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1. Continuous Characteristic applications Temperatures Low Vibra Support Relubri limit friction tions forseals cation temperature high facility Speed HE Low 70 Ball bearings in machine tools o spindle bearings rotary table bearings instrument bearings 90 Ball and roller bearings in blade adjusters in wind turbine rotors packaging machinery rail vehicles 80 Ball and roller bearings in environmentally hazardous applications 70 Ball and roller bearings in applications with food contact NSF H1 registration kosher and halal certification 90 Ball roller and needle roller bearings as well as linear guidance systems in clean room applications 70 Ball and roller bearings in oscillating o o operation slewing rings in wind turbines Schaeffler Technologies IS1 83 Lubricants Features The lubricants available from Schaeffler are designed and tested for bearing arrangement engineering Rolling bearing The Arcanol rolling bearing greases offer very good preconditions greases Arcanol for favourable running behaviour of bearings and a long operating life and high operational security of the bearing arrangement The lubricant range is graduated such that almost all areas of application are covered The areas of application of Arcanol greases were determined under widely differing operating conditions and with rolling bearings of all types by means of modern testing methods an
2. The charging dock mounting pads and additional RFID tags are available by agreement For detailed information see TPI WL 80 64 FAG Detector III The Solution for Monitoring and Balancing or www FAG Detectorlll de Enquiries industrial services schaeffler com 49 2407 9149 66 IS1 119 120 Online monitoring system IS1 FAG SmartCheck Plug and play system Parameters monitored Control using Mitsubishi controllers Vibration diagnosis FAG SmartCheck is a compact innovative modular online measur ing system for continuous monitoring of machinery and process parameters on a decentralised basis It can be used on assemblies where such monitoring was previously too cost intensive FAG SmartCheck is suitable for example for early detection of rolling bearing damage imbalances and misalignments on electric and geared motors vacuum and fluid pumps ventilators and fans gearboxes and compressors spindles and machine tools separators and decanters FAG SmartCheck is ready for immediate use When supplied it already has a set of key data that facilitate general reliable machinery monitoring In addition predefined configuration templates are available for monitoring of items such as fans pumps and bearings These can easily be matched to individual requirements Due to the integrated bearing database of FAG and INA standard bearings data configuration and later analysis are simpler The system has an
3. 0008AB02 ARCA PUMP BARREL GUN METER ARCA PUMP WIND SERVICE KIT 00017AC3 00017A4D Schaeffler Technologies Grease pumps ARCA PUMP ARCA PUMP BARREL Grease dispensing units Drum pumps 00019331 000179BC Lever grease guns ARCA GREASE GUN 000179B4 Schaeffler Technologies IS1 87 Features Automatic relubrication 88 IS1 devices Lubricator CONCEPT2 Advantages Lubrication devices Rolling bearings are automatically provided with the correct quantity of lubricant by lubricators and lubrication systems This prevents the most frequent cause of rolling bearing failure inadequate or incorrect lubrication Approximately 90 of bearings are lubricated with grease Relubrication with the correct quantity of grease at the appropriate intervals gives a significant increase in the life of rolling bearings For manual relubrication grease guns are suitable Automatic relubrication devices convey fresh lubricant in the defined quantity at the correct time to the contact points of the rolling bearing The devices adhere to the lubrication and maintenance intervals and prevent undersupply or oversupply of grease Plant downtime and maintenance costs are reduced as a result The relubrication devices are matched to the bearing positions They have a wide range of applications for example on electric motors gearboxes pumps compressors and fans in linear systems conveying equipment m
4. 1 Belt TRUMMY2 cableless measurement probe Figure 4 Measurement 102 IS1 Schaeffler Technologies Shaft alignment device The FAG Top Laser EQUILIGN Figure 5 is an alignment system for FAG Top Laser EQUILIGN coupled and decoupled shafts in motors pumps ventilators and gearboxes with rolling bearings The advantages of the system are as follows simple mounting error free handling even by untrained personnel using step by step display on the manual control device automatic tolerance checking A symbol indicates when the shafts are correctly aligned more precise alignment than with conventional methods rapid simple measurement by means of Active Clock measure ment mode robust control device Watertight and insensitive to contamination in accordance with IP 65 user interface in 20 languages easy generation of reports real time display of displacement in all axes A Do not look into the laser beam or point the laser beam into another Caution person s eyes Figure 5 Shaft alignment device FAG Top Laser EQUILIGN Schaeffler Technologies IS1 103 Scope of delivery Ordering designation 1 Manual control device 2 Transmitter receiver 3 Reflector 4 Batteries LR6 AA DC 1 5 V 5 pieces 5 Allen key 4 mm 6 Cable for USB memory stick 7 Cable for PC Bracket 9 Chain 300 mm long Post 115 mm long 1 Tape measure 42 Case Figure 6 Scope of delivery FAG Top Laser EQUILIGN 1
5. Hydraulic mounting and dismounting Hydraulic nuts HYDNUT F gure 1 and table are used to press components with atapered bore onto theirtapered seat Presses are mainly used if the drive up forces required cannot be applied using other accessories e g shaft nuts or pressure screws it Ei 0008A1B0 The main applications are as follows mounting and dismounting of rolling bearings with tapered bore The bearings can be seated directly on a tapered shaft an adapter sleeve or a withdrawal sleeve The hydraulic nut can also be used for the dismounting of adapter or withdrawal sleeves mounting and dismounting of components such as couplings gears and ships propellers HYDNUT50 to With metric fine pitch thread Standardised adapter HYDNUT200 to DIN 13 and withdrawal sleeves HYDNUT205 to With trapezoidal thread With metric dimensions HYDNUT1180 to DIN 103 HYDNUT90 INCH to With inch size thread to ABMA Sleeves with inch HYDNUT530 INCH Standards for Mounting dimensions Accessories Section 8 Locknut Series N 00 HYDNUT100 HEAVY to Increased capacity design For high mounting HYDNUT900 HEAVY with smooth bore forces for example in shipbuilding Schaeffler Technologies 1 Hydraulic nut 2 Replacement seals 3 Screw plug 4 Eye bolt 5 Connecting nipple 6 Hand lever 7 Mounting paste User manual Figure 2 Scope of delivery Hydraulic nut 0008AE1A Scope of delivery 1 hydrauli
6. Online monitoring system ProTorg ProTorq 124 IS1 Schaeffler Technologies Monitoring of components Features Online monitoring systems of this type are used for estimating the remaining life of heavily loaded components as well as for process monitoring Online monitoring system The online monitoring system FAG ProTorq is suitable for monitoring FAG ProTorq applications in many sectors due to its versatility It facilitates early detection of overload and possible failure of components reliable estimates of remaining life optimised component utilisation and maintenance planning increased quality and production performance design verification and optimisation of power train elements Function FAG ProTorg can be used to detect signals such as torque elonga tion force pressure temperature and displacement changes in parallel on up to 32 channels These can be correlated with product specific data for evaluation of the signals In addition the system allows calculation and comparison of signals with each other as well as automatic analysis As a result the user receives a reliable statement on the condition of the component or process The measurement sensor system is also suitable for harsh ambient conditions such as those in rolling mill or offshore applications Customer specific solutions The versatile application possibilities covered by FAG ProTorq require precise definition of the key values to be monitored when
7. aaneen 80 Greases for high loads moderate speed neen 80 Greases for high loads moderate speed annen 80 Greases for high loads low speed noen eenen 80 Multi purpose grease for high speed high loads high temperatures anssen oen seenvevenn 80 Multi purpose grease for bearings under normal loads D 62 enen veenen rer rrrr rss 80 Multi purpose grease for bearings under normal loads D gt 62 acoden i 80 Special grease for very high speeds low temperatures 82 Special grease for low and high temperatures 82 Special grease for low and high temperatures high speed 82 Special grease for high temperatures high speed 82 Special grease for very high temperatures neen 82 Special grease for high loads high temperatures oscillating motion een 82 Transport and mounting tool sanne nnen enes nere 72 Two point lubricator CONCEPT2 with grease cartridge 86 Multi point lubrication system CONCEPTS with LC unit 86 Schaeffler Technologies DETECT3 KIT DETECT3 KIT RFID DETECT3 BALANCE KIT DTECTX1 S DTECTX1 S WIPRO FEELER GAUGE 100 FEELER GAUGE 300 FITTING TOOL ALU 10 50 GLOVE PRO GLOVE PRO CUT GLOVE PRO TEMP GREASE CHECK HEATING RING HEATING RING PASTE HEATER10 HEATER20 HEATER40 HEATER150 HEATER300 HEATER600 HEATER1200 HEATER PLATE HEATER PLATE 370C HEAT GE
8. 110 IS1 Checking the operating condition TEMP CHECK PLUS TACHOMETER 00017AD2 00019E25 TEMP CHECK PRO gt STAS x SOUND CHECK 000179C1 000179B7 Schaeffler Technologies Checking the operating condition Features These devices can be used to manually check the following parameters of rolling bearing arrangements temperature speed and noise Infrared thermometer The infrared thermometer FAG TempCheck PLUS is suitable FAG TempCheck PLUS forthe thermal monitoring of machine components This prevents unplanned downtime of machinery The infrared thermometer measures the infrared radiation emitted by an object and uses this to calculate the surface temperature The non contact measurement makes it possible to easily determine the temperature of difficult to access or moving objects The features of FAG TempCheck PLUS are as follows up to date infrared temperature technology with high precision glass optics for precise non contact temperature measurement small measurement spot of 13 mm ata distance of up to 140 mm measurement spot size corresponds to 20 1 distance measure ment spot size at a distance of more than 140 mm rapid precise temperature measurement over a temperature range of 32 C to 530 C degree of emission adjustable to material low mass 150 g USB interface report software simple to use low purchase costs Do not look into the laser beam or point the laser
9. Ordering designation IS1 Checking the operating condition The speed counter is suitable for two types of operation direct speed measurement using an adapter track wheel and measurement stylus non contact optical speed measurement using a reflective mark For direct speed measurement the supplied adapter must be fitted The rubber stylus of the adapter tracks the end face and this is used to determine the speed The track wheel which is in contact with the circumference of the shaft or the surface of the belt measures the surface velocity For non contact measurement a reflective mark is applied to the machine partto be measured This mark is detected by photoelectric means using visible red light The device displays the speed in revolutions per minute 1 digital hand tachometer 1 adapter for direct measurement 1 1 1 measurement wheel 6 inch 1 measurement wheel 100 mm 1 rubber stylus 10 reflective marks 1 user manual 1 case TACHOMETER 10 reflective marks TACHOMETER MARKS REFLEX Schaeffler Technologies Sonar device FAG SOUND CHECK Scope of delivery Base device Ordering designation Schaeffler Technologies 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 ofthe bearing can be detected at an early stage if regular inspection is carried out In this way unforeseen operational stoppages and
10. PROCUCTINGOK ee 8 Tide en E AO RR BR elas 12 Products MOU Stretta 15 Products Eubrication 2 22 eu 77 Products Condition Monitoring ssessersersrrrrerrrerrerrrrrerrrrrrrrs 95 SERVICES nisin a a ae aao ieia 130 TAAL see E E E ONA 150 Appendix PU DIGG H R sense een 158 Addiesses Branne leisen ENE TRA AON 160 IS1 7 ARCA GREASE GUN ARCA PUMP ARCA PUMP BARREL ARCA PUMP BARREL GUN METER ARCA PUMP WIND SERVICE KIT ARCANOL ANTICORROSIONOIL 8 IS1 ARCANOL MOUNTINGPASTE ARCANOL BIO2 ARCANOL CLEAN M ARCANOL FOOD2 ARCANOL LOAD150 ARCANOL LOAD220 ARCANOL LOAD400 ARCANOL LOAD460 ARCANOL LOAD1000 ARCANOL MULTITOP ARCANOL MULTI2 ARCANOL MULTI3 ARCANOL SPEED2 6 ARCANOL TEMP9O ARCANOL TEMP110 ARCANOL TEMP120 ARCANOL TEMP200 ARCANOL VIB3 BEARING MATE CONCEPT2 CONCEPT8 Product index Page Lever grease Ueo es 87 Grease dispensing UNIt sssssssssssereserrrrerrrrrrrrrrerrrerrrrrrrrrrrrrrrrrrrr nns 87 DUM DUMP essen anime 87 PISLOLSTEASE gun aka 86 Service pump for wind turbines s ssersserssrrssrersrrrrrrrrrerrrerrrrrres 86 ANTI CONOSION DL een ak 72 Mounting PASTE een eee kben verhaart aeta 72 Special grease for environmentally hazardous applications 82 Special grease for clean room applications 82 Special grease for applications with food contact 82 Greases for high loads high speed aaneen 80 Greases for high loads high speed
11. Product overview Thermal mounting and dismounting contact heating Electric heating plates HEATER PLATE HEATER PLATE 370C 00017999 00017A5A Heating rings _HEATING RING HEATING RING PASTE Heat conducting paste 00017997 48 IS1 Schaeffler Technologies Thermal mounting and dismounting contact heating Features Electric heating plates and heating rings are used to heat rolling bearings and other components with a cylindrical bore where a tight fit on the shaft or in the housing is intended Adequate expansion of the bearings is achieved in most cases at 80 C to 100 C During the heating operation the maximum heating temperature must be observed The temperature of rolling bearings must not normally exceed 120 C in order to prevent changes to the structure and hardness of the bearing In all devices for heating the temperature can be steplessly controlled T Wear protective gloves during mounting and dismounting of heated parts Electric heating plates Heating plates see table are used to heat rolling bearings or small machine parts by means of contact heat Heating plates are maintenance free and easy to use The heating plate HEATER PLATE 370C is suitable principally forthe heating of heating rings HEATING RING Both heating plates are also available as a version with 115 V 60 Hz suffix 115V Available heating plates Power at Temperature Device 230 V 50 Hz min mm mm W 2G HEATER
12. practical use of measurement systems and the handling of confi guration and analysis software The theoretical knowledge acquired is consolidated by means of practical exercises Schaeffler has its own training centres worldwide Qualified present ers with considerable experience ensure practice oriented knowl edge transfer in various languages at local sites Alternatively we will be pleased to train your employees at your location The Schaeffler training centres headquarters in Eltmann Germany offer theoretical and practical training courses in their modern training facilities All product and services portfolios of Schaeffler Technologies are covered in detail Starting from the principles and progressing to more detailed special knowledge training courses communicate knowledge of rolling bearing theory mounting and dismounting as well as all levels of condition monitoring and mechatronics Through continuous market monitoring and exchange of experience Schaeffler is in a position to continuously improve its training courses What is particularly important to us is the ideas and sugges tions that we receive through feedback from our training partici pants Certification of the Schaeffler Technical Training Centres to ISO 9001 2008 underlines our continuous aspiration to increasing quality Schaeffler Technologies Training courses standard and individual Excerpt from the Schaeffler training portfolio Schaeffler Techno
