1. MAAG Gear: A pioneer of modern gear technology
The mill’s gearbox
MAAG Gear: A pioneer of modern gear technology
August 09

2. MAAG Gear on the move
1913 Foundation of MAAG Zahnräderfabrik in Zurich, Switzerland
1927 Start of internationalisation (MAAG Italy, MAAG France, etc.)
1989 Foundation of MAAG Gear AG, Switzerland
1997 Acquired by FLSmidth
2000 Acquisition of factory in Elblag/ Poland
Move to Winterthur, Switzerland
Sales of marine and turbo business
2009 Move into City of Winterthur
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

3. Facts
MAAG Gear is a leading global player and belongs to FLSmidth since 1997
Engineering, sales, marketing and project management in Winterthur
Production in Poland and Winterthur
Quality ISO 9001 certified
More than 90 years of grown expertise
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

4. Figures 2008 Turnover: 115 mio CHF
Production capacity 80 –100 gear units
Employees: 280
Engineers: 105
Technicians: 78
Service: 30
Administrative: 45
External Assistance: 14
Trainees: 8
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

5. Know-how in engineering and technology
Engineering experts
Gearing technology - parallel gears
Gearing technology - bevel gears
Metallurgy
FEA
Antifriction bearings
Journal bearings
Toothed couplings
Acoustics/vibration analysis
CAD/PDM
Integrated Logistic Support (ILS) / Reliability Availability Maintenance (RAM)
Supporting tools
CAD / Solid Works
PDM-Systems / Team Center
Ansys for FE-Analysis
Various tools for material analysis
MAAG Gear-developed program systems representing the unique experience of generations of gear exports
Collaboration with our customer
Cooperation with universities and research centers
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

6. MAAG Gear, a member of FLS since 1997
FLSmidth & Co.
FLSmidth Project Division
Cement
FLSmidth
FLSmidth Customer Services
FLSmidth Airtech
Pfister
Ventomatic
Dansk Eternit Holding
Minerals
FLSmidth Minerals
FLSmidth Minerals Division
FLSmidth Dorr-Oliver EIMCO
FLSmidth Krebs
FLSmidth Buffalo
FLSmidth Koch / MVT
FLSmidth Möller
Excel Foundry & Machine
FLSmidth RACHO
FLSmidth ABON
MAAG Gear
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

7. Driving equipment for the cement industry
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

8. Cement processes driven by MAAG Gear
CPU/CPV/LGD
Cemet mill
WPU
Coal mill
WPU/WPV
Raw mill
PPU
Roller Press
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

9. Driving equipment for the cement industry
Roller mills
vertical drive
WPV
Roller mills vertical drive
WPU
Ball mills
lateral drive
LGD
Ball mills
central drive
CPU/CPV
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

10. Roller mills drive, 2-stage (Type WPU)
Benefits to customer
High operational reliability
Efficiency exceeds 96.5%
Customers-specific design of gear units
Very high efficiency Planetary stage and thrust bearing for grinding table with very long service life
Low-cost maintenance
Technical overview
Fully developed compact two-stage design (bevel gear / planetary gear stage)
Case hardened or hardened and quenched tooth
Bevel gear stage with its own casing
Thrust bearing mill table hydro static and hydro dynamic lubricated
Power: 250 to 6,000 kW
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

11. Roller mills drive, 3-stage (Type WPV)
Benefits to customer
Torque split for compact design
Flex pin solution for optimized load distribution
Efficiency exceeds approx. 95 %
Slide bearing application in bevel and planetary gear stage
Simple mechanism for assembly and adjustment of bevel gear stage without remove the gear unit
Technical overview
1st stage 3 planets, 2nd stage 5 planets
Toothing case hardened or quenched and tempered
Thrust bearing mill table hydro static and hydro dynamic lubricated
Power: 2,500 to 9,000 kW
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

12. Installation / Maintenance
Installation and commissioning
Experienced and skilled service engineers
Timely managed
Maintenance
Preventive
Monitoring / short reports
Assessments
Service plan agreement
Overhaul
Planning and project management
Execution and support
Troubleshooting
24/7 Hotline Tel
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

13. Support Customer training During installation and commissioning
In house / in MAAG Gear workshop
Tailor-made
On-site
Expert reports
Vibration and operating readings
Material analysis and monitoring
Advisory opinion
Service packages
Better performance for longer periods
Guaranteed productivity and profitability
Continued customer satisfaction
Enhanced reliability
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

14. WPU: The Gear Drive System
Mill thrust bearing
Thrust pads Thrust bearings lined with babbitt metal
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

