2 - BW-Z Maintenance+Service

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL
AUMUND Day 2012

MAINTENANCE + SERVICE
BUCKET ELEVATOR WITH CENTRAL CHAIN
BW-Z / BW-ZL / BW-D
AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 1
WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL
Chain Bucket Elevators
More than 2.600 with central chain in last 35 years

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL Central chain Bucket elevator
„ Conveying capacities from just 5 t/h to more than 1300 t/h
„ Lifting heights from just 10 to more than 70 m
„ Forged central chain with large link surfaces
„ Heat-resistant in continuous operation
„ Withstanding material temperature peaks to 400°
„ Outstanding service live with sealed and lubricated

forged chain
„ Speed up to 1,9 m/s

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL Application
90°
60°
Bucket elevator
40°
30°
0°

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL Components and assemblies
Head Dedusting Point

casing
Guide Frame
Chain and Buckets
U Frame
Assembly casing
Feed Point
Boot

WE CONVEY QUALITY
Drive shaft
Slow drive
Hub
Gear box
Drive bearings
Main motor
Fluid coupling

WE CONVEY QUALITY

WE CONVEY QUALITY
Double drive for AUMUND- Bucket elevator BW-Z / BW-ZL with inching drive

WE CONVEY QUALITY
Double drive for AUMUND- Bucket elevator BW-D with inching drive

WE CONVEY QUALITY
Drive option without inching drive but with frequency converter

up to 30 kw

WE CONVEY QUALITY
1- Drive shaft
2- Segment / Drive ring
3- Hub
4- Screw
5- Loose bearing
6- Fix bearing
8- Sealing
10- Screw
11-14 Segment’s screw
15-17- Lager screw
18-19- Position screw

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Elevator boot
Bucket elevator boot
Guide beams
Guide frame
Tension ring & tension shaft

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Elevator boot BW-Z / BW-ZL

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Elevator boot BW-D

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Tension frame with tension shaft and segmented tension ring

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Bearing Type Ni-Hard

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BW-Z / BW-D / BW-ZL AUMUND Chain types
AU 01.1 AU 02.2 AU 04.2 AU 06.3 AU 13.3 AU 15.3
Breaking load Bucket spacing
- AU 01.1: 400 kN 280,0 mm
- AU 02.2: 540 kN 304,7 mm
- AU 04.2: 800 kN 355,6 mm
- AU 06.3: 1200 kN 355,6 mm
- AU 13.3: 1500 kN 355,6 mm
- AU 15.3: 1800 kN 355,6 mm

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BW-Z / BW-D / BW-ZL AUMUND Chain
AU 04.2

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AU 06.3 / AU 13.3 / AU 15.3

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Sealing
Pin
Inner link
Outer link
Bush
Since 1996
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Chain support on friction ring
Larger contact surface four-point support

Reduced wear of chain bush

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NEW CHAIN AND NEW SEGMENTS

If the chain or drive ring is new there is
always a gab between chain link and
shoulder of the drive ring!
The contact between chain link and shoulder

of the drive ringoccurs after certain time of
operation!
The wear between bushing and drive ring will

ensure that the chain link and the shoulder of
the drive ring get in contact smoothly!

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL Chain strand
Bucket Characteristic design

for optimum discharge
and short bucket spacing
Angular bracket Patented tolerance
between pin and bracket
Reduced vibration
(polygon effect)
No cracks in welding
seem and bucket
fixation
Self-locking
screws
Close bucket spacing =

Nearly no spillage

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL Bucket fixing
AU 04 / AU 06 / AU 13 / AU 15
AUMUND standard

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BW-Z / BW-D / BW-ZL Buckets
„ 1.Bucket with or without Das Bild k ann zurzeit nicht angezeigt werden.
reinforced lip
„ 2. Angular bracket Reinforced lip
„ 3. Inner link with without

„ 4. Connecting bolt

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BW-Z / BW-D / BW-ZL
Maintenance

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BW-Z / BW-D / BW-ZL Maintenance / Requirements
A precondition for perfect operation of the bucket elevator is proper

maintenance, i. e.:
- Qualified/trained maintenance personal

- Regular inspections according to the operation manual
- Prompt replacement of worn or damaged parts
- Immediate elimination of defects
- Regular lubrication according to the operation manual
- Operation according operation manual

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BW-Z / BW-D / BW-ZL Maintenance intervals
The inspections and checks to be carried out are subdivided in the following plan according to
operating hours and maintenance intervals
Legend:
Daily Weekly Monthly Yearly
X Daily
X Weekly
X Monthly
X Yearly
2 Every 2 weeks
3 or 6 Every 3 months (quarterly)
every 6 months (half yearly)
2 Every 2 years
Start With each commissioning
Team Before beginning of each shift
Need As required
to see in the AUMUND Operation Manual: Chapter 5