13. 100 mm Set of ten hook wrenches LOCKNUT HOOK KMO 16 SET The joint allows one hook wrench LOCKNUT FLEXIHOOK to be used for mounting or dismounting locknuts of various sizes Jointed hook wrenches are available in sizes suitable for locknuts KM1 to KM36 suitable for diameters from 20 mm to 230 mm Jointed hook wrench suitable for locknuts KM14 to KM24 LOCKNUT FLEXIHOOK KM 14 24 The jointed pin wrench LOCKNUT FLEXIPIN is hooked into radially arranged holes in the nut Jointed pin wrenches are available in sizes suitable for locknuts AM15 to AM90 suitable for diameters from 35 mm to 155 mm Jointed pin wrench suitable for precision locknuts AM35 to AM60 LOCKNUT FLEXIPIN AM35 60 IS1 23 Nn Jointed face wrenches Ordering example Ordering designation Double hook wrenches Scope of delivery of double hook wrench set Ordering example Ordering designation Ordering example Ordering designation Further information 24 IS1 Mechanical mounting and dismounting The jointed face wrench LOCKNUT FACEPIN is hooked into axially arranged holes in the nut Jointed face wrenches are available in sizes suitable for precision locknuts LNPO17 to LNP170 suitable for diameters from 18 mm to 200 mm Jointed face wrench suitable for precision locknuts LPNO17 to LPNO25 LOCKNUT FACEPIN LNP17 25 Double hook wrenches LOCKNUT DOUBLEHOOK are intended for the mounting of spherical roller bearings and self aligning ba
14. 30 97421 Schweinfurt Germany Internet www schaeffler com services E mail industrial services schaeffler com Phone 49 2407 9149 66 Fax 49 2407 9149 59
15. C to 240 C 40 C to 240 C 40 C to 240 C 40 C to 240 C adjustable up to adjustable up to adjustable up to 99 min 99 min 99 min 99 min 99 min adjustable up to adjustable up to adjustable up to adjustable up to adjustable up to 99 min and 240 C 99 min and 240 C 99 min and 240 C 99 min and 240 C 99 min and 240 C Schaeffler Technologies IS1 59 Heating devices HEATER sen Product range 00019102 Dimension table Characteristics Unit HEATER10 115V UL HEATER20 115V UL Operating voltage U Frequency F Power consumption P Nominal current Residual magnetism H Duty cycle ED 60 IS1 Schaeffler Technologies HEATER40 115V UL HEATER150 460V UL 100 Schaeffler Technologies HEATER300 460V UL 100 HEATER600 A ER HEATER1200 460V UL 460 60 28 9 46 85 lt 2 100 100 IS 1 61 Product overview Thermal mounting and dismounting medium frequency technology Medium frequency devices _HEAT GENERATOR HEAT INDUCTOR HEAT GENERATOR HEAT INDUCTOR 62 IS1 Schaeffler Technologies Thermal mounting and dismounting medium frequency technology Features Induction heating devices with medium frequency technology are used to heat rolling bearings and other components with a cylindri cal bore where a tight fit on the shaft or in the housing is intended Adequate expansion ofthe bearings is achieved in most cases at 80 C to 100 C During the heat
16. Design Pump holder without connector for manometer 46 181 Schaeffler Technologies Manometers Available manometers High pressure pipes Ordering example Ordering designation Sleeve connectors Ordering example Ordering designation Schaeffler Technologies In addition to the manometer with digital display there are three analogue manometers with an indicator see table When selecting amanometer pay attention to the maximum oil pressure Threaded connector Maximum oil pressure G1 7 2500 Designation PUMP1000 MANO DIGI PUMP1000 MANO G1 2 PUMP1600 MANO G1 2 PUMP2500 MANO G1 2 High pressure pipes used with high pressure pumps are sheathed in a PVC hose The maximum permissible oil pressure is 2 500 bar The connector to the pump holder is G3 4 The connector to the consumer device is available in the sizes G1 4 G3 g G1 2 and G3 4 For other thread sizes a reduction nipple can be used Check the oil pressure using a manometer High pressure pipe with a connector G 4 on the consumer device side PUMP PIPE G1 4 Sleeve connectors can be used at pressures up to 800 bar The connector to the pump holder is G1 4 The connector to the consumer device is available in the sizes M6 M8 G1 g and G1 4 For other thread sizes a reduction nipple can be used Check the oil pressure using a manometer Sleeve connector with a connector G g on the consumer device side PUMP SLEEVE CONNECTOR G1 8 IS 1
17. Lloyd The automatic messaging function by means of TCP IP wifi modem optional landline modem or DSL router allows efficient worldwide monitoring The data can be transferred to other locations by remote access and analysed there for example by the Schaeffler vibration experts For detailed information see WL 80 373 Flyer FAG WiPro Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies Online monitoring system FAG ProCheck is an online monitoring system It can be used to FAG ProCheck prevent unplanned downtime and for quality control The system offers a high level of functionality and is available in a range of variants from an 8 channel to a 16 channel system Parameters monitored FAG ProCheck continuously records data on vibration temperature and other process parameters and subsequently carries out their evaluation As a result incipient damage and its causes can be detected at a very early stage and the appropriate countermeasures can be introduced in good time This gives a considerable reduction in operating costs In addition FAG ProCheck offers the possibility of correlating a large number of analogue and digital input and output signals to the vibration data These channels also allow simple communication with higher level systems such as process control systems Versatile system Due to its extremely robust and compact design this system is ideally suited for use in almost a
18. PLATE 390X270X56 380X180 200 HEATER PLATE 370C 360360170 350X350 2 200 100 370 Designation Further information For detailed information see TPI 200 FAG Heating Devices forthe Mounting of Rolling Bearings Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies IS1 49 Thermal mounting and dismounting contact heating Heating rings Heating rings HEATING RING are suitable for the dismounting of inner rings with a rib and the inner rings of cylindrical and needle roller bearings without ribs Heating rings are particularly advan tageous forthe occasional extraction of smalland medium sized bearing rings with a bore diameter of 50 mm to 200 mm The heating rings are made from aluminium alloy They are easy to handle due to the heat insulated handles Heating rings are heated using an electric heating plate to a temperature between 200 C and 300 C Figure 1 1 Heating ring 2 Heating plate 3 Temperature measuring device 0001A7A9 Figure 1 Heating ofthe heating ring Each bearing size requires a specific heating ring In order to prepare a quotation we require the following information the bearing designation or ring dimensions a drawing of the mounting position including information on fits the approximate number of parts to be extracted per day 50 IS1 Schaeffler Technologies Recommended accessories Ordering example Ordering d
19. Rolling bearing theory conveys the necessary knowledge on subjects such as bearing clearance load distribution in the bearing rating life and lubrication In workshops the participants concentrate on applications for example the bearing arrangements in a machine tool or a shaft bearing arrangement All process steps are covered from bearing selection and bearing calculation through to mounting We also offer workshops in the field of mechatronics Optionally we offer training courses on condition based main tenance in the field of vibration analysis These courses include product training as well as the certification of personnel to DIN ISO 18436 2 IS1 153 154 Training locations Training centres worldwide IS1 Quality assurance Training Several training modules cover the mounting and dismounting of rolling bearings and linear guidance systems Based on perception and exercises the participant gains the mounting knowledge and skills that he will require in practice Our training courses on mounting cover a large number of applications Mounting exercises on individual products are followed by work on more complex systems such as gearboxes or wheelsets The possibilities for plannable and economical design of main tenance work on machines plant and rolling bearings are communi cated to the training participant in appropriate courses Our trainers communicate the theoretical principles of vibration analysis the
20. The bearing can be dismounted without damage if the extractor is in contact with the tightly fitted bearing ring In the case of mechanical extractors the extraction force is normally applied by means of threaded spindles In addition to the two arm and three arm devices as well as a hydraulic pressure tool special solutions are also possible For dismounting of larger bearings hydraulic extractors should be used see page 30 Two arm and three arm extractors Figure 1and tables page 26 are used for the extraction of complete rolling bearings or tightly fitted inner rings The two arm extractor PULLER 2ARM and three arm extractor PULLER 3ARM can also be used to extract other parts such as gears 00019DEO IS1 25 Mechanical mounting and dismounting Available two arm extractors Designation Grip Grip Dimensions Extrac width depth tion oa Ba PULLER 2ARM90 In an In fen 30 PULLER 2ARM130 30 PULLER 2ARM160 50 PULLER 2ARM200 50 PULLER 2ARM250 75 PULLER 2ARM350 75 PULLER 2ARM SEPARATOR45 10 PULLER 2ARM SEPARATOR9O 90 100 2 5 14 1 40 PULLER 2ARM SEPARATOR150 150 150 2 5 28 1 40 Available two arm extractor set Designation PULLER 2ARM SET Two arm extractors included PULLER 2ARM130 PULLER 2ARM200 PULLER 2ARM350 Accessories included Narrow extraction hook for size 130 and 200 tube of spindle grease carry case Available three arm extractors Designation Grip Grip Dimensions Sara width
21. bearings NN3006 K NNU3048 K with separable outer ring N1006 K N1048 K MGA31 Bearings The enveloping circle gauge MGI21 is used to measure by means with separable inner rings of two hardened and precision ground surfaces the internal enveloping circle of a roller and cage assembly One measurement surface is movable Before measurement the gauge is set to the internal enveloping circle of the roller and cage assembly This setting operation requires a snap gauge such as SNAP GAUGE After mounting of the outer ring together with the roller and cage assembly the enveloping circle diameter is then determined using the gauge MGI in a comparative measurement In the case of a bearing with a tapered bore the enveloping circle measurement is used to calculate its position on the tapered seat of the shaft During mounting the bearing is driven to this position This results in the internal clearance or the preload In the case of bearings with a cylindrical bore preground inner rings suffix F12 are used and finish ground to the required bearing diameter Ordering example Enveloping circle gauge for cylindrical roller bearing NNU4920 Ordering designation MGI21 NNU4920 Bearings The enveloping circle gauge MGA31 is used to measure by means with separable outer rings of two hardened and precision ground surfaces the external envel oping circle of the roller and cage assembly The gauge is set to the raceway diameter of the mounted
22. configuring the hardware and software In this way the system can be individually matched to the monitoring task Schaeffler accompanies the customer throughout the project phase Following system configuration by Schaeffler the user receives intensive AN training that equips him to use the system independently Upon m customer request the Schaeffler can undertake evaluation ofthe measurement data Troubleshooting Ifa permanent installation is not required there is also the option of temporary measurement carried out by Schaeffler The objective here is to find short term approaches to solutions where unexpected component failure occurs Further information For detailed information see TPI 199 FAG ProTorg Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies IS1 125 Product overview Monitoring of lubricants Grease sensor GREASE CHECK GreaseCheck 0008A082 Oil sensor Wear Debris Check 00 a a A So oO oO 126 IS1 Schaeffler Technologies Features Grease sensor FAG GreaseCheck 1 Grease sensor 2 Electronic evaluation system Figure 1 Grease sensor and electronic evaluation system Advantages Further information Schaeffler Technologies Monitoring of lubricants The operating life of the lubricant is the decisive value for the bearing life Depending on the application either a grease or oil Sensor can be used for monitoring The lubricant can be
23. detected with the aid of a high resolution infrared camera The major advantage of thermography is the rapid non contact collection of temperature data If a photograph is taken at the same time the temperature patterns present in a machine part can be assigned on site Thermography can be used for assessment in relation to numerous objects such as in the case of non contact monitoring of rolling bearings during operation thermal monitoring of processes 00017A6F The combination of different diagnostic techniques enables the Schaeffler experts to carry out assessment of new plant irrespective of the manufacturer Frequently occurring installation defects can thus be detected in the commissioning phase These defects include misalignment of motors pumps or fans as well as incorrect electrical connections in switch cabinets The Schaeffler experts check the most common problems and record the actual status Where necessary corrective measures can then be requested from the plant manufacturer or operator in good time If such defects remain undetected overthe period of the warranty their removal and the secondary damage may incur considerable costs and downtime Enquiries industrial services schaeffler com 49 2407 9149 66 IS1 141 Services Corrective maintenance Once a machine problem has been diagnosed it should be elim inated as quickly as possible Two ofthe most frequent problems namely imbalance in pumps and
24. force The correct belt tension is an essential prerequisite for achieving the maximum life of the belt drive In addition this also gives reduced wear of the drive components lower energy costs and increased cost efficiency The FAG Top Laser TRUMMY2 comprises a cableless measurement probe for direct connection a measurement probe with cable for difficult to access locations and a manual control device that displays the relevant measurables for belt tension as a frequency in Hz or force in N Do not look into the laser beam or point the laser beam into another person s eyes The simple and reliable user menu is given in several languages All the parts of the belt tension measuring device are supplied packed in a case figure 3 1 manual control device 1 measurement probe for direct connection 1 measurement probe with cable 1 case LASER TRUMMY2 Q 00019C87 The belt tension measuring device should be calibrated at least every 2 years The FAG Top Laser TRUMMY2 should be sent to us for this purpose Calibration LASER TRUMMY CALI CHECK IS1 101 Alignment Application Before calculating the belt tension the belt mass and length must be entered Vibration of the belt is then induced The device measures the natural frequency by means of clock pulse light and uses this to determine the belt tension figure 4 This technique is less prone to disruptive influences in comparison with measurement sound waves
25. giving further information and an electronic learning system The software Mounting Manager is available online at mountingmanager schaeffler com Bearings with a tapered bore are mounted either directly on the tapered shaft or journal or by means of an adapter sleeve or with drawal sleeve on the cylindrical shaft The internal clearance is set either by measurement of the axial drive up distance or by conven tional means using feeler gauges The bearing is placed in its start position on the tapered bearing seat using a hydraulic nut The start pressure which is defined for each bearing is checked using a digital manometer on the hand pump PUMP1000 4L CONTROL A certain quantity of oil is required in order to reach the specified drive up distance This is achieved by using a defined number of strokes The number of strokes can be read off from the stroke counter on this hand pump The advantages of this mounting method are as follows simplified mounting very high security and accuracy correct mounting of sealed bearings When the bearing is driven onto the tapered seat the inner ring is expanded and the radial internal clearance is thereby reduced This reduction in radial internal clearance is an indication of the tight fit of the bearing Measurement is carried out using a feeler gauge IS1 35 36 IS 1 Hydraulic nuts 1 Handling holes 2 Oil connector Figure 1 Hydraulic nut with thread Available hydraulic nuts
26. independent learning mode that identifies the alarm thresholds In addition to the standard parameters of vibration and temperature it is possible to record other classic operating parameters such as pressure or flow rate All parameters can be correlated with each other and included in the alarm configuration The data are recorded and analysed centrally by the system The cur rent machine condition can be displayed directly on the device or transferred to any control facility as required It is only necessary to integrate FAG SmartCheck in the existing network structure General communication with controllers can be carried out through connection of the analogue and digital interfaces with the controller The communication protocol SLMP has been implemented specially for Mitsubishi controllers of the L and Q series This allows direct transfer of the measurables status and gives information for example on rolling bearing damage imbalance misalignments or temperature fluctuations that can be notified in plain test to the operator by means of the controller Schaeffler Technologies Access via the Internet FAG SmartCheck has an intuitive user concept designed as a Web interface It is therefore possible to access the system via the Internet using any standard Internet browser The Web interface can be used to configure the system and view current data Remote monitoring The data can be transferred to other locations by remote access
