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1. Assessment Inspection Dismounting Washing Examination Definition of repair operations Preparation of proposal Level Requalifying Measurement Mounting Preservation greasing if appropriate Packaging long term packaging if appropriate Despatch Level Il Refurbishment Polishing of raceways Removal of fretting corrosion Mounting Preservation greasing if appropriate Packaging long term packaging if appropriate Despatch Level Ill Remanufacturing E g Regrinding of raceways Manufacture of new rolling elements Replacement of cage if appropriate Removal of fretting corrosion Mounting Preservation greasing if appropriate Packaging long term packaging if appropriate Despatch Level IV Remanufacturing Plus E g Regrinding of raceways Manufacture of inner ring with new bore diameter Redimensioning of internal clearance Manufacture of new rolling elements Replacement of cage if appropriate Removal of fretting corrosion Mounting Preservation greasing if appropriate Packaging long term packaging if appropriate Despatch 78 Services Services relating to rolling bearings Mounting Repair Equipment rental Equipment rental Customers who require special mounting and measuring equipment only occasionally for example in order to carry out repairs can rent t
2. itcan be determined whether the shaft and ring gauge match corrections are made until the ring gauge is in contact over its whole width The inner rings of the bearings are not suitable as ring gauges because their walls are too thin and could be damaged We supply taper ring gauges for taper diameters from 30 to 240 mm KA A MIOS 36 Taper ring gauge Taper diameter Ordering designation mm Products Mounting Repair Measurement and inspection Taper gauges FAG taper gauge MGK 9205 for the inspection of large tapered shaft studs taper 1 12 or 1 30 Measurement principle of taper gauge MGK 9205 When measuring tapered studs of large diameter a master can be used in which the upper and lower edge form an angle the taper angle of the stud 2 a If the upper edge of the master is parallel with the line diametrically opposed to the master the taper angle is acceptable A further requirement is that the taper is in a defined ratio to a reference surface e g to the side face of a roll barrel FAG taper gauge MGK 133 for external tapers 1 12 and 1 30 and 27 to 205 mm taper diameter The taper gauge MGK 133 rests on the taper with four hardened and polished support pins The position of the gauge on the taper is defined by these pins and one stop The stop can be attached to either the front or back of the gauge The gauge contains two movable measuring brackets one of which is in contact wi
3. 450 650 650 850 109 Comparison of ordering designations Comparison of ordering designations Ordering designation for Europe 110 Ordering designation for countries outside Europe Comparison of ordering designations Comparison of ordering designations Ordering designation for Europe Ordering designation for countries outside Europe 111 Comparison of ordering designations Comparison of ordering designations Ordering designation for Europe Ordering designation for countries outside Europe PUMP SLEEVE CONNECTOR PUMP SLEEVE CONNECTOR SNAP GAUGE SNAP GAUGE ELT Baa a eR eine AT aena SOUND CHECK SOUND CHECK TACHOMETER TACHOMETER TEMP CHECK CONTACT TEMP MG TEMP CHECK PLUS TEMP CHECK PLUS TOOL RAILWAY AGGREGATE TAROL MOUNTING AGGREGATE TRAINING CABINET MOD 1A D E F NL MOUNTING CABINET D E F NL TRAINING CARINE MO em MOUNTING CABINET SETS Ese Oe TRAINING VIDEO 201 D E VIDEOFILM201D E TRAINING IDES BOR Be AET TRAINING VIDEO 203 D E VIDEOFILM203D E 112 MATNR 035029528 0000 WL 80 250 3 GB D 2008034 Printed in Germany by Weppert Schaeffler KG Postfach 1260 97419 Schweinfurt Germany Georg Sch fer Strasse 30 97421 Schweinfurt Germany Phone 49 2407 9149 66 Fax 49 2407 9149 59 E Mail info fis services com Internet www fis services com Every care has been taken to ensure the correctness of the information contained in this publication
4. FAG Equipment and Services for the Mounting and Maintenance of Rolling Bearings For increased operational reliability of rolling bearing arrangements SCHAEFFLER GROUP INDUSTRIAL About this catalogue This catalogue is aimed principally Hans Willi Kessler at maintenance managers Bernd Geropp and i Armin Kempkes responsible for plants in which rn anagement of rolling bearings and other rotating FAG industrial Services machine components play a critical role in determining the quality of products and processes Maintenance managers are responsible for the maintenance and production process They must be able to rely every day on the quality of their tools and the expertise of their service providers FAG Industrial Services FIS Questions and ideas on this catalogue therefore offers high quality should be sent to products services and training This catalogue gives a complete Schaeffler KG guide to the range on offer from FIS Postfach 1260 97419 Schweinfurt Germany Georg Sch fer Strasse 30 97421 Schweinfurt Germany PIS employees worldwide will be Service Hotline pleased to help you select the ideal Telephone 49 2407 9149 99 products services and training for E mail info fis services com your needs www fis services com FAG Industrial Services Competence in maintenance FAG Industrial Services FAG Industrial Services GmbH FIS headquartered in Herzogenrath near Aachen
5. extraction sleeve requires a separate oil supply we can upon request supply a two way valve suffix D For detailed information see TPI WL 80 50 PUMP1000 0 7L DIGI PUMP2500 8L D FAG hand pump sets overview of ordering designations Pump Hand pump set Base design With 8 litre oil container With distributor With 8 litre oil container and distributor 1 000 bar PUMP1000 0 7L Twin stage 1 000 bar PUMP1000 4L 1600 bar PUMP1600 4L 2500 bar PUMP2500 4L PUMP1000 8L PUMP1000 4L D PUMP1000 8L D PUMP1600 8L PUMP1600 4L D PUMP1600 8L D PUMP2500 8L PUMP2500 4L D PUMP2500 8L D The 1000 bar pumps with one connector are also available with a digital manometer Ordering example PUMP1000 0 7L DIGI Products Mounting Repair Hydraulic mounting and dismounting High pressure pump High pressure pump sets FAG high pressure pump PUMP4000 0 2L The high pressure pump is suitable for mounting and dismounting of rolling bearings for shaft diameters up to 250 mm Since it generates pressures of up to 4000 bar the pump can be used to expand heavy shaft couplings and gears by the hydraulic method The pump is connected directly or via thick walled adapters The high pressure pump can also be connected via a pump holder with or without a manometer and a 2 m long flexible high pressure hose maximum permissible oil pressure 2 500 bar The pump must always be operated with a manometer
6. For detailed information see TPI WL 80 50 FAG high pressure pump sets In order to make it easier to select the right device we supply complete sets in storage cases FAG high pressure pump set PUMP2500 0 2L KIT For detailed information see TPI WL 80 50 Pull rod Oil container Pump body For width across flats 27 mm Threaded connector G3 FAG high pressure pump PUMP4000 0 2L High pressure pump Connector Oil container Flow rate Max Mass volume oil pressure Ordering designation cm stroke bar kg PUMP4000 0 2L G3 0 2 0 3 4 000 3 8 comprising PUMP4000 0 2L BODY pump body PUMP4000 0 2L TANK oil container FAG high pressure pump set PUMP2500 0 2L KIT with manometer up to 2 500 bar Included in delivery 1 high pressure pump PUMP4000 0 2L 1 pump holder 3 reduction nipples 1 manometer 1 high pressure hose 1 storage case Ordering designation for set PUMP2500 0 2L KIT High pressure pipe EF Oil container Pump body ES C l A Ca g o gt Products Mounting Repair Hydraulic mounting and dismounting Hydraulic systems and units Compressed air driven FAG hydraulic unit The FAG hydraulic unit AGGREG P1000 1 P2500 2 driven by compressed airis mobile and comprises a 13 litre oil container made from light metal and two pumps 1000 bar and 2 500 bar We can supply designs for other operating pressures by agreement
7. be defined in relation to the participants upon customer request and taken from the areas of database management Internet technology server support and authorisation concepts Target group The course is aimed at system administrators and key users Training objective The participants will learn about independent support and administration of a CMMS Duration By agreement Schaeffler Technical Training Centre Hirschaid 99 Training Training aids Rolling bearing mounting cabinet and mounting sets Basic course for vocational training There is plenty of literature available on the the correct mounting of bearings However there is a general lack of parts on which apprentices can practise in as practical a sense as possible The trainers from the Schaeffler training workshops have therefore compiled a basic course The aim of this rolling bearing course is to communicate knowledge on the selection of the correct bearing correct mounting and dismounting and the maintenance of bearing positions It is therefore divided into two parts A theoretical part covers the basic knowledge of rolling bearing technology while the practical part covers the basic skills involved in mounting and dismounting In the theoretical part particular attention is paid to combining technical drawing technical calculation and technical theory in one learning unit The practical part uses exemplary simplified mating p
8. configuration levels can be expanded at any time and can be flexibly adapted to the growing requirements of the industrial environment The customer can start with 4 monitoring channels and progressively expand the system up to 16 channels He also has the option of correlating a large number of analogue and digital input and output signals to his vibration data These signals also allow simple communication with higher level systems such as process control systems Data can thus be easily exchanged or made available For monitoring of complex systems ProCheck uses methods and techniques established in the market such as frequency selective parameters demodulated signal detection and trend monitoring Potential machine defects in complex units can be reliably identified by monitoring vibration in combination with other process parameters such as temperature Counteractive measures can then be introduced in good time Due to its flexibility scalability and extremely robust design this system is destined for use in all industrial segments The system has almost no limits whether it is used in steelworks FAG ProCheck 70 paper machinery or cement plants This is aided by its extremely compact and robust design together with its ATEX and UL approvals For detailed information see TPI WL 80 69 Please direct enquiries to info fis services com Further online monitoring systems Further online monitoring
9. energy costs are reduced and cost effectiveness is increased The user friendly Top Laser TRUMMY2 can be used in many locations and comprises a cableless measurement probe a measurement probe with a cable for difficult to access locations anda microprocessor that indicates relevant measurables for belt tension either as frequency Hz or force N By means of an impulse for example by striking the stationary belt the tensioned belt is excited to natural vibration The individual Static natural frequency thus generated is measured within seconds by the TRUMMY2 sensor using clock pulse light and displayed In order to calculate the strand force of the belt drive the belt mass and length are entered in the microcomputer before measurement TRUMMY2 uses these to calculate the strand force which is then compared with the specified nominal value In comparison with systems operating for example by sound waves this new measurement technique using clock pulse light is clearly superior since the measurement result cannot be distorted by disruptive influences The simple and reliable user instructions are given in several languages Ordering designation Laser measuring device in plastic case LASER TRUMMY2 For detailed information see TPI WL 80 55 37 58 Products Alignment Shaft couplings Shaft alignment device FAG shaft alignment device Top Laser INLINE Case The FAG To
10. medium is conveyed directly from the grease container 25 kg or 180 kg via the metering valve to the application point The grease metering device comprises e a cover e a piston e a metering valve e a hose connecting the pump and valve ea 2 5 m hose e a grease gun Technical data Pump ratio 10 1 Delivery quantity 400 cm min Metering range 10 133 cm Ordering designations ARCA PUMP 25 ARCA PUMP 180 ARCA PUMP 180 FAG grease gun with reinforced hose In difficult operating conditions or aggressive environments rolling bearings must be frequently relubricated via lubrication nipples With the FAG grease gun and the matching reinforced hose this operation can be carried out easily cleanly and quickly The parts comply with DIN 1283 ARCA GREASE GUN with ARCA GREASE GUN HOSE and ARCA GREASE GUN HOOK ON HOSE Grease gun Container diameter 56 mm Total length of gun 390 mm Delivery quantity 2 cm stroke Pressure max 800 bar The gun can either be filled with bulk grease or fitted with a cartridge to DIN 1284 e 500 cm container volume with bulk grease or e 400 g cartridge to DIN 1284 diameter 53 5 mm length 235 mm Connector thread Gi Mass approx 1 5 kg Ordering designation ARCA GREASE GUN Reinforced hose Length 300 mm Connector thread Gi Fitted with hydraulic grip coupling for taper type lubrication nipple to DIN 71412 In place of the hydraulic
11. retained and supplemented by a large number of new functionalities In addition to vibration measure ment contact free temperature measurement and data collection the system is now also capable of carrying out static and dynamic balancing tasks As a result imbalance can not only be detected but easily and efficiently eliminated For this purpose the optionally available Balancing Kit is required With the aid of the software installed on the system the user is guided through the balancing procedure step by step The results of the balancing procedure as well as the vibration measurement are transferred to the software PIS Trendline where they are analysed and evaluated The completely revised F IS Viewer offers the user a large number of functions that make data analysis considerably easier In particular the newly integrated bearing database containing approx 20000 bearings from various manufacturers gives more simple and more efficient analysis of the measured data As a result it is very easy to compare the measured data with possible damage frequencies A completely new feature is the optional functionality of automatic detection of measuring points RFID tags are applied at the measuring points and are thus detected automatically by the system This contributes not only to prevention of errors but also to optimisation of measuring time 66 Further highlights of the system e an expanded memory capacity
12. 0 2L High pressure pump set Hydraulic unit Compressed air Electric PUMP2500 0 2L KIT AGGREG P1000 1 P2500 2 AGGREG E700 GY with high pressure hose Max oil pressure bar psi 2500 36250 Application Mounting and dismounting of bearings Mounting of press fits up to approx 125 N mm contact pressure e g of gears and couplings For press fits with high contact pressure gt 100 N mm Dismounting of bearings with cylindrical bore Flow rate and oil reservoir are small For press fits with high contact pressure gt 100 N mm Dismounting of bearings with cylindrical bore Flow rate and oil reservoir are small Mounting of shaft couplings and press fits gears etc by the hydraulic method Contact pressure up to 100 N mm For driving large hydraulic nuts up to HYDNUT1180 Mounting of large press fits ship shaft couplings ships propellers gears contact pressure up to 50 N mm Max shaft mm Unlimited Unlimited For rolling bearings up tod 250 mm Detailed information on FAG pressure generation devices is given in TPI WL 80 50 23 24 Products Mounting Repair Hydraulic mounting and dismounting Oil injectors FAG oil injectors The INJECT2500 can be used for shaft diameters up to 80 mm the Oil injectors have a small volume INJECT1600 up to 150 mm displacement they can be used in the hydraulic method for th
13. 9721 91 3809 For detailed information see TPI WL 80 72 Large rolling bearings of outside diameter gt 425 mm The statements on wheelset bearings and standard bearings up to an outside diameter of 425 mm can also be applied to larger standard and special rolling bearings Within the framework of maintenance activities rolling bearings are still replaced for reasons of safety that could be restored to an acceptable and functional condition through appropriate cleaning and reconditioning In general the costs of such reconditioning are significantly lower than the costs of a new bearing with shorter delivery times in most cases In individual cases customers may also receive the same warranty on the reconditioned bearing as on a new bearing The FIS experts repair all types of rolling bearings such as cylindrical roller bearings spherical roller bearings tapered roller bearings etc They first carry out a damage diagnosis on the basis of which it is decided whether repair is viable and which level of reconditioning is required on the rolling bearing For detailed information see WL 80 151 Please direct enquiries to Schaeffler KG Mettmanner Strasse 79 42115 Wuppertal Germany Tel 49 202 293 2226 Fax 49 202 293 2437 Services Services relating to rolling bearings Mounting Repair Reconditioning of rolling bearings Overview of the individual stages in reconditioning of rolling bearings
14. Connector Threaded connector Mass Ordering designation kg PUMP SLEEVE CONNECTOR M6 M y y RR E PUMP SLEEVE CONNECTOR M8 MG AA PUMP SLEEVE CONNECTOR G s E BB ar PUMP SLEEVE CONNECTOR GY GYa 0 42 The connector for the hand pump set is Gi For detailed information see TPI WL 80 50 Products Mounting Repair Thermal mounting and dismounting Electric heating plates Induction heating devices FAG electric heating plate HEATER PLATE The temperature controlled FAG heating plate HEATER PLATE can be used to heat rolling bearings up to a maximum of 120 C or small machine components up to 5 kg mass The removable housing cover protects the workpieces from contaminants and ensures uniform and rapid heating This inexpensive device is maintenance free and easy to handle Dimensions WxDxH 390x270x156 mm Plate size 380x180 mm Power max 1500 W at 230 V 50 Hz Temperature control continuously variable from 50 to 200 C Mass 5 6 kg Ordering designation HEATER PLATE Ordering designation for version with 115 V 60 Hz HEATER PLATE 115V FAG heating plate HEATER PLATE FAG electric heating plate HEATER PLATE 370C The HEATER PLATE 370C is used principally for heating the FAG aluminium heating rings HEATING RING see page 34 It can also be used for the heating of rolling bearings Heating rings are suitable for dismounting the inner rings of cylindrical roller and needle roller bearings withou
15. FAG video on the hydraulic method for the mounting and dismounting of rolling bearings Competence in maintenance Lubrication of rolling bearings Arcanol Rolling Bearing Greases For reliable durable and cost effective bearing arrangements FAG lubricator Motion Guard Rolling bearing damage Technical Information Product Information TI WL 80 14 TI WL 80 38 TPI WL 80 50 TPI WL 80 54 TPI WL 80 55 TPI WL 80 56 TPI WL 80 57 TPI WL 80 58 TPI WL 80 60 TPI WL 80 62 TPI WL 80 64 TPI WL 80 65 TI WL 80 66 TPI WL 80 67 TPI WL 80 68 TPI WL 80 69 TI WL 80 70 TPI WL 80 71 TPI WL 80 72 FISOO1 CD ROMs CD Medias 4 2 CD MGSM 2 0 CD MM 1 1 Mounting and dismounting of spherical roller bearings with tapered bore Mounting of self aligning ball bearings using adapter sleeves FAG pressure generators FAG heating devices PowerTherm FAG alignment tools FAG tools for mechanical mounting and dismounting of rolling bearings FAG hydraulic nuts FAG tools for thermal dismounting Condition monitoring using FAG products FAG Detector Il the mobile phone among data collectors FAG Detector Ill the solution for monitoring and balancing Monitoring of plant and machinery Online System FAG DTECT X1 FAG WiPro Wind Turbine Protection FAG VibroCheck online monitoring system for heavy industry FAG Easy Check FAG Easy Check Online FAG ProCheck state of the art machinery monitoring for maximum availability Measurem
