Aumund 3

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BW-G / BW-GL
MAINTENANCE SEMINAR
Belt bucket Elevator
BW-G / BW-GL
AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 1
WE CONVEY QUALITY
BW-G / BW-GL
Belt bucket Elevators
More than 2200 with Belt bucket elevator in last BW-G

30 years
/ BW-GL : 2
AUMUND PREVENTIVE MAINTENANCE TRAINING
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BW-G / BW-GL Belt bucket elevator
• Conveying capacities from just 5 t/h to more than 1700 t/h
• Bucket width up to 1600 mm
• Bucket projection up to 400 mm
• Lifting heights more than 170 m
• Heat-resistant in continuous operation up to 130°C
• Speed up to 1,9 m/s

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BW-G / BW-GL
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
- Instrumentation
5 – Ordering spare parts
6 – Faults

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BW-G / BW-GL Application
90°
60°
Bucket elevator
B
BZ 45°
-Q
KZB
28°
KZB
0°

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BW-G / BW-GL Capacity
Capacity Type BW-G

Bucket Theoretical capacity m³/h
Conveyor speed m/s
Width Projection Volume Conveyor speed Drum With turbo coupling
mm mm dm³ m/s mm Bucket distance

320 360 400 440 480 520 560
400 280 14,5 1,37 800 223 199 179
500 18
630 320 29 1,54 1000 447 402 365 335
800 37 570 513 466 427
1000 46 708 638 580 531
1000 360 58 1,72 1125 898 816 748 691
1250 73 1130 1027 942 869
800 360 46,5 1,88 1250 787 717 656 605
1000 58 981 892 818 755
1250 73 1235 1123 1029 950
1400 400 99 1,88 1250 1523 1396 1289 1196
1600 114 1754 1607 1484 1378
The indicated conveying capacities correspond to a 100%

bucket filling (water filling). Recommended filling degree: 75%

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BW-G / BW-GL Components and assemblies
Head Dedusting Point

casing
Guide Frame
Buckets
Belt
Assembly casing
Feed Point
Boot

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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 = Drum body
3 = Loose bearing
4 = Fixed bearing
5 = Tension unit
6 = Casing sealing ring
7 = Clamping Ring
8 = Friction lining
9-18 Fixing Material

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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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Fixed bearing 1 2
4 3
5
1 = Bearing housing
5
2 = Roller bearing
3 = Nut
4 = Ring
5 = Seal
6 = Ring
6
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Tension drum
1 = Drum
2 = Tension shaft
3 = Loose tension bearing
4 = Fixed tension bearing
6 = Tension unit

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Loosed bearing
1 = Tension bearing body
2 = Bearing lid
3 = End lid
4 = bushing
5 = labyrinth seal
6 = bearing
7 = shaft sealing ring
8 = cheese head screw

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Fixed bearing
1 = Tension bearing body
2 = Bearing lid
3 = End lid
4 = bushing
5 = labyrinth seal
6 = bearing
7 = shaft sealing ring
8 = cheese head screw
9 = bushing
10 = bushing
11 = closing plug
(12) = sensor

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Bucket strand
Bucket Characteristic design
for optimum discharge
and short bucket spacing
Sealing lip To avoid fine material

penetrating into the gap
between bucket and belt
Special Easy assembly and

plate screws disassembly

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Bucket strand
Special
plate screws

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Screws
Belt end
Casting compound box
Casting compound
Clamping
connection Wire ropes
Rope clamps
Belt end
Nuts and counter nuts

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Belt with Steel Wire Cord

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Cross ropes Utmost resistance to

tearing down the
buckets
Longitudinal ropes
Traction element
Belt delivered with 65-67 Shore

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Cross ropes
Longitudinal ropes
Belt delivered with 65-67 Shore

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Available AUMUND Belts

belt strength belt thickness belt width
N/mm² mm mm
AUMUND H8 800 13 300

AUMUND H12 1.250 14 360
AUMUND H16 1.600 14 450
AUMUND H20 2.000 14 550
AUMUND H22 2.250 14 680
AUMUND H25 2.500 14 850
AUMUND H28 2.750 14 1.050
AUMUND H30 3.000 15 1.300

AUMUND H33 3.250 16 1.450
AUMUND H35 3.500 16 1.630
Depending on strength class:

- Longitudinal ropes with diameter of 2.8 – 4.4 mm
- Distance between ropes 5-8 mm
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Bucket-Elevator-Belt-Finishing in Rheinberg/Germany
All Belt sizes are ready within
8 day’s for shipping from
Rheinberg!

