon off the working area and the access points.
● When using scaffolds, comply with the relevant regulations.
● Electrical equipment has to be selected to suit the conditions on site. When
working with electrical equipment and operating electrical systems ensure that
they are used as intended, so that any potential hazards are avoided.
● If possible, do not transport the roller unit after the unit has cooled down to
less than 0°C. However, if transport is absolutely necessary, operate the crane
installation with utmost caution. Shocks and sudden loads must be avoided in
all cases.
Operation
● Any safety checks before or during operation depend on the relevant national
regulations. Ensure that these safety checks are performed and recorded.
● If changes in the machine or its operating behaviour occur that are relevant to
safety, shut it down immediately.
● Always wear hearing protectors in the vicinity of the mill.
Maintenance
● Be sure to comply with the safety instructions in the machine manual for the
roller mill and in the subsuppliers' documentation.
en-QM.DMD.002.A
Safety Machine manual
2 Hydraulic dismounting system for QUADROPOL® QM²
● Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily inflammable substances to clean the
machine.
● Before performing any work inside the machine, you have to obtain the written
permission of the plant manager and shut down the plant section in which the
machine is installed.
● Make absolutely sure 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.
● Make absolutely sure that the flow of material is stopped for the entire
duration of the maintenance work.
● Disconnect the power supply of all electrical components before beginning
any maintenance work.
● Make absolutely sure that all parts of the machine have come to a complete
standstill before you remove any protection devices or open any covers.
● Make absolutely sure that all moving parts are protected against accidental
contact.
● Before performing any work on the machine, make absolutely sure that there
is no danger of suffering burns when touching the machine. Before opening
any inspection and service covers make absolutely sure that there is no hot
material left inside the machine.
● Make absolutely sure that all piping is depressurised.
● Make absolutely sure that no hot gases can enter the interior.
● After shutting down the grinding table drive wait until it has come to a
complete standstill. Reverse rotation of the grinding table up to ¼ of a full
rotation is possible.
● Whenever the mill is shut down, wait until it has swung to a complete stop and
then secure it.
● Before inspecting the machine, remove all incrustations, loose wear protection
lining and other materials that could fall or slide down.
● Only use 24 volt lamps to illuminate the interior of the machine.
● Before performing any work inside the machine, make absolutely sure that the
interior has cooled down so far that the personnel will not suffer any burns.
● Directly after the machine has been shut down, the interior of the machine
may only be entered wearing breathing apparatus with independent
ventilation.
● Cold shock due to excessive temperature differences must be avoided, as it
could cause stress cracks in the roller tyres.
● Do not enter the interior without breathing apparatus until it has been
sufficiently flushed with fresh air. Make absolutely sure that there is sufficient
oxygen inside the machine.
en-QM.DMD.002.A
Machine manual Safety
®
● When work is being performed inside the machine, make absolutely sure that
fresh air is supplied continuously (by injection or suction), so that the inhaled
air remains free of noxious constituents. Aeration with pure oxygen is
forbidden.
● Always wear dust protection masks when working in the machine, as intense
dust formation has to be expected.
● The interior of the mill is slippery, use appropriate safety equipment.
● In order to perform maintenance work in the interior of plant sections, you may
have to install stable auxiliary platforms.
Flame cutting, grinding or welding work

● Observe the welding instructions when performing any welding work.
● When performing electric arc welding or cutting work, make absolutely sure
that personnel cannot come into contact with electrically conductive parts. Use
insulated packing plates for this purpose.
● Never set up the welding current source in a confined space having
electrically conductive walls.
● When performing electric welding work on any part of the machine, never
conduct the welding current through sliding or antifriction bearings, other
moving connecting elements or measuring devices. Always directly connect
the welding current return lead to the part being welded.
● Never carry out any electrical or autogenous welding and flame-cutting work
on the grinding table, the grinding track and the roller tyres, as these points
may become starting points of cracks. Never connect earthing cables to these
components either.
Conclusion of maintenance work

● After all maintenance work has been completed, check all joints and
connections for leaks.
● Remount all protection devices when the maintenance work has been
finished.
● Make absolutely sure that no persons are inside the plant component,
properly close the inspection and service covers.
● Make absolutely sure that all signs are complete and distinctly legible. Mount
new signs if necessary.
en-QM.DMD.002.A
Machine manual Technical data
®
2 Technical data
IMPORTANT
Refer to the separate electrical documentation or to the subsuppliers'
documentation for information on the electrical equipment.
Specifications of the intended use

