tube ball mill

Installation Instructions
 Catalog

1. Working principle and structure...............................................................................3

2. Installation requirements..........................................................................................6

3. Commissioning......................................................................................................14

4. Operation, maintenance and overhaul...................................................................15

5. Annex.....................................................................................................................21

6. Special reminders...................................................................................................22

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 1. Working principle and structure

tube mill is edge drive, tail discharge type tube mill. Open flow and closed circuit a
grinding cement, raw meal, slag and similar materials.
(1.1) working principle
The material enters the first
chamber(coarse grindingchamber) evenly by the feeding device and
t h e f e e d i n g s p i r a l t u b e . A f t e r b e i n g c r u s h e d b y
chamber, it enters the second
chamberthrough thediaphragmplate and continues to be crushed. (for a
two chamber m ill,t s he chamber
econd i sa f gine chamber,
rinding w hichi m su ainly
f g a sed or
d o e s n o t n e e d t o c o n t i n u e g r i n d i n
chamber ( usuallyt f f he g inal chamber)
ine t hrough
rinding
t s he
diaphragm
econd
p late( different
f o o
m i l ld i a p h r a g pml a t e ) . T h e m a t e r i a l i s g r i n d e d i n t o p o w d e r q u a l i f i e d p r o d u c t s b y t h e a c
forging a l ndp ainingf e late,t d nd s inally
t d nters d he
d ischarge
m a p
enter the finished product conveyor.
(1.2) overview of mill structure
The mill is mainly composed of feeding part, main bear
drive device, discharge part and lubrication device.
1.2.1. Feeding part
It includes feeding device and feeding spiral tube. The feeding device is mainly c
hopper, guide plate and support. A gasket is arranged between the hopper and the bracket so as to fit the
installation correction and meet the requirement of adjusting the center height after wearing the b
alloy of the bearing bush. The feeding spiral tube and the feeding material are sealed with felt.
1.2.2. Main bearing

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 The r otary
p o t mart i s f heb t illm bs upported
T i ac ya wo
b tain e
main bearing bush and the
mill trunnion. There is spherical contact between the main bearing bush and
the bearing seat, so that the center can be adjusted automatically when the mill is running. The tile body
is made into a cavity, and cooling water flows through the cavity, so that a large amount of friction heat
generated on the tile is absorbed by water when the mill is running. In addition, a temperature
called e t nd r hermal i i esistance
o o s o t ts bnstalled
o l a mn ne mide ( f he
temperature measuring device of some mills is fixed on the bearing cov
mill trunnion) to obtain the random temperature signal of the alloy bush and transmit it to the instrument
room to display the temperature of the bearing bush. There is a high pressure oil hole in the center of the
bush. W t hen
m s he
a s ill t h tartsp nd
o f tops,
t t o she wigh f oressure
f t il
hole to float the grinding body so as not to scratch the alloy tile surface.
The bearing cover is equipped with a drain pipe. The low-pressure and large flow lubricating oil
from t t heo s hin p il o tation
t mill t runnion
oursf romm ntos any hhe i mall
t o p oles
a e nt he
wedge-shaped c b tavity
mill t runnion
etween
a ndt b he heb earing
s t t f ush, p io l hat he
by d ynamic
p I oressure.
t p o ln rderb e o o t revent
m b il
a e eakage,w o oth
scrapers. A tee cock is installed on the cooling water pipe. The siphon action can drain off the water in
the bearing bush, so as to prevent the alloy tile from cold cracking for a long time in winter.
D ur i ng o pe r at i on , st he
h e l lw i l l e x pa nd w he n he a t ed . S i n ce
dr ith
vees ys te m is i ns ta l l e d at th e
d i s c h a r g e e s n h d,e l oi l tf it sh e n o t a l l o w e d t o e x p a n d a t t
s h e, l lb u t o n l y t o t h e f e e d i n g e n d . T h e r e f o r e , t h e s p h e r i c a l b u s h a
m i l l t r u n n i omna t c h H 11 / F 9 i n l e n g t h . H o w e v e r, t h e r e i s a c e r t a i n c l e a r a n c e a t t h e f e e d e n d
shrinkage and expansion of the grinding body (these values include the installation error)
1.2.3. Rotary part
The rotary part is the main body of the mill, in which the grinding of materials is carried out. It i
mainly composed of mill trunnion and shell.
The shell body is rolled and welded with steel plate, with flat end cover structure at both ends, and
t h e m a t e r i a l i s Q 2 3 5 - B , e t c . T hme i tl w
l tor u n n iso na r e m a d e o f c a r b o n s tZe G2
e l 3( 0 - 4 5 0 ) . T hmei l l
trunnionis connected with the
shellend cover with bolts. The
shellis divided into 2-4 compartments.
The first chamber is equipped with step lining plate or lifting ring groove lining plate. It can increase the
steel ball appropriately and enhance the crushing ability of the steel ball to the product. The installation
of such liners is related to the rotation of the mill. The thin end of the liner is in the direction of rotation.
I f i t i s a t h r eceh a m b e rm i l l , t h e s e c o cn hd a m b e rc a n b e e q u i p p e d w i t h s t e p p e d l i n e r, a c t i v a t e d l i n e
grooved liner, etc. (if it is a two
chamber mill, only fine grinding liner can be installed, such as wavelet

