Machine manual

en-PQ.CPT.004.C
9 Maintenance
9.1 Maintenance work during operation
9.1.1 Safety instructions
WARNING
Hot surfaces
Components in contact with the material may heat up during operation, as
may bearings and motors. Skin contact with hot surfaces may cause
severe burns.
Always wear personal protective equipment and heat-resistant protective
clothing when working in the vicinity of hot surfaces.
WARNING
Hydraulic energy
Hydraulically operated components may move unexpectedly due to stored
residual energy. If any components are damaged, hydraulic oil can spurt
out under high pressure. This could lead to severe or even fatal injuries.
I. Only allow qualified hydraulics specialists to carry out work on the
hydraulic system.
II. Never alter pressure settings to exceed the maximum values.
WARNING
Escaping hot material
Hot material may escape through leaky points of the machine, or if
inspection covers, service covers or inspection doors are opened during
operation. Skin contact with hot material may cause severe burns.
I. Wear personal protective equipment.
II. Only operate the machine with properly installed and closed inspection
covers, service covers and inspection doors.
III. Only open inspection covers, service covers or inspection doors when
the machine is switched off.
IV. If any leaks occur, immediately shut down the machine, and repair or
replace the damaged components.

Maintenance
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POLYTRACK Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
WARNING
Falling conveyed material
During operation, the material being conveyed can fall off the conveyor
belt at any time or be ejected. This could cause severe injuries.
I. Do not enter danger areas when the plant is in automatic mode.
II. Always wear a safety helmet, safety shoes and protective clothing
when entering the danger area.
WARNING
Rotating parts
If you reach past rotating components, parts of your body may be pulled
in and crushed or severed.
I. During operation, do not reach past or work on rotating components.
II. Do not open any guards or maintenance covers during operation.
III. Shut down the respective functional unit and secure it against
restarting.
IV. Pay attention to after-running time. Before you open any guards or
maintenance covers, make sure that all components have come to a
complete standstill.
WARNING
Moving components
If you reach past moving components, parts of your body may be pulled in
and crushed or severed.
I. Operate the machine only with properly mounted protection devices.
II. Only open protection devices, inspection covers, service covers or
inspection doors when the machine is switched off.
WARNING
High noise level

The noise level in the working area may cause hearing loss.
I. Wear hearing protectors
II. Measure noise emission on-site and introduce further protective
measures as required.
III. Do not spend more time than necessary in the working area.
IV. Take breaks at regular intervals and leave the working area.
Maintenance
POLYTRACK 9-117 Clinker cooler with end-of-cooler crusher
Machine manual
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9.1.2 Prior to any maintenance work
Ensure the following prior to any maintenance work during operation:
Ensure that there is adequate space to perform the work.
Keep the place of work clean and tidy. Components or tools that are loosely
lying on top of each other or lying around on the floor are potential causes of
accidents.
9.1.3 Table of maintenance work
The following sections describe the maintenance work required for optimal and
trouble-free operation of the plant. If increased wear is detected during regular
checks, shorten the required maintenance intervals to suit the actual signs of
wear.
No. Work to be performed Frequency Qualification
of staff
Remarks
1 Check the fans (9.0) See
subsupplier's
instructions.
2 Check the hydraulic drive (7.0) See
separate
machine
manual
3 Visually check for leaks Daily Maintenance

personnel
4 Check the lighting (4.6) for proper
functioning
Daily Maintenance
personnel
Replace defective
lighting (4.6) during
the next plant
stoppage.
Maintenance
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Machine manual
en-PQ.CPT.004.C
No. Work to be performed Frequency Qualification
of staff
Remarks
5 Check the inspection holes (4.5.5,
4.5.6) for cracks
Daily Maintenance
personnel
The glass panes
(4.5.5.1) of the
inspection holes
(4.5.5) can be
changed during
operation.
However, the
glass panes
(4.5.6.1) of
inspection holes
(4.5.6) have to

be changed
during the next
plant stoppage.
6 Check the aeration compartments
(4.1.3) to see if any clinker is falling
into them
Daily Maintenance
personnel
7 Check the upper housing section
(4.2) for burn marks
Daily Maintenance
personnel
Cause: Damage to
the refractory lining
(10.0)
Replace the
refractory lining
(10.0).
8 Check the measuring, control and
monitoring devices for proper
functioning and cleanliness.
Weekly
9 Check the slide plates (2.4) for wear Monthly Maintenance
personnel
(see page 9-119,
Checking the slide
plates for wear)
Maintenance
POLYTRACK 9-119 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
9.1.4 Checking the slide plates for wear

Required personnel
Maintenance personnel
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
Wear forecasts
In order to forecast the wear, record the following points in writing:
When were the slide plates (2.4) replaced or turned?
How long did it take for the wear to progress from 2.5 mm to 1 mm at the wear
marker (X) of the slide plate (2.4)?
The condition of slide plates (2.4) and slide rails (2.2) that are installed at
different
locations in the cooler may be different, even though they have reached the
same
operating time.
In the case of the bearing blocks (2.3) of the outer transport tracks (1.1), you can
see these wear markers from outside the clinker cooler, even while it is in
operation.
You can only replace the slide plates (2.4) during a stoppage of the clinker
cooler(see page 9-152, Replacing the slide plates).
You can assess the wear condition of the slide plates (2.4) on the basis of
the wear markers that are machined into the plates.
Fig. 25: Wear marker (X) on the slide plate (2.4)
Wear is permitted up to a maximum of 2.5 mm. This corresponds to the depth of
the wear marker (X).
9.1.5 After any maintenance work
Be sure to do the following after any maintenance work:
Check all joints and connections for leaks.
Remove all tools from the machine.
Mount all protection devices. Close all doors previously opened.
Properly close the doors and inspection holes (4.5).
Maintenance
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Machine manual
en-PQ.CPT.004.C
9.2 Maintenance work during a stoppage
9.2.1 Safety instructions
DANGER
Work inside the clinker cooler
Raw meal could flush into the clinker cooler. This could result in persons
being buried in material and suffering severe injuries.
I. Wear personal protective equipment.
II. Access to the clinker cooler must not be possible as long as cleaning
work is being performed in the preheater.
III. The plant manager must take precautionary measures to ensure the
safety of the maintenance personnel.
DANGER
Work inside the clinker cooler
Clinker or parts of the refractory lining may fall down or give way. This
could result in persons being buried in material and suffering severe
injuries.
I. Wear personal protective equipment.
II. Make absolutely sure that there are no clinker incrustations or parts of
the refractory lining that could fall down in the clinker cooler and in the
kiln hood.
III. Make absolutely sure that all clinker/parts of the refractory lining have
a sufficient load-bearing capacity.
WARNING
Hot gases in the interior
The interior of the machine heats up during operation. Entering the hot
interior may cause burns and, if hot gases are inhaled, damage to the
respiratory tracts.
I. Wear personal protective equipment.
II. Before commencing any work, switch off the machine and secure it
against restarting. Allow the interior to cool down.