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BW-G / BW-GL
Maintenance

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BW-G / BW-GL Maintenance / Safety

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BW-G / BW-GL 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-G / BW-GL Maintenance intervals
The inspections and checks to be carried out are subdivided the following plan
according to operating hours and maintenance intervals
to see in the AUMUND Operation Manual: Chapter 5

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BW-G / BW-GL Maintenance / Lubrication
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 6,

»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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Main lubrication points:

1 = Drive bearing
3 = Motor
4 = Fluid coupling
5 = Gearbox
5.1 = Gearbox sealing’s
6 = Backstop
7 = Overrunning clutch
8 = inching drive

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Main lubrication points:

2 = Tension bearings

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BW-G / BW-GL
Wear measurement

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BW-G / BW-GL 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
- Shore-meter
- Feeler gauge
- Spirit level
- Folding rule
- Wire
- Plummet
- Laser
- Theodolite
- Thermometer
- Torque wrench

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What we have to check?
- Shore hardness of the belt

- Torque of the bolts of the clamping connection
- Check the bucket fixing
- Search for deformed or damaged buckets
- Check the state of the friction liners
- Check the distance between bucket lips and discharge plate
- Investigate cuts and other damages at the belt
- Function of the monitoring equipment
For more detailed information please read the operation manual !

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Hardness of the belt (ShoreA°)
Delivery with 65-67 Shore

Change with 92-95 Shore
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Torque of the clamping connection
The tightening torques of the clamp

connecting screws must be checked
regularly according to the maintenance
schedule and retightened by means of a
torque wrench, if required.

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Checking the Torque of the clamping connection

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Check torque wrench before use.

The tightening of the screws with an
incorrect tightening moment can lead
to belt damage and malfunction.

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Fixing of the buckets
The screw head must at least flush with the

belt surface!
The screw head shall maximally be pulled 1

mm deep into the belt!

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Friction liners
The friction liners are worn if no profile is left in the central part of the drive pulley!
Operation with worn friction liners will cause misalignment and may damage the belt!
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Distance between discharge plate and buckets
If the rubber of the discharge plate is damaged it must be replaced

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BW-G / BW-GL Maintenance / Parts replacement
Parts replacement
Before starting any work inside the bucket elevator casings the necessary
steps have to be taken to prevent an unintentional, unauthorised or
automatic starting of the bucket elevator. In case the elevator has to be
moved there must be no persons inside the bucket elevator casings and a
safe distance to all rotating parts must be guaranteed.

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• Replacement of the friction linings:
The friction lining of the belt bucket elevator consists of several segments
being bolted to the drive pulley. The number of segments depends on the
pulley diameter and varies from three up to five segments.
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Work sequence:
1. Empty bucket elevator

2. Move the bucket elevator by means of the maintenance drive unit until a complete
segment will be below in the area of drive pulley not enclosed by the belt.
3. Insert a plank platform underneath the drive pulley.
The exact type of design depends on the local conditions. It, however, must
be ensured that no loose segment can fall inside the bucket elevator casings.
4. Screw off the segment and remove it through the assembly opening.
5. Screw a new segment to the drive pulley. Do not drive in screws!
6. Repeat steps 2, 4 and 5 for the other segments.
7. When all segments being installed on the drive pulley and segment joints forming
a flush surface then: drive in and tight up all screws!

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When moving the bucket elevator it must be

ensured that the working platform (point 3)
does not touch the belt. If appropriate it has
to be removed before moving the bucket
elevator.

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• Replacement of buckets:
If buckets are replaced in the ascending

run, the belt must be supported in order
to prevent self-starting.