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l i n e r, f l a t l i n e r o r s l o w s t e p m i l l , a n d t h e g r i n d i n g b o d y i s s t e e l s e g m e n t ) . T h e g r i n d i n
s e c oc hn ad mi bs e ar s t e e l b a l l w i t h a s m a l l e r
chamber
. Generally, the inclined groove lining plate and the slow step lining plate used in the m
w a r e h o u s e a l s o h a v e d i r e c t i o n a l i t y, w h i c h s h o u l d b e p a i d a t t e n t i o n t o d u r i n g i
chamber is generally a fine grinding
chamber, which has the joint action of fine grinding liner (wavelet
or flat liner, etc.) and steel section, which has better grinding function for materials.
The compartment is separated
diaphragm
by board. A ccording to the characteristics and grinding
forms of grinding materials in the mill, there are threechamber
kinds of
separation devices: ① single-
laye rdiaphra gmplat e; ② doubl e-laye r compa rtment plat e w ith good m ateri al ha ndling pe rforma
multiple internal screening double-layerdiaphragm board with internal powder separation function. The
single-layerdiaphragmboard is composed of a single-layer grate plate and a central plate. The double-
layer compartment plate is generally composed of grate plate frame, front grate plate, rear gr
(some are blind plate), lifting plate, discharge cone and central plate. The structure of the double-l
diaphragm board is designed in consideration of many factors such as feeding, lifting, powder selection,
v e n t i l a t i o n , r e t u r n i n g m a t e r i a l , a n t i s t r i n g g r i n d i n g b o d y, e t c . D i f f e r e n t s i z e s o f g r
d i f f e r e n t m a t e r i a l s , u s i n gd idaipf hf er ra egbnmot a r d d e v i c e . F o r e x a m p l e , t h e g r i n d a b i l i t y
p a r t i c l e s i z e o f s l a g a n d c e m e n t a r e q u i t e d i ff e r e n t , s o t h
diaphragm b oard,e specially
t c c a hes astor
c u f rack
g snd a creen
c a a rack
quite different. In addition, the arc-shaped lifting plate is also directional, so attention should be paid to
the installation and welding.
1.2.4. Gear cover: it is s et to ensure the safe operation and good lubrication of the big an
gears, which is equipped with sealing device and oil leakage prevention device.
1.2.5. drive part
The drive part of mill is generally divided into main drive and auxiliary drive (there is no auxiliary
drive for small mill)
1) Main drive
It is composed of main motor (generally high voltage or low), main reducer, pinion and coupling.
The main motor drives the main reducer through the coupling, and then driv
through the gear coupling. The small gear drives the big gear fixed on the flange of the grinding body to
rotate the mill.
2) Auxiliary drive
T h e a u x i l i a r y r e d u c e r ( u s u a l l y Z S Y o r N Z S h i g h s p e e d r a t i o r e d u c e r ) i s d r i v e n b y Y- t
through the coupling with brake wheel, or the auxiliary reducer is driven b

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electromagnetic braking, and the main reducer is driven by the reducer through the clutch. Finally,
mill rotates slowly at the speed of less than 1R / min for the installation and maintenance of the
When the main mill is started, the two shifting fork Motors should be separated.
It must be pointed out that the arrangement of the mill drive is not allowed to be changed at will. If
it needs to be changed, the force of the small gear on the big gear should always be upward. At the same
time, the direction of the lining plate and guide plate should be considered.
1.2.6. Discharge part
The discharge part is mainly composed of discharge cover, screen shell, discharge spiral tube and
discharge lifting plate in the rotary body. The spiral tube is fixed in the discharge
mill trunnion. During installation, pay attention to align the feed inlet of discharge spiral drum with the
discharge port of discharge lifting plate. The discharge port of the discharge spiral drum is connected
with the screen shell. The materials are screened by the screen shell, and the finished products enter the
conveyor, and the impurities are separated out and discharged into the hood fork tube. The exhaust gas is
discharged from the air extractor. Asbestos rubber gasket is used for sealing between discharge spiral
drum and discharge cover.
1.2.7. Lubrication part（We don’t have for Brazil mill）
The oil cooling and bearing lubrication of the two main bearings and the main reducer are
respectively carried out by their own independent lubrication systems in the way of continuous
circulation.
Please refer to the instruction manual for lubrication of main reducer.
The lubrication system of the main bearing is equipped with two sets of high-pressure and low-
pressure lubrication devices. When starting and stopping the high pressure mill system only. This is
hydrostatic lubrication. When the mill is in normal operation, the low-pressure system carries out
dynamic pressure lubrication through the pipeline to the main bearing oil pipe.

2. Installation requirements

(2.1) mill installation can refer to the following steps:

1) Foundation acceptance
2) Dimension check of each part of mill body
3) Foundation setting out
4) Pad iron placement
5) The main bearing chassis is in place and aligned in the first time

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 6) Primary grouting
7) Foundation maintenance
8) Installation and fine alignment of main bearing seat
9) Grinding body in place
10) Secondary fine search and secondary grouting.
11) Installation inside and outside the mill.
12) Install the lubrication and cooling system
13) Install the operation platform at the inlet and outlet end and safety measures
(2.2) Foundation
2.2.1. Foundation acceptance
The foundation acceptance includes the following contents:
(1) In order to ensure the installation quality and progress, the mortar should be carefully removed
before the installation of the mill. The concrete foundation should not have cracks, loose, pitted surface,
cavity and exposed reinforcement.
(2) The arrangement and size of foundation bolt holes shall allow for possible deviation of any side
of the machine bottom plate by 10-20 mm.
(3) The bottom plate in the anchor bolt hole shall be cleaned, and there shall be no foreign matters in
the hole.
(4) According to the equipment documents modified according to the actual size of the mill, check
the overall dimension of the mill foundation and the relative position of the elevation to the plant to meet
the requirements of relevant technical documents.
2.2.2. Center plate
After the foundation is inspected and qualified, the center standard plate can be embedded on the
foundation according to the revised drawing of the mill's measured size, Its size is about (150-200) ×
(30-60) mm. It is firmly embedded on the foundation surface, and then the center mark is marked. A
small punch is made with a punch (using a theodolite to cast the point), which is used as the basis for
hanging the center line to align the equipment position when installing the equipment.
1) The embedding method and requirements of central standard plate:
a. The central standard plate shall be set at both ends of the equipment, with one piece at each end.
The center of the standard plate shall be on the center line of the foundation, and three center plates shall
not be buried on the same central line.
b. The center plate should be exposed to the foundation surface for 3-5mm after embedding.
c. High grade cement mortar shall be used to pour and fix the center plate firmly. If possible, it shall
be welded on the foundation reinforcement.