27. information Balancing function Vibration diagnosis The system also has the following features non contact temperature measurement speed detection route function report generator For more detailed analysis the PC software Trendline is available free of charge and includes comprehensive functions These include the Viewer which gives the user a wide range oftools for data evaluation The integrated rolling bearing database con taining approximately 20 000 bearings from various manufacturers facilitates easier and more efficient analysis ofthe measured data Since the damage frequencies can be incorporated in the measure ment results simple damage analysis is possible The automatic detection of measurement points through the use of RFID technology gives error free and precise identification of the measurement points on a measurement route FAG Detector III identifies the measurement points by means of RFID tags on the machinery With the proven FAG Detector Ill mobile vibration and temperature monitoring is thus quicker simpler and more reliable The functionality of automatic measurement point detection is not available worldwide Enquiries industrial services schaeffler com 49 2407 9149 66 A further special feature of FAG Detector Ill is the balancing function Forthis purpose the optionally available Balancing Kit is required This makes it possible to not only detect but also eliminate imbalances The result
28. marks are available in optical and electronic versions Figure 1 In the case of electronic target marks the adjustment values are shown in the digital display in real time Misalignments are presented in degrees the parallelism offset is presented in mm Do not look into the laser beam or point the laser beam into another person s eyes 000192A8 IS1 99 100 IS1 Scope of delivery Ordering designation 1 Transmitter 2 Optical target mark 3 Battery 4 Lined case Figure 2 Scope of delivery FAG Top Laser SMARTY2 Spare parts Ordering designation Accessories Ordering designation Alignment All the parts are supplied in a lined case Figure 2 1 transmitter 2 optical target marks attached by magnetism 1 battery 1 lined case LASER SMARTY2 00019CE5 1 optical target mark attached by magnetism LASER SMARTY2 TARGET 1 electronic target mark attached by magnetism 1 case LASER SMARTY2 TARGET DIGITAL Schaeffler Technologies Belt tension measuring device FAG Top Laser TRUMMY2 Caution A Scope of delivery Ordering designation 1 Manual control device 2 Measurement probe direct connection 3 Measurement probe cable connection 4 Case Figure 3 Scope of delivery FAG Top Laser TRUMMY2 Service Ordering designation Schaeffler Technologies The robust handy FAG Top Laser TRUMMY2 is an optical electronic manual measuring instrument for belt tension strand
29. 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 insulated grip is held between the thumb and index finger like a pencil 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 1 sonar device 1 case SOUND CHECK IS1 115 Product overview Vibration measuring device Detector III Online monitoring system SmartCheck Online monitoring system DTECT X1 WiPro Online monitoring system ProCheck 116 IS1 Vibration diagnosis DETECT3 KIT DETECT3 KIT RFID DETECT3 BALANCE KIT SMART CHECK 00017A65 DTECTX1 S DTECTX1 S WIPRO 000190B1 PRO CHECK 000179B9 Schaeffler Technologies Vibration diagnosis Features Vibration diagnosis is the most reliable method for identifying the start of machine damage at an early stage It can be used to precisely detect not only imbalance and misalignment but also rolling bearing damage and gear tooth defects FAG vibration measuring devices help in planning maintenance work increasing bearing life and reducing costs As a result plant availability is increased and the risk of unplanned downtime is reduced Monitoring devices In the field of offline monitoring devices regular monitoring offline and online Sch
30. outer ring This dimension is determined using a conventional internal gauge The tapered shaft with the premounted inner ring and roller and cage assembly is then inserted in the gauge The shaft is driven axially by the hydraulic method until the required radial internal clearance or preload is achieved Ordering example Enveloping circle gauge for cylindrical roller bearing NN3006 K Ordering designation MGA31 NN3006 70 IS1 Schaeffler Technologies Schaeffler Technologies IS1 71 Product overview Transport and mounting tool Gloves Mounting paste Anti corrosion oil IS1 Accessories BEARING MATE 000179A1 GLOVE PRO GLOVE PRO CUT GLOVE PRO TEMP Ka Pd gt 000190AB ARCANOL MOUNTINGPASTE 00017A44 7 5 i a gt Won 2 ARCANOL ANTICORROSIONOIL 00017A45 Schaeffler Technologies Features Transport and mounting tool Available tools Ordering example Ordering designation Schaeffler Technologies Accessories Accessories are used to assist in the storage transport and mounting of rolling bearings The transport and mounting tool BEARING MATE see table is an accessory for the easy handling of medium sized and large rolling bearings It can also be used in the heating of bearings prior to mounting The tool comprises two handles and two steel strips The steel strips are tightly clamped on the outer ring of the bearing During transport of spher
31. subject areas such as mounting and dismounting of rolling bearings using the optimum tools and the condition monitoring of bearing arrange ments especially through the use of noise vibration and torque measurements Systematic learning processes in conjunction with the appropriate methods assist the training participant to discover the world of bearing arrangements With the support of machine building engineers and technicians who have undergone didactic and methodological training there is no longer any obstacle to effective learning progress Our training courses cover the information needs of employees in a very wide variety of areas of activity within a company In this way the technically oriented employee whether a designer fitter or maintenance person can find the right training course in the same way as the employee in business administration for example in purchasing All target groups are considered using a uniform training approach In general the initial steps are provided by basic training covering the different characteristics features and types of rolling bearings plain bearings and linear guidance systems as well as their combi nation to form systems extending all the way to mechatronic units Application examples reflect the selection criteria and the customer benefits achieved These product oriented training courses are followed by modules covering rolling bearing theory as well as selected applications
32. table are used for the metered greasing of rolling bearings The metering range is between 10 cm and 133 cm per stroke Larger metering ranges can also be achieved by operating the devices several times By means of a pneumatically driven double direction piston pump the medium is conveyed directly from the grease container 25 kg or 180 kg via the metering valve to the application point A grease dispensing unit comprises a cover piston metering valve hose connecting the pump and valve hose 2 5 m long metering pistol Available grease dispensing units Designation Pump Delivery Metering range Suitable for container sizes ARCA PUMP 25 ARCA PUMP 180 Drum pumps Drum pumps ARCA PUMP BARREL see table are pneumatically driven and suitable for delivering large quantities of grease under high pressure over long distances Drum pumps can be used either as delivery pumps for individual greasing stations or as a supply pump for central lubrication systems Available drum pumps Designation Delivery Air con Suitable sumption for container sizes l min kg 50 ARCA PUMP BARREL 180 S 70 1 1100 150 180 The following accessories are available for the drum pumps drum cover dust cover follower plate high pressure delivery hoses and pistol grease guns Schaeffler Technologies IS1 93 94 Lever grease gun and reinforced hose Available lever grease guns IS1 Available reinforced hoses Lubrication devi
33. to the application IS1 155 Training Training material Literature on the correct mounting of bearings is readily available howeverthere is a general lack of appropriate equipment on which apprentices can practise in as practical a sense as possible As a result trainers from the Schaeffler training workshops have developed a mounting cabinet and a mounting cross for practising the mounting and dismounting of rolling bearings Mounting cabinet The mounting cabinet is used in the 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 Material from the mounting cabinet is however also used to provide instruction on individual contents with the aid of various mounting sets Figure 1 i i u N ali 5 In ma a Lace Figure 1 Basic course Mounting cabinet Mounting cross In order to provide professional training courses on the correct mounting and dismounting of rolling bearings Schaeffler has devel oped the mounting cross figure 2 This piece of equipment allows the expert to communicate the correct handling procedure visually using a variety of different bearings and under realistic conditions Figure 2 Mounting cross Ne O re lt x 00 oO Oo Oo Further information on the Internet Comprehensive information can be found at www schaeffler de in the menu Pro
34. 0 2L KIT TOOL RAILWAY AXLE Bu SS PUMP1600 VALVE NIPPLE PUMP1600 VALVE SOCKET PUMP1000 MANO DIGI IS1 000190A5 00019EB6 00019DDB 000179BD Product overview Hydraulic mounting and dismounting Manometer PUMP1000 MANO G1 2 PUMP PIPE High pressure pipe PUMP1600 MANO G1 2 PUMP2500 MANO G1 2 000179B5 00017AD7 Sleeve connector PUMP SLEEVE CONNECTOR amp 00017AC7 34 IS1 Schaeffler Technologies Features Software Mounting Manager Mounting methods Measurement ofthe axial drive up distance Measurement ofthe reduction in radial internal clearance Schaeffler Technologies Hydraulic mounting and dismounting Hydraulic tools can be used to apply large forces These tools are therefore particularly suitable forthe mounting and dismounting of large bearings or parts with a tapered bore Hydraulic nuts are used as a mounting tool Pressure can be generated using oil injectors hand pumps or hydraulic units The software Mounting Manager gives assistance in selecting the correct mounting of bearings and offers the following options It shows various mechanical and hydraulic mounting methods It calculates the data required for mounting in relation to reduction in radial internal clearance drive up distance and start pressure It gives advice on mounting It generates a list ofthe accessories and tools required It also contains a library with references to publications
35. 04 IS1 Alignment Allthe parts ofthe shaft alignment device are supplied packed in a case figure 6 1 manual control device 1 transmitter and receiver including cable 2 m long 1 reflector 5 batteries 1 Allen key 1 cable for connecting USB memory stick to device 1 cable for connecting device to PC via USB port 2 brackets 2 chains 300 mm long 4 posts 115 mm long 1 tape measure 1 case LASER EQUILIGN OM h k 00019C8D Schaeffler Technologies Replacement parts Comprehensive range of accessories Accessories individual parts Schaeffler Technologies Description Manual control device Transmitter receiver with cable Reflector Cable for USB memory stick 2 m long Cable for PC 2 m long Bracket Chain 300 mm long Post 115 mm long Tape measure 1 m long Case Scope of Designation delivery Quantity LASER EQUILIGN DEVICE LASER EQUILIGN TRANS LASER EQUILIGN REFLECT LASER EQUILIGN USB CABLE LASER BRACKET LASER CHAIN300 SET LASER POST115 SET LASER TAPE LASER EQUILIGN CASE LASER EQUILIGN PC CABLE 1 A comprehensive range of accessories is available in orderto expand the possible applications of the base device FAG Top Laser EQUILIGN see table and figure 7 page 106 The accessories can be ordered as a set in a handy robust case or as individual parts Description Chain 600 mm long Chain 1500 mm long Post 150 mm long Post 200 mm long Post 250 mm long Po
36. 200 ARCALUB C8 LC800 SPEED2 6 ARCALUB C8 LC800 VIB3 ARCALUB C8 LC800 BIO2 ARCALUB C8 LC800 FOOD2 ARCALUB C8 LC800 CLEAN M Other accessories available by agreement Enquiries industrial services schaeffler com 49 2407 9149 66 IS1 91 Lubrication devices Pistol grease guns Pistol grease guns have a 4 digit digital counter that displays the lubricant quantity in grams The specific mass of the lubricant can be set Ordering designation ARCA PUMP BARREL GUN METER Service pumps These service pumps see table are particularly suitable for the for wind turbines relubrication of bearings in wind turbines They comprise a rigid frame with rollers an electrically driven grease pump a holder for the grease container and a pistol grease gun with a 4 m long hose A hook and eye on the frame can be used to transport the service pump securely into the nacelle The rollers one of which can be anchored can be used to move the device within the nacelle The service pump can be used at temperatures from 10 C to 40 C It can be filled with the greases Arcanol LOAD400 LOAD460 and MULTITOP in 12 5 kg buckets Available service pumps Designation Maximum Delivery rate for wind turbines delivery pressure bar cm min 280 ARCA PUMP WIND SERVICE KIT 92 IS1 Schaeffler Technologies Grease pumps Grease pumps are driven by pneumatic electrical or manual means Grease dispensing units Grease dispensing units ARCA PUMP see
37. 40 79 SET 4 internal extractors 1 countersupport 1 impact extractor 1 carry case PULLER INTERNAL 10 100 SET 6 extraction legs 2 screw spindles 1 carry case For detailed information see TPI 216 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries industrial services schaeffler com 49 2407 9149 66 IS1 29 Hydraulic extractors Available hydraulic extractors with integral hand pump Available hydraulic extractors with separate hand pump Further information IS1 Mechanical mounting and dismounting The hydraulic extractors see tables are used where higher extrac tion forces are required These devices allow rolling bearings gears sleeves and many other shrink fitted parts to be quickly and easily dismounted For larger grip depths longer extraction arms are available accessories Operating personnel can be protected by means of a Safety grid or a Safety cover The advantageous features of hydraulic extractors are as follows parts under mechanical load are made from high quality chromium molybdenum steel the smooth running piston is made from chromium plated hardened and tempered steel stroke travel adjustable by means of standard adapter screw thread for setting of optimum grip depth simple centring by spring loaded steel cone simple conversion to two arm operation if there is insufficient space for three arms optimum operating position due to rotatable pump hand l
38. 80 80 80 80 Characteristic applications Temperatures Low i ibra Support Relubri friction i for seals cation high facility speed Low High Ball and roller bearings in rolling mills construction machinery automotive engineering spinning and grinding spindles Low i Vibra Support Relubri friction 3 tions for seals cation high facility aaa Ball bearings up to 62 mm diameter in small electric motors agricultural and construction machinery household appliances l R i BEE Ball bearings from 62 mm diameter in large electric motors agricultural and construction machinery ventilators Characteristic applications Temperatures Ball roller and needle roller bearings linear guidance systems in machine tools Ball and roller bearings in rolling mills rail vehicles paper machinery Ball and roller bearings in mining machinery construction machinery main bearings for wind turbines Ball and roller bearings wind turbines bearings with pin type cage Ball and roller bearings in mining machinery o construction machinery cement plant Schaeffler Technologies IS1 i Greases Designation Thickener Base oil Base oil Operating for wide temperature ranges viscosity temperature mm s eC to TEMP90 Poly Partially 148 3 40 160 carbamide synthetic oil TEMP110 Lithium Partially 130 2 40 160 complex synthetic oil Definition of s
