KZB / KZB-Q: Maintenance Seminar

WE CONVEY QUALITY
KZB / KZB-Q
MAINTENANCE SEMINAR
PAN CONVEYOR
KZB / KZB-Q KZB / KZB-Q : 1
AUMUND PREVENTIVE MAINTENANCE TRAINING
WE CONVEY QUALITY
KZB / KZB-Q
AUMUND
Apron Conveyor
More than 5.500 units in

service since 40 years
AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 2

WE CONVEY QUALITY
KZB / KZB-Q
Contents of the Training:
1 – Application of pan conveyors
2 – Contents of the operation manual
3 – Components and assemblies
4 – Maintenance
- Requirements
- Inspection intervals
- Lubrication
- Wear measurement
- Parts replacement
- Adjustments
- Erection instruction
- Faults
5 – Ordering spare parts

WE CONVEY QUALITY
KZB / KZB-Q Application of KZB, KZB-Q,

BZB and Bucket elevator
90°
60°
Bucket elevator
Z B
B 45°
Z B-Q
Application of K
KZB, KZB-Q, BZB 28°
with different slopes
Based on a 34° angle of
repose KZB
0°

WE CONVEY QUALITY
KZB / KZB-Q Maintenance / Operation manual

WE CONVEY QUALITY
Content of the operation manual:
Chapter 1 – General Survey

Chapter 2 – Safety
Chapter 3 – Operation
Chapter 4 – Faults
Chapter 5 – Maintenance and servicing
Chapter 6 – Lubricating instruction
Chapter 7 – Spare part list
Chapter 8 – Annex 1
Chapter 9 – Annex 2 - Drawings
Chapter 10 – Erection instructions
Chapter 11 – Package list

WE CONVEY QUALITY

WE CONVEY QUALITY

WE CONVEY QUALITY
KZB / KZB-Q
Components and assemblies

WE CONVEY QUALITY
KZB / KZB-Q Components and assemblies
Runway track Drive Station
Take up station Conveying section

WE CONVEY QUALITY
• Drive station 9 8
1. Motor
2. Fluid coupling
3. Gear box
4. Coupling 7
5. Drive shaft
6. Fixed bearing
7. Hubs
8. Toothed segments
9. Loose bearing 3 2 1 5 6 4

WE CONVEY QUALITY
• Drive shaft
1. Shaft
2. Toothed segments
3. Hub
4. Flange bearing comp.
5. Connecting plate
6. Cone block
7. Feather key
8. Hexagonal screw
9. Washer
10. Hexagonal nut
11. Hexagonal screw
12. Washer
13. Washer
14. Hexagonal nut
15. Hexagonal screw
16. Washer

WE CONVEY QUALITY
• Flange bearing
1. Flange bearing housing
2. Flange bearing housing
3. Flange bearing lid
4. Flange bearing lid
5. Disc
6. Bearing bush
7. Bearing
8. Shaft sealing ring
10. Hexagonal screw
11. Washer
12. Hexagonal screw
13. Washer
14. Grease nipple
15. Fitting

WE CONVEY QUALITY
• Drive shaft
- Toothed segments
- Easy assembly and disassembly
- Not necessary to open the chain
- Self alignment roller bearing
- Lower Maintenance cost

WE CONVEY QUALITY

WE CONVEY QUALITY
TOOTHED RIMS WITH 7,5 TEETH, WHAT DOES IT MEAN ?

WE CONVEY QUALITY
• Runway 5 1
1. Upper run
2. Lower run
3. Curve
4. Supports
5. Upper guiding
4 3 2

WE CONVEY QUALITY
3 1
• Runway 5
1. Upper run
2. Lower run
3. Curve
4. Supports
5. Upper guide line
AUMUND rails are twofold rolled, to provide the surface 2

more hardness, therefore less wear than standard rails.
WE CONVEY QUALITY
• Tension station 1 2 3 4 5 6
1. Frame
2. Springs
3. Spindles
4. Loose Bearing
5. Tension axle
6. Hubs
7. Toothed segments
8. Fixed bearing
7 8

WE CONVEY QUALITY
• Tension axle
1. Tension axle
2. Toothed segments
3. Hub
4. Loose tension bearing
5. Fixed tension bearing
6. Feather key