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 2.2.3. Datum point
The datum point is the standard basis for measuring elevation when installing machinery. It is to
measure and mark the elevation according to the zero point of the plant area.
1) The embedding method of datum point: the datum point is usually made by rivets. A 50 × 50 steel
plate with a thickness of 10 mm is welded on the end of a 50 mm long rivet rod, or two 50 mm long
deformed steel bars are welded, and they are buried in the predetermined place and fixed with high-grade
cement mortar.
2) Points for attention in laying datum points:
a. The exposed part of datum point shall not be too high (no more than 10 mm).
b. The small pit where the datum point is buried shall be made into a small upper opening and a large
bottom.
c. The datum point should be checked frequently to avoid the foundation subsidence or other reasons
which may cause the elevation change and not be found.
d. When it is not in use, it must be covered with an iron box to avoid damage. If there are damage
marks, it must be re measured before use.
e. The reference point must be embedded in the position convenient for measuring elevation, and the
closer to the measuring surface of the installation machine, the better.
2.2.4. Foundation marking
The foundation marking is a very important process in the mill installation process, which has a
direct impact on the mill installation quality. During the marking process, we must fully understand the
technical requirements given in the installation drawing and foundation drawing after checking with the
real object.
According to the drawings, the longitudinal and transverse center lines and datum points of the mill
and the vertical and horizontal center lines of the drive device are drawn on the basis of the drawings.
After the center line is determined, a center point with a diameter of no more than 1 mm shall be
punched out on the center plate, and a red paint circle shall be drawn around the center to show eye-
catching. The quality requirements of foundation marking are as follows:
1) The distance error of the transverse center line on the foundation of the two main bearings shall
not exceed 1 / 10 of the thermal expansion of the grinding body, and the maximum distance error shall
not exceed 1 mm.
2) The displacement between the longitudinal centerline indicated on the center plate and the
longitudinal centerline on the drawing shall not exceed ± 3 mm.
3) The center line of the grinding body and the center line of the drive shaft must be strictly parallel,
and the error of the distance between them shall not exceed ± 0.5 mm.
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 4) The adjacent foundation must be measured to make the diagonal line equal to ensure that the
longitudinal and transverse center line is 90 degrees.
2.2.5. Hanging center line:
The purpose of hanging center line is to check the mutual relationship of various parts during
installation.
(2.3) installation of foundation bolt
2.3.1. Treatment before laying
Before laying the anchor bolt, the rust and oil on the anchor bolt should be removed, but the thread
part should still be coated with grease to prevent rust, and check whether the nut and bolt fit well.
2.3 2. When laying the anchor bolt, it should be vertical, and the tolerance of non perpendicularity is
1 / 1000.
2.3.3. Precautions when tightening nuts:
1) A gasket should be added under the anchor bolt;
2) Locking device shall be used for nuts and bolts;
3) The plane contact between nut and washer, washer and equipment base shall be ensured to avoid
additional load on anchor bolt;
4) Only when the concrete reaches 75% of the design strength can the anchor bolts be tightened;
5) The tightening of anchor bolts should start from the middle of the equipment, and then cross
diagonally to both ends. At the same time, the force should be applied evenly. It is strictly forbidden to
tighten one side and then the other side;
6) After tightening the nut, the bolt must show 1.5-5 bolt moments.
(2.4) main bearing
2.4.1. Bearing chassis
The bearing chassis shall be cleaned before installation, and then the transverse and longitudinal
center line shall be drawn on the upper surface of the bearing chassis with the connecting bolt hole or
side processing surface of the bearing chassis as the reference line, and then the anchor bolt and the base
shall be installed on the foundation together, and the pad iron shall be placed on the base. The anchor
bolt and the base are positioned with special sleeve, and the foundation center line is checked, and the
base is adjusted to the correct position.
1) The distance between the center lines of the two chassis shall generally meet the design
requirements. If the actual size of the shell and mill trunnion after assembly does not conform to the
design, the actual size can be used for construction;
2) The longitudinal center lines of the two bearing chassis shall be parallel, and the allowable non
parallelism error shall not be greater than 0.5mm per meter;