39. AG ProTorq WL 80 366 Flyer FAG Wear Debris Check WL 80 368 Services flyer Thermography WL 80 373 Flyer FAG WiPro WL 80 374 Services flyer Endoscopy WL 80 375 Flyer FAG SmartCheck WL 80 377 Flyer FAG Temperature Measuring Devices WL 80 378 Flyer FAG Top Laser EQUILIGN WL 80 380 Flyer FAG GreaseCheck Rolling bearing reconditioning TPI 207 Reconditioning and Repair of Rolling Bearings WL 80 367 Flyer Maintenance Service of Wheelset Bearings WL 80 383 Flyer Mounting and Reconditioning Services Schaeffler Technologies IS1 159 I haa t re Bra Timu E p Fen Addresses Germany Schaeffler Technologies AG amp Co KG Worldwide You can find allthe addresses and con Postfach 1260 tacts for Schaeffler at www schaeffler com 97419 Schweinfurt Georg Sch fer Stra e 30 97421 Schweinfurt Tel 49 2407 9149 66 Fax 49 2407 9149 59 industrial services schaeffler com www schaeffler com services Schaeffler Technologies AG amp Co KG Industriestra e 1 3 91074 Herzogenaurach Tel 49 91 32 82 0 Fax 49 91 32 82 49 50 info de schaeffler com Schaeffler Technologies AG amp Co KG Industriestra e 2 97483 Eltmann Tel 49 9522 71 503 Fax 49 9522 71 511 schulungszentrum schaeffler com 160 IS1 Schaeffler Technologies MATNR 036908134 0000 1S 1 05 GB D 2015073 Printed in Germany by w nsch Schaeffler Technologies AG amp Co KG Postfach 1260 97419 Schweinfurt Georg Sch fer Stra e
40. E AN ER kistor R i 135 Condition Monitoring een 136 Corrective maintenance anne 142 Rolling bearing reconditioning esssssesesssssssessesssessessessesseeseese 143 Technical consultanity res 146 TOO BO DOEN eier 148 IS1 131 Features Mounting and dismounting Mounting and dismounting services 132 IS1 Services Schaeffler offers irrespective of the manufacturer of the bearing arrangement a wide range of services relevant to the lifecycle of a rolling bearing starting with mounting and progressing through maintenance to the reconditioning of rolling bearings During the operational phase the Schaeffler experts provide support through services in the fields of condition monitoring and corrective maintenance Companies that wish to build up their knowledge in the areas of rolling bearings and condition monitoring also have access to the Schaeffler training and consultancy portfolio on site centrally or online Our e learning portfolio on the Internet provides the first steps into this field In this way customers benefit from the expertise of a leading supplier of rolling and plain bearings The Schaeffler industrial service experts offer mounting and dismounting services for rolling bearings that are applicable across industrial sectors They have detailed knowledge and extensive experience in all industrial sectors The experts in the Industrial Service function are trained and skilled personnel who can provide reliab
41. NERATOR HEAT INDUCTOR HYDNUT INJECT1600 INJECT2500 KLR Schaeffler Technologies Vibration measuring device Detector Ill ssessesseoseoserres 116 Vibration measuring device Detector III with automatic measurement point detection 116 Balancing function for Detector III nennen 116 Online monitoring system DTECT X1 g ssssrsssssrrrsrrsssrerrrrrssre 116 Online monitoring system WiPIOg sssssersrrsrrsrrrrrsssrrserrrrrrrs 116 BEOS edle bant ame be ERR SAARNAK 66 ED ee 66 MOUNTING Tool SET reserver ea 18 Heal tresistant ClOVES mtr ttetersveanebdnen A R 72 Heat resistant and cut resistant gloves nennen 72 Heat resistant and oil resistant gloves nennen 72 Grease sensor GreaseCheck annees reennn oeren 126 Filed HENNE 2a 48 Heat condu cting paste assistere eN 48 Induction heating device for workpieces amtoa mass Or LO Keinen E SE SERENE ESS DERS 52 Induction heating device for workpieces Up toa Mass OL 20 KS eek 52 Induction heating device for workpieces ptoa mass of AO Ko na ae 52 Induction heating device for workpieces Up toa mass Ol LT S KI 2 52 Induction heating device for workpieces pto a miss Or 300 Ks 2 52 Induction heating device for workpieces up to a mass of 600 Ka nennen 53 Induction heating device for workpieces Up toa mass or T200 KB a ae 53 Electic heating plate susanne 48 Electric heating plate 22 An 48 Generator for heati
42. PPLE A G1 4 M14 PUMP NIPPLE B G1 4 M14 PUMP NIPPLE A G1 4 M18x1 5 PUMP NIPPLE A G3 8 G1 4 PUMP NIPPLE B G3 8 G1 4 Designation PUMP ADAPTER A G1 4 PUMP ADAPTER B G1 4 00017A03 Designation PUMP NIPPLE A G3 4 G1 8 PUMP NIPPLE B G3 4 G1 8 PUMP NIPPLE A G3 4 G1 4 PUMP NIPPLE B G3 4 G1 4 PUMP NIPPLE A G3 4 G3 8 PUMP NIPPLE B G3 4 G3 8 PUMP NIPPLE A M18X1 5 G1 4 PUMP NIPPLE A M18X1 5 G3 8 PUMP NIPPLE A M18X1 5 G3 8 Designation PUMP ADAPTER A G3 4 PUMP ADAPTER B G3 4 IS1 45 Hydraulic mounting and dismounting Rapid push fit coupling A suitable connecting nipple is always included in the delivery of ahydraulic nut Each hand pump with an oil pressure upto 1600 bar is supplied with a rapid push fit coupling The rapid push fit coupling allows rapid connection and disconnection of a hose and is suitable for oil pressures up to 1600 bar Figure 10 and table HH After the coupling has been fitted the high pressure hose must be secured to the connection point by means ofa chain or cord 1 Nipple 2 Socket 00019DD9 Figure 10 Rapid push fit coupling Available nipple and socket Designation Threaded connector Component PUMP1600 VALVE NIPPLE Nipple PUMP1600 VALVE SOCKET G1 4 Socket Pump holders Pump holders are available with and without a connector G1 2 for a manometer see table Available pump holders Designation PUMP HOLDER 2 PUMP HOLDER 3 Pump holder with connector for manometer
43. achine tools etc This lubricator from protection class IP65 has a very compact design It has one or two pump bodies that can be individually controlled depending on the design This means it can supply one or two lubrication points with lubricant LC units are available in the size 250 cm The lubricator is supplied with voltage either from a battery or via a mains power pack It can work independently or can be optionally controlled by an external control system The advantages of the lubricator are as follows supply of up to two lubrication points supply of set lubricant quantity independent of temperature reliable piston pump as delivery pump reduced personnel costs compared to manual relubrication favourable price performance ratio operating temperature from 20 C to 70 C different lubrication intervals can be set for each lubrication point battery or mains operation DC 24 V possible pressure build up to 50 bar coupling with machine operation possible can be controlled via an external control system Schaeffler Technologies Available lubrication systems CONCEPT2 Available LC units Further information Schaeffler Technologies Designation CONCEPT2 1P CONCEPT2 2P CONCEPT2 1P 24VDC CONCEPT2 2P 24VDC Designation ARCALUB C2 LC250 MULTITOP ARCALUB C2 LC250 MULTI2 ARCALUB C2 LC250 LOAD150 ARCALUB C2 LC250 LOAD220 ARCALUB C2 LC250 LOAD400 ARCALUB C2 LC250 LOAD460 ARCALUB C2 LC250 LOAD1000 LC units are also avai
44. aeffler offers the FAG Detector Ill The online monitoring systems continuous measurement include FAG SmartCheck FAG DTECT X1 FAG WiPro and FAG ProCheck In order to achieve optimum networking to plant control facilities or monitoring centres all online systems have versatile communication options as standard Worldwide service On all devices relating to condition monitoring Schaeffler offers a worldwide service from the customer hotline to customer specific service contracts Vibration measuring device FAG Detector Ill is a handy easy to use vibration measuring device FAG Detector Due to preinstalled standard configurations in accordance with DIN ISO 10816 this is a plug and play solution allowing early and authoritative information on the condition of machinery entirely without time consuming training or system configuration work This allows for example rapid inspection of ventilators pumps electric motors compressors or vacuum pumps All the user must do is start the measurement process by pressing a few buttons and wait until itis completed The device evaluates the measurement results pcx and presents the results with self explanatory symbols on the device display Figure 1 is Le Je 1 367 I 1 Value OK 2 Prealarm 3 Main alarm Figure 1 Symbols in the device display 00017A6A Schaeffler Technologies IS1 117 Analysis software Automatic detection of measurement points Further
45. and analysed there by the operator or external service providers such as the Schaeffler vibration experts This is particularly important for customers who still have little experience of data analysis or wish to outsource this function Further information For detailed information see TPI 214 FAG SmartCheck or www FAG SmartCheck com Enquiries industrial services schaeffler com 49 2407 9149 66 Online monitoring system FAG DTECT X1 is a flexible online system for the monitoring FAG DTECT X1 of rotating components and elements in the machinery and plant industry Typical applications can be found forexample inthe steel raw materials paper and marine industries The system gives early reliable detection of possible damage and thus helps to prevent unplanned and expensive downtime This reduces the risk of possible production shutdowns As a result the capacity utilisation of machinery and plant is increased Versatile system The system can be tailored to customer specific requirements by means ofthe software The base device is available as a 2 and an 8 channel system The system is suitable for connection of all conventional acceler ation speed and proximity probes AN Due to its compact size and robust housing class IP 67 it is suit ku able fora wide range of monitoring applications It has standardised connectors allowing easy installation on machinery and plant Remote monitoring Defects and damage can be d
46. and inspection The taper gauge MGK133 is used for the measurement of external tapers 1 12 and 1 30 with a taper diameter of 27 mm to 205 mm The reproducibility of the measurement results is less than 1 um The gauge rests on the workpiece with four hardened and polished pins The position of the gauge on the taper is defined by these pins and a stop The stop can be attached to either the front or back of the gauge The gauge has two movable measuring brackets One of these is in contact with the small taper diameter the other with the large taper diameter There is a fixed spacing between the measuring brackets The deviation of the taper diameter from the nominal value is displayed in both measurement planes by a precision indicator The gauge is set using a reference taper available by agreement Available by agreement The taper gauge MGK132 is used for the measurement of external tapers with a taper angle of 0 to 6 and a taper diameter of 90 mm to 360 mm The reproducibility of the measurement results is less than 1 wm The gauge rests on the workpiece with four hardened ground and lapped ledges The ledges form an angle of 90 The position of the gauge on the taper is defined by a stop on the front or back of the gauge The measurement slide runs between the support ledges A dial gauge in the housing acts against the measurement slide and displays the deviation of the taper diameter from the nominal value The dev
47. and shaft remain intact and can be used again The extraction plates can be fitted under the bearing with just a few movements Tae HEE Eel o fu x 00019341 Designation Dimen Recommended for extractor sions Amin dmax PULLER HYD PULLER 3ARM mm mm PULLER TRISECTION 50 12 50 160 PULLER TRISECTION 100 230 PULLER TRISECTION 160 310 PULLER TRISECTION 260 90 260 175 200 250 300 430 PULLER TRISECTION 380 140 380 250 300 400 660 For detailed information see TPI 216 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries industrial services schaeffler com 49 2407 9149 66 IS1 31 Product overview Hydraulic nuts Oil injectors Hand pumps Single stage Twin stage For drive up distance 32 IS1 Hydraulic mounting and dismounting HYDNUT 0008AAFO PUMP1000 0 7L INJECT2500 INJECT1600 0001798F 00089FF1 PUMP1000 4L PUMP1000 8L PUMP1600 4L PUMP1600 8L PUMP2500 4L PUMP2500 8L PUMP1000 4L CONTROL 0008A00C 000179C2 Schaeffler Technologies High pressure pumps Mobile hydraulic unit Tool set Connectors accessories Adapters and reduction nipples Rapid push fit coupling Pump holder Digital manometer Schaeffler Technologies PUMP4000 0 2L TOOL RAILWAY AGGREGATE PUMP NIPPLE PUMP ADAPTER PUMP HOLDER 2 PUMP HOLDER 3 0008A027 0008A039 000179C3 00017AC5 PUMP2500
48. ations Addresses Europe Schaeffler Technologies AG amp Co KG Georg Sch fer Stra e 30 97421 Schweinfurt Tel 49 9721 91 1919 reconditioning schaeffler com Mettmanner Stra e 79 42115 Wuppertal Tel 49 202 293 2226 reconditioning schaeffler com USA Canada Schaeffler Group USA Inc 308 Springhill Farm Road Fort Mill SC 29715 Tel 1 888 462 8227 reconditioning schaeffler com Wuppertal D Schweinfurt D eYinch uan CN Taicang CN Auburn AUS China Schaeffler China Co Ltd Taicang Schaeffler Trading Shanghai Co Ltd No 1 Antuo Road Anting Jiading District 201804 Shanghai Tel 86 21 3957 6500 reconditioning schaeffler com Schaeffler Ningxia Co Ltd Wenchang South Road 86 Xixia District 750021 Yinchuan Tel 86 95 1207 2333 reconditioning schaeffler com Australia Bearing Engineering Services BES A Division of Schaeffler Australia PTY Ltd 10 Melissa Street E Ah Auburn NSW 2144 OF Tel 61 2 987 17 81 11 BES au schaeffler com www schaeffler com au bes 2 1 Reconditioning for bearings with D 500 mm 2 Reconditioning for bearings with D gt 500 mm Further information TPI 207 Reconditioning and Repair of Rolling Bearings Schaeffler Technologies IS1 145 Technical consultancy Condition oriented maintenance 146 Service concepts for plant manufacturers and IS1 operators Example 1 Instruction Services Companie
49. aulic nut is then screwed onto the shaft and the hand pump is connected The hand pump is then operated until the pressure to reach the start position is achieved The pump is then operated further to drive the bearing by the required drive up distance and thus achieve the final position 1 Always operate the pump together with a manometer The user manual for the pump PUMP1000 4L CONTROL contains a table that shows the number of strokes necessary to achieve the required drive up distance of the bearing The required drive up distance is calculated using the software Mounting Manager 1 Hand pump 2 Hydraulic nut 3 Rolling bearing 4 Tapered seat 5 Initial position 6 Start position 7 Drive up distance Final position Figure 5 Mounting of a rolling bearing using PUMP1000 4L CONTROL 00015F9B Scope of delivery 1 hand pump with digital manometer 1 high pressure hose with coupling sleeve 1 spacer ring HYDNUT50 to HYDNUT150 1 push fit coupling nipple 1 user manual 1 metal case Ordering designation PUMP1000 4L CONTROL Schaeffler Technologies IS1 41 Hydraulic mounting and dismounting High pressure pump The high pressure pump Figure 6 is suitable for the mounting and dismounting of rolling bearings for shaft diameters up to 250 mm Due to the high oil pressure available the pump can also be used to expand and mount heavy shaft couplings and gears by means of the hydraulic method The high pressure pump ca
50. beam into another Caution A person s eyes J ir Scope of delivery 1 measuring device Base device 4 battery 1 wrist strap 1 adapter for camera tripod 1 carry case 1 protective rubber slip cover 1 user manual 1 report software 1 case Ordering designation TEMP CHECK PLUS Further information For detailed information see publication WL 80 377 FAG Temperature Measuring Devices Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies IS1 111 112 IS1 Infrared thermometer FAG TempCheck PRO Caution A Checking the operating condition The infrared thermometer FAG TempCheck PRO is suitable for the thermal monitoring of machine components and fluids Tempera tures can be measured by either non contact or contact means The infrared thermometer measures the infrared radiation emitted by an object and uses this to calculate the surface temperature The non contact measurement makes it possible to easily determine the temperature of difficult to access or moving objects Compared with the FAG TempCheck PLUS the FAG TempCheck PRO has a wider measurement range higher optical resolution a data memory and two additional temperature sensors for contact temperature measurement The surface temperature sensor can be used to measure the temperature of surfaces by contact means The immersion sensor can be used to measure the temperature of for example fluids or lubricants The features o
51. brication N St a lt 00 oO Oo Oo Products Condition Monitoring 00019DD6 Services 00017AF2 Training courses 00017B16 Appendix Publications Addresses 0001A281 14 IS1 Schaeffler Technologies FAG Products Mounting Mechanical mounting and dismounting Hydraulic mounting and dismounting Thermal mounting and dismounting contact heating Thermal mounting induction heating devices 16 IS1 Products Mounting Page PEOCUECROVEIVICW nannte 18 Features MOUNTING toolsets a 2a 21 SOCKET ENC NE S auciren a be 22 Hook and pin WIENCHES asie EE 23 Me amp chanicalexfiact fs a 25 Hydraulic extractors saroe ea a 30 Three section extraction plates nennen 31 PIOdUCL OVENI Warn null 32 Features Software Mounting MaNagel ccseceeccsececceeccsscesceeeceesceecs 35 HIYdraulichuts za 36 Pressure generation devices sssssoseorrrrrerrerrerrerrrrrrerrrrrrr 38 Mobile hydraulic unit oaeen ooeneeonnnesenvevenn 43 Connectors ACCESSONES u a sea 45 PIOGUCTIOVEIVICW senteren edad a 48 Features Electric heating Blatesc nase ea lan 49 Heatm SS orero ensure 50 Heat conducting Paste sn 51 Product OVETVIGW as ordrer erne E AA lendenen ide densd 52 Features Induction heating devices HEATER nennen 54 FUN TION Ar een 56 FAG Heating Manager kei 57 Dimension tables Heating devices HEATER product range neen 58 Schaeffler Technologies Thermal