15. The WPU Gear System Roller Mill Mill thrusts Annulus WPU gear reducer
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

16. Schematical Design Concept
Spiral bevel gear set
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

17. Set of instrumentation for trend analysis
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18. Set of instrumentation continue
Process signals – directly wired to CS
51.1: T1 – Bearing temperature (self-aligning roller bearing bevel pinion, coupling side)
51.2: T2 – Bearing tempersature (axial self-aligning roller bearing bevel pinion, gearing side)
51.3: T3 – Bearing temperature (self-aligning roller bearing bevel pinion, gearing side)
51.4: T4 – Bearing temperature (roller bearing bevel wheel, below wheel)
51.5: T5 – Bearing temperature (roller bearing bevel wheel, above wheel)
50.1: T11 – Bearing temperature – Segment of axial thrust bearing
46: T12 – Oil temperature at gearbox outlet
Vibration Sensors – directly wired to CS
86.1: VS1 – Ring Gear (Annulus) of the planetary stage
86.2: VS2 – Ring Gear (Annulus) of the planetary stage (perpendicular to 86.1)
Note: Wiring between gearbox and centre control room shall be done by the customer
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

19. WPV sectional drawing
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

20. Selection chart for vertical mill gearbox
WPU
WPV
Maximum
P/nt
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

21. WPV - Concept Main advantages:
Torque split 30% to 70%, => 2nd stage with smaller dimension
5 Planets on the 2nd PV-Stage, => smaller dimension of the stage
Planets on the 2nd Stage with flex pin, => much better load distribution
No housing integrated Planetary stage => standard components possible => casing optimised to the axial load
Only slide bearings used => unlimited lifetime of bearings
Adjustment of bevel gear => No need of gearbox disassembly
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

22. Slide bearings in the bevel gear stage
Advantages of the slide bearings:
Short delivery time
Unlimited lifetime => high availability of plant
Higher damping compared to anti- friction bearings => less vibration
easy installation and highly service friendly
high know-how basis at MAAG Gear through an enormous amount of deliveries for the Cement, Turbo, and Marine applications
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

23. Easy adjustment of bevel gear
Advantages of the improved adjustment method:
Tooth contact easy to adjust
Bevel pinion is adjustable from outside
Bevel gear wheel is adjustable through conic shoe
Fast removal of bevel pinion, without need to remove gear
Service friendly through large dimensioned man hole => short maintenance stops => no pull out of the gearbox
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

24. WPV 360 – Bevel Gear Stage
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

25. Summary MAAG new developed WPV gearbox show several important
advantages in investment and operation:
First Test run results and assembly show very encouraging results
High potential for optimisation of investment cost
Improvement on maintenance and service friendliness increasing the gearbox availability
Lower transport weight and consequently easier erection and reduced transport costs
The independent gearbox modules allow a more flexible and faster production
Lower delivery time for spares due to the smaller gear parts
The gearbox is build up with long term approved technologies
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

26. Maintenance philosophy
- Permanent surveillance, daily checks (by site personnel)
- Checks after every 1‘000 h of operation (by site personnel)
- Checks after every 6‘000 h – and 12’000 h of operation (annually) (under supervision of MAAG Service personnel)
- Special checks after approx. 80‘000h of operation, or 12 years (under supervision of MAAG personnel)
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

27. Daily checks Permanent surveillance/daily checks (by site personnel)
- Quick check of the whole drive group
- Checking and recording of operating data
- Checking of drive group and accessories for eventual leaks (reducer, couplings, lube oil supply unit, etc.)
- Checking of oil level in lube oil reservoir
- Check p of lube oil filter (if not monitored)
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

28. Routine 1’000 h checks
Checks every 1‘000h of operation (by site personnel), (additionally to
the aforementioned daily checks)
- Record and check operating data (complete checklist 1 of the instruction manual)
- Check lube oil filter and filter/breather for contamination, cleaning or replacing at need
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

29. Regular 6’000 h check
Checks every 6‘000h of operation (under supervision of MAAG
service personnel), (additionally to the aforementioned routine
checks)
- Check all important bolt connections (reducer, lube oil supply unit, coupling, etc.)
- Check and if necessary re-tighten gearbox anchoring
- Check lube oil for water content/contamination, Analysis of lube oil by the supplier (replacement according to recommendation)
- Visual check of lube oil-sample from axial bearing casing
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