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 3) The levelness error of the main bearing chassis is 0.1 mm per meter, the height tolerance of the
two bottom coordinates is 0.5 mm, and only the feed end is allowed to be higher than the discharge end;
4) After the elevation position, horizontal position adjustment, inspection and mutual position
correction of the main bearing chassis are qualified, the foundation bolts of bearing base can be poured
with crushed stone concrete.
2.4.2. Bearing pedestal
The bearing seat is placed on the bearing chassis, and the high center point of the concave spherical
surface of the bearing block is taken as the reference point, and the vertical center line of the bearing seat
is found out by the method of hanging hammer line, so that it coincides with the corresponding center
line of the bearing chassis.
The contact surface between the bearing pedestal and the bearing chassis shall be in uniform contact
along its periphery, the local clearance shall not be greater than 0.1 mm, the non-contact length shall not
exceed 100 mm, and the cumulative length shall not exceed 1 / 4 of the surrounding length.
After installation, the cooling water channel of the bearing block should be connected, and the
hydraulic test should be conducted. The test pressure is 0.4MPa, and the pressure holding time is 10
minutes. (many large and medium mills do not have cooling water channels, so this test is unnecessary.)
2.4.3 bearing bush
Before installation, pressure test shall be carried out on bearing bush, the value shall not be lower
than the rated working pressure (32 MPa) of high-pressure oil pump, and the pressure shall be maintained
for at least 5 minutes. The bearing bush and the spherical surface shall be in good contact, and the
matching shall be in accordance with the drawing.
(2.5) grinding body
2.5.1. Before installing the grinding body, the inner part of the main bearing and the
mill trunnion diameter should be thoroughly cleaned. When lifting the grinding body, it is absolutely
forbidden to tie the steel wire rope on the mill trunnion diameter to avoid scratching the journal. During
the installation process, try to prevent dust and other debris from falling on the surface of the bearing
bush. When the mill trunnion journal falls close to contacting the surface of the bearing bush, the
grinding body stops falling. At this time, wash the bearing surface with diesel oil once, then add a little
lubricating oil to it, and then drop the mill trunnion on the bearing bush, and pay attention not to damage
the bearing bush.
After the grinding body falls on the main bearing, it should be carefully checked and the results
meet the following requirements:
1) After the rotating part is installed on the two main bearings, the contact between the

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mill trunnion and the main bearing bush should be checked to meet the design requirements;
2) The upper busbar of the two mill trunnions should be on the same horizontal plane, and the
deviation should not exceed 1 mm, and only make the feeding end higher than the discharging end;
3) The axial clearance between the shoulder of the feed mill trunnion and the main bearing bush
shall meet the design requirements;
2.5.2. Secondary pouring
Before the secondary pouring of the foundation, the anchor bolts shall be tightened, and the oil,
paint, rust, etc. on the bearing base and pad iron shall be removed. The cement shall be tamped during
pouring, and there shall be no gap or honeycomb defects.
2.5.3. Inner parts of shell
Most of the internal parts of the mill barrel have directionality, such as ladder lining plate, lifting
plate, feeding and discharging spiral tube and grate plate. In the installation of these directional parts, it
must be carried out according to the provisions of the equipment documents, and can not be installed in
reverse, otherwise the mill will not be able to produce. At the same time, the back vent part shall be filled
with cement mortar and assembled after 24 hours. The clearance shall meet the requirements of the
drawing. Otherwise, plug welding can be carried out with a steel bar.
1) End liner
The gap between the end liner and the shell end cover shall be filled with high-grade cement mortar
to avoid slurry or material scouring the end cover (there is a certain distance between them). When
plastering mortar on the end cover, the special wooden pin should be inserted into the bolt hole of the end
cover first, so as to protect the bolt hole of the end cover from being blocked, and leave the hole for the
bolt. Pay attention to coating a layer of grease on the outside of the wood pin, which is for the purpose of
withdrawing the wood pin.
2) Feeding and discharging spiral drum
When installing the spiral drum, first check whether the rotation direction of the screw is consistent
with the rotation direction of the mill. It is not allowed to weld between spiral tube and
mill trunnion, but insulation material, asbestos or rock surface shall be added.
3) diaphragm board and discharge grate plate
When installing the diaphragm board and discharge grate plate, attention should be paid to:
a. When installing the diaphragm board frame, pay attention to the direction of the lifting plate;
b. The hole of grate plate can be divided into feed end and discharge end, and the direction cannot
be reversed;
c. When the gap between two grate plates is too large, round steel shall be used for welding;
d. All nuts inside the shell body shall be tightened again and welded dead after the mill runs at full
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 load.
2.5.4. Big gear installation
Before installing the big gear on the grinding body, install the lower gear cover and check whether
there is oil leakage in the big gear cover. The installation of big gear shall meet the following
requirements:
1) The end face of the big gear mouth and the end face of the shell flange shall be closely fitted. If
there is a gap, it should not be greater than 0.15mm.
2) The clearance of the big gear at the joint flange of half face should not be greater than 0.1mm,
and the pitch deviation here should not exceed 0.05m (m-gear modulus).
3) After the big gear is installed on the shell, the radial circle run out tolerance of the tooth top
circle to the mill trunnions at both ends shall not be greater than 1.23 mm, and the end face runout
tolerance shall not be greater than 1.72 mm.
(2.6) drive device
After that, the drive device can be aligned. The procedure is as follows:
Pinion - Main Reducer - main motor - auxiliary drive
2.6.1 after the pinion is assembled,
1) The tooth side clearance of big and small gears should be between 1.4
～ 2.4 mm;
2) The contact spot of large and small gears should not be less than 40% along the tooth height and
80% along the tooth length, and should be located in the middle of the tooth width.
2.6.2. The installation of the main reducer shall comply with the relevant provisions and
requirements of the technical documents attached to the "installation and operation manual" attached to
the equipment. Between the slow shaft of the main reducer and the pinion shaft, the shaft end clearance
is 8 ~ 10, The coaxiality is φ 0.1, that is, the radial deviation between the center lines of the two gear
coupling is not greater than 0.1 (Note: this data is in accordance with the regulations of the reducer
factory), and the inclination is not more than 0.3 per meter. (the axial clearance between the end faces of
the two tooth coupling at four points along the circumference is not greater than three thousandth of the
diameter of the end face of the coupling)