52. c nut 2 replacement seals 1 screw plug 1 connecting nipple 1 eye bolt 1 hand lever 1 mounting paste 1 user manual Ordering designation HYDNUT Further information For detailed information see TPI 196 FAG Hydraulic Nuts Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies IS1 37 Hydraulic mounting and dismounting Pressure generation devices Pressure generation devices are available in various designs from oil injectors through hand pump sets to high pressure pumps Use of pressure generation devices Type Designation Application Oil INJECT2500 Mounting and dismounting of injector bearings with tapered bore INJECT1600 Mounting and dismounting of bearings with tapered bore Hand PUMP1000 0 7L Mounting and dismounting of pump rolling bearings For driving hydraulic nuts up to HYDNUT395 or HYDNUT300 HEAVY PUMP1000 4L Mounting and dismounting of rolling bearings Mounting and dismounting of components such as ships propellers For driving hydraulic nuts up to HYDNUT800 PUMP1000 4L CONTROL Mounting and dismounting of rolling bearings in conjunction with a hydraulic nut PUMP1600 4L Mounting and dismounting of rolling bearings Mounting and dismounting of components such as rudder splines and rudder blades PUMP2500 4L Mounting and dismounting of bearings Mounting and dismounting of components such as gears and couplings High PUMP4000 0 2L Dismounting of bearings pressur
53. ces The lever grease gun see table can be used to manually relubricate rolling bearings via lubrication nipples The container on the lever grease gun can be filled with 500 g loose grease or with a 400 g cartridge The cartridge must conform to DIN 1284 diameter 53 5 mm length 235 mm The lever grease gun is connected to the lubrication nipple via a reinforced hose The reinforced hose must be ordered separately see table The connector thread is G1 g The reinforced hose has a hydraulic grip coupling for connection to the taper type lubrication nipple in accordance with DIN 71412 Alternatively the reinforced hose can be fitted with a connector for cylindrical lubrication nipples in accordance with DIN 3404 In place of the hydraulic grip coupling slide couplings for button head lubrication nipples in accordance with DIN 3404 or other nozzles can be connected These connectors are available from normal trade outlets Designation Maximum Delivery quantity delivery pressure per stroke cm ARCA GREASE GUN 2 Designation Length Connector mm 300 Cylindrical lubrication nipple with head 16 mm to DIN 3404 ARCA GREASE GUN HOSE 300 Taper type lubrication nipple to DIN 71412 ARCA GREASE GUN HOOK ON HOSE Schaeffler Technologies FAG 96 IS1 Schaeffler Technologies Alignment Checking the operating condition Vibration diagnosis Monitoring of components Monitoring of lubricants Schaeffle
54. cific certification from Schaeffler Further information tel 49 9721 91 4995 fax 49 9721 91 3639 134 IS1 Schaeffler Technologies Lubrication Services Advantages Figure 3 Support from the lubrication service large grease selection Schaeffler Technologies Inmore than half of all cases inadequate lubrication isthe cause of unplanned machine downtime Thelife ofrotatingmachine elements can be significantly extended by the use of greases appropriate to the different operating and environmental conditions as well as the definition of and adherence to lubrication intervals and quantities Services relating to lubrication figure 3 include the selection of lubricants and lubrication systems the preparation of lubrication and maintenance plans lubrication point management consultancy on lubricants lubricant investigations and tests The Schaeffler lubrication service helps to prevent failures of rotating components increase productivity reduce lubrication costs An extensive selection of high quality rolling bearing greases is available These greases were specially tested and selected for use in rolling bearings grean IND _ en f r 000192B4 IS1 135 136 IS1 Condition Monitoring Vibration measurements Continuous monitoring Services The malfunction free and optimised operation of complex machinery and plant can normally only be achieved by means of condition based mainte
55. cured by a quality management system certified to ISO 9001 2008 In order to achieve this objective we have created a network of Schaeffler sales partners This network makes it possible to support all end customers worldwide with the same high level of expertise and is thus the optimum supply strategy The addresses of all sales partners certified by Schaeffler can be found at www schaeffler de sales Mounting Toolbox mounting made easy Here is the link to the Mounting Toolbox http mtb schaeffler de Figure 2 Mounting Toolbox The Schaeffler Mounting Toolbox Figure 2 brings together valuable knowledge relating to the mounting and dismounting of rolling bearings In individual video sequences the service experts present step by step the points that must be paid close attention for correct mounting lubrication and alignment The interface is a Virtual Plant and offers the user easy rapid navigation With just a few clicks of the mouse it is possible to gain an overview of the tools and accessories as well as to select individual video sequences Internet access is all that is needed to enter the Virtual Plant and watch the Schaeffler fitting personnel at work SCHAEFFLER wt db ran Vikan pant Mounieg i Damani Sige lernen Aming Serres Mouang Service Sener praparatans gereral safety genen lt Lu ON ca 00 Oo Oo Oo 6 IS1 Schaeffler Technologies Schaeffler Technologies Contents Page
56. d testing systems Arcanol rolling bearing greases have superior characteristics in all areas compared to normal greases Figure 1 L rating life n speed R mixed friction t lubrication interval 1 Normal grease 00017A41 Figure 1 Characteristics of lubricants 84 IS1 Schaeffler Technologies Grease container sizes Arcanol grease a ies MULTITOP MuLTI2 pH LOAD220 LOAD1000 TEMP90 TEMP120 TEMP200 SPEED2 6 ViB3 BIO2 FOOD2 MoTION2 MOUNTINGPASTE 1 Other containers are available by agreement Grease container sizes TArcanolgrease Drum ln 180 kg MuLTITOP je je Jo jo MuLTI2 e jo Jo Jo MuLTI3 je je Jo Jo LoaD150 CEE CE LoAD220 SE SEEN CE ne LoAD400 e je je je je LoAD460 je je Je je je LoAD1000 eene me TEMP9O LJ EN en RE e TeMP110 a ae Se ee ae TeMP120 ee St RE CEE TemP200 FBE Fr ee SPEED2 6 Ba el ae IE ViB3 en nn en ae CE Bio Sea SE Pr SE Foop2 je je e Je je Jo Morion2 e je je je je MOUNTINGPASTE 1 Other containers are available by agreement Further information For detailed information see TPI 168 Arcanol Rolling Bearing Greases Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies IS 1 Product overview Lubricator Lubrication system Pistol grease guns Service pumps for wind turbines 86 IS1 Lubrication devices CONCEPT2 0008A91C CONCEPT8
57. delivery ofthe tools including all add on parts user manuals available in several languages If one of our qualified experts in the Industrial Service function is commissioned to carry out the particular activity rental costs are not generally incurred Schaeffler Technologies IS1 133 Services Certification Mounting errors are the cause of approximately 25 of all premature bearing failures In addition to basic knowledge of rolling bearings it is particularly important to have theoretical and practical know ledge of the correct mounting and dismounting procedures in order to achieve a long bearing operating life Figure 2 Figure 2 Training on dismounting Inner ring of wheelset bearing 0008B180 In order to ensure that the training received by mounting personnel is as close to reality as possible Schaeffler offers certification of individual mounting and dismounting processes Here information on handling rolling bearings correctly and avoiding errors during mounting and dismounting is imparted by Schaeffler experts This is carried out with direct reference to the specific application and the individual circumstances of the cus tomer A practical demonstration of the mounting and dismounting process is then provided which also covers adherence to the necessary processes and specifications Finally the training participants must put their acquired knowledge to the test Only then do they receive application spe
58. depth tion Eh Kelle PULLER 3ARM160 pn Jan n Im _ PULLER 3ARM230 100 PULLER 3ARM310 100 PULLER 3ARM430 150 PULLER 3ARM660 660 340 22 2 34 2 150 26 IS1 Schaeffler Technologies Hydraulic pressure tool 1 Extractor spindle 2 Pressure tool 3 Shaft end Figure 2 Pressure tool Available pressure tools Schaeffler Technologies The pressure tool PULLER SUPPORT see table is used to loosen tightly fitted parts in conjunction with mechanical extractors It is applied between the shaft end and extractor spindle The spindle diameter of the extractor must not be less than the stated minimum value see table The maximum torque must be observed FAI ka 4 0008AC5B Designation Axial force Minimum Maximum spindle torque diameter kN mm Nm PULLER SUPPORT80 25 PULLER SUPPORT150 150 M30 50 IS1 27 28 IS1 Special bearing extractors Ordering example Base device Ordering designation Ordering example Collet Ordering designation Ordering example Collets Ordering designation Mechanical mounting and dismounting Special bearing extractors PULLER SPECIAL can be used to dismount radial bearings of the following types deep groove ball bearings self aligning ball bearings cylindrical roller tapered roller and spherical roller bearings inner rings only angular contact ball bear ings and four point contact bearings The special bearing extractor comprises the base device and a coll
59. ducts amp Services INA FAG Products Training Enquiries schulungszentrum schaeffler com 49 9522 71 503 156 IS1 Schaeffler Technologies Schaeffler Technologies IS 1 157 Publications FE AD Ordering designation Title Mounting TPI 156 Tapered Roller Bearing Units TAROL Mounting Maintenance Repair TPI 180 FAG Tools for Thermal Dismounting TPI 195 FAG Pressure Generation Devices TPI 196 FAG Hydraulic Nuts TPI 200 FAG Heating Devices for Mounting of Rolling Bearings MH 1 Mounting of Rolling Bearings WL 80 369 Services flyer Heating of Bearings using Medium Frequency Technology WL 80 376 FAG Medium Frequency Heating Device Lubrication TPI 168 Arcanol Rolling Bearing Greases TPI 176 Lubrication of Rolling Bearings Training WL 80 386 Certified Vibration Expert DIN ISO 18436 2 158 IS1 Schaeffler Technologies Publications FAG Ordering designation Title Condition Monitoring TPI 170 FAG DTECT X1 Continuous Monitoring of Plant and Machinery TPI 182 FAG Alignment Tools Top Laser SMARTY2 TRUMMY2 EQUILIGN SHIM TPI 199 FAG ProTorg TPI 214 FAG SmartCheck TPI 234 FAG GreaseCheck Condition Monitoring of Greases in Rolling Bearings TPI WL 80 64 FAG Detector Ill The Solution for Monitoring and Balancing TPI WL 80 69 FAG ProCheck State of the Art Machinery Monitoring for Maximum Availability WL 80 362 Flyer FAG ProCheck WL 80 363 Flyer FAG ProCheck Ex WL 80 365 Flyer F
60. e For interference fits with pump high contact pressure Delivery rate and oil reservoir are small PUMP2500 0 2L KIT Dismounting of bearings For interference fits with high contact pressure Delivery rate and oil reservoir are small Further information For detailed information see TPI 195 FAG Pressure Generation Devices 38 IS1 Schaeffler Technologies Oil injectors Oil injectors have only a small delivery volume see table They are suitable forthe dismounting of rolling bearings and other press fits with direct seating on tapered shafts figure 3 4 Oil injector 2 Valve nipple 3 Shaft Figure 3 Oil injector 00019E27 Conventional O rings can be used as replacement seals OR6 1 5 for INJECT2500 OR10 2 0 for INJECT1600 The oil injector can be refilled with oil without losses by connecting a valve nipple Available oil injectors Connec Oil Maximum For shaft tor volume oil diameter pressure up to Valve nipple cm bar mm INJECT2500 SET INJECT2500 INJECT2500 VALVE Gg 8 2500 80 INJECT1600 SET INJECT1600 INJECT1600 VALVE G3 4 27 1600 150 Designation Set Oil injector Ordering example for set Oil injector with maximum oil pressure of 2 500 bar Valve nipple Ordering designation INJECT2500 SET Oil injectors and valve nipples can also be ordered individually Schaeffler Technologies IS1 39 Hand pumps Single stage pump Available s
61. e is between 30 C and 150 C The paste is resistant to water water vapour and many alkaline and acidic media Available mounting pastes Designation NE ARCANOL MOUNTINGPASTE 70G Tube containing 70 g ARCANOL MOUNTINGPASTE 250G Tube containing 250 g ARCANOL MOUNTINGPASTE 400G Cartridge containing 400 g ARCANOL MOUNTINGPASTE 1KG Can containing 1 kg Anti corrosion oil This oil gives protection of bearings that have been unpacked It also gives long term protection against corrosion of bright metallic surfaces for example on devices and machinery during storage indoors In general it is not necessary to wash the anti corrosion oil out of rolling bearings It gives neutral behaviour towards conventional rolling bearing greases and oils The oil can be removed using alkaline solvents or neutral cleaning agents Ordering example Spray can containing 0 4 Ordering designation ARCANOL ANTICORROSIONOIL 400G Schaeffler Technologies IS1 75 76 IS1 Schaeffler Technologies FAG Products Lubrication 78 IS1 Schaeffler Technologies Lubricants Lubrication devices Schaeffler Technologies Products Lubrication Page Matrix Multipurpose greases sccccssscesscccessccesscceesccesssceessceeeseees 80 Greases for high loads asten esn 20er 80 Greases for wide temperature ranges nennen eenn 82 SPeclal8reases weereens ade Vee venta eee 82 Features Rolling bearing greases Arcanol nennen eenen 84 Product ov
62. e with the original drawings In the case of all bearings work is carried out using only original components and original replacement parts High quality reconditioning is achieved as a result of our comprehensive knowledge of rolling bearings Schaeffler Technologies IS1 143 Market sectors Dimensions Overview Figure 9 Level to Level IV 144 IS1 Services Reconditioning of rolling bearings is of particular interest if these are used in machinery or vehicles in the following market sectors raw material extraction and processing metal extraction and processing pulp and paper railways Reconditioning and where required modification can be carried out on rolling bearings with an outside diameter D from 100 mm to 4 500 mm Please contact us for information on reconditioning or modifying bearings with other outside diameters The operations necessary in reconditioning are dependent on the condition of the rolling bearing In orderto allow a reliable statement of the work required the rolling bearing must be disassembled cleaned and then carefully examined Beyond this requalifying process Level I which is always necessary further reconditioning steps may be appropriate Figure 9 0008703C Schaeffler Technologies Worldwide reconditioning Schaeffler offers the reconditioning of rolling bearings at several locations worldwide figure 10 Fort Mill USA 0008501C Figure 10 Reconditioning loc
63. echnologies IS1 43 Hydraulic mounting and dismounting Toolset Tool sets are produced for a specific application Figure 8 When making enquiries or placing orders information on the bearing type and installation drawings shaft housing additional parts are required Figure 8 u 63 Tool set Ordering designation TOOL RAILWAY AXLE 00019F0C Further information For detailed information see TPI 195 FAG Pressure Generation Devices TPI 156 Tapered Roller Bearing Units TAROL Mounting Maintenance Repair Enquiries industrial services schaeffler com 49 2407 9149 66 44 IS1 Schaeffler Technologies Connectors accessories Adapters and reduction nipples 1 Type A 2 Type B Figure 9 Adapters and reduction nipples Available adapters and reduction nipples Available adapters Schaeffler Technologies Various connectors and accessories are available for use with the devices for hydraulic mounting and dismounting Adapters and reduction nipples are matched to the threads of high pressure hoses and pipes Figure 9 and tables Adapters and reduction nipples of type A with sealing ring are suitable for oil pressures up to 800 bar Figure 9 Type B with blade sealing is suitable for oil pressures up to 2 500 bar figure 9 Designation PUMP NIPPLE A G1 4 G1 8 PUMP NIPPLE B G1 4 G1 8 PUMP NIPPLE A G1 4 G1 2 PUMP NIPPLE B G1 4 G1 2 PUMP NIPPLE A G1 4 G3 4 PUMP NIPPLE B G1 4 G3 4 PUMP NI
