0501 Fuellerversorgung GB

Instruction Manual
Filler Supply
AZ-66323 1
Instruction Manual Filler Supply
Version 3.1.1
© Ammann Asphalt GmbH 2002-2007
Font: Arial, WingDings
Author: Michael Lemper
2 AZ-66323
Inhaltsverzeichnis
1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 General instructions and key to symbols . . . . . . . . . . . . . . . . . . . 9
2.1 Introduction to the Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Use and product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Description of the Filler Supply machine . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Description of the Elevator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Description of the Screw Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5.1 Tubular conveyor screw with radial bearing . . . . . . . . . . . . . . . . . . 17
3.5.2 Tubular conveyor screw with radial and axial bearing . . . . . . . . . . . 18
3.5.3 Tubular conveyor screw with flanged bearing at the free end of the shaft
19
3.5.4 Troughed conveyor feed screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6 Description of the Cell Wheel Sluice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.7 Workplaces at an asphalt mixing plant . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Filler elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.1 Performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.2 Dimensions and Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 Screw conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.1 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.2 Dimensions and Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Cell wheel sluice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1 General instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Lifting eyelets and lifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3 Weights and measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6 Assembly and start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2.1 Installing the elevator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3 Screw conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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6.4 Cell Wheel Sluice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6.5 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.6 Pneumatic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.7 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7.1 Information for the customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2 Emergency-stop devices and safety devices . . . . . . . . . . . . . . . . . . . . . . 38
7.3 Directions for the operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4 Method of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.4.1 Imported Filler With Filler Silos: . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.4.2 Imported Filler With Filler Silo Tower: . . . . . . . . . . . . . . . . . . . . . . 40
7.4.3 Reclaimed Filler: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.4.4 Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.4.5 Screw conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4.6 Cell Wheel Sluice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.5 Daily start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.6 Operation at freezing temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.7 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.7.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.7.2 Heating facility malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.7.3 What to do in the event of fires . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.8 Upkeep work after shut-down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8 Maintenance, repairs and rectification of errors . . . . . . . . . . . . .53
8.1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1.1 Directions for the maintenance personnel . . . . . . . . . . . . . . . . . . . 53
8.1.2 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.1.3 Maintenance work on the electrical system . . . . . . . . . . . . . . . . . . 54
8.1.4 Working on the pneumatic system . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.1.5 Maintenance work in silos, drum, tanks etc. . . . . . . . . . . . . . . . . . 58
8.1.6 Dangers during maintenance work . . . . . . . . . . . . . . . . . . . . . . . . 58
8.2 Access to the maintenance points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.3 Inspection intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.3.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.3.2 Overall plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.3.3 Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.3.4 Screw conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.4 Trouble-shooter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.4.1 Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.4.2 Screw conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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8.5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.5.1 Overall plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.5.2 Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.5.3 Inspection of the filler screw conveyor. . . . . . . . . . . . . . . . . . . . . . . 70
8.6 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.7 Repairs and replacement of elevator parts . . . . . . . . . . . . . . . . . . . . . . . . 73
8.7.1 Replacement of individual buckets . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.7.2 Replacement of all the buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.7.3 Replacement of wear plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.7.4 Replacement of foot wheel, bearing, guide rails and tension slide . 77
8.7.5 Repair and replacement of the gear motor . . . . . . . . . . . . . . . . . . . 79
8.7.6 Repair and replacement of the drive shaft bearings . . . . . . . . . . . . 80
8.8 Repair and replacement of parts on the filler screw conveyor . . . . . . . . . . 82
8.8.1 Repair or replacement of the motor. . . . . . . . . . . . . . . . . . . . . . . . . 82
8.8.2 Repair or replacement of the transmission . . . . . . . . . . . . . . . . . . . 82
8.8.3 Repair or replacement of the inflow bearing . . . . . . . . . . . . . . . . . . 83
8.8.4 Repair or replacement of the outflow bearing . . . . . . . . . . . . . . . . . 83
8.8.5 Repair or replacement of the packing gland . . . . . . . . . . . . . . . . . . 84
8.8.6 Repair or replacement of the screw shaft . . . . . . . . . . . . . . . . . . . . 84
8.9 Repair and replacement of the cell wheel sluice . . . . . . . . . . . . . . . . . . . . 85
8.9.1 Replacement of turnstile (wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.9.2 Replacement of housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.9.3 Replacement of the bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.10 Lubrication instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.10.1Elevator lubrication instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.10.2Lubrication Instructions for Chain Drive of Feed Screw Conveyor . 90
8.10.3Lubrication Instructions for Feed Screw Conveyor With Pedestal Bear-
ing, Pendulum Bearing and Thrust Journal Bearing91
8.10.4Lubrication Instructions for Feed Screw Conveyor With Pedestal Bear-
ings 92
8.10.5Lubrication Instructions for Cell Wheel Sluice . . . . . . . . . . . . . . . . . 93
8.10.6Cylinder mountings lubrication instructions . . . . . . . . . . . . . . . . . . . 94
8.11 Measures to be taken in the winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9 Decommissioning and disassembly. . . . . . . . . . . . . . . . . . . . . . . 97
10 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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6 AZ-66323
1 Foreword
The Filler Supply machine forms part of an asphalt mixing plant.
All Ammann asphalt mixing plants are designed and manufactured individually,
according to the customers' wishes and demands. That is why every plant has a
different structure and configuration. This applies also for positioning and structure
of the machine.
The following notes serve as a guideline and will help you, whether you are owner
or operator of an asphalt mixing plant, to take your responsibility to avert damage
and the costs caused by the damage even prior to start-up of the machine.
After the approval procedure necessary for installation and operation the plant is
installed and the staff is instructed. During this phase Ammann advises and sup-
ports the customer.
During construction, the plant operators have to familiarise themselves with the
plant and this machine. This will be realised in close co-operation with the Ammann
site supervisor.
It includes the erection and installation of the units and devices, the placing of the
supply mains as well as the electric and control wiring (including protection,
grounding etc.). Safety equipment and dangers have to be considered as well.
It has to be ensured that people can walk safely on the plant, and that all handles,
handrails, barriers with safety switches etc. are installed.
It has to be checked if the emergency and breakdown cutout facilities are accessi-
ble and function correctly.
It has to be checked if all information boards and prohibition signs are available.
Inform the site supervisor or another representant of Ammann about maintenance

works and plant components to be maintained.
After having taken over the plant or a plant component the plant operator/customer
must be familiar with the procedure, and the safety equipment and switches.
Besides the requirements mentioned in this instruction manual the conditions of the
operating license, the environmental regulations (German TA Luft (technical
instruction air), WHG (water resources act WRA) as well as the general rules for
accident prevention have to be observed.
AZ-66323 7
Foreword
8 AZ-66323
2 General instructions and key to symbols
2.1 Introduction to the Operating Instructions
These Operating Instructions contain information and procedural guidelines essen-

tial for safe operation of the Filler Supply machine. The Operating Instructions must
therefore be made available to personnel entrusted with any form of work on the
machine.
These Operating Instructions should be used in conjunction with the Operating

Instructions for the overall asphalt mixing plant.
NOTE
As the customer you should read these Operating Instructions before you start
working with the machine!
Operating personnel must be familiarised with these Operating Instructions before

they start working with the machine.
These Operating Instructions are intended to simplify the process of understanding

the machine and making use of the applications it is designed for.
The Operating Instructions contain important information for the safe, correct and
economical operation of the machine. Compliance with these Operating Instruc-
tions helps to prevent accidents, reduce repair costs and downtime and increase
the reliability and service life of the plant.
NOTE
You must also comply with the locally applicable rules and regulations for the pre-
vention of accidents!
These Operating Instructions should be read in conjunction with the requirements

specified under current national regulations on prevention of accidents and protec-
tion of the environment.
The Operating Instructions must always be available on site and must be read and
complied with by all those assigned with operating the plant.
AZ-66323 9
General instructions and key to symbols
Modifications
Operating the plant shall be taken to refer to the following:
operating the plant, setting up the plant, rectifying faults during operation, removing
production waste, upkeep, disposal of process materials, service, maintenance,
inspection, repairs and transportation
2.2 Modifications
NOT PERMITTED
No modifications, additions or conversions to the machine are permitted if they
compromise safety!
This also applies for the installation and adjustment of safety devices and for weld-
ing onto load-bearing structures.
Modifications are not permitted to the electric control system either if they affect the
safety of the machine!
If modifications which affect safety are performed without consulting the supplier,
this will invalidate the Declaration of Conformity with regard to the Machinery Direc-
tive or the Manufacturer’s Declaration. Ammann cannot be held liable for damage
and accidents resulting from such modifications.
10 AZ-66323
2.3 Terms
Reclaimed filler
Filler that is produced in the dust collector during the productionproc-
ess.
Elevator Device to vertically convey material in cups that are mounted on a

belt or chain.
Imported filler
Filler produced by grinding mineral material or by dust collector dur-
ing the production of crushed stone fines, chips or gravel.
Filler Stone flour to add to the asphalt, see also reclaimed filler, imported
filler, recovering filler, remaining filler.
The filler grains are smaller than 30 µm.
filler anti-bridging
The filler in the silo or silo tower is aerated with compressed air to
avoid cakings.
Filler silo Round silo to store filler. Every filler type is stored in its own filler silo.
Filler silo tower

Round silo to store filler. Different filler types are stored in separated
compartments.
Remaining filler
Filler that remains in the mixed material after the drying and dust col-
lecting process during the production of bituminous mixed material.
Recovering filler
Filler that is produced in the dust collector when bituminous mixed
material is processed.
AZ-66323 11
General instructions and key to symbols
Terms
12 AZ-66323
3 Use and product description
3.1 Intended use
The Filler Supply machine is exclusively used for storage and transportation
of filler. Further or different use does not comply with these regulations.
Any other use or use over and above this is considered improper use. The
manufacturer/supplier cannot be held liable for damage resulting from
improper use. The user bears sole risk.
The Filler Supplymachine may only be operated in conjunction with an
asphalt mixing plant!
The machine is designed in accordance with the state-of-the-art and recognised

safety regulations. Improper use, however, can cause risk to life and limb.
NOTE
Only operate the machine when it is in perfect technical condition!
Immediately rectify faults which might compromise safety!
Do not use defective components!
Compliance with the intended use also requires abiding by the Operating Instruc-
tions and adherence to the terms of service and maintenance.
NOTE
National regulations must be complied with for handling the materials.
The filler supply is designed for grain sizes noticeably smaller that 1 mm.
Observe the national regulations when working with filler.
Filler elevators can be used for bulk goods temperatures of up to 130°C. The max-
imum grain size may not exceed 80 mm.
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Use and product description
Improper use
3.2 Improper use
CAUTION
Any use which does not come under the intended use is considered improp-
er use and is therefore prohibited!
Ö Do not make any modifications to the machine!
CAUTION DANGER OF FIRE!