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 Side of main
reducer

Pinion side

Figure: measurement of coupling shaft degree and measurement of single half coupling
It must be pointed out that: when measuring the coaxiality between two couplers, the dial indicator
is used to measure the outer diameter of the coupling. The error obtained by measuring the outer
diameter of the coupling is regarded as the error of the two shafts. Therefore, the coaxiality of the shaft
hole and the outer circle of each half coupler should be guaranteed in the metalworking process,
otherwise this kind of measurement and adjustment is meaningless. Especially for the gear coupling,
there is a certain degree of difficulty in processing, so it must be guaranteed by good process and tooling.
The vibration of the mill caused by the coupling problem, the pin fracture, other parts damage and even
the mill can not run are common. Therefore, it is necessary to strictly check the parameter size of
coupling group affecting its coaxiality before delivery!
2.6.3. The installation of main motor shall meet the requirements of "installation and operation
manual" attached to the equipment.
The coaxiality of the fast shaft of the main motor and the main reducer is 0.05, that is, the radial
deviation between the center lines of the two couplings is not more than 0.05 mm, and the inclination is
not more than 0.05 per meter, that is, the deviation of the axial clearance between the end faces of the two
tooth type coupling at four points along the circumference is not greater than five hundred thousandth of
the diameter of the coupling end face (Note: this data is required by the motor factory) (see Fig. 6)
2.6.4 installation of auxiliary drive: it connects the fast shaft at the other end of the main reduction
shaft with the slow shaft of the auxiliary reducer through two helical gear clutches. After installation, it
should be ensured that there is a space of 10 mm in the middle when the clutch is separated.
2.6.5. Electrical installation of drive part
The distance between the starting cachamberet of the main motor and the substation should not be

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more than 100 meters, the shorter the better. The starting cachamberet should not be more than 10 meters
from the motor, so as to observe the operation of the mill in front of the
cachamberet.
In order to improve the active power of the main motor, it is recommended that the user install the
camera or capacitor cachamberet.
The power line and control line of each motor must meet the requirements of withstand voltage and
current carrying capacity.
(2.7) installation of lubrication system
2.7.1. The installation elevation of the thin oil station should be based on the principle that the
return oil outlet of the lubricated equipment is higher than 450 of the oil return inlet on the thin oil
station, so as to ensure the return oil pressure difference and make the oil return smooth. It should also be
considered that there is space for oil container under the oil drain hole of the oil tank (attention should be
paid when making foundation).
2.7.2. The materials and specifications of all high and low pressure oil pipes and pipe joints meet
the requirements. Before installation, it must be acid washed, cleaned and dried with 10% soda water and
hot water.
2.7.3 for parallel or crossed pipelines, there is a certain distance between the two pipes to prevent
vibration.
2.7.4. After all pipelines are installed, diesel oil shall be used instead of lubricating oil for trial
operation. Before commissioning, attention should be paid to:
1) Cover the mill trunnion to prevent dirt from entering between the mill trunnion and the main
bearing bush;
2) Disconnect the return line at the entry lubrication station to prevent dirt from entering the tank.
Clean 2-3 times in this way.
2.7.5. The low pressure system should be 0.9 MPa, and the high pressure system should be
qualified at 20 MPa.

3. Commissioning

The mill can be put into trial operation only after the mill has been installed and passed the
inspection. The inspection items include:
1) All bolts shall be tightened.
2) All valves on the pipeline shall be flexible and the oil level shall meet the requirements.

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 3) All sealing parts shall be well sealed.
4) The contact signal and protection device have been tested on a single machine and are flexible
and reliable.
5) All auxiliary equipment are installed to ensure smooth material after grinding.
6) There is sufficient reserve of materials in the silo.
7) When the clutch is moved, the clutch should be flexible and the direction should be correct.
8) The rotation direction of each motor is correct.
(3.1) commissioning of air mill
Procedure of air mill commissioning
3.1.1. The motor runs continuously for 4 hours without mill and reducer.
3.1.2. The motor and reducer run together for 8 hours (without mill).
3.1.3. Drive the mill to run for 12 hours, first start the main bearing lubrication system, and then
start the slow drive device after the rotating part is lifted by high-pressure oil, and then turn on the slow
drive device for 1-2 turns. After confirming that the mill has no collision and hindering the operation,
stop the slow drive device, start the high and low-pressure pump of the main motor to supply oil at the
same time, and stop the high-pressure oil supply after 3 minutes.
The test run of air mill shall meet the following requirements:
1) The lubrication condition of each lubricating point is normal without leakage;
2) The temperature of main bearing of mill shall not exceed 40 ℃, and that of rolling bearing shall
not exceed 50 ℃;
3) The mill shall run smoothly, gear drive shall be free of abnormal noise, and the tooth surface
contact shall meet the requirements;
4) There is no looseness in lining plate and drive parts.
(3.2) load test run
After the mill is checked to be in conformity with the requirements, the load test run can be carried
out. During the load test run, the corresponding amount of materials must be added. During the test run,
the load is gradually increased. The operation is divided into the following stages.
3.2.1. Start the high and low pressure lubrication system of the main bearing, start the main motor
after the rotating part is supported by high pressure oil. After running for 5 minutes, turn off the high-
pressure oil pump of the main bearing lubrication system and continue to supply low-pressure oil.
3.2.2. Load 1 / 3 of the designed loading capacity of the grinding body and run for 24 hours;
3.2.3. Load 2 / 3 grinding body with designed loading capacity and run for 72 hours;
3.2.4. Load 5 / 6 grinding body with designed loading capacity and run for 72 hours;
3.2.5. Load all grinding bodies with designed loading capacity and run for 72 hours;

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 Proper amount of material must be added during the load test run, and the mill shall meet the
following requirements during the load test run:
1) Stable operation, no sharpness and periodic vibration;
2) The temperature of main bearing bush should be lower than 65 ℃, and the oil return
temperature should be lower than 50 ℃;
3) All auxiliary equipment operates normally;
4) There is no ash leakage at the bolt parts of mill end cover liner, shell liner, compartment plate
and grinding door;
5) Install 1 / 3 of the total weight of the grinding body, and after running for 24 hours, check
whether the bolts at the joints such as the liner plate and diaphragm plate are loose, broken or
fall off, and the bolts and nuts shall be tightened once.
The problems and solutions in mill commissioning are shown in Table 1

