BW-Z Premas

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BW-Z / BW-D / BW-ZL
MAINTENANCE SEMINAR
BUCKET ELEVATOR WITH CENTRAL CHAIN
BW-Z / BW-ZL / BW-D
AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 1
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BW-Z / BW-D / BW-ZL
Chain Bucket Elevators
More than 1.500 with central chain in last 30 years

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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

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BW-Z / BW-D / BW-ZL

Contents of the Training:
1 – Application of bucket elevators
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

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BW-Z / BW-D / BW-ZL Application
90°
60°
Bucket elevator
Z B
B 45°
Z B-Q
K
28°
KZB
0°

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BW-Z / BW-D / BW-ZL Capacity
Bucket Theoretical capacity m³/h
w ithout turbo w ith turbo

coupling coupling
Width Projection Volume Spacing 1,06 1,16 1,29 1,25 1,39 1,56 1,72 1,87
mm mm dm³ mm 600 655 730 790 890 1005 1115 1215

400 210 7,5 560 53
280 106
250 11 610 75 83
305 149 166
285 16,8 356 212 236 265 292 318
450 250 12,4 305 168 187
285 18,9 356 239 266 298 329 357
500 285 21 356 265 295 331 365 397
560 285 23,5 356 297 330 371 409 444
630 285 26,4 356 334 371 416 459 499
710 285 29,8 356 377 419 470 518 564
800 285 33,6 356 425 472 530 584 635
900 285 37,8 356 478 531 596 657 715
1000 285 41,9 356 530 589 661 729 792
1100 285 46,1 356 583 648 727 802 873
The indicated conveying capacities correspond to a 100%

bucket filling (water filling). Recommended filling degree: 75%
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BW-Z / BW-D / BW-ZL Maintenance / Operation manual

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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

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BW-Z / BW-D / BW-ZL Components and assemblies
Head casing Dedusting Point
Guide Frame
Buckets
U Frame
Assembly casing
Feed Point
Boot

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

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

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Double drive for AUMUND- Bucket elevator BW-D with inching drive

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Drive options with inching drive

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Drive options without inching drive but with frequency converter

up to 30 kw

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

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Loosed bearing
4
6 5
1 = Bearing housing
2 = Roller bearing
3 = Nut
Elevator
4 = Ring
5 = Seal
6 = Disc

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1 2
Fixed bearing 4 3
5
1 = Bearing housing
5
2 = Roller bearing
3 = Nut
4 = Ring
5 = Seal
6 = Ring
6
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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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Tension frame with tension shaft and segmented tension ring
 1= Counter weight
 2 = Wheel
 3 = Frame
 4 = Wear segment
 5 = Pillow block
 6 = Friction bush
 7-9 = Screws

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Counter weight
5
1
1: axle shaft
2: axle end
3-4 : Screw
5: Hub

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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 01.1
AU 01.1 AU 01.1 – T2

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AU 02.2
AU 02.2 AU 02.2 – T2

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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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Four-point support
Creation of larger contact surface
Reducing wear at the chain

bushes

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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 ring
occurs 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!

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Chain support on friction ring
Larger contact surface four-point support

Reduced wear of chain bush

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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

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BW-Z / BW-D / BW-ZL Bucket fixing
AU 04 / AU 06 / AU 13 / AU 15
AUMUND standard
t ed
nsa
ct et pe
i re uck com
n d b n
t i o d to t i o
ra ere r a et
b i b ck
Vi nsf V bu
tra to

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BW-Z / BW-D / BW-ZL Bucket fixing
AU 01 / AU 02
1: Bucket
2 to 5: doppel chain link
6: angular bracket
7à 9: screw
10:chain link
11: outer link plate

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BW-Z / BW-D / BW-ZL Buckets
 1.Bucket with or without

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 / Safety

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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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More
Monthly
Number
Weekly
informati
Yearly
Daily
Operating
Sub-assembly Cat * on Work to be done
hours
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

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Monthly
Number
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
Material Inlet Check for material backings

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

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

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Lubrication General
At each equipment correspond specific lubrication instructions.
Here you will find an example of lubrication list for pan conveyor.
This lubrication list is to find on 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.

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LUBRICATING INSTRUCTIONS
Sub-assembly : Bucket elevator BW-Z Lubricating point drawing : fig BWZ 1
Number Quantity of grease / lubrication point Intervals

of
Item Code Kind of Change of lubricant Re-mark
Designation lubrica- Quantity Quantity Quantity
N° N° * lubrication Relubri- **
ting of first of for
cation
points filling refilling change First Following
Drive shaft 1800h or 1/4

1 III Grease gun 2 1.4 Kg 0.35 Kg
(bearings) yearly
Main drive unit
Motor Lubrication periods, quantity and quality of the grease are indicated on
3 IV Grease filling 2
(bearings) identification plate
4 Turbo coupling 3 Oil filling 1 8.6 L 8.6 L max. 15 000h or analyse 1
Splash 5000H or
5 Gear A14 1 45L 45L 400 H 1
lubrication 18 months
Gear 3600h or 6
5.1 III Grease gun 0.03 Kg 1
(shaft seals) months
Splash 5000H or
6 Back stop A14 1 0.5L 0.5L 400 H 1
lubrication 18 months
Overrunning Splash 5000H or

7 A14 1 2.5L 2.5L 400 H 1
clutch lubrication 18 months
Maintenance drive
Motor
8 Grease filling 2 Life lubrication
(bearings)
Splash 10000h max 2 20000h max

9 Gear C25 1 3.9L 3.9L
lubrication year 4 year 1
* Under this code number you will find the exact designation of lubricant in the lubricant list or in the chapter "Special lubricants" ( code number with the sign S…)
** Remark: 1 Please observe the additional information in chapter 8-annex- since the present chapter partly indicate only standard values

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BW-Z / BW-D / BW-ZL
Wear measurement

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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
!!! Your boss will like it !!!