Risk of fire
Combustible materials such as wood, plastics, etc. and combustible liquids such
as petrol, oil, etc. and aerosols must not be added!
Ö Do not add any combustible materials into the mixing process unless they are
specified as part of the formula and are added using a specially designed feed.
NO PERSONS ALLOWED
The mixer tower hoisting and conveying systems must not be used for trans-
porting people!
Using the hoisting and conveying systems to transport people can result in injury.
Ö Do not use the hoisting and conveying systems (e.g. elevator and conveyor
belts) for transporting people!
3.3 Description of the Filler Supply machine
The filler supply comprises the following components:

• Silo for imported filler
• Silo for reclaimed filler
• Feed screw conveyor for transporting the imported and reclaimed filler to the
elevator or filler scale
• Feed screw conveyor for transporting the reclaimed filler to the elevator
• Coarse dust feed screw from the dust collector to the filler silos
• Fine dust feed screw from the dust collector to the filler silos
• Filler elevator
• Filler storage silo
• Filler scale
14 AZ-66323
For the description of the components, please refer to the corresponding instruc-
tion manuals of the components:
Instruction manual of the supplier
• Filler silo tower
• Silo ventilation filter
AZ-66323 15
Description of the Elevator
3.4 Description of the Elevator
1 9
2
10
3
11
4
12
5
13
14
6
15
8
Key:
1 Driving shaft and pedestal bearing
(geared engine with return stop; shrink disc or coupling)
16 AZ-66323
2 Driving pulley or driving gear
3 Belt guiding element
4 Chute
5 Belt or chain
6 Direction of material flow
7 Inlet funnel
8 Base pulley or base gear
9 Head station
100Discharge chute with discharge plate
11Outlet
12Bucket
13Belt connector
14Belt guiding element
15Base station
3.5 Description of the Screw Conveyors
3.5.1 Tubular conveyor screw with radial bearing
1 2 3 4 5 6
6 7 8 9 3
Key:
1 geared engine
2 coupling
3 stuffing box
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Description of the Screw Conveyors
4 inlet
5 feed screw shaft with filaments (threaded)
6 pedestal bearing
7 emergency outlet
8 screw pipe
9 outlet
In general, the pitch of the screw filament is constant. The screw filaments are
welded on the feed screw shaft. The shaft is driven by a geared engine via a flexible
coupling. The feed screw shaft is sealed by using stuffing boxes. This type of tubu-
lar conveyor screw is generally used for tilt angles up to 12°. The mainly active radi-
al forces are supported by pedestal bearings on both sides of the shaft.
3.5.2 Tubular conveyor screw with radial and axial bearing
1 2 3 4 5 6
7 8 9 10 3
Key:
1 geared engine
2 coupling
3 stuffing box
4 inlet
6 pedestal bearing
7 part of bearing with self-aligning ball bearing, axial deep-groove ball bearing and
oil seal rings
8 emergency outlet
18 AZ-66323
9 screw pipe
10outlet
This type of tubular conveyor screw is generally used for tilt angles larger than 12°
and differs from the screw feed described above only by its type of bearing. Inde-
pendently from the conveying direction and the position of the drive, an axial deep-
groove ball bearing is used in addition to the self-aligning ball bearing in order to
support the increased axial forces resulting from the increased inclination at the
lower end of the shaft.
This part of bearing is protected against penetration of dust and material being con-
veyed by radial oil seal rings.
3.5.3 Tubular conveyor screw with flanged bearing at the free end of the
shaft
1 2 3 4
5 6 7 8 9
Key:
1 screw pipe
2 inlet
3 stuffing boxes
4 pedestal bearing
5 flanged bearing
6 outlet
8 emergency outlet
9 geared engine with shrink disc
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Description of the Screw Conveyors
As there is not much space, this tubular conveyor screw is mainly used for trans-
porting the filling material from the scale to the mixer. For reasons of the flanged
bearing at the free end of the shaft, the construction length is decreased enorme-
ously. A shrink disc is used for power transmission.
3.5.4 Troughed conveyor feed screw
2
3
4
6
8
3
5
10 1
Key
1 chain drive
2 pedestal bearing with spherical roller bearing and grease chamber
3 stuffing box
5 pedestal bearing
6 heating cassettes
7 screw trough
8 outlet
9 inlet
20 AZ-66323
10geared engine
The screw trough of this design has a lining made of wear metal sheets and can
be heated by several heating cassettes. The filaments have a progressive pitch
and can be built extremely wear-resistant, too (optional). The shaft is driven by a
geared engine via a chain. The pedestal bearing on the drive's side consists of a
spherical roller bearing with grease chamber. The feed screw shaft is also sealed
by using stuffing boxes.
3.6 Description of the Cell Wheel Sluice
1 2 3 4 5 6 7
Key
1 Bearing
2 Feeding hopper
3 Input shaft
4 Turnstile (chamber wheel)
5 Bearing
6 Clutch
7 Motor with gearing
8 Feeding hopper
AZ-66323 21
Workplaces at an asphalt mixing plant
3.7 Workplaces at an asphalt mixing plant
Diagram of an asphalt mixing plant without optional components
Workplaces:
1 Control cabin
2 Front-loading truck for charging the feeders
3 Drivers of Collecting Vehicles
4 Additive addition
All other areas of the asphalt mixing plant may only be accessed for maintenance
purposes or for supplying material.
22 AZ-66323
4 Technical data
Type of filler elevator FG 36
For the technical data of the components, please refer to the corresponding
instruction manuals of the components:
4.1 Filler elevator
4.1.1 Performance data
Elevator size Single filler Single filler Double filler

elevator size 1 elevator size 2 elevator
Conveying capacity [m³/h] 15 34 2x34
EP 630/4
Belt quality
Gi 2+2 T
Bucket filling[%] 90
Bucket design DIN 152 34
Bucket width [mm]] 160 250
Bucket content [dm³],
1.5 2.1
levelled
Bucket partition [mm]: 400 280
Conveying speed [m/s]: 1.28 1.39 1.41
Driving speed [min-1] 61 59 60
Driving power: [kW] 2.2 4 5.5
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Technical data
Screw conveyor
4.1.2 Dimensions and Weight
The following data are valid for the installed elevators without head base and with-
out drive. The dimensions of the head base are individually adapted to the require-
ments.
Length: in the conveying direction
Width: length of the driving axle with fixing device
Height: from bottom edge of the base station to top edge
head station
Size 1
Length: 1670 mm
Width: 1100 mm
Height: distance of axle+1120 mm
Size 2
Length: 1660 mm
Width: 1200 mm
Double filler elevator

Length: 1660 mm
Width: 1820 mm
4.2 Screw conveyor
4.2.1 General Notes
Design of the bearing:

Increasing up to 12°: stuffing box, housing for pedestal bearing with
deep-groove ball bearing (without axial bearing)
Increasing between 12° and 35°:stuffing box, lantern with deep-groove ball bear-
ing and additional axial bearing
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The conveying length for single-coil filaments is between 1250 mm and 4500 mm.
The conveying length for coiled-coil filaments is between 4500 mm and 6000 mm.
The drive can be installed on the inlet's or on the outlet's side.
Conveying capacity for feed screw conveyors
Conveying capacity (m³/h) 12 18 25 60

Nominal diameter (mm) 200 200 250 250
Driving power (kW) 1.1 2.2 3.0 5.5
Driving speed (1/min) 102 172 92 157
4.2.2 Dimensions and Weight

The maximum dimensions of the feed screw conveyor are:
Length: 7800 mm
Width: 500 mm
Height: 500 mm
Weight: 900 kg
4.3 Cell wheel sluice

Length: 1100 mm
Width: 500 mm
Height: 600 mm
Weight: 185 kg
Driving power: 0,55 kW
Driving speed: 28 1/min
Conveying capacity: 20 m³/h
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Technical data
Cell wheel sluice
26 AZ-66323
5 Transportation
5.1 General instructions
The machine may only be transported by trained personnel or by personnel who

have received instruction and are being supervised by a trained employee.
If transportation securing devices were supplied with the machine, these should be
used for transportation.
Ammann cannot be held liable for damage caused by improper transportation. This
does not apply for shipments transported by Ammann.
A crane with the following technical specifications is recommended for transporta-

tion and assembly of the machine,:
• Lifting capacity 70 t
• Length of jib up to 40 m
An additional crane with the following technical specifications is required for

assembly of taller and longer machines:
• Maximum load: 10 tonnes
• Length of jib up to 15 m
5.2 Lifting eyelets and lifting gear
Only use lifting eyelets on the machine which are marked yellow and black for lift-
ing.
If no lifting eyelets are marked, attach the lifting gear to sturdy parts of the machine.
Make sure that the machine does not get damaged.
Use mainly chains, wire ropes, webbing slings or round slings for securing loads.
5.3 Weights and measurements
Please see the packing list or transportation documents for the weights and meas-
urements of the individual sub-assemblies.
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Transportation
Weights and measurements
28 AZ-66323
6 Assembly and start-up
6.1 Assembly
The customer is responsible for ensuring that experienced, specialist personnel

are in charge of the assembly work.
The customer must appoint someone to be responsible for assembly.
This coordinator is responsible for ensuring correct performance of the assembly

and for safety on the construction site.
The customer and coordinator are responsible for ensuring that assembly is only
performed by specialist personnel or is managed by specialist personnel.
Ammann recommends that Ammann specialist personnel should in principle per-

form assembly of the machine or that a foreman provided by Ammann should be
in charge of assembly.
Before starting assembly, the foundations have to be levelled and the dimensions
and position of the foundations have to be checked against the foundation plan.
The overall delivery should be inspected to ensure that there is no damage and that
it is complete and the correct model has been supplied.
The installation and attachment of all the components must be performed exclu-
sively in accordance with Ammann blueprints.
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Assembly and start-up
Elevator
6.2 Elevator
6.2.1 Installing the elevator

9 Use two cranes, as described in chapter „General instructions“ pp. 27.
9 Fix the mounting auxiliary and the slings at the elevator head.
9 Fix the slings for the smaller crane at the eyes for suspension above the base
station.
1 Lift the elevator with the aid of both cranes.
2 Put the elevator on the appropriate foundation.