4. Operation, maintenance and overhaul

(4.1) mill operation (start and stop)

4.1.1. Starting the mill
After installation, the mill shall be inspected according to the inspection items mentioned above, and
then the mill shall be started according to the following procedures.
1) Send out the signal according to the regulations, and start the mill only after getting the reply
signal from each post that the mill is allowed to start;
2) The sequence of starting the mill is as follows:
① When the cooling and lubrication systems are started, the two main bearing lubrication systems
should be started synchronously. The low-pressure oil pump should be started first. It is strictly forbidden
to start the high-pressure oil pump without starting the low-pressure oil pump;
② Dust collector and discharge conveying equipment;
③ Main motor;
④ Feeding system;
After the mill is started, the mill operator and relevant personnel shall carry out the following
inspection work in time:
1) Whether all bolts are broken or loose;
2) Whether the lubrication temperature of main bearing, reducer and motor is within normal range
and whether there is overheating phenomenon;

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 3) Whether the gear meshing of reducer is normal and whether there is abnormal sound;
4) Fluctuation of main motor current value;
5) Whether the parts are tight, and whether there is ash leakage, oil leakage and air leakage;
6) Whether the lubrication and cooling system is normal.
4.1.2. Stop grinding
Stop grinding is divided into normal stop and emergency stop.
1) Normal stop grinding: first, inform relevant posts, and then stop grinding in sequence
① Feeding system;
② Mill;
③ Conveying equipment;
④ Main bearing lubrication and cooling equipment;
When the mill is shut down normally, the mill and conveying equipment must empty the remaining
finished products or semi-finished products, so as to avoid blockage caused by long grinding stop time
and bring difficulties to the next start-up.
2) Emergency stop grinding: during the operation of the mill, there are some special circumstances.
In order to ensure the safety of the equipment, emergency stop grinding measures must be taken in the
following cases.
① The meshing of big and small gears is abnormal, especially in case of large vibration or abnormal
noise of reducer and high temperature;
② When the lubrication system fails to supply oil normally;
③ When the temperature rise of main bearing, drive bearing, reducer and motor exceeds the
specified value or the motor current exceeds the specified value;
④ Failure of conveying equipment and loss of conveying capacity;
⑤ When the fixing bolts of lining plate and diaphragm board are loose or broken off;
⑥ The anchor bolts of main bearing, drive bearing, reducer and motor are loose;
In case of sudden accident, the feeding must be stopped immediately and the power supply of the
motor and other units must be cut off for troubleshooting.
3) Several problems in the operation of mill:
① When the noise in the mill is abnormal, carefully check the instruments, instruments and related
phenomena to find out the problems and eliminate the faults to ensure the normal operation of the mill;
② When the grinding is stopped for a long time, the water and lubricating oil in the main bearing
shall be drained, and the water oil channel shall be cleaned at the same time;
③ When the grinding is stopped for a long time, the grinding body should be poured out to support
the middle part of the grinding body to avoid deformation of the shell body;

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 ④ Pay attention to the oil level of the main bearing lubrication system at any time to prevent the
cooling water from seeping in. When the oil level is too low, new oil should be added in time, and the oil
should be filtered first.
(4.2) maintenance
When the mill is in normal operation, the operator must pay attention to and observe the following
matters:
4.2.1. Without feeding, the mill shall not operate for a long time (generally more than 30 minutes),
so as to avoid damaging the liner and consuming the steel ball.
4.2.2. Even feeding is one of the important conditions for the mill to obtain the highest output.
Therefore, the mill operator should carefully adjust the feed rate to achieve high and stable production.
4.2.3. After the newly installed or newly replaced gear shaft bearing and other friction parts have
been operated for one month, all lubricating oil shall be drained out, the oil pool and channel shall be
cleaned, and the new oil shall be replaced.
4.2.4. Regularly check and ensure that there is enough and cleaned lubricating oil at each
lubricating point. For the return oil filter of the thin oil station, check and clean it at least once a month,
check the quality of the lubricating oil once every half a year, and replace the new oil if necessary.
4.2.5. Check the meshing condition of the big and small gears of the mill and whether the matching
bolts are loose, and there shall be no abnormal vibration and sound during the operation of the reducer.
4.2.6. The slow drive device is designed to check the mill and rotate the mill when it stops
grinding. It should be noted that when the mill starts with load, it is not allowed to start the slow drive
device first.
4.2.7. The liner inside the shell shall be inspected regularly, and the worn and broken liner shall be
replaced in time, and the loose or broken bolt shall be tightened or replaced in time to avoid wearing the
shell and ash leakage.
(4.3) maintenance
In the process of operation, the equipment will inevitably wear. If the wear reaches a certain
degree, its performance can not be guaranteed, so it can not operate safely. At this time, the worn parts
must be repaired or replaced in time. Generally, the maintenance of the mill should be carried out
according to the following items.
4.3.1. In the feeding device
① Repair or replace the liner
② Adjusting the sealing ring
4.3.2.In the rotary part
① Repair and replacement of feeding and discharging spiral drum;
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 ② Replacement of feed end lining plate and discharge grate plate;
③ Replacement of lining plate of each chamber;
④ Replacement of grate plate, grate frame, lifting plate and other vulnerable parts of double
compartment plate;
⑤ Repair and replacement of outer ring and inner ring of single layer diaphragm board;
⑥ Replacement of manhole liner and manhole cover;
⑦ Tighten and replace all connecting bolts, washers and nuts of lining plate, compartment plate and
lifting plate.
4.3.3. Main bearing
① Repair, scrape and re cast the liner of spherical tile after wear;
② Repair, adjust and replace the oil scraper and oil scraper after wear;
③ All cooling water systems are inspected and maintained.
4.3.4. drive system
① Check and replace rubber block of rubber block coupling and diaphragm of diaphragm coupling;
② The maintenance of the motor and reducer shall be carried out according to the relevant
provisions in the respective operation instructions.
(4.3.4) problems and solutions during mill operation: see attached table 1