16. Mounting Repair Mechanical mounting and dismounting Socket wrenches and hook wrenches for mounting and dismounting FAG socket wrench LOCKNUT SOCKET For locknuts KMO to KM20 Locknuts can be easily tightened and loosened on shafts adapter sleeves and extraction sleeves using FAG socket wrenches LOCKNUT SOCKET They require less space on the circumference of the nut than hook wrenches and allow the use of ratchets and torque wrenches For increased reliability socket wrenches should be secured using a locking pin and rubber washer FAG socket wrenches therefore have a hole for the locking pin and a groove forthe rubber washer The locking pin and rubber washer are included in delivery Ordering example for FAG socket wrench suitable for locknut KM5 LOCKNUT SOCKET KM5 For detailed information see TPI WL 80 56 FAG hook wrenches LOCKNUT HOOK For locknuts KMO to KM40 FAG hook wrenches of series LOCKNUT HOOK can be used to tighten and loosen locknuts on shafts adapter sleeves and extraction sleeves FAG hook wrenches can be used to mount small bearings on tapered shaft seats adapter sleeves or extraction sleeves Extraction sleeves can also be dismantled using FAG hook wrenches together with the extraction nuts Ordering example for FAG hook wrench suitable for locknuts KM18 KM19 KM20 LOCKNUT HOOK KM18 20 For detailed information see TPI WL 80 56 10 Products Moun
17. Ordering designation and scope of delivery TEMP CHECK CONTACT measuring device with sensor TEMP CHECK CONTACT SENSOR and service case FAG temperature sensor as replacement part can be ordered individually Rapid reaction surface sensor Ordering designation TEMP CHECK CONTACT SENSOR FAG temperature sensor as accessory can be ordered individually for measuring the temperature of fluids lubricants etc Immersion insertion sensor Ordering designation TEMP CHECK CONTACT SENSOR IMMERSION For detailed information see TPI WL 80 54 Products Condition monitoring Operating condition Digital hand tachometer FAG digital hand tachometer TACHOMETER The speed counter is suitable for two types of operation e Direct speed measurement using an adapter track wheel and measurement stylus e Non contact optical speed measurement using a reflective mark Direct speed measurement For direct speed measurement the supplied adapter must be fitted Through contact with the component the rubber stylus measures the speed or the surface speed is determined in conjunction with a track wheel Non contact speed measurement For non contact measurement a reflective mark is applied to the machine part to be measured This mark is detected by photoelectric means using visible red light The device displays the speed in revolutions per minute Ordering designation TACHOMETER Inclu
18. The pump 2 500 bar has two separately controllable outputs and is suitable as a pressure device for expanding shaft couplings and Electrically driven FAG hydraulic unit These units are suitable for driving large hydraulic nuts and mounting of large press fits such as ship shaft couplings ships propellers and gears contact pressure up to 50 N mm Electrical connection plug voltage 400 V at 50 Hz Other voltages and frequencies by agreement Mobile FAG hydraulic unit for batch mounting The mobile unit has a valve controlled double direction pressure cylinder pressure force 700 kN stroke 215 mm driven by a motor pump The height position of the cylinder can be varied between 290 and 690 mm by means of a lifting cylinder and rocker Accessories such as guide bushes mounting sleeves traction and pressure spindles and drawing gears by the hydraulic method The pump 1000 bar can drive a hydraulic nut at the same time The pump is suitable for press fits with contact pressures up to 100 N mm Included in delivery Base device ready to use incl 1 manometer O to 1000 bar 1 manometer O to 2 500 bar 3 high pressure hoses 2 500 bar 2m Compressed air driven FAG hydraulic unit Hydraulic unit volume Ordering designation l Included in delivery Base unit ready to use incl 1 manometer O to 1000 bar Oil container Max oil pressure Mass 1000 or 2500 40 without oil 1 high pr
19. baking machinery piston pins in compressors kiln trucks chemical plant at very high temperatures in chemically aggressive environment SPEED2 6 KE3K 50 Polycarbamide PAO ester oil ISO VG 22 2 3 50 120 80 Special grease for ball bearings in machine tools instruments at very high speeds low temperatures KP3N 30 Lithium complex soap with EP additives Mineral oil 170 3 30 150 Special grease for ball and roller bearings in blade adjusters in rotors for wind turbines packaging machinery rail vehicles at high temperatures high loads with oscillating motion KPE2K 30 Lithium calcium soap Ester oil 58 2 30 120 Special grease for ball and roller bearings in environmentally hazardous applications KPF2K 30 Aluminium complex soap White oil 192 2 30 120 70 Special grease for ball and roller bearings in applications with food contact H1 to USDA 47 Products Lubrication Lubrication systems Motion Guard Motion Guard SELECT MANAGER Automatic FAG lubricators Motion Guard Reliable and economical lubrication for a long bearing life Rolling bearings are reliable machine components that give a long operating life The most frequent cause of failure is inadequate or incorrect lubrication Approximately 90 of all bearings are lubricated with grease Providing a reliable supply of s
20. bearings in German English 101 ni TRAINING VIDEO 203 D E Hydraulic method for mounting and dismounting in German English 101 108 Comparison of ordering designations Comparison of ordering designations Ordering designation for Europe Ordering designation for countries outside Europe kira A Te eee ee A pi e A e o aan amat a pi EIER ARCA GREASE GUN HOSE iaa ARCA PUMP 25 180 rica CA PUMP LEO nen ARCALUB RR UB a maana ARCALUB CLEAR 000000 A tc A ARCALUB ACTIVE 1M 3M 6M 12M IO O O ns ARCALUB ACTIVE CLEAR 1M 3M 6M Nieren ARCALUB ACTIVE POLAR anag id A ARCALUB LC60 LC120 LC250 ARCA LUB LC60 LC120 LC250 22 ARCALUB LC120 KIT LC250 KIT an ARCALUB see LLO SET CICO SET 00 2 0 ARCALUB C6 250 KIT 500KIT aa AB CA LUBC6250 KIT RI ARCALUB C0 ST IND nennen NO ces A es nn IR onto nin SEEN TEEN NEIN NREEEENE ARCANOLFOOD2 0 ARCA GREASE FOOD2 ARCANOL LOAD150 A a at ARCANOL LOAD220 2 2 2 0 ARCA GREASE LOAD220 ARCANOL LOAD400 anal aa naaa READ ee EEA ARCANOL LOAD1000 ARCA GREASE LOAD1000 00 ARCANOL MULTITOP O ia a ea a JENE EEE ARCANOL MULTI2 ARCA GREASE MULTI2 OO ARCANOL MULTI3 ss RA RA ARCANOL TEMP90 A to A ARCANOLTEMP110 ARCA GREASETEMP110 0 ARCANOLTEMP120 ARCA GREASETEMP120 A AR GREASE OOOO ne ARCANOL IBS a nd OOOO OOO e NN aan AR MOA aaa AEA BEARING MATE250 450 450 650 650 850 BEARING MATE250 450
21. can be corrected directly by PIS Balancing Imbalance is one of the main sources of malfunctions that lead to unexpected failure of machine elements Correct balancing gives a decisive increase in the life of rotating machine parts This increases the productivity and plant availability The PIS experts reduce the increased vibration that occurs due to contamination wear repairs etc to a normal level They detect and eliminate the causes of imbalances on machines at speeds of 40 to 10000 rpm such as pumps ventilators compressors turbines motors etc Irrespective of the sector PIS offers not only a detailed analysis of the reasons for the malfunction but also the removal of imbalances in any level of adjustment Alignment Many of the standard pieces of equipment used in industrial facilities are composed of several components for example an electric motor and pump fan After installation repair or overhaul the components of such machines must be aligned with each other If this is carried out incorrectly or not at all it results in high loads being placed on the bearings as well as increased energy demand and wear The methods and tools for machine alignment have changed in recent years away from demanding and inaccurate methods using a dial gauge and Straight edge to laser alignment systems These are highly accurate and effective In addition to service products in this area see page 55 PIS also
22. discussed Target group The course is aimed at head foremen foremen and mounting personnel from maintenance shops and interested employees No special knowledge is required Training objective The participants will gain basic knowledge of spindle bearings and their mounting dismounting and maintenance Duration 1 day 94 Training Training descriptions Mounting Repair Rolling bearing maintenance for railway vehicle maintenance personnel general Training content This training covers the maintenance of wheelset bearings based on cylindrical and tapered roller bearings Rolling bearing experts from railway application engineering will communicate current knowledge on the bearings and their application Experienced setting supervisors will pass on their knowledge concerning manual work for rolling bearing maintenance and show correct handling using selected demonstration items Target group The course is aimed at head foremen foremen and mounting personnel from railway vehicle maintenance workshops Training objective The course participants will receive practical guidance on the maintenance of wheelset bearings based on simple cylindrical and tapered roller bearings Duration 1 2 5 days Rolling bearing maintenance for TAROL bearings Training content The subject of this training is the maintenance of TAROL wheelset bearings These double row tapered roller bearing units are adjusted greased
23. few movements extractors uniform distribution of force Even where parts are firmly seated there These allow the extraction of is no tilting or bending The high complete bearings tightly fitted extraction forces are concentrated inner rings and other components for example on the bearing inner The load capacity and extraction ring In general the bearing and force are precisely matched to each shaft remain intact and can be For detailed information see other used again TPI WL 80 56 Three section FAG extraction plates PowerPull PULLER TRISECTION Ordering designation Dimensions Mass Recommended for Extraction plate hydraulic extractor mechanical extractor Amin O B SPIDER mm kg PULLER TRISECTION 50 12 50 17 0 5 52 085 52 130 Sa arr m en au ea cc a E a eu a m aa NETT ER Ta ee ee ze ans a oe EYELET aaa a aac UA ee aaa TE man O E seen 18 Products Mounting Repair Hydraulic mounting and dismounting Hydraulic nuts FAG hydraulic nuts HYDNUT Hydraulic nuts HYDNUT can be used to press parts with a tapered bore onto their tapered seat Presses are mainly used if the drive up forces required cannot be applied using other devices e g shaft nuts or pressure screws They are mainly used for e mounting of rolling bearings with a tapered bore The bearings can be seated directly on a tapered shaft on an adapter sleeve or an extraction sleeve If the bearing is located using an ext
24. following exercises e Checking the bearing position e Mounting of adapter sleeve and bearing e Mounting as locating bearing e Mounting as non locating bearing e Mounting as through shaft e Mounting in housing closed on one side e Dismounting of bearing and adapter sleeve Ordering designation TRAINING CABINET MOD 1B Training videos 1 x 1 of rolling bearings The film is particularly suitable for communicating initial basic knowledge on rolling bearings It presents all types of bearings and highlights their characteristics features Ordering designation TRAINING VIDEO 201 D Mounting and dismounting of rolling bearings The film explains the most important Mounting sets 2 und 3 The trainer can use the FAG mounting sets 2 and 3 individual exercises from the FAG mounting cabinet to demonstrate the mounting and dismounting of Mounting set 2 Shaft with housing Suitable for the following exercises e Selection of fits e Checking the bearing positions e Mounting the bearing on the shaft e Axial location of the bearing e Mounting of the rotary shaft seal e Assembly locating bearing e Dismounting using extractor Ordering designation TRAINING CABINET MOD 2 rules of mounting in simple pictures and text Cardinal mistakes are named in simple unambiguous terms It is clearly shown step by step how various bearings are to be correctly mounted Ordering designation TRAINING VIDEO 20
25. grip coupling slide couplings for flat lubrication nipples to DIN 3404 or other nozzles can be connected These connectors are available from normal trade outlets Ordering designation ARCA GREASE GUN HOSE A hose with a connector for cylindrical nipples to DIN 3404 is optionally available Ordering designation ARCA GREASE GUN HOOK ON HOSE 53 54 Products Alignment Belt and chain drives nn 56 Belt pulley alignment device 56 Belt tension measuring device 57 Shaft couplings 0 58 shaft alignment device Ten 58 Accessories for alignment 60 56 Products Alignment Belt and chain drives Belt pulley alignment device FAG belt pulley alignment device Top Laser SMARTY2 Top Laser SMARTY2 is an economical measuring device for the alignment of belt pulleys and chain sprockets Through the use of this device the wear of belt drives bearings and seals is reduced Less vibration is generated and the running time and reliability of the machinery is increased Features and advantages e Parallelism and misalignment of both pulleys displayed e Significantly quicker and more precise than conventional methods e Suitable for both horizontally and vertically mounted machinery e Only one person required for alignment e Also suitable for non magnetic sprockets or pulleys The measuring device can be mounted in just a few seconds The laser beam can be clearly seen on the target marks Once the laser bea
26. is an independent company that takes responsibility for the worldwide service business of Schaeffler Group Industrial covering the brands INA and FAG The goal of PIS is to help customers to reduce maintenance costs optimise plant availability and prevent unforeseen machine downtimes The services are provided regardless of the brand of the machine components used FIS is therefore the specialist contact for the maintenance of rotating components In order to provide the qualified and rapid supply of PIS products Mounting Repair services and training to customers worldwide F IS has specialist centres around the world All PIS employees worldwide undergo a comprehensive training programme and are audited regularly This ensures that PIS services throughout the world comply with a uniformly high standard of quality Since each customer has a different set of requirements F IS offers concepts individually tailored to the customer The quality requirements are strongly influenced by a long history of high precision rolling bearing manufacture Each tool accessory and grease in this catalogue has been subjected to intensive testing in practical use and is classified as being of high quality T FIS FAG Industrial Services F IS Competence in maintenance Lubrication Alignment Condition Maintenance monitoring management The F IS range PIS has undertaken ongoing expansion of its range i
27. is measured by two hardened and precision ground surfaces one of which is movable After mounting of the outer ring the gauge is set to the internal enveloping circle of the roller and FAG enveloping circle gauge MGA 31 for setting the radial internal clearance of cylindrical roller bearings NN3006 K to NN3038 K and N1006 K to N1048 K Bearings with a tapered bore have removable outer rings The gauge is used to precisely set the radial internal clearance or preload of cylindrical roller bearings The raceway diameter of the mounted outer ring is measured using a conventional internal gauge This dimension is transferred cage assembly This dimension is measured using a snap gauge for example the SNAP GAUGE see page 38 It is then possible to set the inner ring to the diameter that gives the required radial internal clearance Bearings with a tapered bore are slid onto the tapered seat of the Shaft For bearings with a cylindrical bore preground inner rings are used suffix F12 and finish ground to the required raceway diameter Ordering example for NNU4920 MGI21 4920 to the two hardened and precision ground measuring surfaces of the enveloping circle gauge The tapered shaft with the premounted inner ring and roller and cage assembly can then be inserted in the gauge The shaft is moved axially by the hydraulic method until the precision indicator ofthe enveloping circle gauge shows the required ra
28. means of an electric heating plate The cylindrical outside surface of the bearing inner ring must be coated with a silicone free heat conducting paste HEATING RING PASTE This gives optimum heat transfer The heating ring is then slid over the inner ring to be extracted FAG heat conducting paste HEATING RING PASTE The silicone free heat conducting paste HEATING RING PASTE is used as an aid in the dismounting of bearing inner rings by means of heating rings The cylindrical outside surface of the bearing inner ring is coated with the heat conducting paste before extraction in order to achieve optimum heat transfer from the heating ring to the bearing inner ring 34 The bearing ring must be removed from the heating ring immediately after extraction in order to prevent overheating Each bearing size requires a specific heating ring By agreement we can supply these heating rings made from a special aluminium alloy In order to prepare a quotation we require the following information 1 Bearing designation or ring dimensions 2 Drawing of mounting position stating fits 3 Approximate number of parts to be extracted per day Recommended FAG accessories e Electric heating plate for temperatures up to 370 C HEATER PLATE 370C e Temperature gauge TEMP CHECK CONTACT see page 62 e Gloves GLOVE2 e Heat conducting paste see below HEATING RING PASTE 20ML 20 ml included in delivery Ordering designation
29. means of a threaded spindle In addition to devices with two three or four arms and a hydraulic pressure tool we also offer special extraction devices Ordering designation PULLER54 SET PULLER54 100 PULLER54 200 PULLER54 300 PULLER54 400 PULLER54 500 PULLER54 600 Ordering designation PULLER47 100 PULLER47 200 Ordering designation PULLER52 085 PULLER52 130 PULLER52 230 PULLER52 295 PULLER52 390 PULLER52 640 For detailed information see TPI WL 80 56 Note For the dismounting of larger bearings hydraulic extractors should be used page 15 Products Mounting Repair Mechanical mounting and dismounting Mechanical extractors Hydraulic pressure tool 44 e For loosening of tightly fitted parts in conjunction with mechanical extractors e Significant reduction in effort through generation of an axial force of 80 or 150kN with a hydraulic return mechanism on the larger device Ball bearing extractor 56 e For extraction of complete radial ball bearings e For tightly fitted outer rings e For bearings without radial access e Three sets with different claws available Special bearing extractor 64 e For radial bearings deep groove ball bearings self aligning ball bearings as well as cylindrical roller tapered roller and spherical roller bearings please state the bearing manufacturer e For tight fit of inner ring or outer ring Ordering designation PULLER44 080 PUL
30. mm 8 o FITTING TOOL STEEL 10 50 Mounting tool set steel for rolling bearings of bore diameter 10 50mm 8 gt GLOVE1 2 Heat resistant heat resistant and oil resistant gloves al HEATER10 Induction heating device for workpieces up to 10 kg mass 000 32 HEATER20 Induction heating device for workpieces up to 20kgmass 32 HEATER35 Induction heating device for workpieces up to 35 kg mass 0 32 HEATER150 Induction heating device for workpieces up to 150kgmass 32 HEATER300 Induction heating device for workpieces up to 300 kg mass 3 HEATER600 Induction heating device for workpieces up to 600 kgmass 3 0 HEATER1200 Induction heating device for workpieces up to 1200 kg mass 33 HEATER3000 Induction heating device for workpieces up to 3000 kg mass 33 HEATER PLATE Heating plate 1500 W lyyjaaaaa 31 o HEATER PLATE 370C Heating plate 2 200 W y gyjO aaaaaa 31 HEATING RING Heating ring for inner ring of cylindrical roller bearing or needle roller bearing ME 34 o HEATING RING PASTE 20ML Heat conducting paste 20 ml disposable syringe 34 o o HYDNUT Hydraulic nut with metric internal thread lt Z 12 HYDNUT HEAVY Hydraulic nut reinforced design with smooth bore 0 12 HYDNUT INCH Hydraulic nut with inch size internal thread 19 HYDNUT GAUGE DISPLACE Displacement gauge for HYDNUT OO 20 INJECT1600 2500 Oil injector 1600 bar 2 500 barn 24 INJECT1600 VALVE 2500 VALVE Valve nipple for oil injec
31. shaft Ordering designation PULLER49 100 060 PULLER49 100 075 PULLER49 200 115 PULLER49 300 150 PULLER49 400 210 Ordering designation nine internal extractors with two countersupports in a rigid metal case PULLER62 SET The nine internal extractors can also be ordered individually Ordering designation six sets of extraction legs and two threaded spindles in a toolbox PULLER INTERNAL10 100 SET The individual parts can also be ordered individually Products Mounting Repair Mechanical mounting and dismounting Hydraulic extractors Hydraulic FAG extractors PowerPull SPIDER The hydraulic FAG extractors PowerPull SPIDER are used where higher extraction forces are required The ten extractor sizes have a range of extraction forces from 40 to 400 kN covering a very wide range of possible applications Overview of significant advantages e Safety grip allows pumping while wearing industrial gloves e Optimum operating position due to 360 rotary coupling for pump handle separate pump with SPIDER 175 and 400 Pressure build up or reduction by rotation of handle on cut off valve Pressure control valve prevents overload Parts under mechanical load are made from high quality chromium molybdenum steel Maximum possible reduction in torsional and frictional forces due to chromium plated piston made from quenched and tempered steel Height of stroke adjustabl