64. ent Belt pulley alignment device LASER SMARTY2 LASER TRUMMY2 Top Laser SMARTY2 Belt tension measuring device Top Laser TRUMMY2 00019CE3 00019C83 Shaft alignment device LASER EQUILIGN LASER SHIM Top Laser EQUILIGN Shims Top Laser SHIM 00019C84 00019D92 98 IS1 Schaeffler Technologies Features Belt pulley alignment device FAG Top Laser SMARTY2 Caution A Figure 1 Electronic target mark Schaeffler Technologies Alignment These products assist in the alignment of shafts and belt pulleys and the checking of belt tension FAG Top Laser SMARTY2 is a line laser for the alignment of belt pulleys and chain sprockets with a diameter larger than 60 mm Alignment of belt pulleys and chain sprockets reduces wear and energy losses in traction drives and the associated bearings and seals Less heat is generated and the running time and reliability of the machinery is increased The features of the line laser are as follows The parallelism and misalignment of both pulleys are displayed Both horizontally and vertically mounted belt pulleys can be aligned Alignment is significantly quicker and more precise than with conventional methods Only one person is required for alignment The measuring device adheres by magnetism to the pulleys The laser beam can be clearly seen on the target marks Once the laser beam is adjusted to coincide with the slots in the target marks the machine is correctly aligned The target
65. erview een 86 Features Automatic relubrication devices unsure eneen 88 Pistolgredse SUNS werende te 92 Service pump for wind turbines s ssssserrserrsrrrsrrrrrrrrrrrrrrrrrrrs 92 Grease DUMP Seen kenne rel 93 IS1 79 80 IS1 Multipurpose greases Definition of symbols extremely suitable highly suitable o suitable less suitable not suitable Greases for high loads Definition of symbols extremely suitable highly suitable o suitable less suitable not suitable Designation Thickener Baseoil Base oil viscosity at 40 C mm2 s MULTITOP Lithium soap MULTI2 Lithium soap Lithium soap MULTI3 Designation Thickener Baseoil Base oil viscosity at 40 C mm2 s Lithium complex soap Lithium calcium soap LoAD150 LOAD220 LoAD400 Lithium calcium soap Lithium calcium soap Lithium calcium soap LoAD460 LoAD1000 Mineral oil Mineral oil Mineral oil Mineral 400 oil Mineral 400 oil Mineral oil Operating tem perature rom to 50 I 140 h le Q 30 120 20 120 Consis Operating tency temperature NLGI h le Q rom to 20 140 20 140 130 u u 130 130 1 Measurement values according to Schaeffler FE8 low temperature test Schaeffler Technologies Continuous limit temperature BC 85 5 5 Continuous limit temperature eC 90
66. esignation Further information Heat conducting paste Ordering example Ordering designation Further information Schaeffler Technologies Electric heating plate HEATER PLATE 370C Temperature measuring device TEMP CHECK PLUS or TEMP CHECK PRO Gloves GLOVE PRO CUT Heat conducting paste HEATING RING PASTE 20ML Heating ring for the inner ring of a cylindrical roller bearing NU320 E NJ320E and similar components 20 ml heat conducting paste in expendable syringe HEATING RING 320E For detailed information see TPI 180 FAG Devices for Thermal Dismounting Enquiries industrial services schaeffler com 49 2407 9149 66 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 it is extracted This gives optimum heat transfer 20 ml heat conducting paste in expendable syringe HEATING RING PASTE 20ML For detailed information see TPI 180 FAG Devices for Thermal Dismounting Enquiries industrial services schaeffler com 49 2407 9149 66 IS1 51 Product overview Thermal mounting induction heating devices Tabletop devices HEATER10 HEATER20 0001918F 00019191 HEATER40 HEATER150 00019193 00019195 HEATER300 00019197 52 1S1 Schaeffler Technologies Standalone devices Schaeffler Techn
67. et When the base device is progressively screwed down this closes the collet and clamps it against the inner ring The base device is available in four sizes The collet must be specifi cally ordered to match the bearing Large collets are operated using hydraulic cylinders these collets are available by agreement Base device for bearings with inside diameter up to 30 mm PULLER SPECIAL BASIC30 Collet for deep groove ball bearing 6005 PULLER SPECIAL A 6005 Collets for pair of tapered roller bearings 30203 A in X arrangement PULLER SPECIAL B 30203A PULLER SPECIAL C 30203A Schaeffler Technologies Internal extractor sets Available internal extractor sets Further information Schaeffler Technologies The internal extractor set PULLER BORE see table can be used for the dismounting of small deep groove and angular contact ball bearings where the outer ring has a tight fit The inner ring bore must be easily accessible The internal extractors can also be ordered individually The internal extractor set PULLER INTERNAL can be used for the dismounting of standard deep groove ball bearings where the outer ring has a tight fit It is not necessary to dismount the shaft Internal extractors countersupports and impact extractors can also be ordered individually Designation Scope of delivery min maX mm PULLER BORE5 39 SET 6 internal extractors 1 countersupports 1 impact extractor 1 carry case PULLER BORE
68. etected on machinery without the need fora diagnosis expert on site The data can be transferred to other locations by remote access and analysed there for example by the Schaeffler vibration experts Further information For detailed information see TPI 170 FAG DTECT X1 Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies IS1 121 122 Online monitoring system IS1 FAG WiPro Versatile system Certification Remote monitoring Further information Vibration diagnosis FAG WiPro allows online monitoring of wind farms onshore and offshore The system gives early and reliable detection of possible machine damage This helps to prevent unplanned downtime and expensive secondary damage Due to its small size it can easily be accommodated in small spaces such as the nacelle of a wind turbine FAG WiPro is equipped with a signal processor and evaluates all measurement signals internally Due to the intelligent linking of expert knowledge with information from the turbine it is possible to keep the transferred data volume very small This is particularly important where a large number of turbines must be continuously monitored over a long period Any wind farm can be networked using the 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 The system is certified by Germanischer
69. ever or separate pump Designation Extrac Grip width Grip depth Stroke PULLER HYD40 40 200 PULLER HYD60 XL nin 80 PULLER HYD80 XL PULLER HYD120 XL 120 300 330 240 80 PULLER HYD200 XL 80 PULLER HYD250 XL 250 410 440 315 385 100 PULLER HYD300 XL 300 540 610 1375 405 100 Designation Extrac Grip width Grip depth Stroke ao Standard XL Standard XL force kN mm PULLER HYD400 XL 400 1000 420 120 For detailed information see TPI 216 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies Three section extraction plates Figure 3 Maximum and minimum diameter of extraction plates see table Available extraction plates Amin and dmax see Figure 3 Further information Schaeffler Technologies Three section extraction plates PULLER TRISECTION see table can be used with hydraulic and mechanical extractors These allow the extraction of complete bearings tightly fitted inner rings and other components The load capacity and extraction force are precisely matched to each other The extraction claws grip directly under the screw studs of the extraction plates and give uniform distribution of force Even where parts have a tight fit there is no tilting or bending The high extrac tion forces are concentrated on the bearing inner ring In general the bearing
70. example 1 10 shims with dimension c 15 mm and 0 2 mm thickness Ordering designation LASER SHIM15X0 20 Ordering example 2 10 shims with dimension c 44 mm and 0 1 mm thickness Ordering designation LASER SHIM44X0 10 108 IS1 Schaeffler Technologies Available shims Designation Mass Dimensions in mm m c Thick ness 0 05 0 1 0 2 LASER SHIM15x0 05 LASER SHIM15 X 0 10 LASER SHIM15 x 0 20 LASER SHIM15 x 0 50 LASER SHIM15x 0 70 LASER SHIM15 x 1 00 LASER SHIM15 x 2 00 LASER SHIM23 x 0 05 LASER SHIM23 X 0 10 LASER SHIM23 X 0 20 LASER SHIM23 X 0 50 LASER SHIM23x 0 70 LASER SHIM23 lt x 1 00 LASER SHIM23 x 2 00 LASER SHIM32 x 0 05 LASER SHIM32 x 0 10 LASER SHIM32 x 0 20 LASER SHIM32 x 0 50 LASER SHIM32 x 0 70 LASER SHIM32 X 1 00 LASER SHIM32 X 2 00 2 LASER SHIM44X 0 05 53 125 105 0 05 LASER SHIM44X 0 10 106 125 105 44 Onl MACN LASER SHIM44X 0 20 212 125 105 44 0 2 FA LASER SHIM44x 0 50 530 125 105 44 0 5 LASER SHIM44x 0 70 742 125 105 44 0 7 LASER SHIM44x 1 00 1050 125 105 44 1 LASER SHIM44 x 2 00 2100 125 105 44 2 Further information For further information on FAG alignment devices see TPI 182 FAG Alignment Devices Top Laser SMARTY2 TRUMMY2 EQUILIGN SHIM Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies IS1 109 Product overview Temperature measuring device TempCheck PLUS TempCheck PRO Digital hand tachometer TACHOMETER Sonar device SOUND CHECK
71. f FAG TempCheck PRO are as follows up to date infrared temperature technology with high precision glass optics for precise non contact temperature measurement small measurement spot of 13 mm at a distance of up to 260 mm measurement spot size corresponds to 40 1 distance measure ment spot size at distance of more than 260 mm rapid precise temperature measurement over a temperature range of 32 C to 760 C degree of emission adjustable to material additional temperature sensors for contact measurements low mass 150 g simple handling USB interface memory report software low purchase costs Do not look into the laser beam or point the laser beam into another person s eyes Schaeffler Technologies Scope of delivery Base device Ordering designation Further information Schaeffler Technologies 1 measuring device 1 battery 1 wrist strap 1 adapter for camera tripod 1 carry case 1 protective rubber slip cover 1 immersion sensor for temperature measurement of fluids 1 surface temperature sensor 1 user manual 1 report software 1 case TEMP CHECK PRO For detailed information see publication WL 80 377 FAG Temperature Measuring Devices Enquiries industrial services schaeffler com 49 2407 9149 66 IS1 113 Digital hand tachometer FAG TACHOMETER Direct speed measurement Non contact speed measurement 114 Scope of delivery Base device Ordering designation Replacement parts
72. f or to enlist the services of Schaeffler for online monitoring Due to the communication options of the monitoring systems remote analysis can be carried out by the Schaeffler experts Schaeffler Technologies Figure 4 Continuous monitoring Regular monitoring The failure of so called B or C category plant items not does lead directly to downtime and therefore does not necessarily lead to expensive secondary damage For such machine parts offline monitoring is generallyrecommended as a more economical option The Schaeffler experts can assist in identifying the most economi cally appropriate solution between cost effective continuous moni toring and regular monitoring In this type of monitoring machinery is examined and assessed by vibration analysis at regular intervals for example every four weeks This regularity gives more in depth knowledge ofthe normal condition ofthe machine Deviations can thus be detected Forthe monitoring concept the selection of measurement points and monitoring accessories as well as the measurement interval play a decisive role If deviations occur during measurement or if trends are to be investigated the data can be sent to the Schaeffler Diagnosis Centre Vibration experts willthen analyse the data and prepare a diagnosis report Through working with the Schaeffler experts customers can build up their own know how in analysis If no personnel are available for data logging Schaeffle
73. fans as well as misalignment of machine components to each other can be corrected directly by the Schaeffler experts Balancing Imbalance is one of the most frequent defects that lead to unex pected failure of rotating machine elements Correct balancing gives a decisive increase in the life of rotating machine parts This increases the productivity and availability ofthe machine The Schaeffler experts reduce to anormallevelthe imbalances that for example occur as a result contamination wear and repairs They can detect and eliminate the causes on machinery operating at a speed of 40 min to 10 000 min Typical examples of such machines include pumps ventilators compressors turbines and motors Schaeffler offers not only a detailed analysis of the causes of the problem but also the elimination of imbalances Alignment Many machines consist of different components such as electric motors and pumps After installation repair or overhaul the compo nents of such machines must be aligned with each other Figure 7 If this is carried out incorrectly or not at all this results in high loads being placed on the bearings as well as increased energy demand and wear In addition to laser alignment systems Schaeffler offers the align ment of machinery as a service Where necessary the Schaeffler service technicians will take the necessary laser alignment system to the customer and carry out alignment of the machine in accor dance with
74. gnetic field Figure 3 Functional principle Further information Thermal mounting induction heating devices The induction heating devices can be operated in the following modes temperature control time control size HEATER4O and above ramp control size HEATER40 and above The principle of the heating device is based on a current carrying coil with an iron core primary coil which generates a high induction current at low voltage in a short circuited secondary circuit rolling bearing or other steel part figure 3 As a result the rolling bearing to be mounted is heated Non metallic components and the device itselfremain cold 00018A09 For detailed information see TPI 200 FAG Heating Devices for Mounting of Rolling Bearings Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies FAG Heating Manager The software FAG Heating Manager is a user friendly tool for selection of the optimum heating device for the heating of rolling gt bearings Once the rolling bearing to be heated has been selected the bearing type dimensions mass and the suitable heating device are shown Figure 4 scan ADR FAG Heating Manel rag vam Hanna ine Boheme baninga me 5 Fa Innes ameter di Oder Diameter D Wick Wegt O L A h h a i 380 000 mm F0 mm mo ae 92 500 kal ar i ai AE nck ARE inch SS een EN ee eee Serie Search tnt m mz sede uits E amer
75. he mounting forces through the rolling elements and raceways This error can be avoided by driving the inner ring onto the shaft or driving the outer ring into the housing by applying hammer blows to an appropriate mounting sleeve The carefully matched precision parts ensure that the forces are uniformly transmitted to the side faces of the bearing rings Mounting tool set comprising 33 mounting rings for bearing bore 10 mm to 50 mm and outside diameter up to 110 mm 3 mounting sleeves 1 recoilless hammer mass 1 kg 1 case FITTING TOOL ALU 10 50 Also available as individual parts For detailed information see TPI 216 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries industrial services schaeffler com 49 2407 9149 66 IS1 21 22 IS1 Socket wrenches Scope of delivery Ordering example Ordering designation Further information Mechanical mounting and dismounting Socket wrenches LOCKNUT SOCKET are suitable for easily tightening and loosening locknuts on shafts adapter sleeves and withdrawal sleeves They require less space on the circumference ofthe nutthan 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 They therefore have a hole for the locking pin and a groove for the rubber washer The locking pin and rubber washer are included in the scope of delivery Soc
76. he company in the use of the systems and accompany them while making the initial steps In difficult cases assistance can be requested from the Schaeffler experts They will help in the analysis and formulation of measures Schaeffler Technologies Example 2 Company B would like to build up its own knowledge in the field of Learning condition diagnosis Condition diagnosis is a complex subject Building up knowledge therefore takes time In such cases Schaeffler offers a two year programme after which even customers without prior knowledge can themselves monitor the condition of their machinery Once the standardised training has been carried out the support given by the Schaeffler experts is progressively reduced in stages and the customer s employees use their new knowledge directly in their daily work Example 3 Company C would like to completely outsource the area of condition Outsourcing diagnosis Schaeffler offers complete packages under which Schaeffler pro vides the entire service This begins with the initial operation of systems and progresses through continuous monitoring to complete leasing of the hardware such that no initial costs are incurred by the customer Such monitoring packages are very attractive for exam ple to operators of wind turbines Example 4 Company Dis a plant manufacturer and would like to offer condition Offering a service monitoring as a service itself In this case Schaeffler acts as a