Ö Make sure that the outlet is positioned in the direction of the mixing tower or
of the corresponding machine component.
3 Hang the elevator in the appropriate articulated devices.
4 Adjust the elevator perpendicularly in all directions.

Ö Check the position with a water level.
Ö Unintended deviations from the perpendicular position reduce functionality
and increase wearing!
5 Screw the elevator to the foundation.
6 Adjust the discharging plate such that the distance between the buckets is
between 10 and 20 mm.
7 Install the belt of elevators with a distance of axle of more than 20 m as

described in chapter „Installation of the belt for belt elevators“ pp. 31.
Ö In case of elevators with a distance of axle below 20 m the belt is already
installed.
8 Install the hood as described in chapter „Installing the elevator hood“ pp. 33.
;The elevator has been installed.
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6.2.2 Installation of the belt for belt elevators 1
9 Some of the following steps are not necessary if
the belt you get is completely preinstalled.
9 Check whether the buckets are fixed correctly if
the belt you get has been completely preinstalled.
Tightening torque for buckets of belt elevators
Tightening torque
Screw (Name)
(Nm)
M 10 40
M 12 70
M 16 100
1 Screw the buckets to the belt.

Ö Keep to the tightening torques mentioned in the
table above.
2 Fix the ropes at the uninstalled ends of the belt.

Ö Use ropes which are 3 m longer than the eleva-
tor's distance of axle.
3 Fix slings in the middle of the belt.
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Elevator
6 Installation of the belt for belt elevators- continu-

ation
4 Lift the belt into the elevator by using a crane.

Ö By using the ropes you can guide the ends of
the belt.
5 Loosen the ropes.
6 Close the belt under the pulley in the base station

by using belt connectors, screws and safety nuts.
Ö The first picture shows a belt elevator, the sec-
ond picture shows a filler elevator.
7 Install the hood as described in chapter „Installing

the elevator hood“ pp. 33.
;The belt has been installed.
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6.2.3 Installing the elevator hood 1
1 Remove the mounting auxiliary.
2 Put the hood onto the head station of the elevator.
3 Tighten the hood.
;The hood has been installed.

2
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Screw conveyor
6.3 Screw conveyor
During installation, the feed screw conveyor must be adjusted in a way that pre-
vents the feed screw shaft from being subjected to bending.
If the shaft has been adjusted correctly, it can be rotated manually without resist-
ance or remarkable noise.
In case of screw feeds with chain drive, it is additionally necessary to ensure that
the chain wheels are exactly aligned in order to minimise wearing of chain wheels
and chain.
6.4 Cell Wheel Sluice
Instructions in the chapter “Mounting and commissioning” must be followed during

installation and commissioning Operating instruction for asphalt mixing equipment.
The turnstile gate must be installed exclusively by the specialized personnel of

Ammann or should at least follow the instructions of the mounting foreman appoint-
ed by Ammann. Installation and mounting of all components must be made in
accordance with Ammann company drawings.
The turnstile gate will be screwed through flange under the silo outlet or will be inte-
grated into the piping.
NOTE
The material must flow through the turnstile gate always vertically (perpendicular-
ly)!
The turnstile closure shall never be installed sideways.
34 AZ-66323
6.5 Electrical connection
Earth the machine.
The individual conductors should follow the shortest route from the wiring arrange-
ment to the terminal board. This avoids damage to the conductors through vibra-
tions.
Set up the electrical connections as marked. You will find the layout marked on the
circuit diagrams in the electrical plans.
6.6 Pneumatic connection
The compressor must be started up in accordance with the Operating Instructions

supplied by the compressor manufacturer. The same applies for the other compo-
nents of the compressed air supply.
Blow the pipelines, tubes and hosing of the pneumatic system through without
attachments to remove foreign bodies.
Pipelines, tubes and hosing are to be installed in such a way that they cannot be
damaged during operation.
6.7 Initial start-up
Read and abide by the Operating Instructions for the structural components.
Perform these operations before initial start-up of the machine in the follow-
ing order:
9 Remove foreign material from the machine.
9 Remove all transportation securing devices!
9 Inlets and outlets must allow free passage for material conveyed.
9 Check the correct installation and operation of all hoisting and conveying sys-
tems.
9 Check the correct installation and operation of all measuring systems and
switches.
9 Check the correct installation and operation of all safety devices.
9 Check that operation is hitch-free during a test run without aggregate!
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Initial start-up
36 AZ-66323
7 Operation
7.1 Information for the customer
The machine must only be operated when in perfect condition.
Make sure that only trained personnel who have received instruction operate the
machine.
Make sure there are information signs prohibiting unauthorised personnel from
entering the work-site.
We recommend a barrier around the work-site.
Because only few employees work on an asphalt mixing plant, each workplace is
considered as a separate workplace.
Make sure that the operating personnel have access to a wireless voice-communi-
cation system, because eye contact is not always possible between those working
on the mixing plant.
Make sure that this voice-communication system is free of technical defects and is
suitable for use in an asphalt mixing plant.
Ammann recommends that the voice-communication system should be installed

by a specialist.
Ammann supplies the machine without lighting.
Make sure there is sufficient lighting if the machine is to be operated at night or in

poor visibility.
Ammann can provide lighting for the machine on request, but this must be ordered
separately.
Make sure there is written stipulation of the registration system for sub-contractors
and self-collection customers.
Make sure there are safe zones designated for drivers and co-drivers of vehicles
to stop in.
Lay down regulations for unloading and loading vehicles.
Make sure drivers and co-drivers receive training on the possible dangers linked
with the machine.
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Operation
Emergency-stop devices and safety devices
Make sure that all the personnel operating in the vicinity of the machine are
instructed about the location of the machine’s emergency-stop devices and safety
devices and how they work.
7.2 Emergency-stop devices and safety devices
Safety first!
In the event of danger, press the “emergency-stop” button!
NOTE
The Plant Manager must ensure that all the machine‘s safety devices are inspected
before start-up each day by a trained specialist.
The safety devices of the Filler Supply machine comply with the requirements of
EN536.
The following sub-assemblies are equipped with an emergency-stop button:

• Elevator
Before starting to operate the machine the personnel must check where the near-
est safety device is.
The operating personnel must check the safety devices before starting up each
day.
The doors at the bottom of the elevator shaft and the maintenance flap opposite
are fitted with safety locks. For further details see the “Safety Lock System” section
in the Operating Instructions for Asphalt Mixing Plants.
7.3 Directions for the operating personnel
Pay heed to the material temperatures permitted.
Switch on the power supply and the control voltage before the start-up.
Only operate the machine when the entire plant is on.
No fault message must appear before the start-up.

This applies in particular after a fault has been reported and the machine has con-
sequently been switched off.
Remove hardened material from the machine components before start-up.
38 AZ-66323
This applies in particular after extended stoppage and in the event of frost.
In the event of malfunctions or unusual noises, please notify Ammann’s Customer

Service Department immediately.
Empty the machine before extended periods of stoppage to prevent damage and
simplify re-start.
To empty the machine, allow it to run without feeding material until it is empty.
DANGER OF BURNS
Risk of burns!
The components can reach temperatures of up to 100° C. Contact can cause
burns.
Ö Keep a safe distance away and avoid contact!
Danger of squashing!!
Flaps and cylinders!
There is a risk of crushing on movable parts of the flaps and cylinders.
Ö Keep a safe distance away!
WARNING
Danger of stone fall!
If the feed screw conveyors are not operated according to the rules, e.g. with open
outlet, material may drop out.
Ö It is prohibited to stay under the outlet of the feed screw conveyor!
Wear protective helmet!
Wear protective clothing!