WE CONVEY QUALITY
• Tension spindle
1. Tension spindle
2. Parallel bolt without head
3. Washer
4. Split pin
5. Pressure spring
6. Spring washer
7. Spindle nut

WE CONVEY QUALITY
• Tail axle
- Toothed segments
- Not necessary to open the chain
- Self alignment roller bearing
- Lower Maintenance cost

WE CONVEY QUALITY
• Tension station

WE CONVEY QUALITY
• Conveyor Section
1. Pan with roller bracket
2. Pan without roller bracket
3. Baffle plate
4. Chain (right)
5. Chain (left)
6. Hexagonal screw
7. Lock nut
8. Hexagonal screw
9. Pan with baffle plate
10. Pan without baffle plate
11. Hexagonal screw
12. Nut

WE CONVEY QUALITY
• Conveyor Section
- Patented beats in sideboards
- Dust tight
- Separately mounted rollers
- Overlapping pans
- Self supporting chain design

WE CONVEY QUALITY

WE CONVEY QUALITY
Patented overlapping system

contact free no wear and
tear
no spillage exact determination
of discharge position
low maintenance
requirements
design Transport of
characteristics clinker up to an
inclination of
28°
without baffle
Conveying direction

WE CONVEY QUALITY
KZB / KZB-Q
- old design - - current design -

without beaded With beaded sideboards
sideboards

WE CONVEY QUALITY
• Chain (AU 4540.1) 3

1
1. Inner link 5
2. Outer link
3. Bushing
4. Bolt
5. Closing link
2
5

WE CONVEY QUALITY
Explanation of Chain Designation

Chain generations
Pitch x Width / Side bar height x Side bar thickness
160x45 / 70X10
1960 to 1980

WE CONVEY QUALITY

Chain generations
Pitch x Width / Side bar height x Side bar thickness
250x45 / 70X10
early 1980 to 2005

WE CONVEY QUALITY

Chain generations
Bush diameter
Chain width Development phase
AU 4540.1
since 2005

WE CONVEY QUALITY
• Chain (AU 4540.1)

1. 10-20 % higher breaking load
2. Pre-mounted chain locking link
3. Shorted delivery period
4. Geometry of pans and
…..buckets kept unchanged
5. High precision laser cut
6. Press-fit for bolts and
…...bushings
9. Fabricated fine grained steel

WE CONVEY QUALITY
Frequently asked questions

Will the bolts potentially shift in the holes due to the missing locking
ring?
NO! Long experience with bolts of bucket elevator chain
with press fit
Will the plates wear more than the old design?

NO! Wear of plates possible, if conveyor misaligned.
This applies to chains of new and old generation.
Will it be easy to duplicate the new chain generation?

NO! Special fine grained steel
New cam design only possible in laser-cut technologies
Design of the press fit not exactly reproducible after first
…………assembly

WE CONVEY QUALITY
• Rollers
1. Roller body
2. Roller axle
3. bush
4. bush
5. bush
6. lid
7. Sealing lamella
8. Sealing lamella
11. Circlips for bores
12. Circlips for shafts
13. Bearing
14. Cupped lubrication nipple
15. Sealing lamella
16. Sealing lamella

WE CONVEY QUALITY
• Rollers
- Sturdy design
- Three sizes: 108, 140, 160 mm
- Stub shaft
- Forged roller body
- Inductively hardened
- SKF Bearings
- Lifetime lubrication
- Special sealing's
- Low maintenance
- Long service life

WE CONVEY QUALITY
• Rollers

WE CONVEY QUALITY
KZB / KZB-Q
Maintenance

WE CONVEY QUALITY
KZB / KZB-Q Maintenance / Safety

WE CONVEY QUALITY
KZB / KZB-Q Maintenance / Requirements
A precondition for perfect operation of the pan conveyor KZB 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
- Operation according operation manual

WE CONVEY QUALITY
KZB / KZB-Q Maintenance / Inspection intervals

WE CONVEY QUALITY
The inspections and checks to be carried out are subdivided in the operation manual according
to operating time and maintenance intervals.
The following means:
Daily Weekly Monthly Yearly

X daily
X weekly
X monthly
X yearly
2 Every 2 weeks
3 or 6 Every 3 or 6 months
2 Every 2 years
Start With each commissioning
Team With each beginning of shift
Need As required
to see in the AUMUND Operation Manual: Chapter 5

WE CONVEY QUALITY

WE CONVEY QUALITY
KZB / KZB-Q Maintenance / Lubrication

WE CONVEY QUALITY
Lubrication General
Here you will find an example of lubrication list for pan

conveyor.
This lubrication list is to find in each “Operation Manual” in

chapter 5,
»for each machine there is a specific lubrication list that you
have to take in consideration.
All these instructions are to protect your equipment against

normal wear but also excessive wear.
An optimal lubrication will give you a good function of your

equipment and also to your complete installation.