III. Directly after the machine has been shut down, you may only enter the
interior wearing self-contained breathing apparatus.
IV. Sufficiently purge the interior with fresh air. Never use pure oxygen for
ventilation of the interior.
V. Make absolutely sure that no more hot gas can reach the working area,
before entering the interior without self-contained breathing apparatus.
Maintenance
POLYTRACK 9-121 Clinker cooler with end-of-cooler crusher
Machine manual
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WARNING
Hot surfaces
Components in contact with the material may heat up during operation, as
may bearings and motors. Skin contact with hot surfaces may cause
severe burns.
I. Always wear personal protective equipment and heat-resistant
protective clothing when working in the vicinity of hot surfaces.
II. Before commencing any work, switch off the machine and secure it
against restarting. Allow surfaces to cool down to ambient
temperature.
WARNING
Hydraulic energy
Hydraulically operated components may move unexpectedly due to stored
residual energy. If any components are damaged, hydraulic oil can spurt
out under high pressure. This could lead to severe or even fatal injuries.
I. Wear personal protective equipment.
II. Only allow qualified hydraulics specialists to carry out work on the
hydraulic system.
III. Never alter pressure settings to exceed the maximum values.
IV. Before carrying out any work, switch off and completely depressurise
the hydraulic system.
V. Check that the hydraulic system is depressurised.

WARNING
Residual pressure in air blast units after switching off
Even after the electricity supply has been switched off, compressed air
may shoot out of the air blast units. This could cause severe injuries.
I. Depressurise the storage vessels of the air blast units.
II. Let the compressed air escape via vent piping.
III. Do not open doors and/or poke holes until the pressure has been
relieved.
Maintenance
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Machine manual
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WARNING
Rotating parts
If you reach past rotating components, parts of your body may be pulled
in and crushed or severed.
I. During operation, do not reach past or work on rotating components.
II. Do not open any guards or maintenance covers during operation.
III. Shut down the respective functional unit and secure it against
restarting.
IV. Pay attention to after-running time. Before you open any guards or
maintenance covers, make sure that all components have come to a
complete standstill.
WARNING
Moving components
If you reach past moving components, parts of your body may be pulled in
and crushed or severed.
I. Before commencing any work, switch off the machine and secure it
against restarting.
II. Pay attention to the after-running time. Do not open any protection
devices, inspection covers, service covers or inspection doors until all

components have come to a complete standstill.

III. After performing any work, mount all protection devices. Close the
inspection covers, service covers and inspection doors properly.
WARNING
Inspection covers or inspection doors swinging out
When inspection covers or inspection doors are opened, they may swing
out. There is an impact hazard.
I. Wear personal protective equipment.
II. Stay out of the area in which inspection covers or inspection doors
may swing out.
Maintenance
POLYTRACK 9-123 Clinker cooler with end-of-cooler crusher
Machine manual
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9.2.2 In the case of any maintenance work
Be sure to observe the following in the case of any maintenance work:
Stop the material feed.
Switch off the mill and secure it against restarting.
Let the mill cool down and, if necessary, flood it with fresh air.
Ensure that there is adequate space to perform the work.
Keep the place of work clean and tidy. Components or tools that are loosely
lying on top of each other or lying around on the floor are potential causes of
accidents.
9.2.3 Table of maintenance work
The following sections describe the maintenance work required for optimal and
trouble-free operation of the plant. If increased wear is detected during regular
checks, shorten the required maintenance intervals to suit the actual signs of
wear.
No. Work to be performed Frequency Remarks
1 Service the end-of-cooler crusher
(8.0)
See separate

machine manual
2 Service the hydraulic drive (7.0) See separate
machine manual
3 Service the fans (9.0) See
subsupplier's
instructions.
4 Replace faulty conveying elements
(1.1.1, 1.1.2) and pin (1.1.5)
As required (see page 9-132, Replacing
the conveying elements)
5 Replace faulty aeration units (1.2.1) As required (see page 9-136, Replacing
the aeration units)
6 Replace faulty nozzles (1.9.4) of the
air blast units (5.0)
As required
7 Replace worn-out slide plates (2.4) As required (see page 9-152, Replacing
the slide plates)
8 Replace worn-out slide rails (2.2) As required (see page 9-145, Replacing
the slide rails)
Maintenance
9-124
POLYTRACK Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
No. Work to be performed Frequency Remarks
9 Replace worn-out sliding seals As required Replace if the wear is > 1 mm.
10 Replace any worn seals at doors
and inspection holes (4.5)
As required
11 Replace any defective areas of the
refractory lining (10.0)
Annually

12 Clean the inside of the glass panes

(4.5.5.1, 4.5.6.1) of the inspection
holes (4.5.5, 4.5.6)
Annually
9.2.4 Replacing the aeration units of the static grate
Required personnel
Assembly personnel
Maintenance personnel
Required consumables
Elastic sealing compound
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)

Maintenance
9-126
POLYTRACK Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
Fig. 26: Static grate (1.9)
Maintenance
POLYTRACK 9-127 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
No. Denomination Description
1.9.1.1 Aeration unit 498 x 300 mm
1.9.1.2 Aeration unit 248 x 300 mm
1.9.1.3 Aeration unit With nozzle 498 x 300 mm
1.9.1.4 Aeration unit After nozzle 498 x 300 mm
1.9.1.5 Bolted connection For aeration unit
1.9.2.1 Internal part For aeration unit 498 x 300 mm
1.9.2.2 Internal part For aeration unit 248 x 300 mm
1.9.2.3 Internal part For aeration unit with nozzle 498 x 300 mm

1.9.2.4 Internal part For aeration unit after nozzle 498 x 300 mm
1.9.3 Cover plate
1.9.4 Nozzle For air blast unit
1.9.4.1 Connecting bolts For nozzle
1.9.6 Connecting sleeve For nozzle
1.9.7.1 Connecting sleeve For air distributors 140 x 140 mm (air nozzle)
1.9.7.2 Connecting sleeve For air distributors 54 x 150 mm (sides in end zone of
grate)
1.9.7.5 Connecting bolts of the connecting sleeve (1.9.7.1)
1.9.7.6 Connecting pin of the connecting sleeve (1.9.7.2)
TA Tightening torque 70 Nm for every bolt
TD Tightening torque 40 Nm for every bolt
Maintenance
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Machine manual
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Depending on the condition of the components, you can or must replace either
only the internal part or the entire aeration unit.
Step 1: Replacing the internal parts (1.9.2.1, 1.9.2.2, 1.9.2.3, 1.9.2.4) of the
aeration
units (1.9.1.1, 1.9.1.2, 1.9.1.3, 1.9.1.4):
1.1 Unscrew the four bolted connections (1.9.1.5).
1.2 Replace the internal part (1.9.2.1, 1.9.2.2, 1.9.2.3, 1.9.2.4) of the
respective aeration unit (1.9.1.1, 1.9.1.2, 1.9.1.3, 1.9.1.4).
1.3 Tighten the bolted connections (1.9.1.5) to a tightening torque (TA) of
70 Nm per bolt.
Step 2: Replacing entire aeration units (1.9.1.1, 1.9.1.2, 1.9.1.4):
2.1 Dismount the air distribution switches (1.10.1, 1.10.2) which are mounted
underneath the aeration units (1.9.1.1, 1.9.1.2).
2.2 In the case of aeration units (1.9.1.2) at the end zone of the grate:
2.2.1 Lift the connecting sleeve (1.9.7.2) and pull out the connecting pin (1.9.7.6)