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Buckets can be replaced best through the assembly openings of the assembly
casing.
It is expedient to replace buckets in the descending run since in this case self-
starting of belt is prevented by the back stop.
Opposite to the clamp connection several buckets with balancing weights are
installed. These buckets have a color marking and must only be replaced by
buckets of the same type.
For the assembly of the new buckets it is necessary to use new screws,
nuts and washers.
Tighten the plate screws of bucket fixture in such a way that they are
least flush with the belt surface, however, not more than 1 mm drawn
in the belt.

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• Replacement of the belt:
All buckets must be dismounted before the belt may be

replaced.
We urgently recommend to start the dismounting of buckets

in the descending run, as in this case the backstop will
prevent self-starting of the belt.

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While mounting and dismounting

buckets, an imbalance between
ascending and descending run may
occur. Proceed in accordance with the
below described order of operations to
minimize this imbalance. However, the
belt shall in any case be secured to
prevent it from self-starting.

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Procedure:
Use the maintenance drive to move the bucket strand for an individual
section at a time and then dismount all those buckets within reach of the
assembly opening. If the bucket fixing screws are flame-cut, this may not
result in damage to the buckets.
Dismount three buckets
Advance the belt by 10 to 20 bucket spacing’s (depending on the bucket
elevator height)
Repeat the two previous work steps until all the buckets have been
dismounted.
Opposite to the clamping connection several buckets with balancing
weights are installed. These buckets are to be the last ones to be
dismounted.

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1. Move the clamping connection in the ascending run (!) into a position in
front of the assembly opening.
2. Release the belt tension
Untighten the upper nuts at both clamping spindles, pull up the take-up axle
and support it.
3. Jack up the new belt in front of the assembly opening in such a position that
it can freely roll when pulling in the belt.
4. Secure the belt above and below the clamping connection. Keep such a
distance to the clamping connection that the connection can be cut out and
the new belt fixed at the upper end of the old belt.
5. Cut off the old belt above and below the clamping connection by means of
an cutting machine. (Angel grinder)

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6. Fix the belt at the upper end of the old one.

Use the existing bucket holes to connect the belt ends by screws. Make
sure to place large washers underneath screw head and nut
7. Connect the lower end of the old belt to a pulling device (e.g. electric
winch).
The old belt can be pulled out through the same assembly door as the
new one. For reasons of space, it will probably be preferable to pull it
out through the door in the bucket elevator boot.
8. Remove the securing supports of the old belt
9. Pull in the new belt by means of the maintenance drive, while at the same
time pull the old belt out of the bucket elevator using a pull-out device.

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Before the pulled in (new) belt is fully rolled off

the drum, it must be secured against self-
started rolling off. It must be secured prior to
starting to move and run away on its own due
to the unbalanced weight of the descending
belt while being pulled into the elevator.

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10. After the new belt has been pulled in completely, pull both belt ends out of the
assembly door so that the clamping connection can be prepared outside the
elevator casing.
What door should be selected, depends on the conditions on site. If

required, pull the take-up axle further up. The work can be done also in the
elevator boot.

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Mounting of the buckets
It is recommended to mount the buckets through the assembly opening of

the assembly casing. During the mounting of the buckets, the bucket elevator
shall only be operated by means of the maintenance drive.
We urgently recommend not to start the mounting of buckets in

the descending run!

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While mounting and dismounting buckets, an

imbalance between ascending and descending run
may occur. Proceed in accordance with the below
described order of operations to minimize this
imbalance. However, the belt shall in any case be
secured to prevent it from self-starting.

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Assembling of the buckets:
• Use the maintenance drive to move the bucket strand for an individual section at
a time and mount the buckets through the assembly opening.
• Run the clamping connection downwards onto the take-up pulley
• Install three buckets
• Advance the belt by 10 to 20 bucket spacing's (depending on the bucket elevator

height)
• Repeat the two previous work steps until all buckets have been
mounted.