WE CONVEY QUALITY
• Main lubricating points

1. Gearbox / Drive bearings
2. Tension bearings
3. Rollers
4. Chain – only to avoid creaking

WE CONVEY QUALITY

WE CONVEY QUALITY
• Specification
See chapter 6 of the operation manual

WE CONVEY QUALITY
Drip feed lubrication of the chain
1- Oil tank
2- Valve
3- Pipe
4- Injector

WE CONVEY QUALITY
Lubrication or
no lubrication ?

WE CONVEY QUALITY

WE CONVEY QUALITY
• Lubrication of the rollers

WE CONVEY QUALITY
KZB / KZB-Q 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
!!! Your boss will like it !!!

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

WE CONVEY QUALITY
1 – Visual check
- seeing
- feeling
- touching
- hearing

WE CONVEY QUALITY
2 – Dimensional check
- Measure tape
- Calliper gauge
- Feeler gauge
- Spirit level
- Folding rule
- Wire
- Plummet
- Laser
- Theodolite
- Thermometer
- Torque wrench

WE CONVEY QUALITY
• Toothed Segments
- Toothed segments must be replaced once the hardened zone of the tooth
paces has been worn away.
- Considerable wear of the toothed segments occurs:

- if the tooth shape differs by more than 6 mm at any point from the
shape of a new toothed segment compared with new toothed segment
or a template (see Fig. 4a and 4b)
- if the chain does not leave the tooth space of the sprocket wheel
smoothly, but jerkily.

WE CONVEY QUALITY
The toothed segments must be replaced :

- If wear acc. to the drawings can be ..observed
- When the chain is exchange with a new ..one
- If the chain elongation has not yet

exceeded ..the X50 wear dimension

WE CONVEY QUALITY
• Toothed Segments Wear limit
End of the hardening zone
! This segments are working at the wear limit and must be changed !

WE CONVEY QUALITY
!!! Don’t wait too long !!!

WE CONVEY QUALITY
!!! Typical catching due worn sprockets !!!

WE CONVEY QUALITY
If you wait too long
!!! This will happen !!!

WE CONVEY QUALITY
• Chain
- The table in the operations manual shows two different dimensions
of :::wear:
X 50
& X max
What does that mean ??
WE CONVEY QUALITY
• Chain

WE CONVEY QUALITY
• Chain (new generation)
X 50 : until this value it is possible to replace chain parts or segments
X max: when this value is reached, it is necessary to replace the

. complete chain and segments!

WE CONVEY QUALITY
• Chain (old generation)


WE CONVEY QUALITY
• Chain (forged chains)
AU 725 W AU 625
Chain-type Ø Bush Ø Pin X50 Xmax
(mm) (mm) (mm) (mm)
AU 625
250 x 60 /
Pitch 250mm 66,5 44 317,7 318,6
AU 725 W
250 x 80 /
75,95 49,95 328 330
Pitch 250 mm

WE CONVEY QUALITY
If you change the You must change

chains of the left the chain on the
side right side too!
Chains always must be replaced in pairs!

WE CONVEY QUALITY

WE CONVEY QUALITY
• Chain (measurement)
The chain must be

tensioned and cold. The Never take the measurement
measurement must be taken at an inner link!
between two outer inks!!

WE CONVEY QUALITY
• Bushings
This bushing is worn
!!! Replace the chain and the toothed segments !!!

WE CONVEY QUALITY
• Bushings
Pittings

WE CONVEY QUALITY
• Bushings
Cracks

WE CONVEY QUALITY
• Rollers

WE CONVEY QUALITY
• Rollers

WE CONVEY QUALITY
• Rails
Rail: S18

WE CONVEY QUALITY
• Rails
Rail: S18

WE CONVEY QUALITY
• Rails
! Always check the supports and the weldings of the rails !

