How to Replace High-Pressure Suspension Roller Mill Parts: Step-by-Step Guide

Introduction

High-Pressure Suspension Roller Mills are critical equipment in mineral processing and powder production industries. Regular maintenance and timely replacement of worn components ensure optimal performance and extended service life. This guide provides a systematic approach to replacing key parts while highlighting ZENITH’s engineering excellence in grinding technology.

Exploded view of high-pressure suspension roller mill components

Safety Precautions

  1. Lockout/Tagout all power sources
  2. Allow complete system cooling (minimum 2 hours after shutdown)
  3. Wear PPE including heat-resistant gloves and safety goggles
  4. Use certified lifting equipment for heavy components

Step 1: Preparation

Required Tools

  • Torque wrench (200-500 Nm capacity)
  • Hydraulic jack (10-20 ton capacity)
  • Laser alignment tool
  • ZENITH OEM replacement parts kit

For optimal performance, we recommend using genuine replacement parts from ZENITH’s MTW Series Trapezium Mill line, featuring:

  • Anti-wear shovel blades with curved design
  • Integrated oil lubrication system
  • High-strength alloy grinding rollers

Step 2: Grinding Roller Replacement

  1. Disconnect the hydraulic piping and electrical connections
  2. Remove the protective cover using 24mm hex bolts
  3. Extract the worn roller assembly with overhead crane
  4. Clean the roller shaft seating surface with solvent
  5. Install new roller assembly with ZENITH’s patented quick-mount system

Technician installing new grinding roller in high-pressure mill

Step 3: Grinding Ring Installation

When replacing the grinding ring, consider upgrading to ZENITH’s XZM Ultrafine Mill components for enhanced durability:

  • Special alloy composition extends service life 3x longer
  • Precision-machined surface reduces energy consumption
  • Modular design allows sectional replacement
  1. Remove all residual material from grinding chamber
  2. Unbolt the retaining segments (typically 8-12 sections)
  3. Install new ring sections with 0.5mm maximum gap tolerance
  4. Torque bolts to manufacturer’s specification (usually 380±10 Nm)

Step 4: Pressure System Maintenance

  1. Inspect accumulator bladder pressure (should maintain 5-7MPa)
  2. Replace all hydraulic seals in the cylinder assembly
  3. Calibrate pressure sensors using ZENITH’s proprietary software

High-pressure hydraulic system components inspection

Step 5: Alignment and Testing

  1. Perform laser alignment of roller-to-ring clearance (1-2mm gap)
  2. Conduct no-load test run for 30 minutes
  3. Gradually increase material feed to full capacity
  4. Verify particle size distribution meets specifications

Why Choose ZENITH Replacement Parts?

With over 30 years of grinding technology expertise, ZENITH offers:

  • Precision-engineered components with ISO 9001 certification
  • Global service network across 170+ countries
  • Custom material formulations for specific applications
  • 12-month warranty on all mechanical parts

For technical support or to order genuine replacement parts, contact ZENITH’s engineering team through our worldwide service centers.

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