Table 1 problems in mill operation and their solutions:

Problems in commissioning Causes processing method

1. The pinion shaft is not parallel to the

Adjust the center line of pinion shaft
shell center line
and mill to meet the requirements.
T h e 2. T he r ma adiald e xial
os l g heviation
i i n f arge
g ear s
H i g h s p e e d m e s h i
vi bra ti on of bi g and too large
grinding contact surface, mak
small gears is noisy 3. P oor m qeshing ( c ualitys top learance, ide
a c c u r a c y m
big gear clearance and contact area accuracy do not
requirements.
wheel meet the quality requirements)
I n g e n e r a l , t h e b i g gProperly e a r e i s st enlarge cr i o du s l he yo enter
Frequent b o reaking f
deformed. E t tvery
H f ime t t large
he and
aff small acegears, andurnsit is better
o
bolts o t nh fhe uff ace
the small gear, the bolt is forced to exceedn o t t o e x c e e d t h e u p p e r l i
of large gear
the limit and be pulled and broken. backlash or not much.
main Bearing bush heating 1 . P o o r s c r a p i n g a n d g r i n d i n g o f b e a r i n g
bearing bush wit h oil l ubrication (t he precision of
s i d e c l e a r a n c1. Scrape e and
c ogrind n thet bearing
a c bush.t s u r f
unqualified) 2. Light load running in
2. T he m achining
a o o l ccuracy f il ubricated
tile surface is low
2 . I n s u f f i c i e n t l u b r i c a t i n g o i l Change
o r p o o the
r o ilubricating
l oil to make it
quality. sufficient.

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 Problems in commissioning Causes processing method

3. The grade of lubrica ting oil is not

Change lubricating oil with specified
correct, the oil film is too thin and too
viscosity
thick, and the flow is slow
Check w thether
c w hep ooling
4. The cooling water is not good
flow is sufficient.
Check the cause of vibrati
5. Vibration
adjust it.
1 . C h e c k a n d a d j u s t t
Oil spills from the
difference of inlet and outlet pipes
seal of mill trunnion Poor oil return
2. C hange t o w he l v il iith ow
and main bearing
winter
The grinding body Adjust the high pressure to
Insufficient high pressure oil pressure
cannot float 15MPa
T h e c e n t e r l i n em oi lf l t threu n insi oAn d j u s t t h e c e n t e r
swing
inconsistent with that of the shell mill trunnion
mill 1. The strength of bolt connection is not
trunnion enough 1. High strength bolt
Bolt cut or broken
2. The bolt tightening force is insufficient 2. Tighten all fastening bolts
or uneven
1 . T h e c e n t e r e l e v a t i o n o f bAdjust o t h thee n center
d s i height
s of both ends
Barrel movement unequal M a k e t h e g e a r m e s h
shell
2. Bad meshing of pinion and pinion requirements
Ash leakage of mill Liner screw loose Tighten the liner screws
M o s Tah e c ii r c u mc f e r e n t i a ll g a p i o f The i nn l ca i di ircumferential
l i n inn gg go l p ap f
collapse plate is not firmly welded. shall be braked and welded firmly.
Ash leakage of mill The liner is broken Replace the liner
The connection between the castor plate
d i a pb ho r a a r gd m We l d f i r m l y, i t i s b e t t e r t o c h a
lifting plate and the castor plate frame is
collapse welding to bolt connection
not firm
The hole of sieve plate is grinded out, and
To o l a rg e p a rt ic le s
the l eakage a a oround b s o nd
a Check
n andoth plug theides
welding f rc
out of grinding
screen mouth is too large
Inside
P o o r g r Rae vde r is e n c ag s t i nog af n d a s s e m b l y o f g r a d e d
the mill Remanufacturing and installation
grinding body liner
After the section is
W r o n g d i r e c t i o n o f p r o d u c t i o n a n
p o u r e d i n t o t h e Remanufacturing and installation
installation of return pipe
overflow plate
I t ' s n o t g o o d t oT hge or e t u r n p i p e i s n o t m a d e w e l l a n d t h e
Remanufacturing and installation
back return section is not smooth
The d ischarge
c T h e astor
design of the gap in front of the
p l a t e i s d si s ceh ar r gi i nog uc a s t ol r yb o a r d i s n o t g o o Cancel
d , a n dthe section easy to block
blocked the section is too small
Spiral A f t e r g r i n d i n g t h e g r o o v
tube S p i r a l t u b e f l a n g e drilling seam at both ends
Flange too thin
crack crack, grind it flat, and then paste the
plate for re welding
Flange bolt broken 1 . T h e s t r e n g t h o f b o l t c o n n e c t i o1.n Replace i s n o tthe high strength bolt