32. sive analysis of the relevant processes On this base the PIS team prepares customer specific improvement concepts to integrate Phases in a consultancy process Analyses The PIS team analyses the actual situation by carrying out workshops with employees and investigating the available documents The analysis considers subjects including e business processes costs personnel structure tasks responsibilities machine utilisation e commercial and production KPIs technical support for processes e utilisation of IT and condition monitoring systems e maintenance strategies e knowledge management individual solutions to an overall solution PIS offers support during the implementation phase and as part of a partnership in following project phases Implementation CMMS IT network Diagnostic system Reporting Concepts Maintenance strategy Condition monitoring Reporting CMMS KPI Analyses Maintenance analysis Damage analysis IT benefit analysis Materials management Knowledge management e maintenance KPIs e co operation between departments Based on their experience the PIS consultants can evaluate the information obtained and place it within an overall context Anonymous data from other companies and sectors are also drawn upon for comparison As requested by the customer the results are presented at a management and or plant level Services Maintenance management Maint
33. symptoms and causes Target group The course is aimed at head foremen foremen and mounting personnel from maintenance shops and interested employees No special knowledge is required Training objective The participants will learn the correct and professional handling of rolling bearings and gain basic knowledge of mounting and dismounting Duration 1 2 days Product training Mounting tools Training content This training focuses on various tools for the correct mounting and dismounting of rolling bearings Particular emphasis is placed on the correct use of tools on a day to day basis The content of customer specific training is always agreed with the customer Target group The course is aimed at head foremen foremen and mounting personnel from maintenance shops and interested employees No special knowledge is required Training objective The participants will learn the correct handling of mounting and dismounting tools that they use day to day Duration By agreement Basic training Spindle bearing technology Training content In this training the participants will acquire basic knowledge of spindle bearings and their use Our spindle bearing experts will explain the types characteristics and designations of spindle bearings In the practically based part of the training correct mounting and dismounting of spindle bearings will be communicated Specific spindle bearing failures will be
34. systems for the requirements of specific sectors are available on request Products Maintenance management CMMS Interface 72 71 Products Maintenance management CMMS Interface CMMS Interface With the CMMS Interface PIS offers an intelligent link between vibration measurement analysis and the Computerized Maintenance Management System MAXIMO By means of a software module the portable FAG vibration measuring device Detector and its software Trendline is linked to the Computerized Maintenance Management System MAXIMO In addition to the advantages of the two systems in themselves the link created by the CMMS Interface gen erates the following synergy effects e Central storage of diagnostic and maintenance data e Redundancy free administration of master data e Fully automatic generation of current routes for Detector e Updating of follow up orders in MAXIMO in an alarm situation e Build up a measurement value history in MAXIMO Please direct enquiries to info fis services com Computerized Maintenance Management System 12 Services Services relating to rolling bearings Mounting Repaitr a A R a E 75 NOC ELITES SCARY e E EC aaa E A E pe Reconditioning of rolling bearings 76 Eq UHI eENe rental ye i S AE sen S A 78 Lubricante a enya 79 Corrective maintenance 80 Beal ane Satire TE eee E lel oy SO 80 Condition monitoring 8 Continuous measurement online 81
35. to identify machine defects and damage in detail based on trend analysis using the measuring system by remote diagnosis and online Duration 2 days Also usable for FAG WiPro Product training FAG ProCheck with Administrator 4 0 Training content In this training the participant will learn to apply the knowledge acquired in the training unit FAG Administrator 4 0 to the online measuring system FAG ProCheck The focus is on configuration and independent preparation implementation and evaluation of a measurement process using examples Target group The course is aimed in particular at technicians and engineers working in maintenance as well as interested employees Participants must have previously attended the product training course FAG Administrator 4 0 Training objective Following attendance at this course the participant should be in a position to configure the measuring system FAG ProCheck and independently prepare implement and evaluate measurement processes Duration 2 days 97 Training Training descriptions Condition Monitoring Product training FAG VibroCheck Installation hardware Training content The course communicates knowledge on the use of the VibroCheck VC hardware The focus is on the interaction between the VC hardware and software e g in hardware tests sensor tests The participant will learn to use terminal and circuit plans so he ca
36. 0 mm A 14 PULLER TRISECTION Three section extraction plate for hydraulic and mechanical extractors SA 17 NA PUMP1000 L 1600 L 2500 L Hand pump and accessories OO 25 PUMP2500 0 2L KIT High pressure pump set 2 500 ba 26 PUMP4000 0 2L High pressure pump 4000 bar and accessories 26 PUMP ADAPTER A B Pressure device accessory adapter 28 PUMP HOLDER 2 3 Pump holder without with manometer connector 29 PUMP MANO G1 2 Manometer 29 PUMP MANO DIGI Digital manometer A PUMP NIPPLE A B Pressure device accessory reduction nipple 28 Index of FAG products Index of FAG products Ordering designation Product Page E CONME TOR e ccoo Pressure device accessory sleeve connector for hand pumps a e a EA tataa kA AN m alak an GE MG Ta EEE O Aa a A AAGAKAANAGAD Naan T Polyscope sonar device nennen NG cs a EEE EIER LALA AA O E an TEMP CHECK CONTACT a Temperature measuring device contact type aan a La as Infrared temperature measuring device contact free u an TOOL RAILWAY AGGREGATE Mobile hydraulic unit for batch mounting of TAROL bearings 27 TRAINING CABINET MOD 1A D E F NL Mounting cabinet with contents and mounting bracket for basic course in German English French Dutch 100 TRAINING CABINET MOD 1B 2 3 Training case with rolling bearing mounting tool 101 TRAINING VIDEO 201 D E 1x1 of rolling bearings in German English Tr 101 TRAINING VIDEO 202 D E Mounting and dismounting of rolling
37. 0816 as well as the rolling bearing condition using the demodulated signal detection method Temperatures can also be measured by non contact means using an infrared sensor The data collected by the device are transferred to a computer They are then evaluated analysed and presented in graphic form with the aid of the software Trendline Any incipient damage can thus be detected at an early stage Detector II can also be used by personnel who have no experience of vibration measurement A very useful feature in this respect is the e mail button This allows the collected data to be sent to an FAG Detector Il external diagnosis expert for further analysis Included in delivery e Basic device with rechargeable battery e Acceleration sensor with magnetic foot e Temperature sensor e Power pack e PC data cable e User manual e Protective bag with holder for temperature sensor e PC software Trendline e Case e USB serial adapter Accessories e Second attachable bag for holding acceleration sensor e Sensor extension cables for lengths of 5m and 15 m are available on request Ordering designation DETECT2 1MB KIT For detailed information see TPI WL 80 62 Please direct enquiries to info fis services com 65 Products Condition monitoring Vibration diagnosis Detector Ill FAG Detector Ill Detector Ill is based on the successful Detector Il The proven simple operating concept was
38. 1 21 Products Mounting Repair Hydraulic mounting and dismounting Overview of pressure generation devices Overview of pressure generation devices Pressure device Oil injector Hand pump set Single stage Twin stage INJECT2500 INJECT1600 PUMP1000 0 7L PUMP1000 4L PUMP1600 4L Oil container volume 0 008 0 027 0 7 4 4 Connector G3 8 G3 4 G4 GY G14 Max oil pressure bar 2500 1600 1000 1000 1600 psi 36250 23 200 14500 14500 23 200 Application Mounting and Mounting and Mounting and Mounting and Mounting and dismounting of dismounting of dismounting of dismounting of dismounting of bearings with bearings with rolling bearings rolling bearings rolling bearings tapered bore tapered bore Mounting of press Mounting of press Mounting of Press fits up to Press fits up to fits up to approx fits up to approx press fits up to approx approx 50 N mm 50 N mm 80 N mm 125 N mm 80 N mm contact pressure contact pressure contact pressure contact pressure contact pressure For driving e g of ships e g of rudder hydraulic nuts up propellers For spindles and to HYDNUT395 driving hydraulic rudder blades HYDNUT300 HEAVY nuts up to HYDNUT800 Products Mounting Repair Hydraulic mounting and dismounting Overview of pressure generation devices Overview of pressure generation devices Pressure device Hand pump set Twin stage PUMP2500 4L High pressure pump PUMP4000
39. 2 filled with FOOD2 pack of 10 containers without activation screw In addition to FOOD2 seven other Arcanol grease grades as listed for COMPACT on page 49 as well as chain oil can be used Variant POLAR The variant POLAR of the lubricator Motion Guard COMPACT is designed for operation in temperatures from 25 Cto 10 C The metal housing is filled with 120 cm of Arcanol rolling bearing grease MULTITOP it is only available with this grease Ordering designation ARCALUB POLAR MULTITOP filled with MULTITOP pack of 10 containers without activation screw For the dispensing time as a function of the actual temperature present see the following table The special activation screws for the variant CLEAR with dispensing times of 1 3 or 6 months are offered separately Ordering designation 10 pieces ARCALUB ACTIVE CLEAR 1M ARCALUB ACTIVE CLEAR 3M ARCALUB ACTIVE CLEAR 6M Variant POLAR Temperature Dispensing time 10 C 1 week as ein NG ee Aa na ma een a maman na a re The black activation screw must be ordered separately Ordering designation 10 pieces ARCALUB ACTIVE POLAR Products Lubrication Lubrication systems Motion Guard CHAMPION Lubricator drives LC units sets and accessories FAG lubricators Motion Guard CHAMPION The automatic lubricator Motion Guard CHAMPION is electromechanically driven The robust electronically controlled geared mo
40. 2 6 6 With optional longer extraction arms replacement parts can be ordered individually SPIDER 100 300 For difficult dismounting work with Extra strong hydraulic extractor extraction forces up to 300 kN with with integral hand pump longer extraction arms on request With accessories in rigid metal case SPIDER 100 300 Ordering designation Extraction force Grip width Grip depth Stroke Mass Extractor kN mm mm mm kg PULLER HYD100 100 280 182 220 82 5 6 a a Ten Aa ANG IE a n AA ta a a mining en a a Ta ana a oe Te ee nn a O a With optional longer extraction arms replacement parts can be ordered individually SPIDER 175 400 Extractor for restricted spaces Extra strong hydraulic extractor connected to hand pump by hydraulic with separate hand pump hose extraction force up to 400 kN top of the range model SPIDER 175 400 Ordering Extraction force Grip width Grip depth Stroke Mass designation Extractor kN mm mm mm kg PULLER HYD175 175 356 229 300 82 15 6 PULLER HYD400 400 800 1200 405 635 250 49 Products Mounting Repair Mechanical mounting and dismounting Three section extraction plates Three section FAG extraction plates The SPIDER extraction claws grip The PULLER TRISECTION is field PowerPull PULLER TRISECTION directly under the screw studs of tested and can be fitted under the for hydraulic and mechanical the PULLER TRISECTION and give bearing with just a
41. 2 D Hydraulic method for mounting and dismounting of large rolling bearings The film shows using simulated and real scenes all the common methods and devices in hydraulic rolling bearings during teaching or have the apprentices carry these out The shaft and housing parts can be clamped in a vice for mounting Mounting set 3 Hydraulic mounting Suitable for the following exercises e Mounting with the aid of pressure screws e Mounting using a hydraulic nut e Setting and checking the radial internal clearance e Axial location using a locknut and tab washer e Dismounting using an oil injector Ordering designation TRAINING CABINET MOD 3 mounting pumps hydraulic nuts special extraction devices adapter and extraction sleeves It is also demonstrated what must be paid attention in the case of tapered or cylindrical shaft seats and how the radial internal clearance or axial displacement should be correctly measured so that the mounted parts have the correct seating on the shaft Ordering designation TRAINING VIDEO 203 D 101 102 Publications Index FAG products Comparison of ordering designations 104 Publications Publications WL 80 100 WL 80 102 WL 80 134 WL 80 135 WL 80 143 WL 81 115 WL 81 116 WL 81122 WL 82 102 Mounting of rolling bearings Hydraulic method for mounting and dismounting of rolling bearings FAG video on the mounting and dismounting of rolling bearings
42. 5 kg hobbock HY ARCANOL LOAD150 10KG FAG rolling bearing grease LOAD150 in 10 kg bucket an ARCANOL LOAD220 180KG FAG rolling bearing grease Arcanol LOAD220 in 180 kg drum YY ARCANOL LOAD400 400G FAG rolling bearing grease Arcanol LOAD400 in 400 g cartridge 10 pieces o ARCANOL LOAD1000 5KG FAG rolling bearing grease Arcanol LOAD1000 in 5 Kg bucket o ARCANOL TEMP90 1KG FAG rolling bearing grease ArcanolTEMP90 in 1 kg can 24 ARCANOL TEMP110 400G FAG rolling bearing grease Arcanol TEMP110 in 400 g cartridge Be ARCANOL TEMP120 25KG FAG rolling bearing grease Arcanol TEMP120 in 25 kg hobbock HY ARCANOL TEMP200 70G FAG rolling bearing grease Arcanol TEMP200 in 70 g tube ARCANOL SPEED2 6 250G FAG rolling bearing grease Arcanol SPEED2 6 in 250 g tube 10 pieces MA ARCANOL VIB3 25KG FAG rolling bearing grease Arcanol VIB3 in 25 kg hobbock SU ARCANOL BIO2 1KG FAG rolling bearing grease Arcanol BIO2 in 1 kg can Products Lubrication Lubricants Arcanol rolling bearing greases Selection table Overview of Arcanol rolling bearing greases Arcanol MULTITOP MULTI2 MULTI3 LOAD150 LOAD1000 DIN 51825 Thickener Base oil Base oil viscosity at 40 C Imm s Consistency NLGI class Operating temperature C Long term limit temperature C KP2N 40 Lithium soap with EP additives Mineral oil ester 85 2 40 150 Lithium soap Mineral oil ISO VG 100 2 30 140 K3N 30 Lithium soap Mineral oi
43. LER44 150 Ordering designation PULLER56 020 SET PULLER56 120 SET PULLER56 220 SET Ordering example for deep groove ball bearing 6000 Base device PULLER64 400 collet PULLER64 COLLET A 6000 Ordering example for tapered roller bearing pair 30203 A in X arrangement Base device PULLER64 400 collet PULLER64 COLLET B 30203A collet PULLER64 COLLET C 30203A 13 14 Products Mounting Repair Mechanical mounting and dismounting Mechanical extractors Extraction device 49 e For all rolling bearing types For extraction of complete rolling bearings or tightly fitted inner rings The extractor and the separator device are available in five sizes with grip widths of up to 210 mm Principally for cases in which the inner ring is adjacent to a shoulder on the shaft without extraction slots Good radial access to the bearing position is required Internal extractor 62 For deep groove ball bearings and angular contact ball bearings The internal extractor set comprises nine extractors and can be used on bearings with a bore of 5 mm up to approx 70 mm e For tightly fitted outer rings e The inner ring bore must be free Internal extractor PULLER INTERNAL10 100 SET For standard deep groove ball bearings The set containing 6 sets of extraction legs and 2 threaded spindles can be used on bores from 10 to 100 mm e For tightly fitted outer rings e No dismantling of
44. Pro options an appropriate solution can be found for any wind farm With WiPro the operator is kept informed at all times of the condition of the most important components This gives a high level of investment security and active machine protection The modular concept of the WiPro system allows all types of wind turbines to be retrofitted with the system Any wind farm can be networked using the WiPro system whether the turbines are connected using copper cables fibre optics ISDN or analogue lines or even if no telephone connection at all is present For detailed information see TI WL 80 66 Please direct enquiries to info fis services com Products Condition monitoring Vibration diagnosis VibroCheck FAG VibroCheck For detailed information see TPI WL 80 67 The online monitoring system Please direct enquiries to VibroCheck is ideally used wherever info fis services com a large number of measuring points must be continuously and reliably monitored such as in rolling mills paper factories or power stations In its most extended configuration up to 2048 sensors can be integrated in the system Forthe detection of defects such as imbalance and misalignment VibroCheck generates spectrum based parameters that are managed within narrow frequency bands according to speed In addition to general parameter monitoring the user has available an automatic rule based expert system that can monitor up to 20 c
45. T 500 KIT Multi point lubrication system CONCEPT6 with LC unit 250 500 cm 52 ARCANOL ANTICORROSIONOIL 400G Spray can containing Arcanol anti corrosion oil 42 ARCANOL BIO2 Special grease for environmentally hazardous applications 47 AA naa AA a ee A een AP o pi ARENA ae AA ee 3 NAA een SA TA ee se AG ee u ee en ore ARCANOL MULTITOP Universal grease for high speeds high loads high temperatures 46 ARCANOL MULTI2 cc Universal grease for bearings under normal loads D lt 62mm 46 ARCANOL MULTI3 Universal grease for bearings under normal loads D gt 62 mm 46 ee AA io emote Ls io ee pera E ce oe oe O ee een q ol ae A ee ete ane tee tetera nn i nc en ae a ARCANOL MOUNTINGPASTE Arcanol mounting paste 42 BEARING MATE250 450 450 650 650 850 Transport and mounting tool for rolling bearings of outside diameter 250 450 mm 450 650 mm 650 850 mm 40 Index of FAG products Index of FAG products Ordering designation Product Page COIL X LOW Coil for electric induction heating device with low voltage 35 COIL TRAFO Single phase dry transformer for heating device with low voltage 35 DETECT2 1MB KIT Detector AAO nn rennen SR DETECT3 KIT Detector 0 aaaaaad 66 EASY CHECK Easy Chel jjj 67 EASY CHECK ONLINE Easy Check e 000 67 un FEELER GAUGE 100 300 Feeler gauges 100 300 mm long 13 23 blade 36 FITTING TOOL ALU 10 50 Mounting tool set aluminium for rolling bearings of bore diameter 10 50
46. allow economical and secure mounting of rolling bearings up to 50 mm bore They can also be used to easily mount sleeves intermediate rings seals and similar parts Where inner or outer rings with a tight fit are to be driven onto a shaft or into a housing bore respectively this can be achieved by applying hammer blows to an appropriate mounting sleeve This prevents the mounting forces from being trans mitted through the rolling elements and raceways which can lead to damage The carefully matched FAG precision parts ensure that the forces are uniformly transmitted to the side faces of the bearing rings The FITTING TOOL ALU SET10 50 includes mounting sleeves made from aluminium and mounting rings made from plastic The parts are economical and easy to use The steel mounting sleeves and steel mounting rings in the FITTING TOOL STEEL SET10 50 give long wear free operating life These tools can also be used in combination with workshop power presses FAG mounting tool sets FITTING TOOL ALU 10 50 and FITTING TOOL STEEL 10 50 Included in delivery Mounting rings For bearing bore Outside diameter up to Mounting sleeves Hammer recoilless Dimensions of case For detailed information see TPI WL 80 56 Ordering designation FITTING TOOL ALU 10 50 33 pieces 10 50 mm 3 pieces 1 kg 440x350x95 mm FITTING TOOL STEEL 10 50 33 pieces 10 50 mm 5 pieces 0 7 kg 370x320x70 mm Products