See machine manual of the No.
QUADROPOL® QM² roller mill
Basic data
Year of manufacture
Travel-out cylinder (2.0)

Type
Quantity
Piston diameter mm
Piston stroke mm
Dismounting cylinder (1.0)

Type
Quantity
Piston diameter mm
Piston stroke mm
Dismounting cylinder (optional)

Type
Quantity
Piston diameter mm
Piston stroke mm
en-QM.DMD.002.A
Machine manual Components and mode of functioning
®
3 Components and mode of functioning

3.1 Components
IMPORTANT
Some details of the drawings in this manual may not be identical with the
contract-specific drawings.
en-QM.DMD.002.A
Components and mode of functioning Machine manual
Fig. 1
en-QM.DMD.002.A
Machine manual Components and mode of functioning
®
No. Name Description
1.0 Dismounting cylinder
2.0 Travel-out cylinder with hand pump
A Dismounting cylinder customer's supply
en-QM.DMD.002.A
Components and mode of functioning Machine manual
3.2 Mode of functioning

The hydraulic dismounting system for the QUADROPOL ® QM² roller mill
essentially consists of the travel-out cylinder (2.0) and the dismounting cylinder
(1.0).
With the travel-out cylinder (2.0) for QUADROPOL ® QM² you can move the roller
units of the QUADROPOL® QM² roller mill
Conventional roller units are used for lifting the roller units. The dismounting
cylinder (1.0) has the purpose of keeping the roller unit in balance when it is lifted.
IMPORTANT
For a detailed description of the individual functions, see sections
Commissioning and Operation.
en-QM.DMD.002.A
Machine manual Transport and assembly
®
4 Transport and assembly

4.1 Transport and storage instructions
The machine is transported in individual parts or in subassemblies. Make
absolutely sure that suitable hoisting gear is employed for lifting all the parts from
the transport vehicles and transferring them to the storage area.
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.
4.2 Assembly
Required personnel
To ensure correct performance of the work, only assign repair work to personnel
that have received special training for the tasks to be performed.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required. However, you may need torque wrenches of a
bigger size than normal. Whether or not you need auxiliary equipment, such as
scaffolds or hoisting gear, depends on the operating conditions in your plant.
en-QM.DMD.002.A
Transport and assembly Machine manual
Fig. 2: Sequence of assembly
 Mount the dismounting cylinder (1.0).

 Unscrew the threaded pipe fittings of the oil and hydraulic piping and the
grease supply system for the guide rails.
 Unscrew the anchor bolts for the fixed bearing housing and the tension
frame and take out from below.
 Unscrew the bolts of the mill housing seal.
 Position the dismounting cylinder (A) on the tension frame.
 Lift the tension frame and the fixed bearing housing by means of the
dismounting cylinder (A) and the dismounting cylinder (1.0).
IMPORTANT
The tension frame and the fixed bearing housing must remain in a horizontal
position.
 Install the shifting carriage and place the tension frame on it.
 Install the travel-out cylinder (2.0) and withdraw the roller unit step by step
from the mill housing repositioning the travel-out cylinder (2.0) accordingly.
en-QM.DMD.002.A
Machine manual Lubrication
®
5 Lubrication
IMPORTANT
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 of lubricants gives a
complete list of all manufacturers 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 this 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 general information about the lubrication.
WARNING
Contact with lubricants
Contact with lubricants can cause allergic reaction and skin irritation.
I. Wear personal protective equipment to prevent any contact.
II. Never inhale vapours. Always ensure that the workplace is sufficiently
aerated.
III. Avoid any skin contact. If skin contact has occurred, wash the skin
thoroughly.
IV. Avoid any contact with eyes. If eye contact has occurred, thoroughly
rinse the eyes with large amounts of water and consult a doctor if
necessary.
V. Do not swallow.
VI. Observe the manufacturer's safety data sheet.
NOTICE
Environmental hazard due to improper handling of lubricants
Lubricants such as greases and oils can contain toxic substances. If they
are released into the natural environment, they can harm humans, animals
and plants.
I. Ensure that the environment is not polluted when you store, use and
dispose of lubricants.
II. Be sure to comply with the applicable national regulations for the
protection of the environment when handling lubricants.
en-QM.DMD.002.A
Lubrication Machine manual
Lubrication points Quantity (l, kg) per Lubrication intervals (weeks)

lubrication point
No. Qty. Designation Lubricant Initial Topping up Topping up First Further

ref. no. filling change changes
1 Hydraulic pump 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.
Table 1: Lubrication chart
en-QM.DMD.002.A
Machine manual Commissioning
®
6 Commissioning
IMPORTANT
It is a prerequisite of our warranty that the first test run is carried out in the
presence of specialists from POLYSIUS AG and in accordance with their
instructions.
6.1 Checks prior to the test run