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 Problems in commissioning Causes processing method

enough
2. The bolt tightening force is insufficient 2. Tighten all fastening bolts evenly
or uneven 3. Modify the design and increase the
3. The quantity, specification and strength intensity on site
of designed bolts are not enough
T h e m a t e r i a l c a n n oThe
t s piral
p i t slate t ni w he piral ube s elded
Replace the spiral shell
be fed in reversely.
The coaxiality between the distribution
circle of nylon pin hole and the shaft hole Replace the coupling
Broken nylon pin is too large
Number a s nd opecification
n p h C a n c e fl t hylon
e c o u p l iin n g r i ole
ng groove o
design replace the coupling
coupling 1. The coaxiality between the distribution
L a r g circle e of nylonc pin holeo and
u thep shaftl hole
1. Replace
i n the coupling
g
vibration i s t o o 2 , a n d t h e c o a x i a l i t y o2.f Readjust
t w o hthe a l two
f half couplings
couplings is not good
T h e i n s t a l l a t i o n R e ea dr j ru sot r t h eo cf o a dx i ia la i tpy h o rf at hg
Tear of diaphragm
coupling is too large coupling halves
1. Poor sealing Handling seals
Serious oil leakage 2.Poor installation of oil scraper Adjust the oil scraper
Big gear
3. There is too much oil in the gear ring Reduce the oil level in the oil pool
cover
E x c e s s i v e wThe e fa r i elt
ot f c s t oo
t o glose o t o I he n c r e a sile t h eroove
c l e a r a n c e nw h ehe
n making
sealing felt ring gear or installing the gear cover
Bearing damage Replace the bearing
There are problems with the flow, oil
Bearing temperature quality a o pnd i il t oressure
s o Adjust n these he parameters
il tation f
t o o h i g h ( o vthee reducer r 8 0
Main
degrees) The design and manufacture of the oil
reducer
i n j e c t i o n h o l e a t t hOpen e htheeoila filling t i n hole
g b e a r i n g
position is wrong or blocked
1 . M a n u f a c t u r i n g p r o b l e m s , 1. 2C. Contact o u tp l imn g he 2 anufacturer;
A
The vibration is large
and other external parts and replace the coupling
T h e p o w e r g r i d v o l t a g e i s t o o l o w, Shifta n thed gear and raise the voltage.
Starting difficulty
the machine is jammed Check and remove the jamming.
S t a r t c a n no t be puSt t a r t i n g r h e o s t a t d e v i c e d o e s n o t Rme ap tl ca hc e o r a d j us t f r e q ue nc y s e ns o r
into operation with motor or electrolyte
The dust around the motor is too large,
Main Excessive spark of Replace the brush and take du
the brush wear is serious, and the gap is
motor slip ring proof measures.
too large
G r i n d i n g b o Add d rye a c t i v e p o w e r c o m p e n s a t i o n ,
Power factor too low
under current full such as camera or capacitor
B e a The
r B i aush sn d nd gn f w haft a b t o Cuh eotc k tsheit s c rhaell pi n g p and d , c h e chek a n d
heating lubrication is not good adjust the oil flow, etc

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Table 2 types and consumption of lubricants

Lubrication point lubricant

Allowable Oil
Lubricatio Once added
NO name temperature name Standard No change
n mode quantity (liter)
（℃） period
Industrial extreme
According to
pressure gear oil
Continuou the light oil
N220（Winter 6
1 main bearing s cycle ≤65 GB5903-86 station,
use） months
lubrication operation
N320（Summer
manual
use）
3# Open gear oil
Big and small Oil (winter)
2
gears immersion 4# Open gear oil
(summer)
Regular
3 Pinion bearing Oil cup ≤65 Lithium grease 2L-4 SY1412-75
refueling
4 Main reducer In general, change the oil every 3000 hours (refer to the equipment manual)
5 Main motor In general, change the oil at least once every half a year (refer to the equipment manual)
explain: 1. After using the lubricating oil for the first time in the main bearing and reducer for 1-2 months, all the
lubricating oil should be poured out and cleaned, and then the clean lubricating oil should be added. In
comchamberation with the intermediate repair, the oil should be changed according to the above table.
2. In winter, it is below + 10 ℃ and above + 10 ℃ in summer.

5. Annex

5.1. Random data map

① General layout
② Rotating part diagram
③ Compartment device diagram
5.2. Atlas of vulnerable parts
5.3. Instructions for oil station of main motor and main reducer
5.4. Packing list and product certificate

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 6. Special reminders

6.1 for the connecting bolts of important parts, especially the connecting bolts between
mill trunnion and grinding body, the fastening of huff face connection of big gear must be done as
follows:
1) No matter in the test run or normal production, before or after the start-up or shutdown, all parts,
especially the bolts of the above parts, must be checked regularly and carefully, and there should be no
fracture and loosening. Otherwise, it must be replaced and tightened in time. This is especially true in
every small stage of commissioning.
2) Especially for the larger bolts above M30, it is suggested to lengthen the force arm of the wrench
by using the force bar to increase the tightening force. At the same time, it is emphasized that the
tightening force of bolts in the same circle should be uniform, so as to avoid tightening with hammer
impact wrench.
6.2 the reducer and the main motor shall be strictly checked again according to the installation
dimension requirements specified in the installation and operation instructions of the reducer and the
motor when it operates for 1500 hours (2 months). If it does not meet the requirements, it must be
readjusted to avoid serious accidents that damage the motor and reducer.
6.3 gear cover
Due to the large area of the gear cover of the ball mill and the large deformation during handling, it
is necessary to pay attention to the following during installation:
1) The parts with large deformation should be reshaped on site
2) The outer annular felt should not be close to the oil groove, otherwise it will be easy to wear the
felt
3) The reasons for the individual phenomenon of oil leakage of gear cover are as follows:
A. During installation, the oil flow plate inside the gear cover is not aligned with the oil groove
installed on the big gear. The whole circle range should be carefully checked. If the end of the oil flow
plate is not in the oil groove, it must be reshaped and installed again.
B. The lower part of the gear is too deep to be submerged by oil, and there is too much oil brought
up by the gear.
It is suggested that the submerged depth should not exceed one tooth height.

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