47. allowing storage of up to 1600 measurement points and at the same time up to 270 time signals e the speed measurement function e and the revised report generator system Ordering designation DETECT3 KIT Included in delivery e Basic device with rechargeable battery e Acceleration sensor with magnetic foot e Temperature sensor e Charger e PC data cable serial USB e User manual e Protective bag with holder for temperature sensor e PC software Trendline e Case Ordering designation DETECT3 KIT RFID Included in delivery e As DTECT3 KIT e RFID reader integrated e RFID tags Ordering designation DETECT3 BALANCE KIT Included in delivery e Acceleration sensor with magnetic foot and sensor cable e Trigger sensor optical and inductive e Scales e Magnetic holder for trigger sensor e Extension for magnetic holder e Cable for trigger sensor length 10 m e Reflective mark for trigger sensor e Dongle for activation of balancing function e Case Accessories e Sensor extension cables for lengths of 5m and 15 m are available on request e Further RFID tags are available on request This functionality is not yet available worldwide Please direct any enquiries to info fis services com For detailed information see TPI WL 80 64 FAG Detector Ill and Balancing Kit Products Condition monitoring Vibration diagnosis Easy Check DTECT X1 FAG EASY Check series Th
48. alues and trigger an alarm If necessary the remote monitoring function can be used to monitor machines without the need for a diagnosis expert on site Any changes are automatically notified via telecommunication systems fixed line mobile or GSM modem to the operating company plant manufacturer or service provider regardless of where the system is located throughout the world Stored and current data can be remotely retrieved and analysed by the FAG Diagnosis Centre For detailed information see TPI WL 80 65 Please direct enquiries to info fis services com FAG WiPro WiPro is a cost effective online monitoring system for the condition based maintenance of wind turbines The system certified by the AZT Allianz Zentrum f r Technik can monitor not only the drive train main bearing gearbox coupling generator but also vibrations in the tower If required other information such as rotor blade speeds or oil quality can be integrated in the condition monitoring WiPro is equipped with a signal processor and evaluates all measurement signals in the nacelle itself Due to the intelligent linking of expert knowledge with information from the turbine it is possible to keep the transfer data volume very small This is particularly important where a large number of turbines are to be monitored on a permanent basis allowing transfer data quantities to be kept to a minimum Due to the different communication FAG Wi
49. and sealed on both sides Rolling bearing experts from railway application engineering will communicate current knowledge on the bearings and their application Experienced setting supervisors will pass on their knowledge concerning manual work for the maintenance of TAROL bearings and show the particular aspects of this maintenance using selected demonstration items Target group The course is aimed at head foremen foremen and mounting personnel from railway vehicle maintenance workshops Training objective The course will enable the participants to carry out maintenance of TAROL bearings independently Duration 1 day by agreement only Training Training descriptions Lubrication Alignment Lubrication Product training FAG lubrication systems Motion Guard Training content This training covers the FAG lubrication systems Motion Guard in relation to functionality possible applications usage and handling The focus is on the safe handling and boundary operating conditions of the FAG lubrication systems Target group The course is aimed at head foremen foremen and mounting personnel from maintenance shops and interested employees No special knowledge is required Training objective Following the course the participants will be able to correctly select and use the various products in the lubrication system Motion Guard to ensure that unplanned machine downtime due to defective
50. ants and lubrication systems the lubrication of bearing positions the preparation of lubrication and maintenance plans lubrication point management lubrication consultancy and lubricant investigations and tests A comprehensive selection of high quality FAG Arcanol greases specially tested and selected for use in rolling bearings is available The consistent quality of Arcanol lubricants is ensured by ongoing investigation on special test rigs The use of names that are easily remembered and matched to the application allows rapid grease selection The F IS team also deals with special requirements such as rapidly biodegradable greases and greases for use in the food industry The software Motion Guard SELECT MANAGER Version 2 0 allows e selection of lubricators e definition of dispensing times and relubrication quantities e selection of suitable preferred Arcanol greases e management of a lubrication and maintenance plan Use of the PIS lubrication service can prevent the failure of rotating machine parts and increase productivity while reducing lubrication costs Services Services relating to rolling bearings Corrective maintenance Balancing Alignment Corrective maintenance Once a machine problem has been diagnosed it should be eliminated as quickly as possible Two of the most frequent problems imbalance in pumps and fans as well as machine components incorrectly aligned to each other
51. arts shafts housings on which the mounting and dismounting of common types of bearings can be practised with the aid of mechanical or hydraulic devices The content is composed of smaller learning stages and does not go beyond the degree of difficulty that is currently required in vocational training Building on this basic course other assemblies such as gearboxes pumps spindles road vehicle wheels etc can be prepared for training Handbook 1 Theoretical part e Technical theory e Technical calculation e Technical drawing Handbook 2 Practical part e Mounting of bearings with cylindrical bore e Mounting of bearings with tapered bore e Hydraulic method e Exercises on shafts and housings 100 Technical data Mounting cabinet Dimensions 1135x710x380 mm Mass including contents 94 kg Designed for 10 mounting exercises on 5 shafts on 2 housings on 3 shafts and housings Smallest shaft diameter 15 mm Largest shaft diameter 55 mm Ordering designation mounting cabinet with contents and mounting bracket TRAINING CABINET MOD 1A D Further demonstration models for training are always available on request Please contact info fis services com Training Training aids Mounting set 1 Mounting set 1 is an additional exercise to the FAG mounting cabinet and facilitates the mounting of a self aligning ball bearing in a housing Mounting set 1 Plummer block housing Suitable for the
52. atabase The mobile system avoids most of manual data input Data quality and analysis potential are increased through the use of standardised coding Establishment expansion of the reporting system The integration of reports into the CMMS offers versatile possibilities for data analysis and representation Typical applications in this field include evaluation and failure analyses with multi stage reports stock and master data lists as well as internal and external business paperwork Reports can be generated quickly and easily Quality of information is improved by electronic completion of forms The use of standardised reports conforms to the requirements of certification Services Maintenance management CMMS Further services for CMMS e Release and database platform changeover e CMMS modifications and expansion functions e Data analysis and corrective data administration e Implementation of automated processes e Training of your personnel to user and administrator level Please direct enquiries to info fis services com 89 90 Training Overview A 92 Training descriptions 93 MU Caio Condition Monitor De 2 Maintenance management 99 Training aids 100 91 Training Overview PIS offers in relation to the product training course on the basis of The current training offer including and service range both standard these training components After dates for the standard training trai
53. ave gained over many years Endoscopy If damage has been detected for example but the component cannot be replaced in the short term for production reasons the precise extent of the damage can be determined using endoscopy The interior of the machine is examined using digital optical endoscopes The images are stored in the form of digital photographs or videos and are used as the basis of diagnosis by PIS experts Individual components such as rolling bearings or gear teeth can then be easily assessed If the bearings inspected are Schaeffler KG products the customer also has access to the knowledge of Schaeffler application engineers They will prepare a detailed damage analysis and submit well qualified proposals for improvement This is an advantage that clearly demonstrates the benefits of obtaining products and services from a single source Thermography Thermography is one of the most important non destructive diagnostic techniques Many technical problems manifest themselves in the form of heat generation which can be detected with the aid of a high resolution infrared camera The major advantage of thermo graphy is the rapid non contact collection of temperature data Simultaneous recording of a digital optical image allows precise allocation of the temperature gradients to visible features on site There is a wide range of objects that can be examined by this method itextends from assessment of electr
54. be supplied Ordering designations ARCALUB C6 250 KIT ARCALUB C6 500 KIT Only the following must be ordered specially hose and connectors for the lubrication point and LC units in sizes 250 cm and 500 cm LC units are available with the 13 suitable Arcanol grease grades see page 46 47 except for MULTI3 and VIB3 Ordering examples ARCALUB C6 LC250 MULTITOP ARCALUB C6 LC250 LOAD400 ARCALUB C6 LC500 SPEED2 6 ARCALUB C6 LC500 TEMP200 By agreement we supply LC units with other greases whose Suitability has been checked Variant CONTROL The variant CONTROL of the lubricator CONCEPT6 is controlled by the machine i e lubricant is only dispensed while the machine is running We also supply starter kits for the variant CONTROL as a basis for multi point lubrication systems Ordering designation ARCALUB C6 CONTROL 250 KIT ARCALUB C6 CONTROL 500 KIT For single point lubrication the parts required are ordered individually from the range of accessories For detailed information see publication WL 81 122 Products Lubrication Lubrication systems Grease metering devices Grease gun FAG grease metering devices These devices are used for the metered greasing of rolling bearings The metering range is between 10 and 133 cm Larger metering ranges can also be achieved by operating the device several times By means of a pneumatically driven double direction piston pump the
55. but no liability can be accepted for any errors or omissions We reserve the right to make technical changes Schaeffler KG 2008 March This publication or parts thereof may not be reproduced without our permission WL 80 250 3 EA
56. ce and reduction in radial internal clearance can be precisely set For detailed information see TPI WL 80 56 Double hook wrench kits e g LOCKNUT DOUBLEHOOK KM5 KIT and LOCKNUT DOUBLEHOOK KM13 KIT Double hook wrench kits LOCKNUT DOUBLEHOOK KM5 8 SET and LOCKNUT DOUBLEHOOK KM9 13 SET Double hook wrenches e g LOCKNUT DOUBLEHOOK KM5 and LOCKNUT DOUBLEHOOK KM13 11 Products Mounting Repair Mechanical mounting and dismounting Mechanical extractors Mechanical FAG extractors PowerPull Mechanical extractors can be used to dismount small rolling bearings up to approx 100 mm bore diameter that are located with a tight fit on a shaft or in a housing The bearing can be dismounted without damage if the extractor is Two arm extractor 54 For extraction of complete rolling bearings or tightly fitted inner rings as well as other parts e g gears e Grip width 80 350 mm grip depth 100 250 mm Available as set stand with 6 extractors or individually Two arm bearing extractor 47 e For extraction of complete rolling bearings or tightly fitted inner rings e Grip width 45 and 90 mm grip depth 65 and 100 mm Three arm extractor 52 e For extraction of complete rolling bearings or tightly fitted inner rings e Grip width 85 640 mm grip depth 65 300 mm in contact with the tightly fitted bearing ring In mechanical FAG extractors the extraction force is normally applied by
57. ce is very light it weighs only 150 g and can be taken practically anywhere it is needed The FAG infrared thermometer TempCheck PLUS can measure temperatures in a range between 32 C and 530 C It has high precision glass optics for accurate contact free temperature measure ment It is suitable for monitoring the temperature of components ofa machine FAG temperature measuring device TempCheck CONTACT This handy device has a display range from 60 C to 1000 C The surface temperatue sensor TEMP CHECK CONTACT SENSOR has a measurement range from 60 C to 300 C The device is suitable for measuring the temperature of e rolling bearings housings and lubrication systems for operational monitoring e heated rolling bearings and joints during mounting The microprocessor controlled measuring device has a single line display The touch keyboard has Overview of the advantages of TempCheck PLUS e Rapid and precise temperature measurement e State of the art infrared temperature measurement technology e Simple to use e Reduction of unplanned downtime e Low purchase cost Ordering designation and scope of delivery TEMP CHECK PLUS measuring device with battery strap user manual and carry case Caution Do not look into the laser beam Do not point the laser beam into other people s eyes the following switching functions e On Off e Hold hold the measurement value in the display
58. criptions Condition monitoring Maintenance management Product training FAG Detector Il Training content In this course soundly based knowledge will be communicated on the measuring system FAG Detector II in relation to functionality possible applications usage and handling Target group The course is aimed in particular at technicians and engineers working in maintenance as well as interested employees No special knowledge is required Training objective The participant will then be able to identify machine defects and damage based on trend analysis using the measuring system Duration By agreement Maintenance management User training for implemented CMMS Training content This course focuses on the established Computerized Maintenance Management System CMMS on the customers site The content is defined in relation to the participants upon customer request Target group The course is aimed at persons who have to operate the CMMS in their company No special knowledge is required Training objective The participants will learn how to use CMMS ina correct way and why it is important to enter the specified information into the system They will also learn how to find certain information in the system which is needed in the daily work Duration By agreement CMMS administrator training Training content This training covers the support and administration of the CMMS The content can
59. ction hook Ordering designation LASER SHIM SET Individual or replacement parts As replacement parts we supply 10 shims each of one of the 4 sizes and one of the 7 thickness values stated above Ordering examples 10 shims of dimension C 15 mm and 0 20 mm thickness LASER SHIM15X0 20 10 shims of dimension C 44 mm and 0 10 mm thickness LASER SHIM44X0 10 For detailed information see TPI WL 80 55 60 LASER SHIM SET Ordering designation Dimensions Total quantity Mass A B C Thickness of shims mm kg 55 50 15 0 05 1 0 360 6 7 so A eee as w O o LASER SHIMs Individual or replacement parts Ordering designation Individual or replacement parts FAG Dimensions Total quantity Mass A B C Thickness of shims mm g 55 50 15 0 05 2 0 10 each 11 440 Ha 75 70 23 0 05 2 0 10 each 21 840 90 80 32 0 05 2 0 10 each 29 1160 125 105 44 0 05 2 0 10 each 53 2100 Products Condition monitoring MT ae q Te Oe a e m N NG u bo A F f ty x mg Y Products Condition monitoring Operating condition Temperature measuring devices FAG infrared thermometer TempCheck PLUS The FAG infrared thermometer TempCheck PLUS measures the infrared radiation emitted by an object and uses this to calculate the surface temperature The contact free measurement makes it possible to easily determine the temperature of difficult to reach or moving objects The devi
60. ctor Ill Participants must have previously attended the product training course FAG Detector Ill Basic Training objective The participants will learn how to safely use the FAG Detector Ill during a balancing procedure Duration 1 day Product training FAG Detector Ill Advanced Training content Building on the training FAG Detector Ill Basic this course goes into greater detail on the theory of vibration examination and monitoring covered in the aforementioned course This course comprehensively covers special subjects such as the symptomatic form of individual machine defects Aspects relating to the condition monitoring of individual machine parts will be discussed in detail in relation to defects and problems and reconstructed in some cases using practical exercises Target group This course is aimed in particular at technicians and engineers working in maintenance as well as interested employees who have already attended the course FAG Detector lll Basic or have at least one year s experience in the use of measuring systems Training objective After the training the participant should be in a position to identify the symptomatic form of individual machine defects and determine their cause Duration 2 days Training Training descriptions Condition Monitoring Product training FAG Administrator 4 0 Training content This training is concerned with the installation and indi
61. ded in delivery e Digital hand tachometer e Adapter for direct measurement 1 1 e Track wheel 6 inch e Rubber stylus e 10 reflective marks e User manual e Case Replacement parts 10 reflective marks Ordering designation TACHOMETER MARKS REFLEX 64 Products Condition monitoring Operating condition Sonar device FAG sonar device SOUND CHECK The sonar detector can be used to check rolling bearing noise very easily quickly and reliably Changes in noise due to wear pitting formation or distortion of the bearing can be detected at an early stage if regular inspection is carried out In this way unforeseen operational downtimes and more significant machine damage can be prevented The device is used in the same way as a doctor s stethoscope The tips of the earpiece are placed in the ear canals to provide insulation against background noise The insulating grip is held like a pencil between index finger and thumb and the sensor is placed firmly on the part to be measured If a noise is heard the sensor is moved until its volume reaches a maximum Ordering designation SOUND CHECK Products Condition monitoring Vibration diagnosis Detector Condition monitoring by vibration diagnosis Vibration diagnosis is the most reliable method for identifying machine damage at an early stage Imbalance and misalignment defects can be detected accurately as well as
62. dia Available in 70 g tubes 250 g tubes 400 g cartridges 1 kg cans Ordering designation ARCANOL MOUNTINGPASTE 70G ARCANOL MOUNTINGPASTE 250G ARCANOL MOUNTINGPASTE 400G ARCANOL MOUNTINGPASTE 1KG It can be easily and effectively removed using alkaline solvents and neutral cleaning agents Available in 0 4 litre spray can with ozone safe propellant CO Ordering designation ARCANOL ANTICORROSIONOIL 400G Hale on Lasam x 4 Products Lubrication Ir ill Ay al E l mi mm banat wg SE AA gt o 0 caco oo O a SAREE A AA AA AA e A ern DB BE Be Br ur Br a BL AA AA AA Ver Meteringgddiices m 5 Grease gun 53 E ee 44 Products Lubrication Lubricants Arcanol rolling bearing greases Special rolling bearing greases like Arcanol at first glance cost a little more than standard greases But they are worth the price For with Arcanol you can buy some extra security since Schaeffler KG carries out selection tests provides quality assurance and gives practice based lubrication recommendations Bearings that fail prematurely due to incorrect grease selection together with all the unpleasant and expensive consequences are increasingly a thing of the past In co operation with renowned lubricant manufacturers we have for many years developed lubricating greases that are particularly suitable for rolling bearings However before a new gr