to the side.
2.2.2 Remove the connecting sleeve (1.9.7.2) by taking it out in downward
direction.
If an elastic sealing compound was used for sealing the aeration units (1.9.1.2)
on the girder, you may have to use extra force to detach them.
2.3 Unscrew the four bolted connections (1.9.1.5).
2.4 Replace the entire aeration units (1.9.1.1, 1.9.1.2, 1.9.1.4):
2.5 Tighten the bolted connections (1.9.1.5) to a tightening torque (TA or TD)
of 70 Nm or respectively 40 Nm per bolt.
Be sure to comply with the instructions for tightening torques (see figure 26,
page 9-126).
2.6 In the case of the aeration units (1.9.1.2) at the end zone of the grate:
2.6.1 Use an elastic sealing compound to seal the aeration units (1.9.1.2) on the
girder.
2.6.2 Install the connecting sleeve (1.9.7.2), by inserting it from below.
2.6.3 Lift the connecting sleeve (1.9.7.2) and secure it by inserting the
connecting pin (1.9.7.6) from the side.
2.6.4 Tighten the bolted connections (1.9.1.5) to a tightening torque (TA) of
70 Nm per bolt.
2.7 Mount the air distribution switches (1.10.1, 1.10.2) underneath the aeration
units (1.9.1.1, 1.9.1.2, 1.9.1.4).
Maintenance
POLYTRACK 9-129 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
Step 3: Replacing entire aeration units (1.9.1.3) with nozzle:
3.1 Dismount the air distribution switches (1.10.1, 1.10.2) which are mounted
underneath the aeration units (1.9.1.3).
3.2 Undo the connecting bolts (1.9.7.5).
3.3 Dismount the connecting sleeve (1.9.7.1) for air distributors.
3.4 Undo the connecting bolts (1.9.4.1) of the nozzles.
3.5 Dismount the nozzles (1.9.4) of the air blast unit.

If the condition of the air blast unit nozzles (1.9.4) makes it necessary, you
should replace them while carrying out this work. Be sure to comply with the
relevant instructions (see page 9-130, Replacing air blast unit nozzles).
3.6 Mount the nozzles (1.9.4) of the air blast unit.
3.7 Tighten the connecting bolts (1.9.4.1) of the nozzles.
3.8 Mount the connecting sleeve (1.9.7.1) for air distributors.
3.9 Tighten the connecting bolts (1.9.7.5) to a tightening torque (TA or TD) of
70 Nm or respectively 40 Nm per bolt.
Be sure to comply with the instructions for tightening torques (see figure 26,
page 9-126).
3.10 Mount the air distribution switches (1.10.1, 1.10.2) underneath the aeration
units (1.9.1.3).
Maintenance
9-130
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Machine manual
en-PQ.CPT.004.C
9.2.5 Replacing air blast unit nozzles
Required personnel
Assembly personnel
Maintenance personnel
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
Fig. 27: Replacing the nozzles (1.9.4) of air blast units (5.0)
No. Denomination Description
1.9.1 Aeration unit
1.9.1.3 Aeration unit With nozzle
1.9.1.4 Aeration unit After nozzle
1.9.4 Nozzle For air blast unit
1.9.4.1 Connecting bolts
1.9.6 Connecting sleeve For nozzle
1.9.7.1 Connecting sleeve For air distributors

TN Tightening torque 200 Nm for every bolt

Maintenance
POLYTRACK 9-131 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
Step 1: Undo and remove the connecting bolts (1.9.4.1).
Step 2: Then remove the nozzles (1.9.4) in upward direction.
Step 3: Mount new nozzles (1.9.4) from above.
Step 4: Tighten the connecting bolts (1.9.4.1) to a tightening torque (TN) of 200
Nm
per bolt.
Step 5: Alter the position of the nozzles (1.9.4) in transverse direction:
For process-technological reasons, it may be necessary to alter the position of
the nozzles.
5.1 Change the position of the aeration units (1.9.1.3) with the nozzle and the
aeration units (1.9.1.4) after the nozzle.
5.2 Correspondingly modify the connections for the connecting sleeve (1.9.7.1)
for the air distributors and the connecting sleeve (1.9.6) for the nozzle.
For exchanging the aeration units (1.9.1): (see page 9-124, Replacing the
aeration units of the static grate)
Step 6: At the pipe bends, inspect for leaks in the air pipes from the air blast unit
(5.0) to the aeration unit (1.9.1.4) after the nozzle.
9.2.6 Repairing the HORSE SHOE
Required personnel
Assembly personnel
Maintenance personnel
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
Repair any worn-out or broken-off parts of the HORSE SHOE (1.9.8) in
accordance with the instructions given by the refractories supplier.
If the shape of the HORSE SHOE (1.9.8) has to be changed for
processtechnological
reasons, you may also have to alter the positions of the nozzles

(1.9.4) of the air blast units (5.0) (see page 9-130, Replacing air blast unit
nozzles).
Maintenance
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Machine manual
en-PQ.CPT.004.C
9.2.7 Replacing the conveying elements
Required personnel
Assembly personnel
Maintenance personnel
Required consumables
Spray lubricant
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
The conveying elements (1.1.1) installed in different zones of the clinker cooler
may be different in shape.
Make absolutely sure that the new conveying elements (1.1.1) are of the same
shape as the original conveying elements (1.1.1).
The conveying elements (1.1.1) at the beginning of aeration floor 1 (after the
static grate (1.9)) have holes for the tip of the thermocouple (6.1). Make sure
that
the new conveying elements (1.1.1) also have this hole at the identical location.
Deviations from this are only permissible after prior consultation with
ThyssenKrupp Industrial Solutions.
With the exception of the conveying elements (1.1.2) at the end of an aeration
floor and the conveying elements (1.1.3) at the beginning of an aeration floor,
each conveying element (1.1.2) is attached by two pins (1.1.5). One drill hole of
the mounting lug (1.1.4) is cylindrical and one is oblong. The oblong hole permits
unhindered thermal expansion of the conveying elements (1.1.2).
Maintenance
POLYTRACK 9-133 Clinker cooler with end-of-cooler crusher

Machine manual
en-PQ.CPT.004.C
Fig. 28: Conveying elements (1.1.1, 1.1.2)
No. Denomination Description
1.1.1 Conveying elements
1.1.2 Conveying elements End
1.1.3 Conveying elements Beginning
1.1.4 Mounting lug
1.1.5 Pin
1.1.5.1 Disc
1.1.5.2 Weld seam
6.1 Thermocouple
TM Tightening torque 670 Nm for every bolt
TA Tightening torque 400 Nm for every bolt
Maintenance
9-134
POLYTRACK Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
In the case of conveying elements (1.1.1) which are provided with a
thermocouple (6.1) for temperature measurement, you must first remove the
thermocouples (6.1), in order to avoid damaging the tip of the thermocouple
(6.1) when moving the conveying elements (1.1.1) out.
Provided that they are undamaged and functional after their removal, the
thermocouples (6.1) can generally be reused after replacement of the conveying
elements (1.1.1). Therefore be very careful when removing them.
Step 1: Remove the thermocouple (6.1)
(see page 9-162, Replacing the thermocouples of the conveying elements)
WARNING
Removing the pins
Components of the bearing assembly could be damaged.
I. Never hammer out the pins with heavy blows.