30. Regular 12’000 h check
Checks every 12‘000h of operation (under supervision of MAAG service
personnel), (additionally to the aforementioned regular checks)
- Checking of alignment to driving- and driven machine
- Inspection of central bearing no. 1 (input shaft)
- Check of instruments and interlocks, record setting points (complete checklist no. 2)
- Inspect and clean lube oil cooler (if required)
- Partial disassembly and inspection of in- and output coupling, replacing of lubricants and seals
- Functional and alignment check of auxiliary drive
- Inspection of spare parts (if available), special tools
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

31. Special checks - Overhaul
Special checks, overhaul after approx. 80‘000 h of operation, or 12
years (under supervision of MAAG personnel)
Disassembly of the entire reducer, inspection of all parts. Ultrasonic bonding test of all bearings. (replacement of parts if required)
Maintenance of components (motors, instruments, etc.) (according to the individual supplier)
Estimated shutdown time 2 weeks, depending upon accessibility,
availability of facilities as well as findings and results of the
inspection.
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

32. Customer Service Products
Overview Customer Service Products
Service & Spare Parts Contracts
Easy – Training Concept
Performance – Gear Box upgrade
Prevention – Security thanks obviating
Speed – Security thanks fast information flow
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 32 32

33. Customer Service Products
Easy – Training Concept
- training of customers service personnel
Challenge – Gear Box upgrade
- exchange of an existing gear box, incl. gear boxes from
competitors
Prevention – Security thanks obviating
- checks via vibration measuring, incl. gear boxes from competitors
Speed – Security thanks fast information flow
- 24 h/day vibration measurement thanks direct access of
customers data’s via internet.
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 33 33

34. How to handle material availability
Gearbox Damage
How to handle material availability
August 09

35. Source of information and procedures
Emergency situation:
a) Customer contacts Field Service Dept: Emergency description, detailed information
b) Customer contacts Sales: availability of spare parts, delivery schedules
Service report at customer
Sales travel report at MAAG Gear
Customer / Agency request once procedure defined
Monitoring system
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

36. Material planning for repair (1)
Emergency case:
Damage assessment and evaluation
Material selection (parts, spares)
Availability at customer site
Service report:
History of the gearbox
Detect background of failure
Recommendations for repair
Sales travel report:
Spare parts already delivered
Identification of spares required
Contact persons
Express delivery
Quotes
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

37. Material planning for repair (2)
4. Customer / Agency request:
Contact Field Service Dept. for details / history
Proceed standard spare parts quotation
Monitoring system
Data exchange
Analysis
Recommendations
Follow up after repair
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

38. Information flow Customer address
Contact name; ; phone No.
Plant code name
Gearbox type & ex. Order No.
Parts description
Drawing No.
SAP No. (If available)
Quantity
Reason for material request
Time frame
Service Report
Basic Info
Material Info
Gen. Info
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

39. Repair options (1) On site repair by MAAG Gear Field Service Engineers
Field Service Dept. to contact customer & make proposal for service intervention (material inspection on site)
If damage material is already specified, then standard part quotation is issued
If defective material is already inspected, then procedure according to inspection report recommendations
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

40. Repair options (2) In house repair at MAAG Gear production site
Delivery of damaged parts
Quote for damage assessment and inspection
Quote for repair
Repair by 3rd. Party
Cooperation under customer responsability
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

41. MAAG Gear locations and service centers
MAAG Gear locations for development, production and sales
Winterthur, Switzerland / Elblag, Poland
Bethlehem, North America / sales office
Beijing, China / sales office
Service Centers including agents and FLS partner offices world wide
(MAAG Gear service centers in USA, Mexico, Poland and Denmark)
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

42. MAAG Gears in operation around the world
Algeria
Angola
Argentina
Austria
Bangladesh
Belgium
Bolivia
Brazil
Bulgaria
Canada
China
Colombia
Costa Rica
Croatia
Denmark
Ecuador
Egypt
El Salvador
France
Germany
Greece
Honduras
India
Indonesia
Iran
Ireland
Israel
Italia
Japan
Jordan
South Korea
Kuwait
Lebanon
Malaysia
Mexico
Nigeria
Pakistan
Peru
Philippines
Poland
Russia
Saudi Arabia
Senegal
South Africa
Spain
Sudan
Sweden
Switzerland
Syria
Taiwan
Thailand
Togo
Turkey
UAE
Ukraine
Uruguay
USA
Vietnam
Yemen
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

43. MAAG Gear‘s vision Core Elements of our Corporate Strategy
Sustainable sales growth
Dynamic, relevant innovation pipeline
Operational excellence
Winning organization
Ensure we have the right people and the right working environment to deliver our vision
Constant willingness to innovate and close collaboration with our customer
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.