63. dial internal clearance or preload Ordering example for NN3006 K MGA31 3006 FAG enveloping circle gauge MGI 21 for setting the radial internal clearance or preload of cylindrical roller bearings with removable inner ring FAG enveloping circle gauge MGA 31 for setting the radial internal clearance of cylindrical roller bearings with removable outer ring 39 Products Mounting Repair Accessories Transport and mounting tool FAG transport and mounting tool BEARING MATE is an accessory for the secure rapid and easy handling of medium sized and large rolling bearings lt can also be used where bearings are heated prior to mounting The tool comprises two handles and two steel strips Turning the handles clamps the steel strips firmly on the outer ring of the rolling bearing The compact packaging also includes two brackets These are used on spherical roller bearings and self aligning ball bearings in order to prevent tilting of the inner rings The tool and bearing is carried either by two people or a crane If two carrying slings are used the rolling bearing can be rotated to any position when transported by Accessories Replacement parts crane During heating on an induction heating device the tool Long brackets to prevent tilting of Short brackets to prevent tilting of remains mounted on the bearing self aligning bearing inner rings self aligning bearing inner rings The ste
64. duction heating devices Heating device HEATER300 HEATER600 HEATER1200 HEATER3000 Power consumption max 12 8 kVA 25 kVA 40 kVA 100 kVA Voltage frequency 400 V 50 Hz 400 V 50 Hz 400 V 50 Hz 400 V 50 Hz Current 32A 63 A 100 A 250A Mass 75 kg 25 kg 350 kg 850 kg 1800 kg Length 870 mm 1100 mm 1500 mm 2500 mm Width 300 mm 850 mm 1100 mm 1 500 mm Height 580 mm 1250 mm 1400 mm 1800 mm 900 mm Dimension a 330 mm 430 mm 700 mm 700 mm Dimension b 260 mm 400 mm 450 mm 800 mm Ledges incl 115 mm 145 mm 215 mm 285 mm for workpieces of min bore Ledges accessories for workpieces of min bore 3 Convertible to a mobile version by adding HEATER300 TROLLEY 30 mm 45 mm 60 mm 70 mm 85 mm 100 mm 85 mm 115 mm 145 mm 33 Products Mounting Repair Thermal mounting and dismounting Heating rings Heat conducting paste FAG heating rings Heating rings are suitable for dismounting the inner rings of cylindrical roller and needle roller bearings without ribs and inner rings with one rib Heating rings are particularly advantageous for the occasional extraction of small and medium sized bearing rings bore diameter 50 to 200 mm Depending on the size of the ring heating takes between 5 and 30 seconds The heating rings are made from light metal They have a radial slot They are easy to handle due to the heat insulated handles Heating rings are heated to between 200 and 300 C by
65. e dismounting of rolling bearings and other press fits with direct seating on tapered shafts e g in machine tools for cylindrical roller bearings FAG NNU49 S K NN30 AS K N10 K N19 K Conventional O rings can be used as replacement seals OR6x1 5 for INJECT2500 OR10x2 0 for INJECT1600 For detailed information see TPI WL 80 50 FAG oil injectors Oil injector Valve nipple Connector Oil volume Max Mass Ordering designation mine cm eran told 1 cennonesune ER INJECT1600 INJECT1600 VALVE 6 27 oil pressure bar kg 2500 0 91 1600 2 18 The oil injector can be refilled with oil without losses by connecting the valve nipple to the oil injector In this case the oil injector is ordered with a valve nipple Ordering designation for INJECT2500 INJECT2500 VALVE INJECT2500 SET Ordering designation for INJECT1600 INJECT1600 VALVE INJECT1600 SET Products Mounting Repair Hydraulic mounting and dismounting Hand pump sets FAG hand pump sets FAG offers one hand pump set with a single stage pump and three hand pump sets with a twin stage pump The twin stage pumps have a high flow rate in the low pressure range up to 50 bar and then switch automatically to the high pressure stage This gives a high work rate Where there is an increased oil requirement the twin stage pumps are available with an 8 litre oil container suffix 8L In cases where the type of installation of the adapter or
66. e FAG Easy Check devices are economical vibration monitors for permanent monitoring of critical machinery in plants with constant operating conditions e g pumps fans electric motors etc Since Easy Check vibration monitors are easy to mount and operate they can also be used without difficulty by employees who have no knowledge of condition monitoring The devices monitor vibration in accordance with ISO 10816 the condition of rolling bearings with the aid of the demodulated signal method and the temperature at the bearing locations The use of Easy Check devices can contribute to a considerable cost reduction as arising damage is detected at an early stage and the necessary work can be integrated into maintenance planning FAG Easy Check basic device FAG Easy Check is a standalone device that is powered by a battery and is applied directly to the critical machine The vibration monitor draws attention to any problem by means of LEDs traffic light function FAG Easy Check basic device The status of the LEDs on the Easy Check must be checked at regular intervals Ordering designation EASY CHECK FAG Easy Check Online In contrast to the basic device FAG Easy Check Online has an external power supply Additional alarm outputs for vibration and temperature offer the possibility of presenting alarm conditions on a control station or traffic light device This eliminates the need for regular inspections and all
67. e by means of standard adapter High load capacity of extraction arms and claws through manufacture as single piece Simple centring by spring loaded steel cone Quick screw thread for setting of optimum grip depth Simple conversion to two arm operation if insufficient space for three arms These devices allow rolling bearings gears sleeves and many other shrink fitted parts to be quickly and easily dismounted In addition the low mass of the extractors mean that they can be used in any position If necessary greater grip depth can be achieved through the use of extra long extraction arms available as accessories For protection of operators the extractors SPIDER 40 to 80 have a safety grid All larger hydraulic extractors are supplied with a transparent very tough safety cover The cover can be easily placed around the workpiece or tool and secured using velcro strips For detailed information see TPI WL 80 56 LULU 15 Products Mounting Repair Mechanical mounting and dismounting Hydraulic extractors SPIDER 40 80 Compact extractor for extraction Hydraulic standard extractor with forces up to 80 kN together with integral hand pump safety grid in rigid case SPIDER 40 80 Ordering designation Extraction force Grip width Grip depth Stroke Mass Extractor kN mm mm mm kg PULLER HYD40 40 150 152 55 4 5 PULLER HYD60 60 200 152 190 82 4 9 PULLER HYD80 80 250 190 229 8
68. ease is included in the Arcanol range it must pass a series of stringent tests in the Schaeffler lubricant laboratory The greases are tested thoroughly On our lubricant test rigs FE8 DIN 51819 and FE9 DIN 51821 the greases are tested in rolling bearings to find out how they improve service life and reduce friction and wear Only the best greases are then selected to undergo the subsequent tests under simulated field conditions in far more complicated rolling bearing test rigs If the results meet the requirements of the stringent FAG specifications the greases are included in the Arcanol range They thus receive the Arcanol seal of quality In addition we test every single batch to ensure the uniform quality ofthe product It is only after the grease has passed this final test that it is allowed to be filled into containers labelled Arcanol The range is structured such that these greases cover nearly all fields of application in an optimum manner The overview on pages 46 47 shows chemical physical data fields of application and the conditions for which these greases are Suitable The selection of a suitable grease is considerably facilitated by the electronic INA FAG rolling bearing catalogue e More than 80 of all rolling bearings are lubricated with grease e Incorrect lubrication causes more than 40 of all cases of rolling bearing damage e Users therefore need lubricants and lubrication recommendations
69. ectronic learning system Calculation possibilities for mounting methods Bearings with a tapered bore are mounted either directly on the tapered shaft or journal or by means of an adapter sleeve or extraction sleeve on the cylindrical shaft The internal clearance is set either by conventional means using feeler gauges or by means of the axial displacement a Mounting of bearings with tapered bore by measurement of the axial displacement The bearing is placed in its starting position on the tapered bearing seat with a hydraulic nut The required starting pressure defined for each individual bearing is set in the hydraulic nut by means of the digital manometer The dial gauge mounted on the hydraulic nut is used to measure the axial drive up until the final position is reached on the tapered seat This mounting method e shortens and simplifies mounting considerably e offers very high security and accuracy e allows the correct mounting of sealed bearings b Mounting of bearings with tapered bore by measurement of the reduction in radial internal clearance When the bearing is pushed onto the tapered seat the inner ring is expanded and the radial internal clearance is thereby reduced This reduction in radial internal clearance is valid as a measure of the firm seating of the bearing It is measured by means of a feeler gauge The FAG Mounting Manager is available on CD ROM Ordering designation CD MM 1
70. ed alignment work using the measuring systems Duration By agreement Training Training descriptions Condition Monitoring Condition Monitoring Product training FAG Detector Ill Basic Training content This training conveys basic knowledge both of vibration theory and vibration monitoring as well as the handling of the measuring system FAG Detector Ill The course participants will receive an overview of the functionality possible applications configuration and handling of the measuring system Target group The course is aimed at head foremen foremen and mounting personnel from maintenance shops and interested employees No special knowledge is required Training objective The participants can subsequently detect simple machine defects by means of trend analyses and determine the cause on the basis of the time signal and spectrum Duration 3 days Product training FAG Detector III Balancing Training content The course covers in particular the subject of balancing using the FAG Detector Ill in theory and practice and is aimed at participants who have completed the course FAG Detector Ill Basic and now wish to learn about using the Balancing Kit The participant will learn to use the device safely and independently carry out balancing operations with the FAG Detector Ill Target group The course is aimed at participants who are already familiar with use of the Dete
71. el strips expand uniformly 2 pieces 2 pieces with the bearing Optimum tension Ordering designation Ordering designation is thus maintained BEARING MATE LOCKBAR270 BEARING MATE LOCKBAR170 The three sizes of tool are matched to different bearing outside Carrying sling 1 m long 2 pieces Pack of spare parts diameters see table below BEARING MATE SLING 1M BEARING MATE SERVICE KIT FAG transport and mounting tool Ordering designation Bearing outside diameter Bearing mass Operating temperature Tool mass Transport and min max max max mounting tool mm kg C kg BEARING MATE250 450 250 450 500 160 6 3 BEARING MATE450 650 450 650 500 160 6 4 Products Mounting Repair Accessories Gloves Heat resistant FAG gloves GLOVE1 Heat resistant FAG gloves are particularly suitable for the handling of heated rolling bearings or other parts in mounting or dismounting The outside comprises rugged polyester and can withstand temperatures up to 150 C The inside is made from comfortable cotton Heat resistant and oil resistant FAG gloves GLOVE2 Heat resistant and oil resistant FAG gloves are particularly suitable for the handling of heated and lubricated rolling bearings in mounting or dismounting Their principal characteristics derive from the multiple layer construction comprising different fibres The principal characteristics are e resistant up to 150 C e lint free e asbestos free e comfortable e cut resis
72. enance consultancy Concepts and implementation Implementation concept for a CMMS The concepts are prepared by F IS consultants together with the customer and are focused on the situation and vision of the customer Each customer gets an individual solution The concepts are implemented in partnership with the customer e Software selection e Master data structures e Strategy for recurring maintenance and inspection tasks e Specification and implementation of interfaces e Transfer of old data IT network e Selection of software based on required attributes e Development of a thorough data model e Specification of interfaces e Specification of the necessary hardware Improvement of reporting system e Creation of KPls e Automatical reports e Electronic reporting via the Internet Maintenance strategy e Benchmarks with partner companies e ABC analysis of plant stock e TCO Total Cost of Ownership e LCC Life Cycle Cost e TPM Total Productive Maintenance e Condition based maintenance see page 84 Care of concepts In order to keep the optimisation of costs and benefits achieved in the long term regular assessments are carried out after the implemen tation phase These assessments are made by the customer himself and the support of the PIS consultants as a neutral partner Maintenance controlling can be managed by an extended reporting system KPls and benchmarks It is im
73. ent and dimensioning of tapered studs using the FAG taper gauge MGK9205 Training Courses Rolling Bearings and Condition Monitoring For Beginners and Advanced Students Reconditioning and Repair of Rolling Bearings Smart Performance Program Success through Collective Competence Electronic INA FAG rolling bearing catalogue FAG Motion Guard Select Manager FAG Mounting Manager Index of FAG products Index of FAG products Ordering designation Product Page AGGREG E700 Electrically driven hydraulic Unit 27 AGGREG P1000 1 P2500 2 Compressed air driven hydraulic unit 27 ARCA GREASE GUN Arcanol grease gun UOOl ja 3 ARCA GREASE GUN HOSE Arcanol reinforced hose Z 53 o ARCA PUMP 25 180 Grease metering device for 25 180 kg grease container 53 ARCALUB Lubricator COMPACT with grease charge without activation screw 49 ARCALUB CLEAR Lubricator COMPACT CLEAR with grease charge without activation screw 5 0 EG ARCALUB ACTIVE 1M 3M 6M 12M Activation screw for lubricator Motion Guard COMPACT 49 o ARCALUB ACTIVE CLEAR 1M 3M 6M Activation screw for lubricator Motion Guard COMPACT CLEAR 50 o ARCALUB ACTIVE POLAR Activation screw for lubricator Motion Guard COMPACT POLAR 20 50 o ARCALUB LC60 LC120 LC250 LC unit with 60 120 250 cm of grease for lubricator CHAMPION YA 51 ARCALUB LC120 KIT LC250 KIT Lubricator kit CHAMPION with LC unit 120 250 cm 51 ARCALUB C6 250 KI
74. essure hose 1000 bar 2 m 1 pressure control valve Electrically driven FAG hydraulic unit Oil container volume suction quantity Ordering designation Hydraulic unit frames must be ordered according to the individual application When making enquiries or placing orders information on the bearing type and power connection as well as installation drawings shaft housing additional parts are required This unit is predominantly used for the mounting and dismounting of FAG wheelset bearings TAROL see also publication TPI WL 80 50 Ordering designation TOOL RAILWAY AGGREGATE Oil Max oil Motor Mass volume pressure rating flow l min bar kW kg 0 9 700 1 1 40 with oil 27 Products Mounting Repair Hydraulic mounting and dismounting Connectors accessories FAG adapters and reduction nipples Adapters and reduction nipples are matched to the threads of high pressure hoses and pressure pipes Adapters and reduction nipples of type A with sealing ring are suitable for oil pressures up to 800 bar Type B with blade sealing is suitable for oil pressures up to 2 500 bar Other adapters and reduction nipples can be supplied by agreement For detailed information see TPI WL 80 50 Reduction nipple Reduction nipple G gt 6 6b lt 6s Ordering designation Type A with sealing ring Type B with blade sealing Reduction
75. expendable syringe containing 20 ml silicone free heat conducting paste HEATING RING PASTE 20ML For detailed information see TPI WL 80 58 Expected to be available from April 2008 Ordering examples for heating rings HEATING RING 320E for inner ring of cylindrical roller bearing NU320 E NJ320 E etc HEATING RING 2317E for inner ring of cylindrical roller bearing NU2317 E NJ2317 E etc For detailed information see TPI WL 80 58 Expected to be available from April 2008 4 A Products Mounting Repair Thermal mounting and dismounting Electric induction heating devices Electric induction heating devices Electric induction heating devices are suitable for the dismounting of inner rings on medium sized and large cylindrical roller and needle roller bearings bore diameter 90 mm and larger They can also be used to heat labyrinth rings couplings ring rolls and other rotationally symmetrical parts Heating devices with low voltage This design comprises an induction coil and a transformer The coil runs on harmless low voltage and is water cooled This allows continuous heating which is particularly suitable for batch mounting Due to the lightweight construction these devices are easy to handle Each bearing size requires a specific coil The coil is connected to a mobile transformer that can be designed for any mains voltage The voltage for the coil is adju
76. for inspecting the diameter of cylindrical shafts and workpieces of all types directly on the machine tool and for setting the enveloping circle gauge MGA 21 see page 39 The actual dimension of the workpiece can be determined precisely The snap gauge functions as a comparator gauge Its setting is checked using shims We supply the shims required for each diameter preloaded roller bearings A dial gauge fixed in the housing acts against the measurement slide and indicates the deviation of the taper diameter from the nominal value A precision indicator is fixed to the measurement slide Its blade shaped tip is in contact with the workpiece and measures the deviation of the taper from the nominal value The gauge is set using a gauge taper available by agreement Available snap gauges Measurement Ordering designation mm Ordering example for shaft diameter 120 mm SNAP GAUGE 100 150 snap gauge SNAP GAUGE MASTER120 shim s FAG taper gauge MGK 132 FAG snap gauge Products Mounting Repair Measurement and inspection Enveloping circle gauges FAG enveloping circle gauge MGA 21 for setting the radial internal clearance of cylindrical roller bearings NNU4920 K to NNU4964 K and NNU4920 to NNU4964 Bearings of bore diameter 100 to 320 mm have removable inner rings In the FAG enveloping circle gauge MGI 21 the internal enveloping circle of the roller and cage assembly
77. gh continuous monitoring to complete leasing of the hardware so that no initial costs are incurred by the customer Such monitoring packages are very attractive for example to customers in the wind power industry Services Services relating to rolling bearings Condition monitoring Technical consultancy e Customer D is a plant manufacturer and wishes to offer condition monitoring as a service itself In this case PIS acts as a subcontractor of mostly portable monitoring systems a trainer of the service employees of the plant manufacturer and as an expert team that can always be called upon to assist when matters arise that cannot be clearly assessed by the employees of the plant manufacturer The plant manufacturer can thus offer ts customers a highly qualified monitoring service without having to establish its own experts These four examples show how customised service concepts can vary Based on individual customer requirements PIS prepares a concept to meet the needs and assists in its implementation Please direct enquiries about the services described to info fis services com 85 Services Maintenance management Maintenance consultancy Maintenance consultancy Maintenance consultancy by F IS helps to make costs more transparent and design maintenance more effective Therefore it is based on classical consulting but with a strong technical focus Consulting starts with a comprehen
78. hese from F IS on a weekly basis for a fee FAG Industrial Services primarily rents e taper gauges e enveloping circle gauges e hydraulic nuts e hand pump sets e heating devices The equipment is stored at our mounting workshop and its function is checked and maintained by our mounting specialists Please direct enquiries about this service to Schaeffler KG Tel 49 9721 91 1133 Service Hotline Tel 49 2407 9149 99 Services Services relating to rolling bearings Lubrication Lubrication as a service on the basis of ongoing innovation In more than half of all cases inadequate lubrication is the cause of unplanned machine downtime FAG Arcanol rolling bearing greases are also suitable for use in FAG automatic lubricators Motion The use of suitable greases Guard for different operating and environmental conditions as well as know how in when how frequently and with what quantities bearings should be lubricated makes it possible to significantly extend the life of rotating machine elements Specialised employees offer their service across market sectors and have special experience for example in the areas of railway transport power transmission steel and aluminium paper wind power agriculture and forestry the food and delicacies industry as well as mining and processing technologies PIS services include the selection and installation of lubric