II. Never force out the pins by using mounting jacks braced against the
sidewall of the upper section of the cooler or against a neighbouring
transport track (conveying element).
Step 2: Remove the pins (1.1.5)
The pins (1.1.5) are secured by welded-on discs (1.1.5.1).
2.1 To detach the discs (1.1.5.1), you must remove the weld (1.1.5.2) by flame
cutting or flame grooving.
When selecting the flame cutting method, you must take into account the fact
that
the pins (1.1.5) are made of heat-resistant steel.
Fig. 29: Removing a pin (1.1.5)
2.2 Drive the pins (1.1.5) through the holes in the conveying element (1.1.1)
and the mounting lugs (1.1.4) by means of light hammer blows.
It is helpful to use a spray lubricant to reduce the friction.
Maintenance
POLYTRACK 9-135 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
If the pin (1.1.5) cannot be driven out of the hole by means of light hammer
blows,
see the following point.
2.3 Weld a threaded rod onto the head of the pin (1.1.5) and pull out the pin
with the aid of a suitable device braced against the same conveying
element (1.1.1).
2.4 Alternatively, you can first open up a gap between the head of the pin
(1.1.5) by means of light hammer blows between the head of the pin and
the head contact area on the surface of the conveying element (1.1.1) and
then insert wedges to move it.
Step 3: Dismount the conveying element (1.1.1).
Make absolutely sure that the direction of installation of the conveying elements
is correct.
Step 4: Mount the conveying element (1.1.1).
4.1 Secure the conveying element (1.1.1) by means of pins (1.1.5) inserted

through the holes in the conveying element (1.1.1) and the mounting lugs
(1.1.4).
When inserting the pins in outside plates, make absolutely sure that the
direction of installation is correct. Insert the pin from the side nearest the wall, in
order to facilitate the next disassembly, and the welding of the disc (1.1.5.1).
4.2 Weld the pin (1.1.5) and the disc (1.1.5.1) with heat-resistant filler metal.
Step 5: If you previously removed any thermocouples (6.1), you must now
reinstall
them (see page 5-96).
Maintenance
9-136
POLYTRACK Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
9.2.8 Replacing the aeration units
Required personnel
Assembly personnel
Maintenance personnel
Required spare parts
Aeration units (1.2.1)
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
Fig. 30: Aeration units (1.2.1)
No. Denomination Description
1.1.1 Conveying element
1.1.4 Mounting lug
1.2.1 Aeration units
1.2.1.1 Aeration units
1.2.1.2 Aeration units Internal part
1.2.1.3 Aeration units Internal part, narrow
1.2.2 Bolted connection
1.4 Sealing frame

TA Tightening torque 70 Nm for every bolt

Maintenance
POLYTRACK 9-137 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
Without dismounting the conveying elements (1.1.1), mounting lugs (1.1.4) and
sealing frames (1.4), you can only remove or replace the internal part (1.2.1.2,
1.2.1.3) of the aeration unit.
For this purpose, see the corresponding detailed description.
Step 1: Replacing the internal part (1.2.1.2, 1.2.1.3) of the aeration unit (1.2.1):
1.1 Unscrew the four bolted connections (1.2.2).
1.2 Replace the internal part (1.2.1.2, 1.2.1.3) of the respective aeration unit
(1.2.1).
1.3 Tighten the bolted connections (1.2.2) to a tightening torque (TA) of 70 Nm
per bolt.
Step 2: Replacing entire aeration units (1.2.1):
2.1 Dismount the conveying elements (1.1.1) and the fixing strap (1.1.4) (see
page 9-132, Replacing the conveying elements) and (see page 9-138,
Replacing the conveying element mounting lugs).
2.2 Dismount the sealing frame (1.4) (see page 9-140, Replacing the sealing
frame).
2.3 Unscrew the four bolted connections (1.2.2).
2.4 Replace the aeration unit (1.2.1).
2.5 Tighten the bolted connections (1.2.2) to a tightening torque (TA) of 70 Nm
per bolt.
2.6 Mount the sealing frame (1.4) (see page 9-140, Replacing the sealing
frame).
2.7 Mount the conveying elements (1.1.1) and the fixing strap (1.1.4).
(see page 9-132, Replacing the conveying elements) and (see page 9-138,
Replacing the conveying element mounting lugs)
Maintenance
9-138

POLYTRACK Clinker cooler with end-of-cooler crusher

Machine manual
en-PQ.CPT.004.C
9.2.9 Replacing the conveying element mounting lugs
Required personnel
Assembly personnel
Maintenance personnel
Required spare parts
Mounting lugs (1.1.4)
Personal protective equipment
Personal protective equipment for all work (see page 2-15)
Fig. 31: Mounting lugs (1.1.4) for conveying elements (1.1.1)
No. Denomination Description
1.1.1 Conveying elements
1.1.4 Mounting lugs
1.1.4.1 Bolted connections
1.2.1 Aeration units
1.3 Angle brackets
1.3.5 Bolted connections
1.3.6 Dowel pin
TA Tightening torque 400 Nm for every bolt
TM Tightening torque 670 Nm for every bolt
Maintenance
POLYTRACK 9-139 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
Step 1: In the case of conveying elements (1.1.1), which are provided with a
thermocouple (6.1) for temperature measurement, you must first remove
the thermocouple (6.1).
Step 2: Dismount the conveying elements (1.1.1) that are installed above the
mounting lugs (1.1.4) (see page 9-132).

Step 3: Unscrew and remove the bolted connections (1.1.4.1) of the mounting
lugs
(1.1.4).
The mounting lugs (1.1.4) are bolted on between the angle brackets (1.3).
One of these angle brackets (1.3) is secured in position on the longitudinal
girder (2.1) by dowel pins (1.3.6). You must not detach this angle bracket (1.3),
as otherwise it would be necessary to realign the mounting lugs (1.1.4).
3.1 Unscrew one of the bolted connections (1.3.5).
Step 4: Replace the mounting lugs (1.1.4).
Step 5: Tighten the bolted connections (1.1.4.1) of the mounting lugs (1.1.4) to a
tightening torque (TM) of 670 Nm per bolt.
Step 6: Tighten the bolted connections (1.3.5) to a tightening torque (TA) of 400
Nm
per bolt.
Step 7: Mount the conveying elements (1.1.1) that are installed above the
mounting
lugs (1.1.4).
Step 8: In the case of conveying elements (1.1.1) which were provided with a
thermocouple (6.1) for temperature measurement, you must mount the
thermocouples (6.1).
Maintenance
9-140
POLYTRACK Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
9.2.10 Replacing the sealing frame
Required personnel
Assembly personnel
Maintenance personnel
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
Fig. 32: Sealing frame (1.4)
No. Denomination

1.1.1 Conveying elements

1.1.4 Mounting lugs
1.2.1 Aeration units
1.4 Sealing frame
1.4.1 Thrust piece
1.5.2 Spring system
Maintenance
POLYTRACK 9-141 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
Step 1: Make a written record of the spring tensions of the horizontal spring
system
(1.5.2)
Step 2: Relieve the tension of the sealing frame (1.4) in longitudinal direction by
means of the horizontal spring system (1.5.2).
(see page 9-142, Replacing the spring system).
Step 3: Dismount the conveying elements (1.1.1) and mounting lugs (1.1.4) that
are
installed above the sealing frame (1.4) (see page 9-132, Replacing the
conveying elements) and (see page 9-138, Replacing the conveying element
mounting lugs).
Step 4: Remove the sealing frame (1.4) in an upward direction.
Step 5: Install the sealing frame (1.4) from above.
5.1 Install the thrust pieces (1.4.1).
When installing the thrust pieces (1.4.1), make absolutely sure that they are in
the
correct position (direction).
Step 6: Mount the conveying elements (1.1.1) and mounting lugs (1.1.4).
(see page 9-132, Replacing the conveying elements) and (see page 9-138,
Replacing the conveying element mounting lugs)
Step 7: Tension the sealing frame (1.4) in longitudinal direction by means of the
horizontal spring system (1.5.2) (see page 9-142, Replacing the spring
system).