WE CONVEY QUALITY
KZB / KZB-Q 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
• Replacement of the toothed segments:

WE CONVEY QUALITY
1. Empty the conveyor

2. Move the conveyor until the toothed segments to be replaced
....are not located in the meshing area!
3. Switch off the conveyor and protect it against any unauthorized
restarting!
4. Remove the bolts and the toothed segments
5. Put the new segments in place and tighten the bolts
6. Carry out steps 2, 3, 4 and 5 for the other toothed segments
7. Once all new toothed segments have been installed,
tighten ....all the bolts to the correct torque
8. Run the conveyor for one or two hours and check the
torque, ...making any corrections needed

WE CONVEY QUALITY

2. Move the conveyor until the toothed segments to be
replaced ....are not located in the meshing area!

WE CONVEY QUALITY
4. Remove the bolts and the toothed segments

WE CONVEY QUALITY
5. Put the new segments in place and tighten the bolts

WE CONVEY QUALITY
6. Carry out steps 2, 3, 4 and 5 for the other toothed segments

WE CONVEY QUALITY

NOTE:
The toothed segments is indicated by engraved figures in the intersections!
1–1 2–2 3–3 4–4
!!! THE SAME FIGURES = MATCHING INTERSECTIONS!!!

WE CONVEY QUALITY

NOTE:
The type of toothed segments are marked by engraved figures in the segments!
!!! THE TOOTHED SEGMENTS HAVE TO FIT WITH THE CHAIN !!!

WE CONVEY QUALITY
• Wrong assembling of the toothed segments
5–1
Contact area Different

of the wear
bushings
THE USE OF OLD WITH NEW TOOTHED SEGMENTS WILL CAUSE EXTREMLY WEAR
AND MAY DAMAGE THE CHAIN
WE CONVEY QUALITY

NOTE:
All bolts must be tightened with the correct torque

WE CONVEY QUALITY
• Replacement of the chain:

WE CONVEY QUALITY
How to open the chain?
1. Empty the conveyor

2. Switch off the conveyor and protect against any unauthorized restarting!
3. Loose the tension spindle nuts so far that
the ...springs will be completely tension-free.
4. Support the chain and/or the conveyor section at the cut-off point so that
...it cannot fall down after separation.
5. Use an angle grinder to cut/open one outer link plate at both bolts at
each end of the chain strand to be replaced

WE CONVEY QUALITY

Use a angle grinder to cut the chain!
! Never cut the link plates by flame-cutting. The high temperatures may cause
the loss of the chain strength !
WE CONVEY QUALITY

WE CONVEY QUALITY
How to close the chain!
1. Close the chain by means of the mounting device!

2. Remove the support of the conveying elements
3. Reinstall any previously removed rollers
4. Tension the chain again
5. Carry out a test run and make the necessary adjustments

WE CONVEY QUALITY

WE CONVEY QUALITY
KZB / KZB-Q Maintenance / Adjustments
Tensioning the chain:
1. Trouble-free operation of the conveyor is only possible if the chain

is ....tensioned correctly.
2. The correct chain tension is set by tensioning the springs on
both ....tensioning spindles.
3. Only check and adjust the chain tension without load.
4. Only check and adjust the chain in cold conditions! ....
(Environment Temperature).
5. Do not compress the springs completely (to a block)
6. Pretension both springs to the same size

WE CONVEY QUALITY

WE CONVEY QUALITY

WE CONVEY QUALITY

WE CONVEY QUALITY

WE CONVEY QUALITY
KZB / KZB-Q Maintenance / Erection instructions

WE CONVEY QUALITY
Assembly:

WE CONVEY QUALITY
Preparation of the site of installation:
1. The side of installation of the conveyor and the required transport

path ...must be cleaned and free from any possible obstacles
!!! KEEP THE SITE ALWAYS CLEAN AND ORGANIZED !!!

WE CONVEY QUALITY
Where can I find the machine parts?

WE CONVEY QUALITY
Position of tension station and drive station:

2. The cross points of the tension axle and the drive shaft center with
the ... conveyor axis define the locations of the stations.
Cross point of the
tension axle!
Cross point of the

drive shaft!
!!! Determine these points with utmost accuracy !!!