79. ible to customise the right package of training and services together with the activities carried out by the customer himself The scope is enormous and depends on the prior knowledge and usable work capability of the customer as well as the requirements for quality of monitoring Some selected examples should help to clarify this e Customer A has employees with experience in the field of condition monitoring In such a case it is sufficent to instruct the employees in handling the systems and accompany them while making the initial steps Furthermore PIS acts as a team of experts that can be called in on difficult cases and support the customer in the analysis and formulation of activities Customer B would like to build up its knowledge in the field of condition monitoring The field of condition monitoring is a complex subject building up knowledge will therefore take some time For such cases PIS offers a 2 year programme after which even customers without prior knowledge can themselves monitor the condition of their machinery The support given by PIS is progressively reduced in various steps and the customer s employees use their new knowledge directly in their daily work Customer C wishes to completely outsource the area of condition monitoring PIS offers complete packages in which the entire service is provided by PIS This begins with the initial operation of systems and progresses throu
80. ical connections in switch cabinets through rolling bearing arrangements in motors and fans to thermal linings in cement works O FLIR Systems Approval inspection of a new plant The combination of different diagnostic techniques enables FIS to carry out an assessment of a new plant regardless of the manufacturer Frequently occurring installation errors such as defective alignment of motors and pumps fans to each other or incorrect electrical connections in switch cabinets can thus be detected in the initial operation phase and their correction required by the plant manufacturer If such defects remain undetected over the period of the warranty their removal and the secondary damage may cause considerable costs and downtime As part of the new plant approval inspection PIS checks the most common problems and records the actual status Where necessary corrective measures can then be required of the plant manufacturer or operator in good time 83 Services Services relating to rolling bearings Condition monitoring Technical consultancy Technical consultancy In addition to providing services consultancy is one of the main activities of PIS Companies that wish to change to the concept of condition based maintenance are supported by F IS with initial training attendance during the introductory phase expert backup and customised service contracts Furthermore F IS offers support in the introducti
81. ice for the particular application e Suitable for batch mounting For the mounting of workpieces up to 300 kg mass FAG supplies five table top heating devices PowerTherm HEATER10 to 300 suitable for mobile and or stationary use For workpieces up to 3 000 kg mass we recommend the particularly heavy duty standalone devices HEATER600 HEATER1200 and HEATER3000 For detailed information see TPI WL 80 54 31 Products Mounting Repair Thermal mounting and dismounting Induction heating devices Overview of induction heating devices Heating device HEATER10 HEATER20 HEATER35 HEATER150 Power consumption max 2 3 kVA 3 6 kVA 3 6 kVA 12 8 kVA Voltage frequency 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz 400 V 50 Hz Current 10A 16A 16A 32A Mass 7 kg 17 kg 31 kg 51 kg Length 230 mm 345 mm 420 mm 505 mm Width 200 mm 200 mm 260 mm 260 mm Height 240 mm 240 mm 365 mm 440 mm Dimension a 65 mm 120 mm 180 mm 210 mm Dimension b 95 mm 100 mm 160 mm 210 mm Ledges incl 20 45 65 mm 20 mm 70 mm 100 mm for workpieces graduated supports 35 mm of min bore 60 mm Ledges accessories 10 mm 10 mm 15 mm 20 mm for workpieces 15 mm 15 mm 20 mm 30 mm of min bore 35 mm 45 mm 45 mm 60 mm 60 mm 70 mm 85 mm 1 If lower voltage is used the power will be reduced 2 Upon request we can also supply heating devices with other rated voltages and frequencies as well as higher power ratings 32 Overview of in
82. ispensable in many cases Access at any time to precise information on the condition of the machine offers the only effective protection against unplanned downtime and expensive production breakdowns as well as preventing secondary damage For this reason online monitoring generally pays for itself over a period of a few months Depending on the area of application F IS offers a wide range of solutions including standalone solutions for smaller aggregates medium sized systems with up to 8 channels that can be extended on a modular basis and also complex monitoring systems with up to 2048 sensors In addition to giving expert advice in selecting the right system PIS also implements plant monitoring This includes not only hardware selection but also system configuration and if necessary its integration into existing systems Depending on know how the customer can either carry out plant monitoring himself or enlist the PIS monitoring service The PIS monitoring systems have e service functionality allowing external monitoring by F IS experts under favourable terms Regular measurement offline The failure of individual machines is not always critical for production The failure of so called B or C category plant items does not lead directly to downtimes and therefore does not induce expensive secondary damage For such machine parts the more economical offline monitoring is generally recommended I
83. l 80 3 30 140 75 KP2N 20 Lithium complex soap with EP additives Mineral oil ISO VG 150 2 20 140 LOAD220 LOAD400 KP2N 20 KP2N 20 Lithium Lithium calcium soap with EP additives calcium soap with EP additives Mineral oil Mineral oil ISO VG 220 400 2 2 20 140 25 140 80 80 KP2N 20 Lithium calcium soap with EP additives Mineral oil ISO VG 1000 2 20 140 Characteristic areas of application for Arcanol rolling bearing greases Universal grease for ball and roller bearings in rolling mills construction machinery automotive engi Universal grease for ball bearings D lt 62 mm in small electric motors agricultural and construction machinery household appliances Universal grease for ball bearings D gt 62 mm in large electric motors agricultural and construction machinery fans Special grease for ball roller and needle roller bearings linear guidance systems in machine tools at high loads with wide speed range swivel movements Special grease for ball and roller bearings Special grease for ball and roller bearings in in rolling mill mining plant machinery rail vehicles construction machinery wind turbines Special grease for ball and roller bearings in mining machinery construction machinery preferably under shock loads and large bearings at very high loads moderate te
84. le from April 2008 35 Products Mounting Repair Measurement and inspection Feeler gauges Taper gauges FAG feeler gauges Feeler gauges are used to measure FEELER GAUGE 100 and the radial internal clearance FEELER GAUGE 300 especially for mounting on tapered FAG feeler gauges FEELER GAUGE 100 and FEELER GAUGE 300 Ordering designation Feeler length Feeler thickness mm mm FEELER GAUGE 100 100 0 03 0 08 0 14 A MI AA o NT AG Aa AA EEE yaaa k eae A A A a omen A AA AN RENNENS EDEN Een series FEELER GAUGE 300 300 0 03 0 12 0 20 ta AMA sehen u ea ae AA A O AG a AA PAP AA AS AA AAP O ae ee A E EA N u a ee EEEE EEE AEEA A es A A AA E Ta BAY anes Taper gauges precisely machined so that the fit surfaces match precisely When a bearing with a tapered bore We supply various gauges for shaft seats and on adapter and extraction sleeves FAG feeler gauges FEELER GAUGE 100 and FEELER GAUGE 300 taper 1 12 Only spherical roller bearings of series 240 and 241 have a taper 1 30 is seated directly on the shaft the measuring the taper Most bearings tapered bearing seat must be with a tapered bore have a FAG taper ring gauge Ordering designation example KLR20 The simplest means of measuring Taper ring gauge for bearings of tapered shaft seats on small 100 mm bore e g for double row bearings is the taper ring gauge cylindrical roller bearings By application of inking material NN3020 AS K or NNU4920 S K
85. lected 1 3 6 or 12 months for CONCEPT6 1 day to 24 months No risk of confusion or contamination of lubricants Pressure build up to 4 bar COMPACT to 5 bar CHAMPION or to 25 bar CONCEPT6 thus overcoming any obstructions Suitable for connection to the FAG monitoring system Easy Check e Comprehensive range of accessories Motion Guard SELECT MANAGER The software Motion Guard SELECT MANAGER Version 2 0 allows e selection of lubricators e definition of dispensing times and relubrication quantities e selection of suitable preferred Arcanol greases e management of a lubrication and maintenance plan Detailed information on FAG automatic lubricators is given in publication WL 81 122 Products Lubrication Lubrication systems Motion Guard COMPACT Lubricators and activation screws FAG lubricator Motion Guard COMPACT This automatic lubricator is electrochemically driven The electrolyte is environmentally friendly citric acid The metal housing is filled with 120 cm of FAG Arcanol rolling bearing grease The dispensing time is determined by the different coloured activation screws Automatic lubricators Motion Guard COMPACT are available with suitable lubricants as standard in packs of 10 containers Ordering examples ARCALUB LOAD400 filled with LOAD400 pack of 10 containers without activation screw ARCALUB TEMP90 filled with TEMP9O pack of 10 containers without acti
86. ler bearings n DEAN Large Th i men rust ball bearings Cylindrical Small Angular contact thrust ball bearings Medium Cylindrical roller thrust bearings Spherical roller thrust bearings Large Self aligning ball bearings Tapered Small Self aligning ball bearings with adapter sleeve Barrel roller bearings Barrel roller bearings with adapter sleeve Medium Spherical roller bearings Spherical roller bearings with adapter sleeve Spherical roller bearings with withdrawal sleeve Adapter sleeve Withdrawal sleeve Large B pH KO TE kg it ik Cylindrical roller bearings double row Tapered Small Medium Large Hydraulic method Dismounting With heating Without heating Symbols Hydraulic method M aX E Induction heating device Heating plate Hot air cabinet Heating cabinet Oil bath Induction heating device coil Heating ring Hammer and mounting sleeve Mechanical and hydraulic presses Double hook wrench Nut and hook wrench Socket wrench Nut and mounting screws End cap Hydraulic nut Hammer and drift Extraction device Hydraulic method Products Mounting Repair Mechanical mounting and dismounting 8 Products Mounting Repair Mechanical mounting and dismounting Mounting tool sets FAG mounting tool sets FITTING TOOL ALU 10 50 and FITTING TOOL STEEL 10 50 FAG mounting tool sets
87. lignment device Accessories The possible applications of the LASER INLINE basic device can be expanded with the aid of a comprehensive range of accessories see table The accessories can be ordered as a set in a handy robust case or individually compiled as individual parts For detailed information see TPI WL 80 55 Accessories for LASER INLINE Accessories for LASER INLINE Included Ordering designation in delivery Accessory set complete 1 piece LASER INLINE ACCESS SET Chain 600 mm long 2 pieces LASER INLINE CHAIN600 Chain 1 500 mm long 2 pieces LASER INLINE CHAIN 1500 Post 150 mm long 4 pieces LASER INLINE POST150 Post 200 mm long 4 pieces LASER INLINE POST200 Post 250 mm long 4 pieces LASER INLINE POST250 Post 300 mm long 4 pieces LASER INLINE POST300 Magnetic holder 2 pieces LASER INLINE MAGNET Accessory case empty 1 piece LASER INLINE CASE ACCESSORIES Products Alignment Accessories Shims FAG shims Top Laser SHIM Top Laser SHIMs are used to eliminate any vertical misalignment detected using the FAG Top Laser devices These shims are available in seven thickness values 0 05 0 10 0 20 0 50 0 70 1 00 2 00 mm and four sizes dimension C 15 23 32 or 44 mm Composition of set The practical case contains 20 shims each of 3 sizes C 15 23 and 32 mm and 6 thickness values 0 05 to 1 0 mm i e a total of 360 shims together with one extra
88. lubrication is avoided Duration By agreement Product training FAG Arcanol lubricants Training content In this training the participants will acquire further knowledge of the FAG lubricant family Arcanol in relation to possible applications usage and handling It will be shown how selection of the correct lubricant can increase the performance capacity and life of rolling bearings Target group The course is aimed at head foremen foremen and mounting personnel from maintenance shops and interested employees No special knowledge is required Training objective Following the course the participants will be able to select the correct grease for their particular application Duration By agreement Alignment Product training FAG Top Laser SMARTY2 TRUMMY2 and INLINE Training content This course communicates well founded knowledge on the alignment of belt drives and shafts and the measurement of belt tension The functionality possible applications and handling ofthe measuring systems Top Laser TRUMMY2 SMARTY2 and INLINE are explained The focus is on the safe handling and boundary operating conditions ofthe measurement systems Target group The course is aimed at head foremen foremen and mounting personnel from maintenance shops and interested employees No special knowledge is required Training objective Following the course the participants will be able to carry out the requir
89. m is adjusted to coincide with the slots in the target marks the machine is correctly aligned The target marks are available in J J MAN 0 NY A I AT IT O Nae IT li fi optical and digital form In the case of the digital target mark adjustment values are shown in the display in real time Misalignments are presented in degrees and the parallelism offsetin mm Since the measuring instrument is so light the emitter and target marks can be easily attached to non magnetic drive pulleys using a strong double sided adhesive tape Ordering designation and scope of delivery Complete laser measuring device incl 2 optical target marks 2 batteries and user manual in padded case LASER SMARTY2 Replacement part 1 optical magnetic target mark LASER SMARTY2 TARGET Accessories 1 digital magnetic target mark LASER SMARTY2 TARGET DIGITAL For detailed information see TPI WL 80 55 Products Alignment Belt and chain drives Belt tension measuring device FAG belt tension measuring device Top Laser TRUMMY2 The robust handy Top Laser TRUMMY2 is an optical electronic instrument for measuring and setting optimum belt tension strand force Optimum belt tension like precise alignment of the belt pulleys see Top Laser SMARTY2 page 56 is an essential precondition for achieving the maximum possible life of the belt drive There is also less wear of the drive components
90. mperatures low speeds Low temperatures High temperatures Low friction high speeds High loads low speeds Vibrations Support for seals Relubrication facility neering spinning and grinding spindles at increased speeds high loads low and high temperatures O O at at high loads with very high loads wide speed moderate range high temperatures humidity moderate speeds O O O ISO VG ISO viscosity group 46 highly suitable very suitable o suitable less suitable not suitable TEMP9O KP2P 40 Calcium polycarbamide with EP additives PAO oil 130 2 40 160 Special grease for ball and roller bearings in couplings electric motors automotive engineering at high temperatures high loads TEMP110 KE2P 40 Lithium complex soap Ester oil ISO VG 150 2 40 160 Special grease for ball and roller bearings in electrical equipment automotive engineering at high temperatures high speeds TEMP120 KPHC2R 30 Polycarbamide with EP additives PAO ester oil ISO VG 460 2 35 180 Special grease for ball and roller bearings in continuous casting plant at high temperatures high loads TEMP200 KFK2U 40 PTFE Fluoro polyether oil 400 2 40 260 Special grease for ball and roller bearings in track rollers in
91. n be used to tighten and loosen precision locknuts on shafts if no torque value is specified FAG jointed face wrenches can be used to mount small bearings on tapered shaft seats Tightening is achieved by means of axially arranged holes Ordering example for FAG jointed face wrench suitable for precision locknuts LNP017 to LPNO25 LOCKNUT FACEPIN LNP17 25 For detailed information see TPI WL 80 56 Products Mounting Repair Mechanical mounting and dismounting Hook wrenches and pin wrenches for mounting and dismounting FAG double hook wrenches For locknuts KM5 to KM13 FAG double hook wrenches are intended for the mounting of self aligning ball bearings with a tapered bore They are available as kits sets or individual wrenches FAG double hook wrench kits LOCKNUT DOUBLEHOOK KIT include a case containing a double hook wrench a torque wrench and a user manual The torque wrench allows a precisely defined tightening torque to be achieved at the start of the mounting operation FAG double hook wrench sets LOCKNUT DOUBLEHOOK SET contain four or five double hook wrenches The other items in the case are the same as in the kits Individual double hook wrenches LOCKNUT DOUBLEHOOK KM5 to LOCKNUT DOUBLEHOOK KM13 are also available Each double hook wrench is engraved with the torsion angles for the self aligning ball bearings to be mounted using that particular wrench so that the sliding distan
92. n independently undertake extension of the VC hardware Target group This course is intended in particular for those persons who are responsible for the installation and maintenance of the measuring system FAG VibroCheck Important preconditions are therefore PC and Windows knowledge as well as knowledge of electrical installation work Training objective After the course the participants should be in a position to independently maintain the measuring system in relation to hardware extension and troubleshooting as well as independently carry out hardware and software installations Duration 2 days Product training FAG VibroCheck Application software Training content The knowledge acquired in the course Detector III Advanced on vibration analysis willbe expanded and deepened on the measuring system VibroCheck The focus will be on monitoring configuration ofthe measuring system FAG VibroCheck and evaluation of the recorded measurement data Target group This course is aimed at persons who have already attended the training Detector Ill Advanced or have at least one year s experience in the use of measuring systems and wish to add to this the specifics concerning the measuring system FAG VibroCheck Training objective Following the course the participants will be able to work correctly with the online measuring system VibroCheck The focus of the training is on configura
93. n recent years It covers products services and training in the areas of e Mounting Repair e Lubrication e Alignment e Condition monitoring e Maintenance management The designation system of the INA and FAG brands has been harmonised This catalogue contains for the first time the new ordering designations which are currently only valid for Europe Customers outside Europe are requested to continue using the old ordering designations please see the comparison on page 109 Contents CES a ee 7 A ee 8 cat a ol a er 43 ment FA MAMANA NAN ng Condition monitorin aa a 61 Maintenance management nn 71 Services 0 AA 73 Mounting Repair T SA E Lubrication A nag Corrective maintenance IN Ze 80 Condition monitoring gg 81 Maintenance management u 86 Training US PE ee AL tips Repalr Per Poo 93 Lu Drea ie I de Fle SD 95 Conditio nimemtali A 96 Maintenance management Mt L Publi gtions NA 103 Index of FAG products 105 Tools for mounting and dismounting Overview Bearing type Bearing Bearing Mounting bore size With Without heating heating Tapered Deep groove roller bearings Cylindrical Small ball bearings Angular contact ball bearings Spindle bearings Barrel roller bearings Medium Spherical roller bearings p 8 M Four point contact bearings Self aligning ball bearings Large Cylindrical roller bearings Cylindrical Small Medium Needle rol