Step 8: Seal the openings in the sealing frame (1.4) (see page 5-85, Mounting
the
clinker cooler).
Maintenance
9-142
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Machine manual
en-PQ.CPT.004.C
9.2.11 Replacing the spring system
Required personnel
Assembly personnel
Maintenance personnel
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
As a rule, it is not necessary to replace the spring systems (1.5).
Replacement is necessary if the springs have lost their original spring
characteristic e.g. due to extreme overheating or overloading.
The springs are checked by measuring the spring length in non-tensioned
condition.
The nominal lengths in new condition are:
horizontal spring system (1.5.1) = 33.5 mm
vertical spring system (1.5.2) = 60.5 mm
It is possible to replace some of the spring systems (1.5) or parts of them from
below, working from the cooling air compartment.
However, it is easier to replace parts of the horizontal spring system (1.5.2) from
above after dismounting the sealing frame (1.4).
Maintenance
POLYTRACK 9-143 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
Fig. 33: Spring system (1.5)
No. Denomination Description

1.1.1 Conveying elements

1.1.4 Mounting lug
1.3 Angle bracket
1.4 Sealing frame
1.5 Spring system
1.5.1 Spring system Horizontal
1.5.2 Spring system Vertical
1.5.12 Stud bolt
1.5.13 Adjusting nuts
Maintenance
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Machine manual
en-PQ.CPT.004.C
No. Denomination Description
1.5.22 Stud bolt
1.5.23 Adjusting nuts
Step 1: Make a written record of the preloading condition of the individual springs
This written record is required in order to readjust the springs to the same
preloading condition after reassembly. A measure of the preloading is the
position
of the adjusting nuts (1.5.13, 1.5.23) or the projecting length of the stud bolts
(1.5.12, 1.5.22).
Step 2: Unscrew the locknuts of the adjusting nuts (1.5.13, 1.5.23).
Step 3: Relieve the spring systems (1.5) by turning the adjusting nuts (1.5.13,
1.5.23).
Step 4: Dismount the spring systems (1.5.1, 1.5.2).
Step 5: Mount the spring systems (1.5.1, 1.5.2).
Step 6: Tension the spring systems (1.5) by turning the adjusting nuts (1.5.13,
1.5.23).
Step 7: Lock with the counternuts of the adjusting nuts (1.5.13, 1.5.23).
For details: (see page 12-179, Technical drawings) "Spring system".

Step 8: Calibrate the spring systems (1.5) in accordance with the instructions:
(see
page 12-179, Technical drawings) and (see page 7-104, Initial settings).
Step 9: Secure the settings by carefully locking the adjusting nuts (1.5.13,
1.5.23).
Maintenance
POLYTRACK 9-145 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
9.2.12 Replacing the slide rails
Required personnel
Assembly personnel
Maintenance personnel
Wear forecasts
In order to forecast the wear, record the following points in writing:
When were the slide plates (2.2) replaced or turned?
How long does it take for the depth of wear on the slide rail (2.2) to reach
1 mm?
When is a slide rail worn out?
The slide rail (2.2) has to be regarded as worn out and must be replaced when
the sliding surface shows a wear depth of 1 mm or is damaged [e.g. irregular,
undulating wear]. When the specified wear depth (Y) of 1 mm has been reached,
the slide rail (2.2) can be turned over and the reverse side can then be used as
the sliding surface. This is subject to the precondition that the opposite side has
not suffered any damage and does not show signs of serious wear. The
turnedover
slide rail (2.2) must be permanently and clearly marked, so that the need for
spare parts can be determined in good time during inspections.
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
The replacement of slide rails (2.2) must always be seen in connection with the
replacement of slide plates (2.4) and slide plate holders (2.3.2).

When replacing the slide rails (2.2), the condition of the parts determines
whether
it is necessary to also replace the respective slide plates (2.4), and - the other
way around - whether it is necessary when replacing the slide plates (2.4) to also
replace the respective slide rails (2.2).
It is good policy when replacing slide rails (2.2) to also replace the associated
slide plates (2.4).
The condition of slide rails (2.2.1, 2.2.2, 2.2.3) and slide plates (2.4.1, 2.4.2,
2.4.3)
that are installed at different locations in the cooler may be different, even
though
they have reached the same operating time.
Maintenance
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Machine manual
en-PQ.CPT.004.C
Fig. 34: Example of a worn-out slide rail (2.2)
No. Denomination Description
Y Wear depth 1 mm
Fig. 35: Slide rail (2.2)
No. Denomination Description
2.1 Longitudinal girder
2.2 Slide rail
2.2.1 Slide rail Upper
2.2.1.5 Bolted connection
2.2.1.7 Nuts
Maintenance
POLYTRACK 9-147 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
No. Denomination Description
2.2.2 Slide rail Middle

2.2.2.5 Bolted connection

2.2.2.7 Nuts
2.2.3 Slide rail Lower
2.2.3.5 Bolted connection
2.2.3.7 Nuts
2.4.1 Slide plates Upper
2.4.2 Slide plates Middle
2.4.3 Slide plates Lower
TS.1 Tightening torque:
100 Nm per bolt
With oblong hole
TS.2 Tightening torque:
200 Nm per bolt
With hole
Step 1: Position the respective longitudinal girder (2.1) such that the bolted
connections (2.2.1.5, 2.2.2.5, 2.2.3.5) are accessible.
1.1 To permit dismounting of the upper slide rails (2.2.1), you must raise and
support the longitudinal girders (2.1) such that the respective slide rail
(2.2.1) is relieved of load.
Step 2: Unscrew and remove the bolted connections (2.2.1.5, 2.2.2.5, 2.2.3.5).
The nuts (2.2.1.7, 2.2.2.7, 2.2.3.7) of the bolted connections have a metallic
locking element. Every time the bolted connections are unscrewed and
subsequently retightened, the locking effect is reduced. In order to ensure that
the bolts are reliably secured against loosening during operation, you must
install
new nuts (2.2.1.7, 2.2.2.7, 2.2.3.7) after a maximum of 3 replacements.
Step 3: Remove the respective upper slide rails (2.2.1), middle slide rails (2.2.2)
or
lower slide rails (2.2.3).
The middle slide rails (2.2.2) are attached to the bolted connections (2.2.2.5) in
pairs.
Step 4: Install the new slide rails (2.2.1, 2.2.2, 2.2.3)
Make absolutely sure that the contact surfaces of the new slide rails (2.2.1,

2.2.2, 2.2.3) (surface in contact with the slide plates (2.4.1, 2.4.2, 2.4.3)) are free
of damage.
Maintenance
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Machine manual
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Step 5: Install the bolted connections (2.2.1.5, 2.2.2.5, 2.2.3.5)
The nuts (2.2.1.7, 2.2.2.7, 2.2.3.7) of the bolted connections (2.2.1.5, 2.2.2.5,
2.2.3.5) have a metallic locking element. Every time the bolted connections are
unscrewed and subsequently retightened, the locking effect is reduced. In order
to ensure that the bolts are reliably secured against loosening during operation,
you must install new nuts after a maximum of 3 replacements.
Be sure to tighten the bolted connections (2.2.1.5, 2.2.2.5, 2.2.3.5) to the
stipulated tightening torque.
Fig. 36: Tightening torques of the slide rails (2.2)
TS.1 Tightening torque: 100 Nm per bolt with oblong hole
TS.2 Tightening torque: 200 Nm per bolt with hole
Step 6: Dismount the support of the longitudinal girder (2.1)
Maintenance
POLYTRACK 9-149 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
9.2.13 Replacing the slide plate holder
Required personnel
Assembly personnel
Maintenance personnel
Required consumables
Nut-locking agent
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
The replacement of slide plate holders (2.3.2) must always be seen in connection