When handling hot or skin-incompatible materials, we recommend wearing appro-
priate protective clothing.
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Operation
Method of operation
7.4 Method of operation
7.4.1 Imported Filler With Filler Silos:
Imported filler is stored in the according silos.
From there it is discharged using a feed screw conveyor and then transported to
the elevator.
The elevator is used to transport the imported filler to the filler storage silo.
From the filler storage silo the imported filler is fed into the filler scale.
In the filler scale, the imported filler is weighed according to the recipe and added
to the mixing process.
7.4.2 Imported Filler With Filler Silo Tower:
Imported filler is stored in the upper deck of the filler silo tower.
the filler scale.
In the filler scale, the imported filler is weighed according to the recipe and added
7.4.3 Reclaimed Filler:
Reclaimed filler is store in the according silos or in the lower deck of the filler silo
tower.
the elevator.
The elevator is used to transport the reclaimed filler in the filler storage silo.
From the filler storage silo the reclaimed filler is fed into the filler scale.
In the filler scale, the reclaimed filler is weighed according to the recipe and added
The filler supply can additionally be operated with a discharge system for the
reclaimed filler silo.
40 AZ-66323
The reclaimed filler silo is provided with an according outlet under which a rotary
flap is installed.
The rotary flap is operated manually using a chain block.
The connected pipe transports the reclaimed filler into a screw feed.
This screw feed is used to transport the reclaimed filler to a loading system.
The loading system usually consists of a rubber hose.
The reclaimed filler is loaded on a lorry.
WARNING
Danger of spilling and suffocation!
Incorrect usage of the loading system causes filler to flow out.
Ö It is prohibited to stay under the loading system!
Wear breathing protection when working in the proximity of the loading system!
Provide an appropriate drip container.
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Operation
Method of operation
The silos are provided with ventilation filters, which extract cleaned air, and add the
filtered dust to the production process again.
• The residual dust content certificate for the filters can be found in the supplier
documents, chapter 12.
• For detailed and additional information, please refer to the instruction manual of
the filter.
42 AZ-66323
7.4.4 Elevator
The material being conveyed is supplied to the buckets via the inlet funnel at the
elevator pedestal.
The buckets are fixed at the conveying device (chain or belt) and transport the
material vertically to the elevator head.
In the elevator head the buckets are emptied above the discharge chute and the
material being conveyed falls through the outlet.
The conveying device (belt or chain) is driven by a geared engine which is fixed at
the elevator head.
The geared engine drives a shaft with driving pulley or gear which rotates in ped-
estal bearings.
The geared engine is either equipped with a return stop or designed as a brake
engine in order to eliminate the danger of return due to the material being conveyed
which is in the increasing line.
Design see technical specification in the confirmation of order.
In case of filler elevators the power between geared engine and driving shaft is
transmitted by means of a flexible coupling, in case of all elevators it is transmitted
by means of a shrink disc delivered by the manufacturer of the geared engine.
Belt elevators (despite filler elevators) are equipped with devices for guiding the
belt (belt guiding devices). In case of all Ammann belt elevators the belt path is reg-
ulated by using spherical pulleys.
In case of filler elevators it is additionally possible to correct the belt path manually
with the aid of the chucking device.
In case of chain and belt elevators the conveying devices are retightened automat-
ically by the weight of the turn and chucking devices.
NOTE
You always have to make sure that the guiding devices on the guide rail run free
(exception filler elevators).
For a safe guiding of the chain, toothed gears are installed in the base station of
chain elevators. In case of Ammann chain elevators of the sizes 2 and 3, „even“
driving gears are installed on the driving side; only in case of chain elevators with
small conveying capacity (chain elevator size 1) toothed gears are used.
Design see technical specification in the confirmation of order.
AZ-66323 43
Operation
Method of operation
Otherwise, in case of chain elevators size 1 the power transmission may not be suf-
ficient due to the lower tension forces at the driving gear.
The low tension forces result from the lower total weight of the conveying device
(own weight of the chain plus the weight of the material being conveyed)
7.4.5 Screw conveyor
Tubular conveyor screw
Material is fed into the feed screw conveyor via the inlet.
The engine rotates the feed screw shaft with the filaments.
As the filaments are arranged like a screw, the material is transported to the outlet.
Due to gravity, the material drops out of the feed screw conveyor.
Behind the outlet, filaments are installed which are opposite in rotation and which
prevent the material from being pressed against the wall of the screw feed.
Troughed conveyor feed screw
Due to gravity, the material drops out of the feed screw conveyor.
For reasons of the two parallel feed screw shafts with intersecting filaments, the
material within a troughed conveyor screw can be mixed.
Stuffing screw
44 AZ-66323
In case of a stuffing screw, the outlet is the open end of the screw pipe.
Emergency outlet
Each feed screw conveyor has at least one emergency outlet.
If necessary, the material can be removed via this outlet, e.g. if the feed screw con-
veyor is blocked.
NOTE
Only open the emergency outlet for maintenance and observe the notes in
chapter „Maintenance, repairs and rectification of errors“ pp. 53!
7.4.6 Cell Wheel Sluice
The material will be stored or transported through the turnstile gate to the silo, pipe-
line or conveyor screw.
The motor turns the turnstile into motion.
The material falls to the turnstile chamber through the feeding hopper.
The material is transported downwards by turning.
Below, on the outlet feeder, the material flows from the turnstile gate outwards.
This procedure allows to batch material by the number of revolutions and length of
operation.
If the turnstile is not revolving, the self-acting falling of the material is limited. The
closing sliding valve or the flap is recommended to provide complete closure.
7.5 Daily start-up
The operating personnel must check the safety devices before starting up each
day.
There must be no fault message before the daily start-up.

This applies in particular after a fault has been reported and the machine has con-
sequently been switched off.
AZ-66323 45
Operation
Operation at freezing temperatures
Remove hardened material from the machine components before start-up.

This applies in particular after extended stoppage and in the event of frost.
Use an explosion-protected dust collector for the removal of dust.
Comply with the instructions regarding daily start-up in the Operating Instructions
for the sub-assemblies and the Operating Instructions for sub-contractors.
Before start-up the Plant Manager must ensure the following:

• There must be no unauthorised personnel in the plant’s safety zone!
• Where the safety of any procedure is uncertain, it must be refrained from!
• The plant must be in safe and fully-functioning condition!
• Protective devices such as: detachable covers, safety hoods, emergency-stop
facilities, sound insulation and extraction facilities are present, properly assem-
bled and fully-functioning condition!
To ensure that employees are not placed in danger, the operating personnel must
make sure of the following before starting up the plant:
• All inspection and maintenance flaps must be closed!
• All locks on inspection and maintenance flaps must be closed!
To ensure trouble-free start-up, the operating personnel must check the following:
• The imported filler and recovered filler silos must be full.
Top up if required.
• Any components which have been shut down must be unlocked (this avoids any
time being wasted when starting up the plant)
• All the master switches must be switched on
• If the compressed air supply was switched off after stopping operations then it
must be switched on.
A minimum pressure of 6 bar is required before start-up. If the air pressure falls,
all the pneumatically controlled flaps, valves etc. go to closed.
7.6 Operation at freezing temperatures
If temperatures fall close to freezing, unblock frozen material and ice.
46 AZ-66323
7.7 Malfunctions
7.7.1 General instructions
Safety first!
In the event of malfunction press the nearest emergency-stop button or pull the
nearest safety ripcord!
NOTE
Always make sure you are in no personal danger!
Perform the appropriate first aid measures!
Perform the appropriate counter measures!
Notify your supervisor!
7.7.2 Heating facility malfunctions
Danger from electricity!

Danger of electric shock and burns!
Heating facility malfunctions caused by the electrical system can also entail risk to
life and limb.
Ö Perform the appropriate protective measures.
In the event of a heating facility malfunction, perform the following measures:

• Switch off the pumps
• Close the supply and discharge pipes
• Switch off the heating
• Notify your superiors
7.7.3 What to do in the event of fires
NOTE
Call the fire service
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Operation
Upkeep work after shut-down
NOTE
Notify the fire service about the type of materials involved in the fire!
• Put out incipient fires (make sure you are in no personal danger)
• Switch off pumps, close supply and discharge pipes, switch off heating equip-
ment
• Notify your superiors
WARNING
Risk of explosion!
Never try to extinguish bitumen fires using water!
• Cover hot bitumen pools with sand or appropriate fire extinguishing materials
• Inform the fire service / product information
• Perform first-aid measures
NOTE
Any work to or on bitumen storage tanks and to pipelines, pumps and fittings may
only be performed with the approval of the works management!
7.8 Upkeep work after shut-down
Check the machine for escaped material.
Remove the material.
Check the machine for leaks and rectify these faults.
In order to avoid deposit crusts, ensure that no material is left in the machine.
To do this, allow the machine to run without feeding any material until it is empty.
If there is a crane then the operating personnel must secure it after use.
NOTE
Follow the directions in the Operating Instructions for the respective sub-assem-
blies!
48 AZ-66323
8 Maintenance, repairs and rectification of errors
8.1 Maintenance
8.1.1 Directions for the maintenance personnel
Perform all the inspection work specified in this section.
Perform any resulting maintenance work and repair work immediately.
Comply with the directions regarding the mixer tower sub-assemblies.

When working on live components, you are exposed to the risk of electric
shocks and burns caused by electricity!
Do not work on live components.
Ö Fully disconnect the machine from the electricity mains before any maintenance,
inspection and repair work!
Check the bolts are correctly tightened in accordance with the maintenance inter-
vals.
The torque specifications for tightening the attachment screws can be found in the
following table:
Tightening torques for screws DIN 933
Tensile strength Tightening torque

Thread designation
class (Nm)
M 12 8.8 85
M 16 8.8 210
M 20 8.8 425
M 24 8.8 730
Wear protective clothing!

Wear appropriate protective clothing during maintenance work!
AZ-66323 53
Maintenance, repairs and rectification of errors
Maintenance
Wear protective helmet!

Wear a protective helmet during maintenance work!
8.1.2 Welding
Welding, burning and grinding may only be performed if approved by the Operation
Manager in writing.
NOTE
Set up a fire watch when performing welding, burning and grinding work!
Remove dust and other combustible materials from the machine and its surround-
ings before welding, burning or grinding work.
Cover openings and ventilation slits on the machine and in the surrounding area
using non-combustible, water-impermeable material.
Clean the machine through drenching it thoroughly or hosing out the work area.
No water must get onto the electric components.
Connect one pole of the welding device directly to the part to be welded.
Connect the other pole as near as possible to the welding point.
NOTE
Cool the relevant work area to the ambient temperature at the end of the repair
work and look for possible ignition sources and smoulder spots!
8.1.3 Maintenance work on the electrical system
NOTE
In the event of faults with the electricity supply, switch off the machine immediately!
Selection of staff
The customer is responsible for ensuring that work on electrical facilities or electri-
cal equipment is only performed by qualified electrical engineers or by trained per-
54 AZ-66323
sonnel under the direction and supervision of qualified electrical engineers and in
accordance with electrical engineering regulations!
The customer is responsible for ensuring regular inspection and testing of a facili-
ty's electrical equipment.
Before performing any work on the electrical system, you should notify the Plant
Manager about the performance and nature of the work.
Make arrangements with other operating personnel working on the machine with
regard to the maintenance work and with regard to switching machinery on and off.
When changing fuses only use original fuses with the set current strength.
Faults such as loose connections or damaged cables must be immediately rectified

by qualified electrical engineers.
In the event of heat-damaged cables, check the entire circuit concerned.
Rectify the cause of the damage and also replace other parts which might have
caused the damage.
This reduces the possibility of further damage.
Abide by the following 5 safety rules when working on electrical facilities or electri-
cal equipment:
• Disconnect
• Secure against restart
• Check that disconnected
• Earth and short-circuit
• Cover or cordon off adjacent parts which are live
Disconnect
Notify the Plant Manager about which parts you need to work on and which parts
you are disconnecting.
Disconnect the components on which the work is to be performed.
NOTE
Affix a sign on disconnected master switches detailing who is performing the main-
tenance and what the maintenance is for.
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Maintenance
Secure against restart
Affix a sign, for the duration of the work, on switch knobs or mechanisms, control
units, buttons or dials, on fuse bases and automatic cut-outs used to disconnect or
reconnect a component.
Affix the sign in a way that ensures it is easy to see and does not come off easily.
If you cannot affix the sign directly to the switch, affix a sign close-by which clearly
indicates which switch it relates to.
Check that disconnected
Check that the parts are disconnected using suitable measuring devices.
Earth and short-circuit
Before starting work, earth the electrical components at the work-place and then
short-circuit them.
Cover or cordon off adjacent parts which are live
Cover adjacent electrical parts with non-conducting materials.
8.1.4 Working on the pneumatic system
NOTE
It is your responsibility as the customer to ensure that only personnel with specialist
knowledge and experience in pneumatics work on pneumatic equipment!
NOTE
Comply with the information regarding maintenance in the Operating Instructions
issued by the compressor manufacturer!
The Plant Manager is responsible for the following aspects:

• Work must only be performed on the pneumatic system once the pressure has
been fully released.
• The tightness of fittings and leads must be checked during operation.
Leakages must be immediately reported to the works management.
56 AZ-66323
• All hose lines must be replaced at the set times or at appropriate intervals, even
if no faults are evident.
• All leads, tubing and bolts must be checked regularly for tightness and visible
damage.
Damage must be rectified immediately. Otherwise there is the risk of injury!
The maintenance personnel are responsible for the following aspects:

• Pressure must be released from the system sections and pressure pipes of sub-
assemblies on which repair work is to be performed and they must be secured
against restart using a padlock before work commences.
• Condensation accruing in the leads must be bled on a regular basis.
• Pneumatic pipes must be expertly laid and assembled.
Do not confuse the connections!
The fittings and length and quality of the hose lines must comply with the
requirements.
• Regular manual lubrication is required for pneumatic consumers which are not
lubricated via a maintenance unit.
• When topping up with oil, the surrounding area must be pre-cleaned and pre-
cautions taken to prevent impurities getting in.
• When regreasing, use grease reasonably sparingly.
A thin film of grease is completely sufficient.
• With the cylinders it is important that the grease silos of the double drip sleeves
are also filled with grease.
• In principle pneumatic devices must be removed in low-dust areas.
WARNING
Risk of fire and explosion!
Mixing different oil types can lead to increased friction.
Ö Do not mix different oil types!
Maintenance unit
The maintenance units ensure uniform oiling and filtering of the compressed air.
As the customer, you are responsible for ensuring that the right oil is selected.
The sealing components and pneumatic piping must not get caught in the equip-
ment and must be compatible with the grease used for permanent lubrication.
You must therefore follow the lubricant recommendation!
AZ-66323 57
Maintenance
8.1.5 Maintenance work in silos, drum, tanks etc.
The following notes apply for entering

• the dryer drum
• the filter
• the screen
• the hot mineral silo
• Mineral scale
• Mixer
• connected silos and tanks
Wear protective clothing, helmet and protective gloves.
Use a personal protection equipment when working in heights of 1m and more.
A person has to look out outside the component.
Always keep contact with this person.
If you do not see the person, make acoustic noise.
Immediately leave the component if you have no contact to the person outside.
The person outside has to look after the person inside and if necessary has to
implement emergency measures if no contact is given to the person inside the
component.
Safety first!
Never perform work inside components if this protection is not guaranteed!
8.1.6 Dangers during maintenance work
WARNING
Danger of sinking and spilling!
There is a danger of sinking in the filler or spilling the filler when entering the silos.
Ö Only enter empty silos!
Only enter the lower filler silo tower compartment if the upper and lower com-
partments are empty!
Do not fill the silos and towers during maintenance!
58 AZ-66323
Burns and electric shocks can occur when working on live components.
Do not perform work on live components!
Ö Disconnect components completely from the electricity mains before performing
maintenance work.
CAUTION
Risk of injury!
Injuries can occur when performing maintenance work on components which are
operating.
Ö As Plant Manager you must ensure that the relevant component and related
components are switched off before opening maintenance access points.
WARNING
Risk of suffocation!
When working on sub-assemblies of the Filler Supply machine you run the risk of
suffocation caused by aggregate dust.
Ö Wear breathing protection!
You can find the risks present when performing maintenance work on the Filler
Supply machine in the table below.
Danger point Danger due to Solution

Submersion through Empty the plant before you perform
Maintenance access material escaping maintenance work.
points when opening mainte- Do not stand directly in front of or
nance flaps under maintenance access points!
Components at con- Take precautions to stop yourself
Risk of fall
siderable height falling!
Only perform work on components
Live parts through- Electricity (electric
which have been disconnected
out the plant shocks)
applying the 5 safety rules!
Disconnect the compressed air cyl-
Compressed air cyl-
Crushing inders from the compressed air
inders
supply!
Injury caused by com- Only work on facilities which have
The plant as a whole
ponents operating been switched off!
AZ-66323 59
Access to the maintenance points
Tools, parts and material can fall when performing maintenance work on the
machine.
8.2 Access to the maintenance points
CAUTION
Danger of injury!
Maintenance work at running plant components may cause injuries.
Ö You as the plant operator must make sure that the corresponding plant compo-
nent and all connected parts have been switched off before opening the main-
tenance openings.
Close all maintenance openings after having finished the maintenance work before
switching on the plant again!
WARNING
Danger of life!
When switching on the plant.
Ö Before switching on the plant or plant components make sure that no one is in
or at this component!
The plant operator must make sure that the corresponding plant component and
all connected parts have been switched off before opening the maintenance open-
ings.
The plant must not be put into operation again if not all maintenance openings are
closed.
Repair Openings
These openings are necessary to check the machine or the plant component.
Inspection openings are movable flaps and cannot be used for entering the plant.
Maintenance openings
These openings are necessary to perform maintenance work.
Maintenance openings are flaps which can be taken off and have no hinges. These
openings can also have a screwed grid which must be removed for maintenance.
60 AZ-66323
NOTE
Insert these flaps after maintenance and install the grids!
The plant must not be put into operation again if these grids are not installed.
Maintenance openings at the elevator
Key:
1 Maintenance doors at the bottom of the elevator shaft
2 Maintenance access at the top of the elevator
3 Maintenance hatch on the outflow shaft
AZ-66323 61
Access to the maintenance points
The Plant Manager is responsible for ensuring that the relevant part of the plant
and associated parts are shut down before opening maintenance access points.
The maintenance access point at the top of the elevator consists of a maintenance
flap with latch and a grille behind. The grille is screwed on and does not have hing-
es or other mobile attachments.
The flap is to be opened for inspection. The grille must not be unscrewed during
operation.
The grille is unscrewed for maintenance.
WARNING
Danger of crushing and being drawn in!
Body parts can be crushed between the buckets and fixed parts.
Body parts and items of clothing can be drawn in between the chain wheel and the
chain or between the drum and the belt.
Ö The maintenance personnel must ensure that the elevator is not in operation
and cannot be brought into operation when the grille is unscrewed!
The maintenance hatch on the outflow shaft must not be opened during operation.
If so there would be the risk of injury from falling rocks.
This maintenance hatch is designed to allow removal of any obstructions in the out-
flow shaft and to check the wear of the fixtures and components. Both these oper-
ations should only be performed when the elevator is shut-down.
The maintenance doors and the maintenance flap opposite at the bottom of the ele-
vator shaft are lockable.
The keys for these locks also close the master switch.
This means that the doors can only be opened if the master switch is switched off.
NOTE
No change to this lock system is permitted!
If a change is made to the lock system by the customer or the customer’s person-
nel, this invalidates the Declaration Of Conformity with the Machinery Directive and
the Manufacturer’s Declaration. Ammann cannot be held liable for damage and
accidents resulting from such modifications.
For an exact description of the lock system see the “Safety Lock System“ section
in the Operating Instructions for Asphalt Mixing Plants.
62 AZ-66323
NOTE
Open the maintenance doors in the elevator pedestal after having switched off the
elevators at least for times a year and remove, if necessary, the material accumu-
lated in the machine!
Pay attention to the notes about the dangers during maintenance work!
8.3 Inspection intervals
8.3.1 General instructions
NOTE
Perform the prescribed adjustment, maintenance and inspection work and stick to
the deadlines. Abide by instructions on the replacement of parts/part assemblies!
Plant component
This column indicates the location and nature of the inspection
Personnel
This column indicates the person who is responsible for performing the inspection.
Symbol Performed by
Operating personnel
Maintenance personnel
Specialist personnel
or personnel authorised by Ammann
Interval
This column indicates the intervals at which inspection must be performed.
Interval Definition
1 day Every day before starting work or after finishing work
1 week At the start of the week
AZ-66323 63
Inspection intervals
Interval Definition
1 month On the first working day of the month
3 months On a fixed date every 3 months
6 months On a fixed date every 6 months
1 year On a fixed date in the year
When an error is indicated in the control system or is suspected
Where required
during production
When the structural component is being used, assembled or
During use
disassembled
Other At the set intervals
The date of assembly or of the most recent maintenance is the basis used for the
dates given.
8.3.2 Overall plant
Plant component Interval Personnel

· Check electrical connection components 1 day
· Check bolts 1 day
· Check discharge points 1 day
· Check pneumatic cylinders 6 months
· Check bolts 6 months
· Check compressed air supply and pneumatic
1 year
system
· Check motors 1 year
8.3.3 Elevator

· Check chain and belt tension 1 month
· Check bearings 1 month
· Check wearing parts in the inflow 1 month
· Check wear of the chains 6 month
64 AZ-66323
· Inspection of buckets and chains at creep
1 year
speed
· Replace chain, belt, buckets, motor, transmis- Where
sion and bearings required
Where
· Shovelling out the base section
required

· Check stuffing boxes 1 week
· Check feed screw shaft
- Throughed conveyor feed screw 1 month
- Stuffing screw 1 week
· Check chains and chain drive 3 months
· Check bearings 1 year

· Check the bolt connections
- 1. test
after 3-5 h
- 2. test
after 25 h
- 3. test
after 100 h
- other tests
after each
200 h
· Check that the material is not stuck to the turn-

6 months
stile gate.
· Check bearing 1 year
AZ-66323 65
Trouble-shooter
8.4 Trouble-shooter
8.4.1 Elevator
The carrying capacity is too small or the elevator is running too slowly
Check whether enough material is being added.