94. n this case costs and benefits are in an optimum ratio In offline monitoring machinery is examined and assessed by vibration analysis at regular intervals for example every 4 weeks This regularity gives more in depth knowledge of the normal condition of the machine allowing deviations to be easily detected When preparing the offline monitoring concept the selection of measuring points and monitoring accessories as well as the definition of the measurement interval play a decisive role It is not absolutely essential to have expertise on site In the case of irregularities in measurements and trend analysis FIS offers the e service At the bush of a button all relevant data are exported from the database and sent by e mail to the PIS Diagnosis Centre where it is subjected to expert analysis The customer promptly receives easily understandable and authoritative diagnosis reports by e mail 81 Services Services relating to rolling bearings Condition monitoring Regular measurement Troubleshooting Through close teamwork with the PIS experts the customer soon acquires excellent analytical know how PIS also offers support in data acquisition and carries out regular on site measurements ifthe customer s internal personnel cannot be made available Troubleshooting If malfunctions or other problems occur on a machine a detailed defect analysis must be quickly carried out This can be like detective w
95. ning and customer specific successfully attending the training courses can be found at training The individual training units each attendee receives a certificate www fis services com in the section are based on a modular concept The training courses are offered Training with the result that customers can both at Schaeffler Group locations compile their own customised and also on site at our customers Overview of F IS training courses Overview of FIS training courses Training format Training module Standard Individual Basic training Rolling bearing technology o E maana On aaeaaaacal maan AI AA ea a cami general o e ER TE O O e Lubrication O a maana IA TA ee a a ce tame jenes Alignment a maa Product training FAG Detector Ill Basic e II TEE I TR AA En In Te Op O AA A E aca aaa ran AA A A AA PT aaa Se a ES A o AA AA a num AA E e More detailed information on the individual training courses can be found on the following pages 92 Training Training descriptions Mounting Repair Mounting Repair Basic training Rolling bearing technology Training content This training communicates basic knowledge on rolling bearings and their use Our rolling bearing experts will explain types characteristics and designations of rolling bearings In the practically based part of the training correct mounting and dismounting will be communicated Rolling bearing failures will be discussed together with their
96. nipple Reduction nipple G gt G G lt G Ordering designation Adapter Ordering designation Products Mounting Repair Hydraulic mounting and dismounting Connectors accessories FAG pump holders FAG pump holders Pump holder Ordering designation Mass kg Without connector PUMP HOLDER 2 A 1 EEE O oracion With connector GY PUMP HOLDER 3 for manometer 1 95 FAG manometers When selecting a manometer pay attention to the max operating pressure FAG manometers Manometer Threaded connector Pressure display Diameter Mass Ordering designation bar mm kg en Gya a a e EEEE A A PUMP 000 MANO Ge 6 E A FUME e00 MEN SZ Su O e D3 PUMP2500 MANO GY Gi 0 2 500 160 1 7 29 Products Mounting Repair Hydraulic mounting and dismounting Connectors accessories FAG high pressure pipes for high pressure pumps sheathed in PVC hose max permissible pressure of 2500 bar should be monitored by manometer FAG high pressure pipe High pressure pipe Connector Mass Ordering designation kg FUME RETO LA HA PUMPE GR ie as FUME AA ea D en PUMP PIPE G3 G3 0 8 The connector for the pump holder is G3 For other connectors a suitable reduction nipple must be used in addition For detailed information see TPI WL 80 50 FAG sleeve connectors for adapter and extraction sleeves up to 800 bar special lengths available by agreement FAG sleeve connectors
97. o a soft point This is defined as a rigidity problem often caused by Services Services relating to rolling bearings Condition monitoring Troubleshooting a poor quality connection between two machine parts for example a screw connection For analysis the measurements are used to produce an animation showing the movements of the machine Showing the movement of the individual machine parts in relation to each other quickly leads to identification of the soft point of the machine A discussion can then be held to prepare proposals for improving the design of the machine Torque force measurements If damage accumulates at a particular point in the system a design problem may be surmised Overloading of shafts or bearing positions that were not taken into consideration in the design of the machine can be detected by means of torque or force measurements and taken into consideration in an improved structure of the machine Depending on the application temporary installations or fixed installations can be used In particular continuous torque measurement carried out directly on rotating shafts is highly demanding on a technical level the measurement data must be transferred from the rotating shaft and the contact free supply of energy must be provided Implementing the long term installation of such telemetry systems under industrial conditions requires considerable experience which the PIS experts h
98. offers alignment of machinery as a service Where necessary the PIS service technician will take the necessary laser alignment system to the customer and carry out alignment of the machine in accordance with the manufacturer s specifications Successful completion of the work is then documented Please direct enquiries to info fis services com Services Services relating to rolling bearings Condition monitoring Continuous measurement Regular measurement Condition monitoring The malfunction free and optimised operation of complex machinery and systems can only be achieved by means of condition based maintenance The key method used by F IS in condition based maintenance is vibration diagnosis This method makes it possible to detect incipient damage in machinery at a very early stage The customer can thus take a proactive rather than a reactive approach For example damaged components can be replaced as part of planned downtime Above all vibration diagnosis helps to avoid unplanned downtime and expensive secondary damage to increase productivity and improve availability Dependng on the type of machine and its importance for the production process different methods are used in condition monitoring continuous monitoring online and regular monitoring offline Continuous measurement online In the case of production critical machinery permanent monitoring by means of vibration diagnosis is ind
99. omponents per sensor This allows monitoring of all rolling bearing types and tooth meshes in the vicinity of a sensor in relation to the occurrence of component specific frequency windows In addition to vibration signals other process parameters such as temperature power pressure torque etc can also be detected By remote access the data can also be analysed by external service providers or CM experts at other locations The display which is individually tailored to the customer s require ments gives a user interface that allows a rapid overview of the condition of the plant Depending on the complexity of the plant this display can be arranged on several levels Through the high predictive accuracy and early identification of forthcoming damage optimum use can be made of planned stoppages and downtimes due to failure can be drastically reduced FAG VibroCheck Products Condition monitoring Vibration diagnosis ProCheck FAG ProCheck ProCheck is the latest generation of modular concept online monitoring systems Together with the newly developed software the system represents a high performance solution for preventing unplanned downtime and increasing reliability The device records vibration data process parameters and operating data assesses these data and provides the customer with authoritative and reliable information on the condition of his equipment The system is available in several
100. on and adaptation of maintenance planning and control systems CMMS These systems help to improve transparency ofthe services and costs involved in maintenance see page 88 Introduction of condition based maintenance Many customers intend to convert their maintenance activities wholly or partlyto a condition based maintenance strategy in the coming years Maintenance of machinery and plant will no longer be based on failures or times but on their assessed condition The aim of the PIS consultants is to find the perfect balance between the costs and benefits of condition assessment Many years of experience in condition monitoring and main tenance planning give an optimum basis here which allows recom mendations on methods and products for condition monitoring to be made after a soundly based analysis ofthe critical plant and machinery In partnership with the customer plans are prepared that generate recommended activitities for the maintenance personnel derived from the results of condition monitoring Ultimately it are these recommendations and not alarm messages that lead to targeted maintenance activities and thus to cost savings Service concepts for plant manufacturers and operators Services are not volume products the needs and requirements vary from customer to customer so the service concept must be tailored as a result Due to the wide range of services PIS can offer its customers it is poss
101. or the displacement gauge The bearing is first placed in its starting position The oil pressure required is dependent on the bearing size and the number of displacement surfaces and is given in the user manual A hand pump set with a manometer must be used see page 25 The dial gauge is set to zero and the bearing is moved by pumping until the specified drive up distance is achieved The user can determine which of the metering needles supplied should be used from the comprehensive user manual included with each gauge Ordering designation HYDNUT GAUGE DISPLACE 1 displacement gauge with dial gauge 6 metering needles and seals in case For detailed information see TPI WL 80 57 Products Mounting Repair Hydraulic mounting and dismounting Mounting Manager FAG Mounting Manager The FAG computer program MOUNTING MANAGER is a user friendly aid for ensuring the correct mounting of bearings and offers the following options e It shows various mechanical and hydraulic mounting methods e lt calculates the data required for mounting in relation to reduction in radial internal clearance displacement and start pressure e lt gives useful mounting advice e lt generates a list of the accessories and tools required Further information on mounting and dismounting of bearings is offered in the integrated library containing appropriate publications Technical Information documents etc and our el
102. ork Based on many years experience in different sectors and applications the F IS diagnosis experts are well versed in such troubleshooting tasks Their analysis incorporates various information for example from visual observation examination of the machine documentation and discussions with machine operators Problems or malfunctions in machine operation often become apparent through changes in vibration behaviour unusual temperature patterns or similar phenomena The F IS experts there fore also carry out measurements on the machine The measurement methods used will depend on the particular application The PIS experts are familiar with all measurement techniques from vibration measurement to torque analysis or endoscopy As a result they can quickly identify malfunctions and prepare proposed solutions It is important to F IS that customers are in a position to interpret the results of investigations correctly in order to introduce the correct countermeasures At completion of an investigation PIS therefore holds a handover meeting with all relevant employees of the customer to discuss not only the results of the investigation but also the recommended counteractive measures Vibration measurements Detecting problems by using vibration analysis is the state of the art method in the field of trouble shooting Like a doctor with a stethoscope the vibration expert can assess the condition of the machine withou
103. ows the monitoring of difficult to access locations Using the input FAG Easy Check Online can be administered remotely e g for resetting the alarms starting the learning phase or activating a measurement cycle Ordering designation EASY CHECK ONLINE FAG Easy Check Online For detailed information see TPI WL 80 68 Please direct enquiries to info fis services com FAG DTECT X1 DTECT X1 allows early detection of damage by selective frequency vibration monitoring based on individually adjustable frequency bands By means of the selective frequency method specifically selected machine parts can be monitored DTECT X1 has characteristics that would normally only be found on significantly more expensive systems The system is variable and can be specially matched to the requirements of the application The basic device is available with 2 channels 4 channels or as an 8 channel system with an external multiplexer All conventional acceleration speed and travel sensors can be attached It is possible to record process variables such as speed FAG DTECT X1 67 68 Products Condition monitoring Vibration diagnosis DTECT X1 WiPro temperature torque and pressure The signal collected by the sensor is broken down into its frequency components by means of Fast Fourier Transformation FFT It is thus possible to monitor amplitudes within fixed very narrow frequency bands for specified limit v
104. p Laser INLINE is a PC based alignment system for coupled shafts in motors pumps ventilators and gearboxes with rolling bearings Operating benefits e Simple to mount e Error free handling even by untrained personnel due to automatic measurement and positioning process e More precise alignment than with conventional methods e Rapid measurement due to continuous rotary motion e Reduced vibration and friction losses Post Chain PC card Software Reflector Cable Transceiver Bracket e Longer machine running times e Usable with conventional laptops Included in delivery 1 transceiver incl 3 m cable 1 reflector 2 brackets 2 chains 300 mm 4 posts 115 mm 1 software 1 case 1 serial PC card All the parts included in the delivery are also available as replacement parts Actions before alignment Before any alignment operation any tilting foot machine foot that lifts off the floor when slackened should be removed in order to prevent increased vibration tendency and bearing damage due to housing distortion Ordering designation Complete Top Laser INLINE LASER INLINE The Top Laser INLINE helps to quickly identify and eliminate the so called soft foot It is only necessary to loosen each individual screw foot connection The computer determines any foot movement The tilting foot can then be eliminated using shims Products Alignment Shaft couplings Shaft a
105. portant to check permanently the maintenance controlling process itself with the focus on its expressiveness and efficiency 87 88 Services Maintenance management CMMS CMMS Inthe section of Computerized Maintenance Management Systems CMMS PIS experts apply their profound technical knowledge to offer analysis of customer specific requirements This service is independent of the software system Even by using a standard software which is available on the market PIS can configure and optimise this software on the purpose of the customer The PIS service covers both complete solutions in the form of CMMS implementation as well as individual modules for the following areas Systems integration CMMS is incorporated in the IT environment ofthe company by the implementation of interfaces for example to ERP Enterprise Resource Planning systems This allows holistic assessment and data analyses in a complete system so that redundant data administration and multiple data input can be avoided Process operations are standardised and optimised The exchange of information across departments is improved Mobile solutions The use of electronic checklists on a handheld PC enables the data collection during an inspection The processing and feedback of failures can then take place with ongoing acquisition The data determined and checked for consistency are transferred via a workshop PC to the CMMS d
106. raction Sleeve or an adapter sleeve the hydraulic nut can also be used for dismounting mounting of couplings gears ships propellers etc For detailed information see TPI WL 80 57 FAG hydraulic nuts HYDNUT Ordering designation Design Main application HYDNUT50 to HYDNUT200 With metric precision thread to DIN 13 Standardised adapter and extraction sleeves HYDNUT205 to HYDNUT1180 With trapezoidal thread to DIN 13 with metric dimensions HYDNUT90 INCH to With inch size thread to ABMA Standards Sleeves with inch dimensions HYDNUT530 INCH for Mounting Accessories Section 8 Locknut Series N 00 HYDNUT100 HEAVY to Reinforced design For high mounting forces HYDNUT900 HEAVY with smooth bore e g in shipbuilding HYDNUT GAUGE DISPLACE Displacement gauge for HYDNUT Where radial internal clearance cannot be see also page 20 measured using feeler gauge due to poor accessibility 20 Products Mounting Repair Hydraulic mounting and dismounting Displacement gauge for hydraulic nuts FAG displacement gauge for hydraulic nuts If the radial internal clearance cannot be measured with a feeler gauge due to poor accessibility the axial displacement of the bearing can be measured on the tapered seat This can be achieved by means of a gauge screw mounted to the end face of the hydraulic nut If the axial threaded connector hole GY4 of the hydraulic nut is taken up by the pump the second axial hole can be used f
107. ree oline 81 Men A 82 Technical consultancy 84 Maintenance management Maintenance consultancy 86 Computerized Maintenance Management System 88 Services Services relating to rolling bearings PIS defines itself as an independent full service supplier and covers the complete range of services relating to the life cycle of a rolling bearing from mounting through maintenance to reconditioning of rolling bearings During the operational phase PIS experts provide support through services in the field of condition monitoring and corrective maintenance Companies that wish to build up their knowledge in the areas of rolling bearings and condition monitoring have access to the PIS training and consultancy portfolio Through the association with the Schaeffler Group customers also benefit from the expertise of a leading supplier of rolling and plain bearings Detailed information on the individual services is given on the following pages Reconditioning of rolling bearings Corrective maintenance me KA T Technical consultancy Condition monitoring Customer training 74 Services Services relating to rolling bearings Mounting Repair Mounting service Mounting service Please direct enquiries about the services described to The F IS Mounting Team offers mounting services for rolling Schaeffler KG bearings across market sectors Tel 49 9721 91 3142 or 2573 We have e
108. rolling bearing damage and gear tooth defects For this area we therefore offer a comprehensive product portfolio ranging from simple vibration monitors to complex monitoring systems with a large number of measuring points FAG vibration measuring devices help to plan maintenance work extend bearing life reduce costs and increase plant availability In the field of offline monitoring devices we offer Detector II and Detector Ill The online monitoring devices include products from the economical Easy Check range the digital vibration monitors DTECT X1 and WiPro as well as the online monitoring systems VibroCheck and ProCheck For all these devices and on all aspects of condition monitoring PIS offers a worldwide service from the F IS Customer Hotline to customer specific service contracts In order to achieve optimum networking all online systems have versatile communication options as standard FAG Detector Il Detector Il is a portable vibration measuring device and data collector in one Using this economical device is straightforward and easy to learn It weighs approx 450 g and is highly suitable for monitoring extensive plants where measurement rounds involving large distances must be covered Detector II picks up vibration signals at predetermined measuring points and calculates the effective values for vibration rate and acceleration It can be used to monitor machine vibrations in accordance with ISO 1
109. signations ARCALUB LC120 MULTITOP KIT ARCALUB LC250 MULTITOP KIT The lubricator CHAMPION has only been tested in conjunction with Arcanol lubricants By agreement FAG also supplies the lubricator CHAMPION with special fillings Accessories for Motion Guard COMPACT and CHAMPION The Motion Guard product range is supplemented by a comprehensive range of accessories For detailed information see publication WL 81 122 51 Products Lubrication Lubrication systems Motion Guard CONCEPT6 FAG lubrication system Motion Guard CONCEPT6 This single point and multi point lubrication system can supply up to six lubrication points with lubricant constantly precisely and regardless of temperature The dispensing times can be adjusted to between 1 day and 24 months and LC units are available in sizes 250 and 500 cm FAG starter kits Motion Guard CONCEPT6 The starter kits are premounted on a retaining plate and form the basis for the multi point lubrication system Motion Guard CONCEPT6 The patented distribution system MP 6 allows independent supply of between two and six lubrication points The geared motor in the MP 6 is powered and controlled by the drive unit Lubricant is distributed independent of its consistency or solid particle content If the distributor identifies an obstruction in an individual outlet this is indicated on the display of the drive unit The other outlets continue to