with the replacement of slide plates (2.4) and slide rails (2.2).
When replacing the slide rails (2.2), the condition of the parts determines
whether
it is necessary to also replace the respective slide plates (2.4), and - the other
way around - whether it is necessary when replacing the slide plates (2.4) to also
replace the respective slide rails (2.2).
It is good policy when replacing slide rails (2.2) to also replace the associated
slide plates (2.4).
The condition of slide rails (2.2.1, 2.2.2, 2.2.3) and slide plates (2.4.1, 2.4.2,
2.4.3)
that are installed at different locations in the cooler may be different, even
though
they have reached the same operating time.
When replacing the slide plate holders (2.3.2) including the slide plates (2.4) the
condition of the parts determines whether it is necessary to also replace the
respective slide rails (2.2).
As a rule, it is good policy when replacing slide rails (2.2) to also replace the
associated slide plates (2.4).
The condition of slide plates (2.4) and slide rails (2.2) that are installed at
different
locations in the cooler may be different, even though they have reached the
same
operating time.
To speed up the replacement work, you can also prepare slide plate holders
(2.3.2) that are fully fitted with new slide plates (2.4).
Maintenance
9-150
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Machine manual
en-PQ.CPT.004.C
Fig. 37: Slide plate holders (2.3.2)
No. Denomination Description
2.1 Longitudinal girder
2.2 Slide rail

2.2.1 Slide rail Upper

2.2.2 Slide rail Middle
2.2.3 Slide rail Lower
2.3 Bearing blocks
2.3.1 Main casting
2.3.2 Slide plate holders
2.3.3 Bolted connection
2.4 Slide plates
TB Tightening torque 230 Nm for every bolt
Dismounting of the complete bearing blocks (2.3) is only necessary in
exceptional cases. Before dismounting the bearing blocks, you have to carry out
certain preparatory steps.
When doing so, be sure to comply with the corresponding instructions.
Maintenance
POLYTRACK 9-151 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
Step 1: Move the respective longitudinal girder (2.1) of the slide plate holders
(2.3.2)
into an end-of-stroke position.
You can do this by using the local control panel of the hydraulic drive (7.0).
Step 2: Raise and support the longitudinal girders (2.1) such that the respective
bearing point is relieved of load.
You can do this by using mechanical lifting spindles or hydraulic lifting cylinders.
Place the support on the cross girder of the grate substructure (3.0).
Step 3: Unscrew the bolted connections (2.3.3).
Step 4: Remove the slide plate holders (2.3.2) in longitudinal direction of the
clinker
cooler.
Step 5: Install the new slide plate holders (2.3.2) in longitudinal direction of the
clinker cooler.
Make absolutely sure that the contact surfaces between the slide plate holders
(2.3.2) and the bearing block body (2.3.1) are undamaged and clean.

Step 6: Install the bolted connections (2.3.3)

Be sure to retighten the bolted connections (2.3.3) to the stipulated tightening
torque. Do not lubricate the threads.
Fig. 38: Slide plate holders (2.3.2)
TB Tightening torque: 230 Nm per bolt
Step 7: Remove the support
Maintenance
9-152
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Machine manual
en-PQ.CPT.004.C
9.2.14 Replacing the slide plates
Required personnel
Assembly personnel
Maintenance personnel
Required consumables
Special cleaner for preparing the thread for the chemical nut-locking agent
Chemical nut-locking agent of the type medium-strength (liquid)
Wear forecasts
In order to forecast the wear, record the following points in writing:
When were the slide plates (2.4) replaced or turned?
How long did it take for the wear to progress from 2.5 mm to 1 mm at the wear
marker (X) of the slide plate (2.4)?
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
Fig. 39: Wear marker (X) on the slide plate (2.4)
The replacement of slide plates (2.4) must always be seen in connection with the
replacement of slide rails (2.2) and slide plate holders (2.3.2).
When replacing the slide rails (2.2), the condition of the parts determines
whether
it is necessary to also replace the respective slide plates (2.4), and - the other
way around - whether it is necessary when replacing the slide plates (2.4) to also

replace the respective slide rails (2.2).

It is good policy when replacing slide rails (2.2) to also replace the associated
slide plates (2.4).
The condition of slide plates (2.4) and slide rails (2.2) that are installed at
different
locations in the cooler may be different, even though they have reached the
same
operating time.
You can assess the wear condition of the slide plates (2.4) on the basis of the
wear markers that are machined into the plates. Wear is permitted up to a
maximum of 2.5 mm. This corresponds to the depth of the markings (X).
In the case of the bearing blocks (2.3) of the outer transport tracks (1.1), you can
monitor these markers from outside the clinker cooler, even while it is in
operation.
Maintenance
POLYTRACK 9-153 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
You must always replace the upper and/or lower slide plates (2.4) of each
bearing point in pairs. Also, you must always replace the slide plates (2.4) of
both
bearing blocks (2.3) of each track and module together.
Fig. 40: Slide plates (2.4.1, 2.4.2, 2.4.3)
No. Denomination Description
2.2 Slide rail
2.3 Bearing blocks
2.3.2 Slide plate holder
2.4 Slide plates
2.4.1 Slide plates Upper
2.4.2 Slide plates Middle
2.4.3 Slide plates Lower
2.4.5 Bolted connection
TS.1 Tightening torque 20 Nm for every bolt

TS.2 Tightening torque 25 Nm for every bolt

Maintenance
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Machine manual
en-PQ.CPT.004.C
Dismounting of the complete bearing blocks (2.3) is only necessary in
exceptional cases. Before dismounting the bearing blocks (2.3), you have to
carry out certain preparatory steps. (see page 9-156, Replacing the bearing
blocks)
Step 1: Unscrew the bolted connection (2.4.5)
When the bolted connection (2.4.5) of the slide plates (2.4) was installed in the
slide plate holder (2.3.2), a chemical nut-locking agent was applied.
1.1 Unscrew the bolted connection (2.4.5) using the maximum permissible
torque of 50 Nm.
If you try to unscrew the bolted connection (2.4.5) using an impermissibly high
torque, it will be destroyed and a costly and time-consuming repair of the
connection will be necessary.
1.2 If the bolted connection (2.4.5) cannot be unscrewed using the maximum
permissible torque, heat the connection to approx. 250 C and then
unscrew it.
If you have to heat up the components in order to loosen them, you need not
worry about damaging the old slide plates (2.4), as these will not be reused.
Step 2: Remove the slide plates (2.4).
Step 3: Remove any remainder of the old nut-locking agent from the contact
surfaces and threads of the slide plate holder (2.3.2).
Step 4: Install the slide plates (2.4).
Step 5: Install the bolted connection (2.4.5)
5.1 Clean the contact surfaces of the bolted connection (2.4.5) with a special
cleaner.
5.2 Apply chemical nut-locking agent of the type medium-strength to the bolted
connection (2.4.5) in accordance with the subsupplier's instructions.