Check whether there is material in the bottom of the elevator shaft and the material
[sic].
Switch off the elevator, open the maintenance doors at the bottom of the elevator
shaft and remove the material.
In the event of frequent undersize loads, check for damage to the buckets and trac-
tion organ
Inspect the damage
Check whether the drive is still providing the output required.
If necessary perform maintenance on the drive or replace it.
No more material is being transported
Perform the same inspections as for undersize loads.

Check whether the traction organ is still intact.
NOTE
If the belt is torn or if the chain has snapped then the elevator must be stopped
immediately and the traction organ must be replaced.
The screw feed conveys less or no material.
Check whether inlet or outlet are clogged.

Check whether the engine functions correctly.
Check the coupling.
Check the bearings.
Check whether the screw filaments wear.
Check the pitch angle of the feed screw conveyor.
The screw feed conveys too much or too fast.
Check whether the engine is correctly adjusted.
66 AZ-66323
Clogging material can be removed via the emergency outlet.
WARNING
Danger of stone fall!
Material will fall out if the emergency outlet is opened.
Ö Wear protective helmet!
Do not stay under the feed screw conveyor when the emergency outlet is
opened!
Prepare an appropriate receiver.
Too little or no material transported.
Check the motor.

Check the bearings.
Check the clutch.
Check the deposits on the turnstile.
Check the material condition and function of the preceding parts of the system.
The material falls out while turnstile is not moving.
Check the turnstile gate wear.
Transport the turnstile gate material unevenly.
Check the turnstile gate wear.
8.5 Inspection
8.5.1 Overall plant
Read and comply with the directions for inspection in the Operating Instructions for
the individual structural components and the supplier parts.
Check electrical connection components
Check that the electrical connections fit correctly.

Look for defects in the insulation.
AZ-66323 67
Inspection
Look for kinks in the leads.

Replace defective leads immediately with non-defective leads.
Connect leads and plugs which have come unattached.
Check bolts
Look out for loose or damaged bolts.

Retighten loose bolts.
Replace damaged bolts immediately with non-defective bolts.
See page 53 for the tightening torques for the bolts.
Check discharge points
Remove stuck or jammed material.

Replace defective wear protection, such as rubber mats and wear plates.
Check pneumatic cylinders
Replace defective seals with corresponding non-defective seals.

Replace defective hoses and tubing with corresponding non-defective hoses and
tubing.
Replace defective screws and bolts with corresponding non-defective screws and
bolts.
Listen out for unusual noises.
Check whether the cylinders travel in and out fully.
With rotary cylinders, check whether the full angle is being used.
Check compressed air supply and pneumatic system
Watch out for air escaping (draught, whistling)

Replace defective tubing, pipes, bolts and other components with corresponding
non-defective tubing, pipes, bolts and other components.
Bleed the condensation out of the maintenance units and relevant valves.
Check that the pressure is correct.
Check motors
Check the electrical connections for damage and corrosion.

Check the lubrication of the motor and transmission.
Check that the motor is running at the correct revs.
Compare the power consumption of the motor against the values specified.
Replace defective parts of the motor with corresponding non-defective parts.
68 AZ-66323
8.5.2 Elevator
Check chain and belt tension.
Tighten up the chain or the belt.

Replace the chain or the belt with corresponding non-defective parts if the tension
slackens due to wear.
Check bearings.
Listen out for unusual noises during operation.

Check the bearings for play.
Remove the bearings and check them for damage and wear.
Replace defective bearings immediately with corresponding non-defective bear-
ings.
Check wearing parts in the inflow.
Replace excessively worn parts with corresponding non-defective parts.
Check wearing parts in the inflow.
Replace excessively worn parts with corresponding non-defective parts.
Inspection of buckets, chain and belt at creep speed.
Open the maintenance flap on the top of the elevator. Do not remove the grille.
Allow the drive to run in manual until the next bucket can be seen.
Check the bucket and the chain or belt for wear.
Check all the buckets.
Check the attachment of the buckets. Replace the bolts where applicable or per-
form a new spot weld.
Inspect the condition of the chain using the chain inspection report.
Replace excessively worn buckets with corresponding non-defective buckets.
Replace chain, belt, buckets, motor, transmission and bearings
Replace defective parts with corresponding non-defective parts.
Shovelling out the base section
Shut the elevator down and secure it against unintentional restart.

Open the doors of the base section. Do not stand directly in front of the doors
AZ-66323 69
Inspection
when opening them.

Remove all transported material and foreign material in the base section.
Check that the tension slide is working correctly.
Repair the tension slide.

When performing the repairs, take into consideration the tension slide’s readjust-
ment facility. If there is (virtually) no scope left for readjustment, the chain should
be shortened.
8.5.3 Inspection of the filler screw conveyor
Check packing glands
Replace worn or damaged packing glands with corresponding non-defective pack-

ing glands.
Check drive motor
Repair the defective drive motor or replace it with a non-defective drive motor.
Check bearing
Listen out for unusual noises during operation.

Check the bearings for play.
Remove the bearings and check them for damage and wear.
Replace defective bearings immediately with corresponding non-defective bear-
ings.
Check screw tube
Seal up holes in the screw tube.

When doing so, pay attention to the distance to the screws.
Remove deposits in the inflow and outflow.
Check screw
Replace defective screws with corresponding non-defective screws.

Usually the screw shaft has to be replaced along with the entire screws
Remove deposit crusts from the screws.
70 AZ-66323
Check that the material is not stuck to the turnstile gate.
All stuck material must be removed.
The turnstile must be checked for wear.
The turnstile must be replaced.
The housing must be checked for wear.
The housing must be replaced.
The bearings must be checked for wear.
The bearings must be replaced.
8.6 Repairs
Comply with the directions relating to repairs in the Operating Instructions for the
structural components and supplier parts.
Notify the Plant Manager and the operating personnel before starting special work
and repair work.
Appoint a Supervisory Manager.
Secure the work area. This also applies for surrounding areas if the activity can
lead to danger there.
The customer is responsible for ensuring that in the event of any work involving
cleaning and maintaining tanks for warm storage of bitumen, the protective meas-
ures laid down for work in explosion-hazard areas under TRbF 180 No. 3 (TRbF =
Technical Regulations for Flammable Liquids [Technische Regeln für brennbare
Flüssigkeiten]) and TRGS 507 (TRGS = Technical Regulations for Hazardous
Materials [Technische Regeln für Gefahrstoffe]) are always applied. Also to be
applied are the “Guidelines. for work performed in containers and confined spaces”
(published by the German Chemical Industry Trade Association [Berufsgenossen-
schaft der chemischen Industrie]; ZH 1/77).
The customer must ensure that a reliable person is appointed as supervisor (per-
son responsible) in accordance with TRGS 507 and TRbF 180 No. 3. The person
AZ-66323 71
Repairs
concerned must understand the work, the dangers emerging in the course thereof
and the protective measures required.
The customer must ensure that the supervisor receives support in the form of the
provision of specialists and equipment if required.
WARNING
Risk of fire and explosion!
Welding on tank walls and work with ignition sources may only be performed if the
supervisor responsible has issued written authorisation and the safety measures
stipulated therein are complied with, including the measures for prevention of the
risk of fire and explosion! (TRGS 507 “„Surface treatment in interior spaces and
containers“: VBG 15 - “Welding, Cutting and Related Processes” German Trade
Associations [Berufsgenossenschaften] Accident Prevention Regulation)
72 AZ-66323
8.7 Repairs and replacement of elevator parts
AZ-66323 73
Repairs and replacement of elevator parts
8.7.1 Replacement of individual buckets
4, 5
Bucket attachment
Key:
1 Bucket
2 Chain
3 Pin (separation point)
4 Bolt
5 Nut
Tightening torques for buckets with belt elevators
Tightening torque
Bolt (name)
(Nm)
M 10 40
M 12 70
M 16 100
74 AZ-66323
Replacing a bucket
9 Switch off the power supply in accordance with the five safety rules.
9 Open the maintenance doors at the bottom of the elevator shaft.
1 Line up the bucket to be removed behind the opening through turning the motor
ventilator wheel.
2 Free up the return shaft.
3 Remove the old bucket.
4 Install the new bucket.
5 Tighten up the nut and secure it with a spot weld.
6 Reload the return shaft and remove all foreign bodies from the bottom of the ele-
vator shaft.
7 Switch on the power supply.
Î Perform a test run without transported material.
;The bucket has been replaced
8.7.2 Replacement of all the buckets

Tightening torques for buckets
Tightening torque
Bolt (name)
(Nm)
M 10 40
M 12 70
M 16 100
Replacing all the buckets

9 Remove the hood of the head section.
1 Get a mobile crane to lift the chain using the special lifting gear.
AZ-66323 75
3 Free up the traction organ through raising the tensioning device and fixing it on
both sides.
4 Separate the chain at any point required.
5 Attach ropes to the free ends of the chain for guidance.
6 Raise the chain carefully out of the elevator shaft with the help of a mobile crane.
7 Remove the buckets.
8 Assemble the new buckets.