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BW-Z / BW-D / BW-ZL Maintenance intervals
More
Monthly
Number
Weekly
informati
Yearly
Daily
Operating
Sub-assembly
hours
Cat * on Work to be done
chapter
Drive elements (e.g. The drive elements contained in the bucket elevator and the documentation belonging to it, are listed in chapter 8.
* motor, gear unit, The necessary maintenance work may be learn from the manufacturer's documentation and must be carried out in
coupling, brake the time intervals indicated there.
Check fixture
* Torque support 3 S Check for damage
Check bearings for:

-excess grease
-abnormal noise
Drive shaft /
1/1 3 S/B -excess heating
tail shaft Check bolted connections for:
-completeness
-tight fit
Check chain for damage (visual
X S/B
check)
1 Chain
6 S Chapter 5 Check wear (measurement)
Check for :
-function
Tensioning device 3 B -damages, wear
-tight fit of screws

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL

Number
Maintenance intervals
Monthly
Weekly
More
Yearly
Daily
Operating Cat
Sub-assembly information Work to be done
hours *
chapter
Check for : -
damages -
X B completeness of bolted
connections ( visual check)
All Buckets
Check for material backings
X Remove material backings
Check for material backings

Material Inlet
X Remove material backings
Material Outlet
Check bolted connections for :

-completeness -
-tight fit
Check for:
Steel structure 6 S corrosive or other damages
-repair or replace deform or
worm parts
B = Work can (or must) be done during operation S = work must be done during machine stop

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL
Wear measurement

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL Maintenance / Wear measurement
Regularly wear measurement according to the operation manual will

lead to:
- Early detection of wear

- Early detection of failures
- Optimized maintenance management
- Optimized spare part management
- Less spare parts on stock
- Lower maintenance costs
- Less unplanned stops
- Increase of production

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Two different methods of wear measurement
1 – Visual check
2 – By measuring
For a perfect result we have to operate with both methods

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1 – Visual check
- seeing
- feeling
- touching
- hearing

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Wear examples
Tail ring
Drive ring

WE CONVEY QUALITY
Wear mark
Wear mark at the drive ring

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Wear mark
The wheel segments have to be renewed as soon as the wear marks are achieved

WE CONVEY QUALITY
Wear checking on the drive and/or tail ring segments
Wear limit
The wheel segments have to be replaced as soon as the wear marks are achieved
We recommend to replaced the wheel segments when exchanging the chain
See also Operation Manual § 5.10
WE CONVEY QUALITY
Highly wear!
Bushing Cracks
The chain must be exchanged if the bushings are presenting cracks or pittings

WE CONVEY QUALITY
Pitting
The chain must be exchanged if the bushings are presenting cracks or pittings

WE CONVEY QUALITY
Chain pitch Ø Bushes Ø Pin X0 X 50 X max

Chain type
( mm ) (mm) (mm ) ( mm ) ( mm ) ( mm )
AU 01 140 37 25 177 180 183
To define AU 06.1 177.8 58 36.35 235.8 239.8 243.8

the Chain
type AU 13.1 177.8 63 39.7 240.8 245.3 249.8
installed,
AU 15.1 177.8 71 44.5 248.8 253.3 257.8
check on
the G.A. AU 01.1 140 38 25 178 180.5 183
drawing
AU 02.2 152.4 45 27 197.4 199.9 202.4
AU 06.2 177.8 58 36.3 235.8 239.8 243.8
AU 13.2 177.8 63 39.7 240.8 245.3 249.8
AU 15.2 177.8 71 44.5 248.8 253.3 257.8
See also Operation Manual Chapter § 5.9

WE CONVEY QUALITY
„ Measurement of one
double link
„ Using a caliper gauge
„ Measuring the length

over two bushings

WE CONVEY QUALITY
The chain must be tensioned NEVER take the measurement

and cold. The measurement at a inner-link!
must be taken between two
outer-links!! (Behind a bucket)

WE CONVEY QUALITY
• Friction bearings
The friction bearings must be replaced, if
the gap between bushing and pillow block
exceeds 10 mm (≈3/8 inch)

WE CONVEY QUALITY
• Friction bearings
How to measure the gap?
With a feeler gauge! 
The friction bearings must be replaced, if the gap between bushing and pillow block
exceeds 10 mm (3/8 inch)

WE CONVEY QUALITY
• Angular brackets
The angular brackets must be replaced if the gap between bracket and bolt reach 10 mm

WE CONVEY QUALITY
• Tail axle height
Min. 150 mm
The gap between buckets and bucket elevator boot should not be less than 150 mm

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL Instrumentation
Speed Emergency stop

control switches
Boot Level
Control
Monitoring of
take-up length

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL Maintenance / Parts replacement
Parts replacement
BEFORE CARRYING OUT ANY REPAIR OR MAINTENANCE WORK,
ALWAYS STOP AND SWITCH OFF THE CONVEYOR AND PROTECT
AGAINST ANY ACCIDENTELY UNAUTHORISIZED RESTARTING!!!!