IMPORTANT
It is a prerequisite of our warranty that the first test run is carried out in the
presence of specialists from POLYSIUS AG and in accordance with their
instructions.
After completing the assembly work and prior to the first test run, check all parts
of the plant in accordance with the list below. Make absolutely sure that all
material remnants, tools and assembly appliances have been carefully removed.
1. Have the checks been carried out in accordance with the checklist included
in the separate machine manual for the housing of the QUADROPOL ® QM²
roller mill?
in the separate machine manual for the grinding table of the
QUADROPOL® QM² roller mill?
in the separate machine manual for the drive of the QUADROPOL ® roller
mill?
in the separate machine manual for the roller unit of the QUADROPOL ® QM²
roller mill?
5. Have all the units been freed from preservatives, checked for ease of
movement and mounted in the correct installation position, free of stresses
and easily accessible?
6. Are all pipe unions properly tightened?
7. Have the quick plug-in couplings of the hydraulic hoses between the
hydraulic pump and the dismounting and travel-out cylinders been
completely coupled?
8. Have all hydraulic hoses been properly fastened?
en-QM.DMD.002.A
Commissioning Machine manual
6.2 Test run of the hydraulic system

IMPORTANT
Be sure to also comply with the instructions in the machine manuals for the
roller mill and the individual subassemblies for the test run.
Checks during the test run of the hydraulic system
● Check all piping and pipe unions for leaks.

If faults are found during the test run, it must be interrupted and resumed after the
faults have been eliminated.
WARNING
Hydraulic piping subjected to a high system pressure
Oil spurting out under high system pressure can cause severe injuries.
I. Depressurise the hydraulic system.
II. Retighten leaking connections and pipe unions.
● Fill the hydraulic cylinders with hydraulic oil.

● Vent the travel-out cylinder.
● Vent the dismounting cylinders.
● Upon completion of the test run with depressurised hydraulic system, be sure
to retighten all the screwed pipe joints of the piping system, even if they are
not leaky.
en-QM.DMD.002.A
Machine manual Operation
®
7 Operation
Preparations for starting
● The travel-out cylinder (2.0) and the dismounting cylinders (1.0 and A) are
fully retracted when depressurised.
● The hydraulic power cylinder is also depressurised and is in contact with the
roller axle.
● The travel-out and dismounting cylinders are connected by means of hydraulic
hoses to the hydraulic pump or hydraulic hand pumps.
WARNING
Lifting and lowering rollers
Lifting and lowering rollers can cause severe crushing of the limbs.
Make sure that your hands and feet do not get under the rollers.
 Start the hydraulic pump
IMPORTANT
Make sure that the dismounting cylinders extend parallel and that the roller unit
is lifted.
The dismounting cylinders are jointly controlled.

For the lifting, hydraulic oil is supplied to the piston areas of the dismounting
cylinders.
 Mount the shifting carriage
 Withdraw the roller unit by means of the travel-out cylinder (2.0).
The roller units and the travel-out cylinder (2.0) are coupled by means of pins.
 Completely retract the travel-out cylinder (2.0) after the work.
IMPORTANT
When lowering the rollers, make sure that the dismounting cylinders are
completely retracted.
en-QM.DMD.002.A
Machine manual Maintenance
®
8 Maintenance
8.1 Safety instructions
WARNING
WARNING
Lifting and lowering rollers
Lifting and lowering rollers can cause severe crushing of the limbs.
Make sure that your hands and feet do not get under the rollers.
WARNING
High noise level
The noise level in the working area may cause severe hearing loss.
Always wear hearing protectors in the vicinity of the machine.
IMPORTANT
Never retighten leaking connections and pipe unions while the system is under
pressure. Lead-sealed units may only be opened with the written authorisation
of POLYSIUS AG.
IMPORTANT
After you have completed the repair work, check the machine/plant again in
accordance with section Checks prior to commissioning.
en-QM.DMD.002.A
Maintenance Machine manual
8.2 Inspection
No. Work to be performed Frequency Comments
1 Check the hydraulic system for leakage As required
8.3 Servicing
No. Work to be performed Frequency Comments
1 Maintenance work on the travel-out cylinder (2.0) and See