Ö Tighten up the nut and secure it with a spot weld.
9 Assemble the chain with the new buckets applying the procedure in reverse.
10Switch on the power supply.
;The buckets have been replaced
8.7.3 Replacement of wear plates
Replacing wear plates

Wear plates or inserts are located in the infeed hopper and in the transfer chute.
9 Secure the conveyor belt or the chain against unwanted movement.
9 In order to replace the wearing parts in the infeed hopper, the infeed hopper
must be removed from the elevator shaft.
76 AZ-66323
Î Replacement of the discharge plate is performed through the side maintenance
doors at the top of the elevator.
Î Switch on the power supply.
;The wear plates have been replaced
8.7.4 Replacement of foot wheel, bearing, guide rails and tension slide
5
2
6
4
Key:
1 Tension slide
2 Maintenance hatch
3 Bearing
4 Guide rails
5 Maintenance doors
6 Foot wheel
NOTE
Switch off the power supply in accordance with the five safety rules.
AZ-66323 77
Secure the chain against unwanted motion.
2 Free up the return shaft using the chain block.
3 Fix the chain on both sides and then open the chain at any point using an appro-
priate tool.
;The chain has been secured
Replacement of components where there is sufficient space at the bottom of

the elevator shaft
1 Unscrew central strut (with guide rails) between the maintenance doors.
Î Release the bearing housing from the tension slide on both sides.
Î Remove the foot wheel from the tension slide and lift out with bearing.
Î Remove bearing.
Replacement of components in the event of insufficient space at the bottom

of the elevator shaft
9 A chain block is required for removal of the drum and the tension slide.
1 Unscrew central strut (with guide rails) between the maintenance doors.
Î Fully dismantle tension slide with foot wheel or foot drum.
Î Release the bearing housing from the tension slide on both sides.
Î Take foot wheel with bearings out of tension slide and remove bearings.
2 Completely change the foot wheel and/or both bearings if required.
3 Replace the guide elements and rails if required.
4 Reassemble the elevator applying the procedure in reverse.
5 Re-splice the chain under the foot wheel or the foot drum.
6 Reload the return shaft and remove all foreign bodies from the bottom of the ele-
vator shaft.
78 AZ-66323
;The parts have been replaced
8.7.5 Repair and replacement of the gear motor
1 2
Head sections
Key:
1 Pedestal bearing (unit)
2 Gear motor with return stop and torque arm
3 Drive wheel
4 Drive shaft
NOTE
Use lifting devices which are big enough to cope with removing the gear motor!
Only use the specially designed eyelets to lift the gear motor. These eyelets are
only designed for the weight of the gear motor and must therefore not be used to
lift attached components.
Follow the Operating Instructions for the motor!
Working on the gear motor

9 Secure the chain against unwanted motion.
AZ-66323 79
1 Suspend the drive on the crane using the hoist.
2 Remove the torque arm.
3 Dismantle the power transmission (coupling or shrink disc).
4 Remove the drive.
5 Repair the gear motor or replace it where required with a structurally identical,
non-defective gear motor.
6 Mount and screw in the non-defective gear motor.

Ö Comply with bolt tightening torques!
7 Reinstall the power transmission.

Ö Comply with bolt tightening torques!
8 Mount and attach the torque arm.
;The work on the gear motor has been completed
8.7.6 Repair and replacement of the drive shaft bearings
NOTE
The drive shaft bearings should generally be replaced in pairs.
Working on the drive shaft bearings

9 Secure the chain against unwanted motion.
9 Dismantle the gear motor with coupling or shrink disk as described above.
1 Unscrew and remove the pedestal bearing bolts.
2 Lift the drive shaft approx. 3mm using a hydraulic jack.
3 Support the drive shaft and free up the hydraulic jack.
80 AZ-66323
4 Separate the upper and lower sections of the housing and remove both sections.
Ö Mark the adapter sleeve position on the shaft.
5 Dismantle the bearing with adapter sleeve, seals, fixing rings and end cap.
6 Repair the bearing or replace it if necessary with a structurally identical, non-

defective bearing.
7 The shaft must be cleaned before assembly.
8 Mount and install the non-defective bearing with adapter sleeve, seals, fixing
rings and end cap.
Ö Make sure that the adapter sleeve is in the right position!
9 Mount and screw in the upper section and lower sections of the housing.
10Raise the drive shaft using the hydraulic jack.
11Remove the supports under the drive shaft.
12Insert the drive shaft.
13Screw in the pedestal bearing.
14Assemble the gear motor with coupling or shrink disk as described above.
15Reassemble the bearing with the adapter sleeve at the point marked on the
shaft.
16The bearing and the interior of the bearing housing are to be filled with lithium
saponified ball-bearing grease.
17Switch on the power supply.
Î During the trial run, monitor the development of the bearing temperature!
;The work on the drive shaft bearings has been completed
AZ-66323 81
Repair and replacement of parts on the filler screw conveyor
8.8 Repair and replacement of parts on the filler screw conveyor
8.8.1 Repair or replacement of the motor

9 Completely empty the filler screw conveyor.
9 Disconnect the mixer tower and allow it to cool.
1 Disconnect the motor from the power supply applying the 5 safety rules.
2 Support the motor using an appropriate lifting device.
3 Disconnect the motor from the transmission.
4 Repair the motor or replace it with a corresponding non-defective motor.

Ö Follow the Operating Instructions issued by the manufacturer.
5 Reconnect the motor to the transmission as before.
6 Reconnect the power supply.
7 Check that the filler screw conveyor is working correctly without material.
;The work on the motor has been completed.
8.8.2 Repair or replacement of the transmission

1 Remove the motor as described above.
2 Support the transmission using an appropriate lifting device.
3 Disconnect the transmission from the screw shaft.
4 Repair the transmission or replace it with a corresponding non-defective trans-

mission.
Ö Follow the Operating Instructions issued by the manufacturer.
5 Reconnect the transmission with the screw shaft as before.
6 Install the motor as described above.
82 AZ-66323
;The work on the transmission has been completed.
8.8.3 Repair or replacement of the inflow bearing

1 Dismantle the motor and the transmission as described above.
2 Support the screw shaft using an appropriate lifting device.
3 Loosen the bearing attachment bolts.
4 Remove the bearing from the screw shaft.
5 Repair the bearing or replace it with a corresponding non-defective bearing.
6 Reconnect the bearing to the screw shaft as before.
7 Install the motor and the transmission as described above.
;The work on the bearing has been completed.
8.8.4 Repair or replacement of the outflow bearing

1 Undo the cover.
2 Support the screw shaft using an appropriate lifting device.
3 Loosen the bearing attachment bolts.
4 Remove the bearing from the screw shaft.
5 Repair the bearing or replace it with a corresponding non-defective bearing.
6 Reconnect the bearing to the screw shaft as before.
AZ-66323 83
Repair and replacement of parts on the filler screw conveyor
7 Screw in the bearing.
;The work on the bearing has been completed.
8.8.5 Repair or replacement of the packing gland

1 Remove the motor, transmission and bearing, as described above.
2 Remove the packing gland from the screw shaft.
3 Repair the packing gland or replace it with a corresponding non-defective pack-

ing gland.
4 Reconnect the non-defective packing gland with the screw shaft as before.
5 Install the motor, transmission and bearing as described above.
;The work on the packing gland has been completed.
8.8.6 Repair or replacement of the screw shaft

1 Support the screw conveyor using an appropriate lifting device.
2 Unscrew the screw conveyor.
3 Deposit the screw conveyor in an appropriate place.

Ö Make sure there is sufficient space for removal of the screw shaft.
4 Remove the transmission as described above.
5 Remove the outflow bearing as described above.
84 AZ-66323
6 Pull out the screw shaft from the screw tube.
Ö Watch out for the connections to the packing gland and the bearing on the
drive.
7 Repair the screw shaft or replace it with a corresponding non-defective screw

shaft.
8 Push the non-defective screw shaft into the screw tube.

Ö Watch out for the packing gland and the bearing on the drive.
9 Install the bearing as described above.
10Install the transmission as described above.
11Reconnect the power supply.
12Check that the filler screw conveyor is working correctly without material.
;The work on the packing gland has been completed.
8.9 Repair and replacement of the cell wheel sluice
AZ-66323 85
Repair and replacement of the cell wheel sluice
8.9.1 Replacement of turnstile (wheel)
Replace turnstile
9 Disconnect motor from power source according to the 5 safety points.
1 Unfasten and remove motor bracket.
2 Remove turnstile and discard.
3 Install new turnstile (wheel).
4 Replace and fasten the motor bracket.
5 Connect motor to the power source.

Ö Pay attention to voltage and rotation direction!
;Turnstile (wheel) is replaced
8.9.2 Replacement of housing
Replace housing
1 Remove turnstile gate and safely store using appropriate lifting device.
3 Remove turnstile and safely store.
4 Remove bearing and install new housing.
5 Insert turnstile into new housing.
6 Install motor bracket on the new housing.
7 Install and fasten turnstile gate.
8 Discard old housing.
9 Connect motor to the power source.

;The housing is replaced
86 AZ-66323
8.9.3 Replacement of the bearings
Replace bearings
1 Remove turnstile gate and safely store using appropriate lifting device.
3 Remove turnstile and safely store.
4 Unfasten and remove bearing on housing.
5 Unfasten and remove on the motor bracket.
6 Install new bearings.
7 Insert turnstile into the housing.
8 Install motor bracket on the housing.
9 Install and fasten turnstile gate.
10Discard old bearings.
11Connect motor to the power source.

;The bearings are replaced
8.10 Lubrication instructions
NOTE
Old lubricants or cleaning agents must not in any way be disposed of in the envi-
ronment, mixed with other sorts of waste or incinerated in facilities not approved for
the purpose.
AZ-66323 87
Lubrication instructions
Schmierintervall / Betriebsstunden * Interval / Operating hours * Intervalle / heu-

res de travail
1 Spezialvorschriften * Special instructions * Instruction spéciale
2 8
3 40
4 200
5 2000
6 10000
High temperature grease up to 180° C