5.3 Tighten the bolted connection (2.4.5) to the stipulated tightening torque.
Always tighten the central bolts to a higher tightening torque.
Maintenance
POLYTRACK 9-155 Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
Fig. 41: Tightening torques for the bolted connection (2.4.5)
TS.1 Tightening torque: 20 Nm per bolt
TS.2 Tightening torque: 25 Nm per bolt
Maintenance
9-156
POLYTRACK Clinker cooler with end-of-cooler crusher
Machine manual
en-PQ.CPT.004.C
9.2.15 Replacing the bearing blocks
Required personnel
Assembly personnel
Maintenance personnel
Required tools
Hydraulic bolt pretensioning device
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
Fig. 42: Bearing block (2.3)
No. Denomination Description
2.1 Longitudinal girder
2.2.1 Slide rail Upper
2.2.1.5 Bolted connection
2.2.2 Slide rail Middle
2.2.2.5 Bolted connection
2.2.3 Slide rail Lower
2.2.3.5 Bolted connection
Maintenance

POLYTRACK 9-157 Clinker cooler with end-of-cooler crusher

Machine manual
en-PQ.CPT.004.C
No. Denomination Description
2.3 Bearing blocks
2.3.1 Main casting
2.3.2 Slide plate holder
2.3.10.1 Bolted connections
2.3.10.2 Bolted connections
2.3.10.3 Nuts
2.3.10.4 Nuts
2.4 Slide plates
3.0 Grate substructure
TB.1 Tightening torque 400 Nm for every bolt
TB.2 Tightening torque 200 Nm for every bolt
Replacement or dismounting of the bearing blocks (2.3) is only necessary in
exceptional cases.
In order to ensure correct reassembly, you have to carry out certain preparatory
steps before dismounting the bearing blocks (2.3).
Be sure to perform the following work steps:
Step 1: Move the respective longitudinal girder (2.1) into the middle-of-stroke
position.
You can do this by using the local control panel of the hydraulic drive (7.0).
Step 2: Raise and support the longitudinal girder (2.1) such that the respective
bearing point is relieved of load.
2.1 Raise and support the longitudinal girder (2.1) using mechanical lifting
spindles or hydraulic lifting cylinders.
Support the mechanical lifting spindles or hydraulic lifting cylinder on the cross
girder of the grate substructure (3.0).
Maintenance
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Machine manual
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Step 3: Align the position of the longitudinal girders (2.1) in the direction of the
cooler width such that the distances between the vertical surfaces of the
middle slide rails (2.2.2) at the bolted connections (2.2.2.5) and the vertical,
machined surfaces of the bearing block bodies (2.3.1) and/or the slide plate
holders (2.3.2) are equal on both sides.
3.1 Take suitable measures to fix the component in this position (e.g. clamps,
spacers).
3.2 Make a written record of the measurements of the position.
As an alternative to this method, you can also attach a secure stop on both sides
of the cross girder of the grate substructure (3.0) for the inner, vertical machined
surfaces of the bearing block body (2.3.1).
Step 4: Unscrew and remove the bolted connections (2.3.10.1, 2.3.10.2) of the
bearing blocks (2.3)
Step 5: Remove the bearing block (2.3) by moving it in transverse or longitudinal
direction
Step 6: Install the bearing block (2.3)
Step 7: Install the bolted connections (2.3.10.1, 2.3.10.2) of the bearing blocks
(2.3)
The self-locking nuts (2.3.10.3, 2.3.10.4) of the bolted connections (2.3.10.1,
2.3.10.2) have a metallic locking element. Every time the bolted connections are
unscrewed and subsequently retightened, the locking effect is reduced. In order
to ensure that the bolts are reliably secured against loosening during operation,
you must install new nuts after a maximum of 3 replacements.
7.1 Make absolutely sure that there is an adequately large clearance between
the bolted connections (2.2.3.5) of the slide rails (2.2.3) and the bolted
connections (2.3.10.2) of the bearing blocks (2.3) in vertical direction
during the movement of the longitudinal girders (2.1).
In this respect, take into consideration that at maximum permissible wear of the
slide plates (2.4), the longitudinal girder (2.1) can be approx. 2.5 mm lower
Maintenance

POLYTRACK 9-159 Clinker cooler with end-of-cooler crusher

Machine manual
en-PQ.CPT.004.C
7.2 Be sure to fit all bolted connections using the stipulated tightening torque.
Fig. 43: Bearing block (2.3)
No. Denomination
TB.1 Tightening torque: 400 Nm per bolt
TB.2 Tightening torque: 200 Nm per bolt
Step 8: Using the measurements from the written record made earlier, align the
longitudinal girder (2.1)
8.1 Remove the fastening devices.
8.2 Align the longitudinal girder (2.1).
Step 9: Lower the longitudinal girder (2.1) and remove the support
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9.2.16 Replacing the connecting fishplates and pins of the longitudinal girder
Required personnel
Assembly personnel
Maintenance personnel
Required consumables
A good-adhesion lubricant
Personal protective equipment
Personal protective equipment for all work (see page 2-15)
Fig. 44: Connecting fishplates (2.5) and pins (2.6) of the longitudinal girder (2.0)
No. Denomination
2.1 Longitudinal girder
2.5 Connecting fishplate
2.6 Pin
2.6.1 Damper plate

2.6.5 Bolted connections

2.6.5.1 Locking plate
Step 1: Remove the locking plate (2.6.5.1) from the bolted connection (2.6.5)
Step 2: Unscrew and remove the bolted connection (2.6.5)
Step 3: Remove the pins (2.6) and connecting fishplates (2.5)
Step 4: Inspect the hole in the longitudinal girder (2.1) for damage.
Any necessary measures for elimination of damage must be agreed with
ThyssenKrupp Industrial Solutions.
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Step 5: Coat the contact surfaces of the connection of the longitudinal girder
(2.1),
of the pin (2.6), of the disc (2.6.1) and of the connecting fishplates (2.5) with
a good-adhesion lubricant
Step 6: Mount the pins (2.6) and connecting fishplates (2.5)
Step 7: Mount the bolted connection (2.6.5) and locking plate (2.6.5.1)
The pin unit must still have some clearance in the axial direction.
The pin (2.6) must be able to turn freely and the connecting fishplates (2.5) must
not be subjected to excessive forces due to overtightening of the pin (2.6).
Step 8: In order to secure the bolted connection (2.6.5), you must bend up the
ends
of the locking plate (2.6.51), so that they are in contact with the bolt heads.
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9.2.17 Replacing the thermocouples of the conveying elements
Purpose
If proper functioning of thermocouples (6.1) is no longer assured, they have to be
replaced.

The thermocouples (6.1) also have to be removed and later reinstalled whenever
conveying elements (1.1.1) or fastening and sealing elements are replaced.
Required personnel
Assembly personnel
Maintenance personnel
Required consumables
Nut-locking agent
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
Fig. 45: Thermocouple (6.1)
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Machine manual
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No. Denomination
1.1.1 Conveying element
1.1.4 Mounting lug
2.1 Longitudinal girder
6.1 Thermocouple
6.2 Fastening
6.3 Connecting cable
6.4 Protective pipe
6.5 Measuring point
Step 1: Detach the clamp of the connecting cable (6.3) on the longitudinal girder
(2.1) and pull the connecting cable (6.3) so far out of the protective pipe (6.4)
that it allows sufficient freedom of movement for withdrawing the
thermocouple
Depending on the position of the thermocouple (6.1) and of the longitudinal
girder (2.1), you may have to move the affected transport track (1.1) in order to
improve accessibility.
Step 2: Detach the fixing device (6.2) and then pull the thermocouple (6.1)
downward with a gentle rotational movement, always turning in the same