on the dismounting cylinder (1.0) subsupplier's
information
en-QM.DMD.002.A
Machine manual Maintenance
®
8.4 Repair
Required personnel
To ensure correct performance of the work, only assign repair work to personnel
that have received special training for the tasks to be performed.
Required tools
No special tools are required. However, you may need torque wrenches of a
bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or hoisting gear,
depends on the operating conditions in your plant.
General
Before beginning any repair work switch off the power supply to all electrical
components.
Make sure that the machine has come to a complete standstill before you remove
any protection devices or open any covers.
Ensure absolute cleanliness at all times during the repair work in order to prevent
dirt from entering the bearings, the drives or other sensitive parts of the machine
or plant.
Cordon off the entire working area to prevent unauthorised persons from gaining
access.
WARNING
Further instructions for repair work on the hydraulic system are included in the
subsupplier's documentation. Repair work on the hydraulic system may only be
performed by qualified personnel.
IMPORTANT
Never tighten leaky connections and pipe connections before the hydraulic
system has been depressurised.
When maintenance or servicing work is carried out on the mill, lower the grinding
rollers for safety reasons until the bearing blocks are in contact with the basic gap
spacers (see the sections Commissioning and Operation).
IMPORTANT
After completing the repair work, check the machine/plant again in accordance
with section Checks prior to the test run.
en-QM.DMD.002.A
Machine manual Trouble shooting
®
9 Trouble shooting
IMPORTANT
Consult the subsuppliers' documentation for additional information on faults,
their causes and their elimination.
Malfunction Cause Elimination
Leak in the hydraulic system Bolted connections are loose, ● Retighten the bolted
the hydraulic hose is connections;
defective. ● seal the leak;
● sufficiently bleed the
hydraulic system;
● replace the hydraulic hose.
The hydraulic oil quantity in Leakage in the hydraulic Seal the leak and top up the
the hydraulic pump is too low. system oil.
No pressure or insufficient The hydraulic oil temperature Use hydraulic oil with low
pressure in the hydraulic is too low. viscosity; heat up the
system hydraulic oil.
The hydraulic oil becomes The hydraulic system was ● Seal the leak.
frothy. insufficiently bled or air is ● Bleed the hydraulic
being sucked in through a system.
leak.
● The hydraulic oil has to be
changed.
en-QM.DMD.002.A
Machine manual Spare parts
®
10 Spare parts
For detailed spare parts lists refer to the subsuppliers' documentation.
en-QM.DMD.002.A
Machine manual Appendix
®
11 Appendix
11.1 Subsuppliers' documentation
Dismounting cylinder (1.0)
Travel-out cylinder (2.0)
en-QM.DMD.002.A

Hydraulic Dismounting System For QUADROPOL® QM

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Machine manual

Hydraulic dismounting system for QUADROPOL ® QM²

POLYSIUS Order Code (POC)

● The hydraulic dismounting system for the QUADROPOL ® QM² is a component

Flame cutting, grinding or welding work

Conclusion of maintenance work

Specifications of the intended use

Travel-out cylinder (2.0)

Dismounting cylinder (1.0)

Dismounting cylinder (optional)

3 Components and mode of functioning

No. Name Description

1.0 Dismounting cylinder

2.0 Travel-out cylinder with hand pump

A Dismounting cylinder customer's supply

3.2 Mode of functioning

4 Transport and assembly

Fig. 2: Sequence of assembly

 Mount the dismounting cylinder (1.0).

Lubrication points Quantity (l, kg) per Lubrication intervals (weeks)

No. Qty. Designation Lubricant Initial Topping up Topping up First Further

1 Hydraulic pump In accordance with the manufacturer’s instructions

Table 1: Lubrication chart

6.1 Checks prior to the test run

6.2 Test run of the hydraulic system

● Check all piping and pipe unions for leaks.

● Fill the hydraulic cylinders with hydraulic oil.

 Start the hydraulic pump

The dismounting cylinders are jointly controlled.

1 Check the hydraulic system for leakage As required

1 Maintenance work on the travel-out cylinder (2.0) and See

Malfunction Cause Elimination

Dismounting cylinder (1.0)

Travel-out cylinder (2.0)

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