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Assembling of the buckets:
• Opposite to the clamping connection, several buckets with balancing weights will
have to be installed. These buckets are provided with color-markings.
• Run one belt rotation, then install another three buckets; repeat this until all
buckets are mounted.
The buckets on one belt side may not be mounted in

successive order, since then the maintenance drive
will not be able to move the one-sided weight.

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BW-G / BW-GL Maintenance / Adjustments
Adjustments

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• Adjustment of the belt track at the tension drum

Any askew running is indicated by one of the four askew run switches.
There might be several reasons, e.g.:
1. Worn friction lining of drive pulley
2. One-sided and/or irregular material feed
3. One-sided or excessive elongation of belt
4 The tension bearings are blocked by dirt
5. The nuts of the tension spindles are loosed

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Remedy:
Item 1 Replace friction lining

Items 2 and 3 (in case the friction lining is in order)
Check: Does the belt run straight without conveying material?
Yes: Correct material feed in such a way that the buckets are filled regularly
and centrally.
No: Correct belt run by adjusting the tensioning spindles.
Note: Increase tension of belt on the side where the belt runs off the pulley.
Adjust the tensioning spindles only gradually and observe the result.
Item 4: Clean the guidance of the tension bearings
Item 5: Adjust the belt track and fix the nuts and counter nuts

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• Adjustment of the belt track at the drive drum

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BW-G / BW-GL
Instrumentation

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BW-G / BW-GL Instrumentation

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Electronic monitoring system - CONTINFO

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BW-G / BW-GL
Ordering spare parts

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BW-G / BW-GL Maintenance / Ordering spare parts
See chapter 7 of the operation manual
For ordering spare parts please proceed as follows:
Possibility 1:
1. Kindly check the table of contents of the spare part list the component you wish
to replace completely or partly
2. Copy the page of the part list
3. Enter on the copy in the column “Quantity to be ordered” the number of parts
requested. Add the copy to your order
2. Copy the page of the part list

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Possibility 2:
1. Inform the project number
2. Inform the denomination and article number of the requested part
3. Inform the quantity of parts
4. Inform the item number of the requested part

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BW-G / BW-GL Maintenance / Faults
Possible faults:
If you need further information

contact the:
AUMUND AFTER SALES SERVICE

Phone: +49 (0) 2843 72-0
Fax: +49 (0) 72 400
E-Mail: [email protected]

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BW-G / BW-GL
THANK YOU FOR LISTENING

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WE CONVEY QUALITY

Belt bucket Elevators

More than 2200 with Belt bucket elevator in last BW-G

BW-G / BW-GL Belt bucket elevator

• Conveying capacities from just 5 t/h to more than 1700 t/h

• Bucket width up to 1600 mm

• Bucket projection up to 400 mm

• Lifting heights more than 170 m

• Heat-resistant in continuous operation up to 130°C

• Speed up to 1,9 m/s

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 3

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 4

BW-G / BW-GL Application

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 5

BW-G / BW-GL Capacity

Capacity Type BW-G

Conveyor speed m/s

Width Projection Volume Conveyor speed Drum With turbo coupling

mm mm dm³ m/s mm Bucket distance

The indicated conveying capacities correspond to a 100%

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 6

BW-G / BW-GL Components and assemblies

Head Dedusting Point

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 7

BW-G / BW-GL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 8

BW-G / BW-GL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 9

BW-G / BW-GL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 10

BW-G / BW-GL Components and assemblies

Drive options with inching drive

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 11

BW-G / BW-GL Components and assemblies

Drive options with inching drive

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 12

BW-G / BW-GL Components and assemblies

Drive options with inching drive

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 13

BW-G / BW-GL Components and assemblies

Drive options without inching drive but with frequency converter

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 14

BW-G / BW-GL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 15

BW-G / BW-GL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 16

BW-G / BW-GL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 17

BW-G / BW-GL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 18

BW-G / BW-GL Components and assemblies

BW-G / BW-GL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 20

BW-G / BW-GL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 21

BW-G / BW-GL Components and assemblies

AUMUND PREVENTIVE MAINTENANCE TRAINING BW-G / BW-GL : 22

BW-G / BW-GL Components and assemblies