direction
During operation, clinker dust may have formed a deposit in the hole, making it
difficult to remove the thermocouple (6.1). Nevertheless, do not use excessive
force. If a thermocouple (6.1) breaks in the hole, the subsequent repair is
complex and expensive.
Step 3: Completely clear out the hole in the longitudinal girder (2.1), in the
mounting lug (1.1.4) and in the conveying element (1.1.1)
If a used thermocouple (6.1) is reinstalled, the functioning of that thermocouple
(6.1) must be mechanically and electrically checked. Faulty thermocouples (6.1)
have to be replaced with new ones.
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Step 4: Insert the new thermocouple (6.1) into the connecting cable (6.3) with a
gentle rotational movement, and mount the fixing device (6.2)
Step 5: Push the connecting cable (6.3) into the protective pipe (6.4)
Step 6: Fix the connecting cable (6.3) onto the longitudinal girder (2.1), using the
clamp
Step 7: Make absolutely sure that the spring-loaded measuring head of the
thermocouple (6.1) is in contact with the measuring point (6.5) in the
conveying element (1.1.1) and that the spring-loaded protective pipe (6.4) of
the thermocouple (6.1) is pressed against the conveying element (1.1.1)
If this is not the case, reliable measurement is not assured.
Maintenance
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Machine manual
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9.2.18 Replacing the air distribution switches and orifice plates
Purpose
It may become necessary to replace air distribution switches (1.10.1, 1.10.2) and

orifice plates (1.10.3, 1.10.4) or parts thereof if the process-technological

conditions of the clinker cooler are changed.
You can adapt the air distribution switches (1.10.1, 1.10.2) to the
processtechnological
requirements by exchanging the pendulum counterweights
(1.10.1.2, 1.10.2.2).
The various pendulum counterweights (1.10.1.2, 1.10.2.2) that can be used differ
in weight, due to different thicknesses. The different versions of the pendulum
counterweight (1.10.1.2, 1.10.2.2) are identified by punched-in numbers
(thickness of the pendulum counterweight in mm) and by different colours (for
their allocation see the drawing air distribution diagram) (see page 12-179,
Technical drawings). The basis for the designation shown in the air distribution
diagram is the thickness of the pendulum counterweight (1.10.1.2, 1.10.2.2).
You can make other adjustments through the openings (1.10.1.8) in the housing
wall (1.10.1.1), which otherwise have to be kept closed.
If the need arises, ThyssenKrupp Industrial Solutions will issue special
instructions for this purpose.
Required personnel
Assembly personnel: at least 2 persons
Maintenance personnel
Required consumables
Nut-locking agent
Necessary personal protective equipment
Personal protective equipment for all work (see page 2-15)
The optimum outfitting of the clinker cooler with air distribution switches (1.10.1,
1.10.2) and orifice plates (1.10.3, 1.10.4) is determined during commissioning.
See the current version of the drawing relating to the air distribution diagram
provided in the section Appendix (see page 12-179, Technical drawings).
Prior consent for any change in the configuration must be obtained from
ThyssenKrupp Industrial Solutions.
As a rule, it is not necessary to replace these devices because of wear or other
damage.

Instructions for the replacement distinguish between the replacement of entire

units and the replacement of parts thereof.
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Fig. 46: Air distribution switches (1.10.1, 1.10.2) and orifice plates (1.10.3,
1.10.4)
No. Denomination Description
1.10.1 Air distribution switch
1.10.1.1 Housing wall
1.10.1.2 Pendulum counterweight
1.10.1.3 Pin
1.10.1.4 Bolted connection
1.10.1.5 Folding connector
1.10.1.6 Spring cotter
1.10.1.7 Ring
1.10.1.8 Opening
1.10.2 Air distribution switch Narrow
1.10.2.1 Socket
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No. Denomination Description
1.10.2.2 Pendulum counterweight
1.10.2.3 Pin
1.10.2.5 Folding connector
1.10.2.6 Spring cotter
1.10.3 Orifice plate
1.10.3.1 Bolted connection For the orifice plate (1.10.3)

1.10.4 Orifice plate Narrow

1.10.4.1 Bolted connection For the orifice plate (1.10.4)
1.10.4.2 Bolted connection For the orifice plate (1.10.4), loose
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Step 1: Dismount the air distribution switch (1.10.1)
Fig. 47: Air distribution switch (1.10.1)
1.1 Support the entire weight of the air distribution switch (1.10.1) (max. approx.
10 kg).
1.2 Unscrew the bolted connection (1.10.1.4)
1.3 Release and remove the folding connector (1.10.1.5) by folding over the
ring (1.10.1.7).
1.4 Remove the air distribution switch (1.10.1) by shifting it in longitudinal
direction of the cooler.
Step 2: Replace the pendulum counterweight (1.10.1.2)
Pendulum counterweights (1.10.1.2) can be replaced while the air distribution
switch (1.10.1) is installed in the cooler, or when it has been removed.
2.1 Remove the spring cotter (1.10.1.6) and pull out the pin (1.10.1.3).
You can then remove the pendulum counterweight (1.10.1.2).
2.2 Replace the pendulum counterweight (1.10.1.2)
2.3 Mount it together with the pin (1.10.1.3), and secure it with the spring cotter
(1.10.1.6).
Step 3: Install the air distribution switch (1.10.1):
3.1 Install the folding connector (1.10.1.5) and secure it by folding over the ring
(1.10.1.7).
3.2 Install the bolted connection (1.10.1.4).
3.3 Remove the support of the air distribution switch (1.10.1).
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Machine manual
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Step 4: Remove the narrow air distribution switch (1.10.2):
Fig. 48: Narrow air distribution switch (1.10.2)
4.1 Support the entire weight of the air distribution switch (1.10.2) (max. approx.
5 kg).
4.2 Disengage the folding connector (1.10.2.5).
4.3 Remove the air distribution switch (1.10.2) in a downward or lateral
direction.
Step 5: Replace the pendulum counterweight (1.10.2.2)
In the case of the narrow air distribution switch (1.10.2), you can only replace
the pendulum counterweight (1.10.2.2) when the unit has been dismounted.
5.1 Remove the spring cotter (1.10.2.6) and pull out the pin (1.10.2.3).
You can then remove the pendulum counterweight (1.10.2.2).
5.2 Replace the pendulum counterweight (1.10.2.2)
5.3 Mount it together with the pin (1.10.2.3), and secure it with the spring cotter
(1.10.2.6).
Step 6: Install the narrow air distribution switch (1.10.2):
6.1 Mount the folding connector (1.10.1.5).
6.2 Remove the support of the air distribution switch (1.10.1).
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Step 7: Replace the orifice plates (1.10.3, 1.10.4)
Fig. 49: Orifice plates (1.10.3, 1.10.4)
7.1 Unscrew the corresponding bolted connections (1.10.3.1, 1.10.4.1,
1.10.4.2).
The characteristic feature of the orifice plates (1.10.3, 1.10.4) is their orifice
diameter.
These orifice diameters are stated in the air distribution diagram.

Orifice plates (1.10.3) have one orifice, while orifice plates (1.10.4) have three
orifices.
7.2 Replace the orifice plates (1.10.3, 1.10.4) and mount the corresponding
bolted connections (1.10.3.1, 1.10.4.1, 1.10.4.2) again.
9.2.19 After any maintenance work
After completing the maintenance work and before switching on the machine,
carry out the following steps:
After any maintenance work, carry out the checks stipulated in the section
Checks prior to the test run (see page 7-105).
Remove all tools from the machine.
Make absolutely sure that nobody remains inside the machine.
Mount all protection devices.
Properly close the doors and inspection holes (4.5