BENTONIT
A HIGH TEMPERATURE GREASE up to 180° C
NLGI 3
Graisse r haute température jusqu'a 180° C
Ball-bearing grease -25° C up to +120° C
LITHIUM
B BALL BEARING GREASE -25° C up to +120° C
NLGI 2
Graisse pour roulements -25° C jusqu'a +120° C
Long-fibred gear grease -20° C up to +80° C
C LONG FIBRED GEAR GREASE -20° C up to +80° C NLGI 00
Graisse fluide pour réducteurs -20° C jusqu'r +80° C
High pressure grease for open gears
D HIGH PRESSURE GREASE FOR OPEN GEARS
Graisse r haute pression pour engrenages ouverts
VG 100 C-LP / CLPHC
Industrial gear oil VG 150 DIN 51 502
E INDUSTRIAL GEAR OIL VG 220 / DIN 51 517 Part 3
Huile de réducteur industrielV VG 320 FZG test
VG 460 > 12 DIN 51 354
Hydraulic oil H-LP
F HYDRAULIC OIL VG 32 DIN 51 524 Part 2
Huile hydraulique With increased VI
Hydraulic oil
H-LPD
G HYDRAULIC OIL VG 10
DIN 51 524 Part 2
Huile hydraulique
According to special instructions
X ACCORDING TO SPECIAL INSTRUCTIONS
Selon instructions spéciales
88 AZ-66323
8.10.1 Elevator lubrication instructions
Position in the flow chart 05.001
3B
1X
3B
NOTE
Comply with the regulations on the drive units issued by the relevant manufacturer!
AZ-66323 89
8.10.2 Lubrication Instructions for Chain Drive of Feed Screw Conveyor
4X
1X
4X = adhesive lubricant
NOTE
90 AZ-66323
8.10.3 Lubrication Instructions for Feed Screw Conveyor With Pedestal Bear-
ing, Pendulum Bearing and Thrust Journal Bearing
1X 3B 3B
NOTE
Observe the instructions of the drive engine manufacturer!
All bearings are maintenance-free!
Relubricate after 2000 working hours (grease B), if possible!
Check the glands once a week, lubricate and adjust them again, if necessary!
In the event of a packing leak close it by tightening the screws. If the leak has been
closed it is sufficient to tighten the screws a half rotation additionally.
Too strong screw tightening as well as running without lubricant causes the pack-
ing to overheat and thus increased packing wear.
Tighten the screws uniformly in order to guarantee straight and uniform tightening
of the packing and proper aligning of the follower.
AZ-66323 91
8.10.4 Lubrication Instructions for Feed Screw Conveyor With Pedestal Bear-
ings
1X 3B 3B
NOTE
All bearings are maintenance-free!
Relubricate after 2000 working hours (grease B), if possible!
Check the glands once a week, lubricate and adjust them again, if necessary!
In the event of a packing leak close it by tightening the screws. If the leak has been
closed it is sufficient to tighten the screws a half rotation additionally.
Too strong screw tightening as well as running without lubricant causes the pack-
ing to overheat and thus increased packing wear.
Tighten the screws uniformly in order to guarantee straight and uniform tightening
of the packing and proper aligning of the follower.
92 AZ-66323
8.10.5 Lubrication Instructions for Cell Wheel Sluice
Position in the flow chart 04.008, 05.007, 05.008
4B 1X
NOTE
1X: Comply with the manufacturer’s regulations!
AZ-66323 93
8.10.6 Cylinder mountings lubrication instructions
All attachments (with the exception of the pivot mounts) are to be lubricated as nec-
essary.
We recommend cleaning and regreasing all the non-fixed cylinder mountings at
least once a year.
At ambient temperatures of over 120° Celsius use high temperature grease (lubri-
cant “A”).
Cylinder mounted via a bolted pivot mount and bolted base attachment
with joint bearing
5B
The pivot mount is maintenance-free
Cylinder mounting with bearing block and pin with circlips
5B
Piston rod mounting using fork head

Cylinder mounting with bolted bearing block
5B
All connections (with the exception of the pivot mounts) should be lubricated if
required.
94 AZ-66323
We recommend cleaning and regreasing all mobile cylinder mountings at least
once a year.
In the event of ambient temperatures of over 120°C use high temperature grease
(lubricant “A”).
8.11 Measures to be taken in the winter
NOTE
Low temperatures and in particular temperatures below freezing can have an
adverse effect on plant operation.
Empty pipes and tubes before shut-down in the winter to prevent damage and sim-
plify re-start.
Set the burner to the lowest setting. This means that the pilot flame stays on, but
the rotary vane feeders do not transport any more material.
Empty the entire Filler Supply before extended stoppages in the winter. This pre-
vents damage and simplifies re-start. Allow the Filler Supply to continue to run until
the silo and the pipes are empty.
NOTE
During decommissioning the belts of the conveyor belts and belt elevators must be
released as much as possible!
This is necessary as the belts shorten and thus stretch more and more, which may
lead to breaking or damage of the belt.
To do so, run the machine without material supply until all buckets are empty.
In order to avoid frost damages, discharge the belt of belt elevators as far as pos-
sible if the plant is switched off for a longer period of time.
To take care of the conveyor belts and elevators, we recommend to permanently

run the drive with a low power to prevent freezing if the plant is operated in winter.
AZ-66323 95
Measures to be taken in the winter
96 AZ-66323
9 Decommissioning and disassembly
NOTE
Empty the machine Filler Supply.
Disconnect the plant before final shut-down of the Filler Supply machine.

Risk of injury when working on live components!
Do not work on live components.
Ö Disconnect the machine.
Make sure you abide by the five safety rules when disconnecting the power sup-
ply.
Remove the electricity supply lines.

9 Before starting dismantling, all supply lines must be disconnected.
Dismantling with Filler Silos

• Feed screw conveyor from the filler silo to the filler elevator
• Filler silos
• Filler elevator
;The Filler Supply machine has been dismantled
Dismantling With Filler Silo Tower

• Feed screw conveyor from the upper filler silo tower deck to the filler scale
• Feed screw conveyor from the lower filler silo tower deck to the filler elevator
• Filler elevator
;The Filler Supply machine has been dismantled
AZ-66323 97
Decommissioning and disassembly
Dismantling sequence for the machine Elevator

9 Before starting dismantling, all supply lines must be disconnected.
1 Remove the hood at the elevator head.
2 Remove the chain or belt.
3 Fix the slings at the elevator head and above the elevator pedestal.
Î During the following steps, the elevator may turn over under unfavourable cir-
cumstances!
Ö Tighten the slings sufficiently to support the elevator.
4 Loosen the connection to the pulley.
5 Remove the screen connection.
6 Loosen the elevator hinges.
7 Lift the elevator by using two cranes and move it to a horizontal position.
8 Lay down the elevator on a free area and loosen the hoisting tools.
Ö The area should be even. Secure the elevator against slipping in case of
inclined areas!
9 Dismantle the elevator.
;The Elevator machine has been dismantled
Dismounting of the turnstile gate
1 All supply lines must be cut out.
2 Dismount and remove motor.
3 Unfasten turnstile gate and remove using suitable lifting device.
4 Dismount turnstile gate.
;Turnstile gate is dismounted
If the Filler Supply machine is not to be disposed of, it can also be loaded immedi-
ately onto a suitable vehicle.
98 AZ-66323
NOTE
Take transportation dimensions into account!
AZ-66323 99
Decommissioning and disassembly
100 AZ-66323
10 Disposal
If the Filler Supply machine is to be finally decommissioned, safe, environmentally
friendly disposal of all the components is required and of the process materials in
particular.
The Filler Supply machine is predominantly made of steel.

This can be sent for scrap after disassembly.
Make sure you comply with national regulations when disposing of the electronic
equipment.
The electrical cables are to be disposed of as cable scrap.
In addition to the plant components, there will also be residues of aggregate, RA

or filler in the mixer tower.
These materials can be re-used and should be recycled.
The insulation consists of rock wool.

Rock wool can be recycled.
The elevator belts and drive V-belts are made of rubber.

Rubber represents toxic waste and is to be disposed of by specialist companies.
Non-defective belts can be re-used after inspection by a specialist.
Seals and other materials not specified above are to be disposed of by specialist
companies.
Dirty cleaning rags are to be disposed of in an environmentally friendly manner. It

should be borne in mind here that residues of aggregate oils and of other environ-
mentally hazardous materials are present in the dirt.
AZ-66323 101
Disposal
102 AZ-66323
11 Appendix
Separate Operating Instructions apply for the following sub-assemblies:
Additional Operating Instructions may also apply depending on the design of the
mixer tower.
The documents listed in section 12 of the spare parts lists are also to be complied
with.
AZ-66323 103
Appendix
104 AZ-66323

0501 Fuellerversorgung GB

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Instruction Manual

© Ammann Asphalt GmbH 2002-2007

Font: Arial, WingDings

Author: Michael Lemper

6.4 Cell Wheel Sluice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Inform the site supervisor or another representant of Ammann about maintenance

2.1 Introduction to the Operating Instructions

These Operating Instructions contain information and procedural guidelines essen-

These Operating Instructions should be used in conjunction with the Operating

Operating personnel must be familiarised with these Operating Instructions before

These Operating Instructions are intended to simplify the process of understanding

These Operating Instructions should be read in conjunction with the requirements

Operating the plant shall be taken to refer to the following:

Elevator Device to vertically convey material in cups that are mounted on a

Filler silo tower

3.1 Intended use

The machine is designed in accordance with the state-of-the-art and recognised

Observe the national regulations when working with filler.

3.2 Improper use

CAUTION DANGER OF FIRE!

3.3 Description of the Filler Supply machine

The filler supply comprises the following components:

3.4 Description of the Elevator

3.5 Description of the Screw Conveyors

3.5.1 Tubular conveyor screw with radial bearing

3.5.2 Tubular conveyor screw with radial and axial bearing

3.5.4 Troughed conveyor feed screw

3.6 Description of the Cell Wheel Sluice

3.7 Workplaces at an asphalt mixing plant

Diagram of an asphalt mixing plant without optional components

4.1 Filler elevator

4.1.1 Performance data

Elevator size Single filler Single filler Double filler

4.1.2 Dimensions and Weight

Double filler elevator

4.2 Screw conveyor

4.2.1 General Notes

Design of the bearing:

The drive can be installed on the inlet's or on the outlet's side.

Conveying capacity for feed screw conveyors

Conveying capacity (m³/h) 12 18 25 60

4.2.2 Dimensions and Weight

4.3 Cell wheel sluice

5.1 General instructions

The machine may only be transported by trained personnel or by personnel who

A crane with the following technical specifications is recommended for transporta-

An additional crane with the following technical specifications is required for

5.2 Lifting eyelets and lifting gear

5.3 Weights and measurements

The customer is responsible for ensuring that experienced, specialist personnel

The customer must appoint someone to be responsible for assembly.

This coordinator is responsible for ensuring correct performance of the assembly

Ammann recommends that Ammann specialist personnel should in principle per-

6.2.1 Installing the elevator

1 Lift the elevator with the aid of both cranes.

2 Put the elevator on the appropriate foundation.

3 Hang the elevator in the appropriate articulated devices.

4 Adjust the elevator perpendicularly in all directions.

5 Screw the elevator to the foundation.

7 Install the belt of elevators with a distance of axle of more than 20 m as

;The elevator has been installed.

Tightening torque for buckets of belt elevators

1 Screw the buckets to the belt.