WE CONVEY QUALITY
Following parts have be replace when wear limits are reached
- Drive ring
- Tail ring
- Chain
- Angular brackets

WE CONVEY QUALITY
„ 1 Remove the old segment in the chainless part of the sprocket

„ 2 Insert the new segment, tighten bolts slightly only
„ 3 Make the sprocket advance and exchange the other segments
successively
„ 4 Move each new segment upwards into 12 o’clock position.
„ Tighten the bolts of the segment in12 o’clock position adhering to the
correct tightening torque , refer to table
Note: Due to the weight of

the bucket strand the
segment on top is firmly
pressed on the radial
surface and is thus
arranged the correct
position.

WE CONVEY QUALITY

The total length of the bucket elevator chains consists of several strand with 10 double links
each and with several double links for length compensation.
The individual sections are connected with each other by means of normal outer links.
The chain can be shortened if required, by removing one or more double links
Assembly of Chains : AU 01.1- AU 02.2

1=Outer link 2=Outer bar 3=Inner link 4=Double link

WE CONVEY QUALITY

The total length of the bucket elevator chains consists of several strand with 10 double links
each and with several double links for length compensation.
The individual sections are connected with each other by means of normal outer links.
The chain can be shortened if required, by removing one or more double links

WE CONVEY QUALITY
Hydro-Press set-up for chain assembly and disassembly

WE CONVEY QUALITY
Hydro-Press set-up for chain assembly and disassembly

WE CONVEY QUALITY

WE CONVEY QUALITY
How NOT to store Aumund Chain !

WE CONVEY QUALITY
How NOT to pre-assemble Aumund Chain !

WE CONVEY QUALITY
How NOT to lift and

install Aumund Chain
!

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL General Arrangement Drawing

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL Technical Data

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL Technical data

WE CONVEY QUALITY
BW-Z / BW-D / BW-ZL
Thank you for your attention

Drag-chain Conveyors
And
Rotary Feeders

2 - BW-Z Maintenance+Service

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2 - BW-Z Maintenance+Service

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WE CONVEY QUALITY

BW-Z / BW-D / BW-ZL

AUMUND Day 2012

BW-Z / BW-D / BW-ZL

Chain Bucket Elevators

More than 2.600 with central chain in last 35 years

BW-Z / BW-D / BW-ZL Central chain Bucket elevator

„ Conveying capacities from just 5 t/h to more than 1300 t/h

„ Lifting heights from just 10 to more than 70 m

„ Forged central chain with large link surfaces

„ Heat-resistant in continuous operation

„ Withstanding material temperature peaks to 400°

„ Outstanding service live with sealed and lubricated

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 3

BW-Z / BW-D / BW-ZL Application

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 4

BW-Z / BW-D / BW-ZL Components and assemblies

Head Dedusting Point

Chain and Buckets

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 5

BW-Z / BW-D / BW-ZL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 6

BW-Z / BW-D / BW-ZL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 7

BW-Z / BW-D / BW-ZL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 8

BW-Z / BW-D / BW-ZL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 9

BW-Z / BW-D / BW-ZL Components and assemblies

Drive option without inching drive but with frequency converter

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 10

BW-Z / BW-D / BW-ZL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 11

BW-Z / BW-D / BW-ZL Components and assemblies

Bucket elevator boot

Tension ring & tension shaft

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 12

BW-Z / BW-D / BW-ZL Components and assemblies

Elevator boot BW-Z / BW-ZL

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 13

BW-Z / BW-D / BW-ZL Components and assemblies

Elevator boot BW-D

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 14

BW-Z / BW-D / BW-ZL Components and assemblies

Tension frame with tension shaft and segmented tension ring

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 15

BW-Z / BW-D / BW-ZL Components and assemblies

Bearing Type Ni-Hard

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 16

BW-Z / BW-D / BW-ZL AUMUND Chain types

AU 01.1 AU 02.2 AU 04.2 AU 06.3 AU 13.3 AU 15.3

Breaking load Bucket spacing

- AU 01.1: 400 kN 280,0 mm

- AU 02.2: 540 kN 304,7 mm

- AU 04.2: 800 kN 355,6 mm

- AU 06.3: 1200 kN 355,6 mm

- AU 13.3: 1500 kN 355,6 mm

- AU 15.3: 1800 kN 355,6 mm

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 17

BW-Z / BW-D / BW-ZL AUMUND Chain

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 18

BW-Z / BW-D / BW-ZL AUMUND Chain

AU 06.3 / AU 13.3 / AU 15.3