77. iation of the taper from the nominal value is displayed by a precision indicator on the measurement slide The gauge is set using a reference taper available by agreement Available by agreement Schaeffler Technologies Snap gauges Snap gauges SNAP GAUGE see table can be used to inspect the diameter of cylindrical workpieces directly on the machine tool The snap gauge is also used to set the enveloping circle gauge MGI21 The snap gauge functions as a comparator gauge It is set using shims The deviation from the set value can then be determined Available snap gauges Designation Diameter range min max mm mm SNAP GAUGE 30 60 60 SNAP GAUGE 60 100 160 00 100 SNAP GAUGE 100 150 150 SNAP GAUGE 150 200 150 200 SNAP GAUGE 200 250 200 250 SNAP GAUGE 250 300 250 300 Shims for numerous diameters are available as accessories Ordering example Snap gauge for shaft diameter 120 mm Ordering designation SNAP GAUGE 100 150 Ordering example Shim for shaft diameter 120 mm Ordering designation SNAP GAUGE MASTER120 Schaeffler Technologies IS1 69 Measurement and inspection Enveloping circle gauges Enveloping circle gauges see table can be used to set the radial internal clearance or preload of cylindrical roller bearings Available enveloping circle gauges Designation Type For bearings from Te MGI21 For cylindrical roller bearings NNU4920 K NNU4948 K with separable inner ring NNU4920 NNU4948 For cylindrical roller
78. ical roller bearings and self aligning ball bearings tilting of the inner rings is prevented by the brackets supplied The bearing together with the tool is carried by either two people or by means of a crane While it is being transported by crane the bearing is suspended by the tool using the carrying slings and can be rotated into any position required The bearing can remain in the tool during heating It expands to the same extent as the bearing The tool can be used for bearings up to a mass of 500 kg and at temperatures up to 160 C Designation Bearing outside diameter Mass of tool mm kg BEARING MATE250 450 6 3 BEARING MATE450 650 BEARING MATE650 850 Transport and mounting tool for bearings with outside diameter from 250 mm to 450 mm using 2 short brackets and a pair of gloves GLOVE PRO CUT BEARING MATE250 450 IS1 73 Accessories brackets Ordering designation Accessories carrying slings Ordering designation Accessories pack of small parts 74 IS1 Ordering designation Gloves Resistant up to 150 C Ordering designation Resistant up to 200 C Ordering designation Resistant up to 250 C highly resistant to cutting Ordering designation Accessories 2 long brackets to prevent tilting of the inner rings of spherical roller bearings BEARING MATE LOCKBAR270 2 carrying slings 1 m long BEARING MATE SLING 1M Pack of small parts BEARING MATE SERVICE KIT The heat resi
79. ing bearings HEATER300 can also be converted to a mobile unit by means of accessories The scope of delivery of the induction heating devices HEATER covers a basic setup for the initial applications figure 1 Heater 40 Heater 150 Heater 300 00018A3A Schaeffler Technologies The rolling bearing to be heated is either suspended from the ledge or is placed horizontally on the support rails figure 2 Figure 2 Heating a rolling bearing 00019DE4 Advantages of FAG heating devices The advantages of induction heating devices are as follows very Safe operation high reliability certified in accordance with the German inspec tion and certification body TUV effective energy efficient heating high efficiency level uniform controlled heating automatic demagnetisation simple operation high cost effectiveness through selection of the device size most Suitable for the particular application The heating devices have various functions see table Functions Function HEATER zo zo Tao iso 300 600 1200 Demagnetisation e je je je Jo je Program shutdown e je je je e e e Display of actual e temperature value Temperature display in C or F Display of actual 6 e temperature value and time present Schaeffler Technologies IS1 55 56 IS 1 Operating modes Function 1 Primary coil 2 Secondary circuit 3 U shaped iron core 4 Slewing ledge 5 Electroma
80. ing operation the maximum heating temperature must be observed The temperature of rolling bearings must not normally exceed 120 C in order to prevent changes to the structure and hardness of the bearing In all devices for heating the temperature can be steplessly controlled mn Wear protective gloves during mounting and dismounting of heated parts Induction units with The FAG heating device with medium frequency technology gives medium frequency technology rapid simple and effective heating of medium sized to large rolling bearings and similar steel parts for mounting and dismounting The device always comprises two parts an inductor and a generator The inductor can be of a flexible design Figure 1 or rigid design Figure 2 page 64 The rigid design is particularly suitable for batch applications The flexible design of inductor can be wound around the components Figure 1 The flexible inductor can also be used with subframes figure 3 page 65 to rationalise repetitive work Overall this gives a wide range of applications see table page 64 Each device is designed for the specific application and is fitted depending on the workpiece with flexible or rigid inductors The necessary information can be seen in the table page 65 Due to its compact construction the device can also be used for mobile operation The device can therefore be moved to the location of the workpiece It can therefore be used for example at constr
81. ingle stage pump Twin stage pump Figure 4 Twin stage pump 4 loil container Available twin stage pumps 40 IS1 Hydraulic mounting and dismounting Hand pumps have a single stage or twin stage pump with a manometer The hand pump PUMP1000 0 7L has an oil container with a volume of 0 7 I The maximum pressure is 1 000 bar see table A digital manometer is available as an accessory Designation Maximum oil pressure bar PUMP1000 0 7L 1 000 The twin stage pumps Figure 4 and table have a high delivery rate up to 50 bar and then switch automatically to the high pressure stage This gives a high work rate 0008AO5E Where there is an increased oil requirement the twin stage pumps are available with an 8 oil container suffix 8L If the type of installation ofthe adapter or withdrawal sleeve requires a separate oil supply a two way valve is available suffix D For pumps with an oil pressure of 1000 bar and a connector digital manometers are also available as accessories Designation Maximum oil pressure bar PUMP1000 4L 1 000 PUMP1600 4L 1 600 PUMP2500 4L 2500 Schaeffler Technologies Pump for drive up distance Thehand pump PUMP1000 4L CONTROL is particularly suitable as a pressure generation device where rolling bearings are to be driven onto theirtapered seat using a hydraulic nut figure 5 First the bearing is driven smoothly onto the tapered seat as far as the initial position A suitable hydr
82. ings and labyrinth rings for example in the case of wheelset bearings in rail vehicles Figure 2 page 64 dismounting of bearing inner rings from traction motors in rail vehicles heating of large components for example bearings or bearing seats in wind turbines heating of roll rings and couplings for example in steelworks loosening of shrink fit connections Data required in enquiries Ordering information Bearing dimensions if possible with drawings Representation ofthe adjacent construction Data on the fit conditions Description ofthe mounting process and its frequency Power supply data Ambient conditions Your address Further information For detailed information see TPI 217 FAG Tools for Thermal Mounting and Dismounting Medium Frequency Devices Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies IS1 65 Product overview Feeler gauges Taper ring gauges Taper gauges Snap gauges Enveloping circle gauges 66 IS1 Measurement and inspection FEELER GAUGE 100 FEELER GAUGE 300 MGK133 SNAP GAUGE MGI21 000179A9 000179BA 000179A7 000179A5 KLR 0001 GO MGK132 000179BB MGA31 000179A6 Schaeffler Technologies Features Feeler gauges Available feeler gauges Taper ring gauges and taper gauges Taper ring gauges Ordering example Ordering designation Schaeffler Technologies Measurement and inspecti
83. is defined as a rigidity problem often caused by a poor quality connection between two machine parts for example at 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 the soft spot in the machine A joint discussion can be held to prepare proposals for improving the design of the machine Schaeffler Technologies IS1 139 Services Endoscopy Digital optical endoscopes can be used to examine the interior of a machine figure 5 to determine the extent of damage The images can be stored as a digital photograph or video and form the basis of diagnosis by Schaeffler experts The condition of individual com ponents such as rolling bearings and gear teeth can be assessed Ifthe bearings inspected are Schaeffler products the customer also has access to the knowledge of the Schaeffler application engineers These experts will prepare a detailed damage analysis and submit proposals for improvement Figure 5 Endoscopy 140 IS1 Schaeffler Technologies Thermography Figure 6 Thermography FLIR systems Approval inspection of new plant Further information Schaeffler Technologies Thermography is one ofthe most important non destructive diag nostic techniques figure 6 Many technical problems manifest themselves in the form of heat generation which can be
84. ite HEATER150 HEATER300 HEATER600 HEATER1200 Fre Ep ASE I et TERENDE A5 EEE rn Hr r LS pn DELLEN T75 Figure 4 me Een FAG Heating Manager 0001954C The FAG Heating Manager is available online at www schaeffler com under the menu Media Library Schaeffler Technologies IS1 Heating devices HEATER Product range Dimension table Characteristics Operating voltage Frequency Power consumption Nominal current Residual magnetism Duty cycle Mass Length Width Height Dimension Dimension Maximum rolling bearing mass Minimum rolling bearing bore ledge Minimum rolling bearing bore with accessories Minimum rolling bearing bore lying flat Maximum rolling bearing outside diameter Temperature control adjustable with safety mechanism for rolling bearings Time control Ramp control 58 IS1 z V MI CC ce Bee Bee gt Bee oo El 3 Unit HEATER10 H B zp HEATER20 mm 165 290 with LEDGE 45 with LEDGE 60 40 C to 240 C 40 C to 240 C Schaeffler Technologies HEATER40 HEATER150 HEATER300 HEATER600 HEATER1200 a W k A N 1 230 400 400 400 100 100 100 100 100 295 480 570 1250 180 210 330 430 700 with LEDGE 70 with LEDGE 100 with LEDGE 11 5 with LEDGE 150 with LEDGE 225 40 C to 240 C 40
85. k i p 2 Mounting and Maintenance of Rolling Bearings Products Services Training SCHAEFFLER Aountin g and Maintenance of Rolling Bearings Products Services Training All data have been prepared with a great deal of care and checked for their accuracy However no liability can be assumed for any incorrect or incomplete data We reserve the right to make technical modifications Schaeffler Technologies AG amp Co KG Issued 2015 July Reproduction in whole or in part without our authorisation is prohibited Industrial Service Portfolio Figure 1 Portfolio Foreword This catalogue is aimed principally at maintenance managers and operators of plant in which rolling bearings and other rotating machine components play a critical role in determining the quality of products and processes Those responsible for maintenance and production processes must be able to rely every day on the quality of their tools and the expertise of their service providers Within its Industrial Service concept Schaeffler therefore offers high quality products services and training Figure 1 This catalogue gives an overview of the portfolio Mechanical maintenance Lubrication Condition monitoring Reconditioning The employees of Schaeffler worldwide will be pleased to help you select the ideal products services and training courses Figure 1 SCHAEFFLER EK lt gt Fac Products Services Trai
86. ket wrenches are available in sizes suitable for locknuts KMO to KM20 Other sizes and special solutions are available by agreement 1 socket 1 locking pin 1 rubber washer Socket wrench suitable for locknut KM5 LOCKNUT SOCKET KM5 Special sizes available by agreement For detailed information see TPI 216 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies Hook and pin wrenches Hook wrenches Ordering example Ordering designation Ordering example Ordering designation Jointed hook wrenches Ordering example Ordering designation Jointed pin wrenches Ordering example Ordering designation Schaeffler Technologies These wrenches can be used forthe mounting and dismounting of small bearings on shaft seats adapter sleeves or withdrawal sleeves In addition to the sizes named here other sizes are avail able by agreement Hook wrenches LOCKNUT HOOK can be used to dismount not only bearings but also withdrawal sleeves with the aid of extraction nuts Hook wrenches are available in sizes suitable for locknuts KMO to KM4O suitable for diameters from 16 mm to 245 mm Hook wrench suitable for locknuts KM18 KM19 and KM20 LOCKNUT HOOK KM18 20 Hook wrenches can also be ordered as a set The set comprises ten hook wrenches of sizes KMO to KM16 in a roll up pouch and is suit able for diameters from 16 mm to
87. lable by agreement with other greases Design Battery version with one outlet Battery version with two outlets 24 V version with one outlet 24 V version with two outlets ARCALUB C2 LC250 TEMP90 ARCALUB C2 LC250 TEMP110 ARCALUB C2 LC250 TEMP120 ARCALUB C2 LC250 TEMP200 ARCALUB C2 LC250 SPEED2 6 ARCALUB C2 LC250 BIO2 ARCALUB C2 LC250 FOOD2 ARCALUB C2 LC250 CLEAN M IS1 89 Lubrication devices Lubrication system This single point and multi point lubrication system offers high CONCEPT8 flexibility It has one two three or four pump bodies that can be individually controlled depending on the design Each pump body has two outlets and as aresult up to eight lubrication points can be flexibly provided with the required quantity of lubricant in the correct lubrication interval using just one lubrication system The lubrication system CONCEPT8 is designed for a wide variety of operating conditions Designs for linear systems the use of oils as lubricant or with an internal heating facility are also available Lubricant cartridges LC units provide the device with lubricant LC units are available in the size 800 cm The lubrication system is supplied with voltage from a mains power pack Coupling with machine operation is possible Ifthe voltage supply to machine and lubrication system is coupled then the relubrication interval will always be dependent on the number of operating hours Advantages The advantages of the lubrica
88. le rapid and competent assistance The services are provided worldwide either on site at your location or in Schaeffler workshop facilities The mounting and dismounting services figure 1 page 133 include mounting and dismounting of rolling bearings plain bearings and bearing systems of all types by experts available worldwide measurement and condition analysis of bearing arrangements problem solving and preparation of concept solutions design and manufacture of special tools leasing of tools only available in Europe emergency service training courses on products and mounting certification of mounting and dismounting processes Schaeffler Technologies Figure 1 Mounting services Advantages The mounting services give the following advantages readily available service worldwide rapid mounting or dismounting through precise preparation professional mounting and dismounting using special high quality tools increased plant availability and productivity as a result of reduced unplanned downtime correct use of bearings of all types as a result of customer training Rentalof tools European customers who require special mounting and dismounting tools or measuring equipment only infrequently can rent these from Schaeffler on a weekly basis Our service includes rapid delivery to the installation site rental costs include shipment costs checked quality products in keepingwith the latesttechnological developments
89. ll bearings with a tapered bore The individual wrenches are available as a set The double hook wrench sets contain a torque wrench This allows a precisely defined tightening torque to be achieved at the start of the mounting operation Double hook wrench sets are suitable for several sizes of locknuts There is one set each for locknuts KM3 to KM8 and for locknuts KM9 to KM15 All the parts in the scope of delivery are also available individually Each double hook wrench is engraved with the torsion angles for the appropriate spherical roller bearings and self aligning ball bearings The drive up distance and reduction in radial internal clearance can therefore be precisely set Several double hook wrenches 1 torque wrench 1 mounting lever 1 user manual 1 case 1 mounting paste 20 g 4 double hook wrenches suitable for locknuts KM3 to KM8 LOCKNUT DOUBLEHOOK KM3 8 SET 5 double hook wrenches suitable for locknuts KM9 to KM15 LOCKNUT DOUBLEHOOK KM9 15 SET For detailed information see TPI 216 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies Mechanical extractors Two arm and three arm extractors Figure 1 Dimensions of the gripper Schaeffler Technologies Mechanical extractors can be used to dismount small and medium sized rolling bearings that are located with a tight fit on a shaft or in a housing