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

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Wear examples
Tail ring
Drive ring

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Wear mark
Wear mark at the drive ring

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Attention!!
Please check always the contact area wear between chain links and drive wheel.
Even if the wear mark is still not reached, the wear limit of 5 mm might have been
reached!
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

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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
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Highly wear!
Bushing Cracks
The chain must be exchanged if the bushings are presenting cracks or pittings

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

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Ø Bushes Ø Pin X max

Chain pitch X0 X 50
Chain type
( mm ) ( mm ) ( mm )
(mm) (mm ) ( mm )
AU 01 140 37 25 177 180 183
AU 06.1 177.8 58 36.35 235.8 239.8 243.8
AU 13.1 177.8 63 39.7 240.8 245.3 249.8
To define AU 15.1 177.8 71 44.5 248.8 253.3 257.8
the Chain AU 01.1 140 38 25 178 180.5 183
type
installed, AU 02.2 152.4 45 27 197.4 199.9 202.4
check on AU 06.2 177.8 58 36.3 235.8 239.8 243.8
the G.A. AU 13.2 177.8 63 39.7 240.8 245.3 249.8
drawing
AU 15.2 177.8 71 44.5 248.8 253.3 257.8

See also Operation Manual Chapter § 5.9

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 Measurement of one
double link
 Using a caliper gauge
 Measuring the length

over two bushings

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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)

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

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• 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)

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

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

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BW-Z / BW-D / BW-ZL
Instrumentation

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BW-Z / BW-D / BW-ZL Instrumentation
Speed control Emergency stop

switches
Level
Control
Monitoring of
take-up length

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• Speed monitoring

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• Speed monitoring

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BW-Z / BW-D / BW-ZL

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• Filling level indicator

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BW-Z / BW-D / BW-ZL

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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!!!!

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• Replacement of the toothed segments:

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

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 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.

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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

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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

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 1-Observe the instructions and safety regulations in the chapter §5.10 “Bucket exchange”
 2-In order to exchange parts of elevator chain only, dismount the required number of
buckets first.
 3-Before taking the chain apart, the chain must be supported above and underneath the
points where it is divided. Make sure that the chain part which has to be exchanged
is loose. It will have to be supported so that it will not fall down after removal of the bolts.
 4-By means of a pressing-in /out device the chain bolts can be pressed in/out at any
position. Individual double links and sections of any length may be exchanged.
For pressing-in, press one outer link against 2 bolts.
 5-The chain must be separated prior to pressing out any chain bolts for which the outer
links of a chain link have to be separated e.g. flame cutting .
 For better handling, we recommend to pull the chain ends out of the assembly opening.
 The removal and assembly of the chain parts can be implemented outside of the elevator
casing.
 See also instructions concerning the pressing in/out device in chapter 8 of Operating
Manual.

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BW-Z / BW-D / BW-ZL

Pressing in- and out Device
Removable bolts have round edges and center hole

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Hydro-Press set-up for chain assembly and disassembly

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Hydro-Press set-up for chain assembly and disassembly

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How NOT to store Aumund Chain !

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How NOT to pre-assemble Aumund Chain !

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How NOT to lift and

install Aumund
Chain !

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BW-Z / BW-D / BW-ZL

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BW-Z / BW-D / BW-ZL

Documentation of Drive unit Chapter §8

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BW-Z / BW-D / BW-ZL

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BW-Z / BW-D / BW-ZL General Arrangement Drawing

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BW-Z / BW-D / BW-ZL Technical Data

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BW-Z / BW-D / BW-ZL Technical data

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BW-Z / BW-D / BW-ZL 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) 72 400
E-Mail: aumund@aumund.de

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BW-Z / BW-D / BW-ZL
Thank you for your attention

Drag-chain Conveyors
And
Rotary Feeders

BW-Z Premas

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WE CONVEY QUALITY

BW-Z / BW-D / BW-ZL

BW-Z / BW-D / BW-ZL

Chain Bucket Elevators

More than 1.500 with central chain in last 30 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 forged

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 3

BW-Z / BW-D / BW-ZL

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 4

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

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 5

BW-Z / BW-D / BW-ZL Capacity

Bucket Theoretical capacity m³/h

w ithout turbo w ith turbo

mm mm dm³ mm 600 655 730 790 890 1005 1115 1215

The indicated conveying capacities correspond to a 100%

BW-Z / BW-D / BW-ZL Maintenance / Operation manual

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 7

BW-Z / BW-D / BW-ZL Maintenance / Operation manual

Content of the operation manual:

Chapter 1 – General Survey

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 8

BW-Z / BW-D / BW-ZL Maintenance / Operation manual

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 9

BW-Z / BW-D / BW-ZL Maintenance / Operation manual

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 10

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

Head casing Dedusting Point

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 11

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

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 12

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

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 13

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

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 14

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

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 15

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

Drive options with inching drive

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 16

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

Drive options with inching drive

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 17

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

Drive options with inching drive

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 18

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

Drive options without inching drive but with frequency converter

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 19

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

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 20

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

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-Z : 21

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

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

Bucket elevator boot