WE CONVEY QUALITY
Conveyor path / Conveyor center line:

3. The conveyor center line is the connecting line between tension
station ...and drive station
Center line
!!! Detailed information about erection you will find in the operation
manual !!!
WE CONVEY QUALITY
Alignment of the drive station:
- Misalignment of the chain at the drive station occurs due to:
1. Bad alignment during assembling

2. Drive shaft out of level
3. Settling of the steel structure
4. Loose bolts of the drive bearings
5. Bad alignment after assembling of new spare parts…. etc.

WE CONVEY QUALITY
!!! Strong misalignment of the drive shaft at the drive station !!!

WE CONVEY QUALITY
Alignment of the drive station: Center line of the chain
Center line of the toothed segment

WE CONVEY QUALITY
!!! Alignment of the drive shaft !!!

WE CONVEY QUALITY
!!! Alignment of the drive shaft !!!

WE CONVEY QUALITY
!!! Level of the drive shaft !!!

WE CONVEY QUALITY
!!! Level of the drive shaft !!!

WE CONVEY QUALITY
Transport of the conveying elements:

WE CONVEY QUALITY
Assembling the conveying elements:

WE CONVEY QUALITY

WE CONVEY QUALITY
!!! Never do it like these guys !!!

WE CONVEY QUALITY
AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q

15.11.2004, Liß,:Pz
118
WE CONVEY QUALITY

WE CONVEY QUALITY

WE CONVEY QUALITY

WE CONVEY QUALITY
KZB / KZB-Q

WE CONVEY QUALITY
KZB / KZB-Q

WE CONVEY QUALITY
Adjustment of the rails:

WE CONVEY QUALITY
Adjustment of the rails at the drive station:

WE CONVEY QUALITY
Adjustment of the rails at the take up station:

WE CONVEY QUALITY
Test run:

WE CONVEY QUALITY
Checklists for test run in chapter 6 of the operation manual:
!!! Before start up – use the check list !!!

WE CONVEY QUALITY
KZB / KZB-Q Maintenance / Faults
Possible faults:
See chapter 4 of the operation manual
If you need further information

contact the:
AUMUND AFTER SALES SERVICE

Phone: +49 (0) 2843 72-0
Fax: +49 (0) 2843 72 400
E-Mail: aumund@aumund.de

WE CONVEY QUALITY
KZB / KZB-Q Maintenance / Ordering spare parts
Ordering spare parts:
You will find all necessary information

in our operation manual!
Chapter 7

WE CONVEY QUALITY
KZB / KZB-Q Maintenance / Ordering spare parts
Ordering spare parts:
You will find all necessary information

in our operation manual!
Chapter 7

WE CONVEY QUALITY
Thank you for listening!
BW-Z : 132

KZB / KZB-Q: Maintenance Seminar

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

KZB / KZB-Q: Maintenance Seminar

Uploaded by

Copyright:

Available Formats

WE CONVEY QUALITY

More than 5.500 units in

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 2

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 3

KZB / KZB-Q Application of KZB, KZB-Q,

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 4

KZB / KZB-Q Maintenance / Operation manual

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 5

KZB / KZB-Q Maintenance / Operation manual

Content of the operation manual:

Chapter 1 – General Survey

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 6

KZB / KZB-Q Maintenance / Operation manual

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 7

KZB / KZB-Q Maintenance / Operation manual

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 8

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 9

KZB / KZB-Q Components and assemblies

Runway track Drive Station

Take up station Conveying section

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 10

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 11

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 12

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 13

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 14

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 15

KZB / KZB-Q Components and assemblies

TOOTHED RIMS WITH 7,5 TEETH, WHAT DOES IT MEAN ?

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 16

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 17

KZB / KZB-Q Components and assemblies

AUMUND rails are twofold rolled, to provide the surface 2

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 19

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 20

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 21

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 22

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 23

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 24

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 25

KZB / KZB-Q Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 26

KZB / KZB-Q Components and assemblies

Patented overlapping system

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 27

- old design - - current design -

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 28

KZB / KZB-Q Components and assemblies

• Chain (AU 4540.1) 3

AUMUND PREVENTIVE MAINTENANCE TRAINING KZB / KZB-Q : 29