110. stable between 20 and 40 V The transformers for the induction coils are available from FAG in six different power steps The largest transformer and the corresponding coil can be used to heat inner rings up to a maximum mass of 1200 kg to the required dismounting temperature of 80 120 C maximum mass of 600 kg for couplings Ordering example for bearing inner rings 120x150x144 mm COIL152X145 LOW coil COIL TRAFO 45KVA 400V 50HZ transformer Heating device for low voltage with transformer for dismounting of the inner rings of cylindrical roller bearings Heating devices with mains voltage In addition to coils for low voltage FAG also supplies coils for mains voltage with a switch box or foot switch This economical alternative without water cooling is used for sporadic dismounting where batch dismounting is not required Y a bi Heating device for low voltage with mains voltage for dismounting of the inner rings of cylindrical roller bearings Information required for quotation FAG induction heating devices are always produced as one off items In order to prepare a quotation we require the following information 1 Exact designation of the bearing or dimensions of the parts to be extracted 2 Width of the intermediate ring if present 3 The mains voltage and frequency present at the mounting location For detailed information see TPI WL 80 58 Expected to be availab
111. t ribs and inner rings with one rib The heating rings are heated to a temperature of 200 300 C The outside diameter of the workpieces can be up to max 350 mm the mass can be up to 20 kg Dimensions WxDxH 360x360x170 mm Plate size 350x350 mm Power max 2 200 W at 230 V 50 Hz Power control 0 to 100 Temperature control continuously variable from 100 to 370 C Mass approx 13 kg Ordering designation HEATER PLATE 370C Ordering designation for 115 V 60 Hz version upon request FAG heating plate HEATER PLATE 370C FAG induction heating devices Many rolling bearings and other rotationally symmetrical parts made from steel have tight fits on the shaft In particular larger parts can be mounted more easily if they are heated first Rapid and clean induction heating is superior to the conventional methods It is therefore particularly suitable for batch mounting Heating is carried out on complete bearings rings for cylindrical roller or needle roller bearings and rotationally symmetrical steel parts such as labyrinth rings roll couplings tyres etc Advantages e Rapid energy efficient operation e Suitable for rolling bearings and other ring shaped steel parts e Very safe operation e Environmentally friendly oil free no disposal required e Uniform controlled heating e Easy to use e Automatic demagnetisation e High cost effectiveness through selection of the most suitable size of dev
112. t the need for any dismantling A large proportion of possible causes of damage can thus be detected and assessed with little work Modal analysis Modal analysis is a particular form of vibration diagnosis This method does not examine individual components of a machine but the machine as a whole The aim is to determine the overall vibration behaviour of the machine A model of the machine is created on the computer and a large number of measuring points are defined The machine is then specifically excited using an impulse hammer Based on parallel measurement of the excitation and resulting machine vibrations at the various measuring points a vibration model of the machine can be determined by the computer and presented in three dimensions Modal analysis has a wide variety of possible applications e Determination of natural frequencies or resonance frequencies Each machine has one or more natural frequencies that are determined by its design mass and rigidity If a machine is run in such a way that excitation e g the speed of the motor occurs in the region of a natural frequency extreme vibration of the machine can occur Based on the results of modal analysis our experts can submit recommendations for design improvements to the machine Detection of a soft point of a machine If a high level of vibration occurs at initial operation or after a technical modification of a machine this may be due t
113. tant Ordering designation GLOVE1 The principal characteristics are e resistant up to 250 C e non flammable e heat resistant even when damp e authorised for protection against mechanical DIN EN 388 and thermal DIN EN 407 influences e cotton free e cut resistant Ordering designation GLOVE2 41 42 Products Mounting Repair Accessories Mounting paste Anti corrosion oil FAG mounting paste This mounting and multi purpose paste has proven valuable particularly forthe mounting of rolling bearings It facilitates the sliding of bearing rings and prevents stick slip scoring wear and fretting corrosion lt also gives good protection against corrosion It is pale in colour and does not cause contamination The mounting paste is applied ina very thin layer so that the metallic sheen turns matt The permissible operating temperature range is between 30 C and 150 C FAG anti corrosion oil The anti corrosion oil is suitable particularly for unpacked rolling bearings It can also be sprayed on bright metal surfaces of devices machines and machine elements to give long term anti corrosion protection when stored indoors It is not generally necessary to wash anti corrosion oil out of rolling bearings since it gives neutral behaviour towards all conventional rolling bearing greases and oils The paste is resistant to water water vapour and many alkaline and acidic me
114. th the FAG taper gauges MGK 9205 are available in several sizes The delivery of individual gauges and also of complete sets always includes two magnets Delivery also includes belts for fixing the gauge in positions other than on the upper side of the stud Ordering examples for gauge sets each with two saddles and five masters MGK9205 12 SET taper 1 12 MGK9205 30 SET taper 1 30 See also Tl WL 80 70 smaller taper diameter while the other at a fixed distance is in contact with the larger taper diameter The deviation of the taper diameter from the nominal value is displayed in both measurement planes by a precision indicator The reproducibility of the measure ment results is less than 1 um The gauge is set using a gauge taper available by agreement e ecceoe FAG taper gauge MGK 9205 FAG taper gauge MGK 133 37 Products Mounting Repair Measurement and inspection Taper gauges Snap gauge FAG taper gauge MGK 132 for external tapers with 0 to 6 taper angle and 90 to 510 mm taper diameter With the taper gauge MGK 132 the reproducibility of the measurement results is within 1 um The MGK132 rests on the workpiece with four hardened ground and lapped ledges The ledges form an angle of 90 A stop on the front or rear precisely defines the position of the gauge Between the support ledges the measurement slide runs on FAG snap gauge SNAP GAUGE
115. that they can rely on e Arcanol rolling bearing greases ensure that a bearing can be used to its full capacity long service life good running behaviour high operational reliability Relative service life Lubrication interval Mixed friction Speed Products Lubrication Lubricants Arcanol rolling bearing greases Container sizes Ordering examples Arcanol rolling bearing greases Container sizes Arcanol 20 g 70g 250g 4008 1 kg 5 kg 10 kg 25 kg 50 kg 180 kg grease tube tube tube cartridge can bucket bucket hobbock hobbock drum MULTITOP MULTI2 e e e o o o o o o MULTI3 e o e e o e e LOAD1 50 o o LOAD220 o u E LOAD400 une 7 a 7 NG 7 7 N e eae TEMP90 o e TEMP110 TEMP120 TEMP200 a u fr mM E aaa aaa PAANAN SPEED2 6 VIB3 ma o o o e o Pa BIO2 O Oo O FOOD2 O 0 O O e Other container sizes available by agreement Arcanol rolling bearing greases Ordering examples Ordering example Description ARCANOL MULTITOP 5KG FAG rolling bearing grease Arcanol MULTITOP in 5 kg bucket a ARCANOL MULTI2 20G FAG rolling bearing grease Arcanol MULTI2 in 20 g tube 50 pieces a ARCANOL MULT13 25KG FAG rolling bearing grease Arcanol MULTI3 in 2
116. ting Repair Mechanical mounting and dismounting Hook wrenches and pin wrenches for mounting and dismounting FAG jointed hook wrenches LOCKNUT FLEXIHOOK For locknuts KM1 to KM36 and precision locknuts ZM12 to ZM150 as well as ZMA15 33 to ZMA100 140 FAG jointed hook wrenches of series LOCKNUT FLEXI HOOK can be used to tighten and loosen locknuts precision locknuts on shafts adapter sleeves and extraction sleeves if no torque value is specified The joint allows one hook wrench of series LOCKNUT FLEXI HOOK to be used for mounting or dismounting locknuts of various sizes Ordering example for FAG jointed hook wrench suitable for locknuts KM14 to KM24 LOCKNUT FLEXIHOOK KM1 4 24 For detailed information see TPI WL 80 56 FAG jointed pin wrenches LOCKNUT FLEXIPIN For precision locknuts AM15 to AM90 FAG jointed pin wrenches of series LOCKNUT FLEXI PIN can be used to tighten and loosen locknuts on shafts if no torque value is specified FAG jointed pin wrenches can be used to mount small bearings on tapered shaft seats Tightening is achieved by means of radially arranged holes Ordering example for FAG jointed pin wrench suitable for locknuts AM35 to AM60 LOCKNUT FLEXIPIN AM35 60 For detailed information see TPI WL 80 56 FAG jointed face wrenches LOCKNUT FACEPIN For precision locknuts LNP017 to LNP170 FAG jointed face wrenches of series LOCKNUT FLEXI PIN ca
117. tion The course participant can subsequently visualise the machine using the VC software and analyse trend data time signals and frequency spectra He can assess and interpret parameter and expert alarms and handle the alarm logbook Duration 2 days Please note that the product training courses FAG VibroCheck Installation hardware and FAG VibroCheck Application software are only bookable as a single package total duration 4 days Product training FAG DTECT X1 with Administrator 3 8 Training content On the basis of the training unit FAG Detector IlI Basic this course gives well founded knowledge both on vibration diagnosis as well as the online measuring system FAG DTECT X1 in relation to functionality possible applications usage and handling In particular the versatile possible configurations of the system are communicated intensively in practical usage In addition the principles of communication technology for teleservice are presented Target group The course is aimed in particular at technicians and engineers working in maintenance as well as interested employees Training objective Following the course the participants will be able to identify machine defects and damage in detail based on frequency analysis using the measuring system by remote diagnosis and online Duration 4 days by agreement only Also usable for FAG WiPro Training Training des
118. tor 1600 bar 2 500 ba 24 INJECT1600 SET 2500 SET Set comprising oil injector 1600 bar 2 500 bar and valve nipple 24 KLR Taper ring gauge 36 106 Index of FAG products Index of FAG products Ordering designation Product Page LASER INLINE Shaft alignment device 38 LASER SMARTY2 Belt pulley alignment device 56 LASER TRUMMY2 Belt tension measuring device Sf LASER SHIM X Shims for Top Laser alignment devices tr 60 o LOCKNUT DOUBLEHOOK KM Double hook wrench for locknut KM Ilo LOCKNUT DOUBLEHOOK KM KIT Double hook wrench kit for locknut KM 11 LOCKNUT DOUBLEHOOK KM SET Double hook wrench set for locknuts KM5 KM8 KM9 KM13 I1 LOCKNUT FACEPIN Jointed face wrench for precision locknut LNP 10 o LOCKNUT FLEXIHOOK Jointed hook wrench for locknut KM or precision locknut ZM A 10 o LOCKNUT FLEXIPIN Jointed pin wrench for precision locknut AM 10 LOCKNUT HOOK KM Hook wrench for locknut KM gt o LOCKNUT SOCKET KM Socket wrench for locknut KM 9 o MGA31 Enveloping circle gauge for outer enveloping circle 0 39 MGI21 Enveloping circle gauge for inner enveloping circle 39 MGK132 133 Taper gauge for 90 510 mm 27 205mm on 38 MGK9205 12 SET 30 SET Taper gauge set for large studs taper 1 12 1 30 37 PULLER Mechanical extractor for small bearings 12 PULLER HYD Hydraulic extractor 15 PULLER INTERNAL10 100 SET Internal extractor set for bearings of bore diameter 10 to 10
119. tor can be used more than once It allows the dispensing times to be adjusted depending on the temperature and to 1 3 6 or 12 months It is battery powered and the battery set is replaced whenever the cartridge is changed Ordering designation ARCALUB DRIVE Special drive units are available as accessories for machine controlled The complete lubricator comprising operation in explosion hazard a drive unit LC unit and battery areas set is connected to the lubrication point by means of an adapter or The lubricator Motion Guard hose CHAMPION s suitable for all the Arcanol rolling bearing greases Ordering designations described on page 46 47 as well ARCALUB ADAPTER as chain oil Filled LC Lubricant Cartridge units with a dispensing ARCALUB TUBE volume of 60 120 and 250 cm are 3 m hose with connectors available and are screwed onto the drive unit Once the LC unit is empty it cannot be refilled Ordering examples one battery set is included in the delivery ARCALUB LC60 MULTITOP filled with MULTITOP 60 cm ARCALUB LC120 LOAD400 filled with LOAD400 120 cm ARCALUB LC250 VIB3 filled with VIB3 250 cm FAG lubricator sets Motion Guard CHAMPION The automatic lubricator Motion Guard CHAMPION in sizes 120 and 250 cm and filled with Arcanol MULTITOP is offered as a complete lubricator set The sets comprise e a drive unit e an adapter e an LC unit with battery set Ordering de
120. uitable grease is therefore particularly important If an automatic lubricator is used for controlled relubrication a sufficient quantity of fresh grease is continuously supplied to the contact points of the rolling bearing This results in a significant increase in bearing life These reliable economical devices give extended lubrication and maintenance intervals and also prevent under Supply or oversupply of grease 48 Plant downtime and maintenance costs are reduced as a result The sparing and environmentally friendly use of lubricants contribute to higher cost efficiency FAG Motion Guard lubricators are individually matched to the bearing location and eliminate the need for costly central lubrication systems They have a wide range of applications for example on pumps compressors and fans in conveying equipment vehicles etc The single point lubrication systems Motion Guard COMPACT can be used to dispense eight of the Arcanol greases described on pages 46 to 47 while CHAMPION can dispense all these greases Motion Guard CONCEPT6 is used as a single point or multi point lubrication system with thirteen Arcanol greases Advantages of lubricators e Individually configured precise supply to each bearing position immediately after initial operation Fully automatic maintenance free operation Savings on personnel costs compared to manual relubrication e Various dispensing times can be se
121. unity to have their wheelset bearings professionally dismantled cleaned and reconditioned Customers thus benefit from the in depth knowledge in the field of rolling bearings that is only available from a bearing manufacturer The technical expertise of F IS employees guarantees the highest quality in maintenance and the achievement of maximum bearing life The PIS service offer applies to e all wheelset bearings and cylindrical spherical and tapered roller bearings up to a maximum width of 180 mm and a maximum outside diameter of 425 mm e products from all rolling bearing manufacturers e all railway vehicles The service includes e professional dismounting cleaning and reconditioning of railway wheelset bearings at the PIS Service Center in Schweinfurt Germany e identification marking of each individual bearing before dismounting e if required bearing specific documentation of all maintenance activities carried out Operating benefits e longer life of railway wheelset bearings due to high quality maintenance work e short downtime periods due to swift implementation of the maintenance process e minimal mounting work since the wheelset bearings are returned in a condition ready for mounting e reduced maintenance costs due to preventive maintenance Please direct enquiries about the services described to Schaeffler KG Georg Sch fer Strasse 30 97421 Schweinfurt Germany Tel 49 9721 91 1919 Fax 49
122. vation screw Activation screws Ordering designations 10 pieces ARCALUB ACTIVE 1M for 1 month yellow ARCALUB ACTIVE 3M for 3 months green COMPACT lubricators filled with Arcanol MULTITOP and MULTI2 are also available in single packs including activation screws while those with TEMP200 are only supplied in single packs with activation screws Ordering examples ARCALUB MULTITOP 1M filled with MULTITOP including activation screw for 1 month ARCALUB MULTI2 3M filled with MULTI2 including activation screw for 3 months ARCALUB MULTITOP 6M filled with MULTITOP including activation screw for 6 months ARCALUB TEMP200 12M filled with TEMP200 including activation screw for 12 months ARCALUB ACTIVE 6M for 6 months red ARCALUB ACTIVE 12M for 12 months grey 12M cannot be used for MULTITOP and MULTI2 ARCALUB TEMP200 6M Arcanol Suitable Arcanol greases chain oils and activation screws 1M 3M 6M 49 Products Lubrication Lubrication systems Motion Guard COMPACT Variants CLEAR and POLAR Variant CLEAR The variant CLEAR of the lubricator Motion Guard COMPACT is suitable for explosion protected and corrosion inducing humidity areas The lubricator can be used at operating temperatures from O to 40 C The upper temperature limit is determined by the transparent plastic housing with a volume of 100 cm Ordering example ARCALUB CLEAR FOOD
123. vidual modules of the software FAG Administrator 4 0 The focus is on the function of the individual modules and the use of the Data Viewer a special analysis tool The principles of communication technologies are also presented Target group The course is aimed in particular at participants who have already attended the training units FAG Detector Ill Basic Advanced Alternatively at least one year s practical experience with an offline or online vibration measuring system is required Training objective After the training the participant can securely install the software and is familiar with the function of the individual modules Duration 2 days Product training FAG DTECT X1 with Administrator 4 0 Training content On the basis of the training units FAG Detector Ill Basic Advanced and FAG Administrator 4 0 this course gives well founded knowledge on the online measuring system FAG DTECT X1 in relation to functionality possible applications usage and handling In particular the versatile possible configurations of the system are communicated intensively in practical usage Target group The course is aimed in particular at technicians and engineers working in maintenance as well as interested employees Participants must have previously attended the product training course FAG Administrator 4 0 Training objective Following the course the participants will be able
124. xtensive experience for Fax 49 9721 91 3809 example in railways raw material mining and processing steel and aluminium wind power paper oil and gas etc The PIS mounting personnel are specially trained and will provide reliable and rapid assistance The mounting services are provided either at the customer s location or in the PIS workshop facilities The mounting service includes e mounting and dismounting of rolling bearings of all types e approval inspection of adjacent parts shafts and housings e maintenance and inspection of bearing arrangements e defect analysis on bearing arrangements not running satisfactorily e advice on rationalisation of mounting operations e design and manufacture of special tools Operating benefits e extended bearing life e considerable cost reductions e less unplanned downtime e increased plant availability e improved awareness among employees of the correct handling of rolling bearings 76 Services Services relating to rolling bearings Mounting Repair Reconditioning of rolling bearings Reconditioning of rolling bearings Wheelset bearings for railway vehicles and standard bearings up to 425 mm outside diameter Wheelset bearings for railway vehicles are among the most heavily loaded vehicle parts Their life can be increased significantly by appropriate and regular maintenance F IS therefore offers operators of all railway vehicles the opport

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