90. ll industrial segments The system can be used in steelworks paper machinery cement plants or in the oil and gas industry Remote monitoring Defects and damage can be detected on machinery without the need for a diagnosis expert on site The data can be transferred to other locations by remote access and analysed there for example by the Schaeffler vibration experts Explosion protected variant An explosion protected version of FAG ProCheck is available by agreement In this version a specially pressure encapsulated housing prevents the system coming into contact with an explosive atmosphere This is because wherever flammable gases vapours fluids or dust occur the presence of oxygen and an ignition source MACN can rapidly cause an explosion N Further information For detailed information see TPI WL 80 69 FAG ProCheck State ofthe Art Machine Monitoring for Maximum Availability Enquiries industrial services schaeffler com 49 2407 9149 66 Customer specific solutions The plant visualization which is individually tailored to the cus tomer s requirements gives a user interface that allows a rapid overview ofthe condition ofthe plant Depending on the complexity ofthe plant this display can be arranged on several levels Other online Other monitoring systems for the requirements of specific sectors monitoring systems are available by agreement Schaeffler Technologies IS1 123 Product overview Monitoring of components
91. logies The standard programme of training courses is sufficient in most cases to achieve acquisition ofthe knowledge necessary for day to day work Upon customerrequest Schaeffler also offers individually tailored training courses In these cases customers can themselves define the key components of the content The standard training portfolio for the areas of rolling bearing technology and mounting as well as condition monitoring is already comprehensive an excerpt is shown in the table Training courses Rolling bearing Basic training Rolling bearing technology technology and Mounting of rotary bearings mounting Basic training Mounting of rolling bearings in gearboxes Practical training Mounting of rolling bearings using large rolling bearings Linear Products and applications Mounting of linear bearings Rolling bearing failures Identifying causes Optimising operation Mounting and maintenance of rolling bearings for rail vehicle maintenance personnel customer location Maintenance of spindle bearings Condition Detector III Monitoring introduction advanced level machine diagnosis balancing SmartCheck introduction advanced level Vibration based condition monitoring to ISO 18436 2 with certification DTECT X1s ProCheck Administrator 4 Mechatronics Basic training Mechatronics Follow on training Mechatronics Practical training Mechatronics Special training Training completely oriented
92. mounting and Product overview W XWu Wu u ddsesesersereereeereeree renee reer serene eee renees n een 62 dismounting Features medium frequency technology Induction units with medium frequency technology 63 Measurement and inspection Product overview ssseerseesrsersrrsrsrrrrsrrsrsresesrrrsrrrrrnerrrnrrren renen renee 66 Features Feeler SAU GS rennen are nlesn unsre 67 Taper ring gauges and taper gauges s ssssessserrsrsrrrrrsrrrrrrrrrrrrs 67 Snap CAUSES nee senen thee enor dal aken 69 Enveloping circle values 70 Accessories Product overview s sssssseesrrrreserresrrresrrrrssrrr essensen essensen enes een neee 72 Features Transport and mounting tOOl ssssserserrsrrrrrrrrerrrerrrerrrerrrr 73 GIOVE Seneste sad A eneen nets 74 MOUNT Da SLO sense 75 ANLI COITOSI0N Ol 2 nennen 75 Schaeffler Technologies IS1 17 Product overview Mechanical mounting and dismounting Mounting tool sets _FITTING TOOL ALU 10 50 000190A1 os Socket wrenches LOCKNUT SOCKET 000179B6 Hook and pin wrenches LOCKNUT HOOK LOCKNUT HOOK KMO 16 SET Hook wrenches 000190A3 000179C4 Jointed hook wrenches OCKNUT FLEXIHOOK LOCKNUT FLEXIPIN Jointed pin wrenches 0001799C 0001799D 18 IS1 Schaeffler Technologies Jointed face wrenches Double hook wrenches Double hook wrench sets Mechanical extractors Two arm extractors Two arm extractor set Three arm extractors Hydraulic pressure
93. mponents operations and qualification measures as well as their practical implementation Schaeffler is also interested in advising OEMs on product design with favourable maintenance related characteristics in order to achieve a significant contribution to reductions in operating costs as early as the plant design phase Schaeffler Technologies Dr k i sr es a F LI Schaeffler Technologies IS 1 149 Training Product overview Schaeffler Technologies Features Training Page DN 152 ASSE SPAD S see euere een 153 SUCHE ae een E 153 TaN locations 154 Duallty aSssurante u un ana 154 Training courses standard and individual 155 Tanne MALS Alan 156 IS1 151 re Di SN Product overview Rolling bearing technology Training example Mounting of rolling bearings Training example Machinery monitoring Training example 152 IS1 Training TRAINING BEARING BASIC TECH 2 Schaeffler Technologies Features Target groups Schaeffler Technologies Structure Training Appreciating the use of rolling bearings linear guidance systems and plain bearings as indispensable elements in thousands of appli cations requires the necessary understanding ofthese machine elements Courses provided by Schaeffler Technologies guide the participant through the complete product portfolio Starting from product knowledge it is possible to advance into
94. n be connected directly or by means of thick walled adapters It can also be connected by means of a pump holder and a 2 m long flexible high pressure pipe The oil pressure in this case must not exceed the maximum oil pressure see table HH Always operate the pump together with a manometer Figure 6 High pressure pump 00019F0E Available high pressure pump Designation Connector Oil container Delivery volume Maximum capacity per stroke oil pressure l bar PUMP2500 0 2L PUMP4000 0 2L G3 0 2 0 3 4000 Ordering example High pressure pump with maximum oil pressure of 4 000 bar Ordering designation PUMP4000 0 2L Further information For detailed information see TPI 195 FAG Pressure Generation Devices Enquiries industrial services schaeffler com 49 2407 9149 66 42 181 Schaeffler Technologies Mobile hydraulic unit The mobile hydraulic unit Figure 7 is used for the mounting and dismounting of tapered roller bearing units also known as TAROL units These units are used as wheelset bearings in rail vehicles such as goods wagons and passenger carriages The mobile unit has a valve controlled double direction pressure cylinder driven by a motor pump The pressure cylinder is adjustable in height When making enquiries or placing orders information on the power connection is required Figure 7 Mobile hydraulic unit 00017A51 Ordering designation TOOL RAILWAY AGGREGATE Schaeffler T
95. nal enveloping circle 66 Taper AD 66 Tapere AUS E nennen 66 Online monitoring system ProCheck aen 116 Online monitoring system PrOTOrG ssesserserserrersrrsersrererrs 124 Internal extracto ienna e arr ardennen dee vennen 20 Hydraulic exXtract r es eek 20 internal extract sooren ssscssat cn sonecuaees venae norbert 20 Separation and extraction device ns svanse eenen vevenn 19 specialpearine XHraCHO Pensensran san 20 Special Hearing extractor samerne ere 20 Special bearing extractor sauna ae 20 Hydraulicpress re tool nean E 19 Three section extraction plate ssessseersssrsssererrerrsrrrrrrrnrs 20 IOS EXA TO rege eiO 19 TWO armexttra ON soie a heus knee koene 19 TIwo arm extracto eaa ite ae ae 19 Three arm OKWAELON sns eisen 19 Schaeffler Technologies PUMP1000 0 7L PUMP1000 4L PUMP1000 4L CONTROL PUMP1000 8L PUMP1000 MANO DIGI PUMP1000 MANO G1 2 PUMP1600 4L PUMP1600 8L PUMP1600 MANO G1 2 PUMP1600 VALVE NIPPLE PUMP1600 VALVE SOCKET PUMP2500 0 2L KIT PUMP2500 4L PUMP2500 8L PUMP2500 MANO G1 2 PUMP4000 0 2L PUMP ADAPTER PUMP HOLDER 2 PUMP HOLDER 3 PUMP NIPPLE PUMP PIPE PUMP SLEEVE CONNECTOR SMART CHECK SNAP GAUGE SOUND CHECK TACHOMETER TEMP CHECK PLUS TEMP CHECK PRO TOOL RAILWAY AGGREGATE WEAR DEBRIS CHECK Schaeffler Technologies Single stage hand pump s sssossrresrrrrrrrrrrrrerrrrrrrrrrerrrerrrerrrrrrrrr 32 Twin stage hand PUMDP ccc
96. nance Schaeffler uses various methods for this task The measurement of vibrations is a proven method here Vibrations reveal damage in machinery at a very early stage The vibration expert can assess the condition of the machine without the need for any dismantling work A large proportion of possible causes of damage can thus be detected and assessed with little work As a result damaged components can be replaced as part of planned downtime Depending on the type of machine and its importance for the production process condition monitoring can be carried out by means of either continuous online monitoring or regular offline monitoring For production critical machinery continuous monitoring Figure 4 page 137 by means of vibration diagnosis is indispensable in many cases Investment in such monitoring systems often pays for itself after a few months due to the reduced failure costs Depending on the area of application Schaeffler offers a wide range of solutions including single channel standalone solutions for smaller equipment and medium sized systems with up to 8 channels that can be extended on a modular basis In addition to giving advice on selecting the right system Schaeffler also implements monitoring of the machine This includes not only hardware selection but also system configuration and where necessary its integration into existing systems The customer can decide whether to carry out plant monitoring himsel
97. ng device with medium frequency technology ne 62 Inductor for heating device with medium frequency technology en 62 Hydraulic NEER 32 Oilimjector 1600 Hafen 32 Oil INjector 2500 hate ner 32 TADEL MING CAC Ce east 66 IS1 9 LASER EQUILIGN LASER SHIM LASER SMARTY2 LASER TRUMMY2 LOCKNUT DOUBLEHOOK LOCKNUT DOUBLEHOOK SET LOCKNUT FACEPIN LOCKNUT FLEXIHOOK LOCKNUT FLEXIPIN LOCKNUT HOOK LOCKNUT HOOK KMO 16 SET LOCKNUT SOCKET MGA31 MGI21 MGK132 MGK133 PRO CHECK PRO TORQ PULLER BORE SET PULLER HYD PULLER INTERNAL10 100 SET PULLER SEPARATOR PULLER SPECIAL PULLER SPECIAL BASIC PULLER SPECIAL CUSTOM PULLER SUPPORT PULLER TRISECTION PULLER 2ARM PULLER 2ARM SEPARATOR PULLER 2ARM SET PULLER 3ARM 10 IS1 Product index Page Shaft alignment device Top Laser EQUILIGN 98 Shim Top Laser SHIM Sasse ann 98 Belt pulley alignment device Top Laser SMARTY2 98 Belt tension measuring device Top Laser TRUMMY2 98 Double HOOK wrenchn2u 2 een 19 Double hook Wrench Set s ssseressrrrsrrrrrrrrrrrrrrrrrerrrrrrrrrrrrrrerrr gt 19 Jointed facewrench zaren erne eres eee 19 Jointed hook WIENEN sssersosssnns ever een 18 Jointed PIN WIENEN aueh 18 HOOK WENEN see 18 HOOK WIENEN Sels mende AA 18 SOCKEL Wren Cano a Ei 18 Enveloping circle gauge for external enveloping circle 66 Enveloping circle gauge for inter
98. ning Consulting TCO n r N Mechanical Lubrication Condition Reconditioning 3 Maintenance Monitoring 2 Oo oO Industrial Aftermarket Sales partners Foreword Schaeffler Industrial Aftermarket IAM is responsible for replace ment parts and service business forend customers and sales partners in all significant industrial sectors On the basis of innovative solutions products and services relating to rolling and plain bearings the service function of Schaeffler Industrial Aftermarket offers a comprehensive portfolio that covers all phases in the lifecycle ofthe rolling bearing and takes account of the total costs TCO The aim is to help customers save on maintenance costs optimise plant availability and avoid unforeseen machine downtime Schaeffler Industrial Aftermarket offers each customer an individual concept solution Schaeffler has centres of competence all around the world This means we can provide customers worldwide with products services and training quickly and professionally All service employees undergo a comprehensive training programme and are audited regularly by officially certified specialists This ensures that services throughout the world conform to a uniformly high standard of quality The quality requirements are strongly influenced by a long history of high precision rolling bearing manufacture The production and provision of products and all services in this catalogue is proven in practice and is se
99. oil several months in advance Such particles can be identified at an early stage through monitoring of the lubricant This helps to prevent failures and downtime The oil sensor is installed in an ancillary flow of the recirculating lubrication system in the gearbox ahead of the filter or in a separate circuit Typical applications for the FAG Wear Debris can be found for example in gearboxes in raw material extraction plant planetary gearboxes in wind turbines or in ship propulsion systems The features of the oil sensor are as follows monitoring of the number of particles in the oil differentiation of the particles into ferrous and non ferrous metals classification of the particles according to size possible integration in an online monitoring system for linking of oil particle and vibration data Where oil and vibration monitoring facilities are combined damage in gearboxes with recirculating oil lubrication can be detected at an early stage and the source can be determined In this way it is possible to prevent production shutdowns or secondary damage For detailed information see WL 80 366 Flyer FAG Wear Debris Check Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies Schaeffler Technologies IS 1 129 Services Schaeffler Technologies Features Services Page Mounting and diSsMOUNtiNZ s sseesersrerrrerrrrrrrrrrerrerrerrerrrrrrrr 132 WES CA OT PORN EHEN NI
100. ologies HEATER600 HEATER1200 IS1 00018A0A 00018A0B 53 Features Induction heating devices HEATER 1 Heating device 2 Ledges 3 Temperature sensor 4 Remote control 5 Rolling bearing grease 6 Protective gloves 7 Cover User manual Figure 1 Scope of delivery Induction heating device HEATER 54 181 Thermal mounting induction heating devices Induction heating devices HEATER with mains frequency technology are used to heat rolling bearings and other components with a cylin drical bore where a tight fit on the shaft or in the housing is intended Adequate expansion of the bearings is achieved in most cases at 80 C to 100 C During the heating operation the maximum heating temperature must be observed The temperature of rolling bearings must not normally exceed 120 C in order to prevent changes to the structure and hardness of the bearing In all devices for heating the temperature can be steplessly controlled Wear protective gloves during mounting and dismounting of heated parts The induction heating devices HEATER for bearings up to a mass of 1200 kg have been improved further in terms of their performance capability and safety compared with their predecessors They can also be used to heat sealed and greased rolling bearings In addition to the tabletop devices HEATER10 to HEATER300 the range also includes the standalone devices HEATER600 and HEATER1200 for larger roll
101. on Feeler gauges and measurement gauges can be used to inspect the production of bearing seats and the mounting of bearings Feeler gauges FEELER GAUGE see table are used to measure the radial internal clearance especially in mounting on tapered shaft seats and on adapter and withdrawal sleeves Designation Feeler Feelerthickness length mm mm FEELER GAUGE 100 100 0 08 0 14 0 18 oor L FEELER GAUGE 300 300 0 2 0 45 0 1 0 19 These gauges are used to inspect tapered bearing seats in pro duction facilities This is necessary to ensure a good match between the fit surfaces of the bearing and bearing seat With the exception of taper ring gauges gauges are available for different taper angles Taper ring gauges KLR are the simplest option for inspecting the bearing seat on small bearings Inking is used to determine the matching of the ring gauge and bearing seat The bearing seat is machined until the ring gauge is supported over its whole width The inner rings of bearings are not suitable since they can be damaged during inking Taper ring gauges are available in designs for taper diameters of 30 mm to 240 mm Taper ring gauge for bearings with 100 mm bore and 37 mm taper length for example double row cylindrical roller bearings NN3020 AS K KLR D100 L37 IS1 67 68 IS1 Taper gauge fortapers 1 12 and 1 30 Ordering designation Taper gauge for taper angle 0 to 6 Ordering designation Measurement
102. pproached at different angles These must be measured at an angle of at least 90 The intelligent control system prevents incorrect usage here The actual condition of the subassembly is then displayed Figure 8 When the foot screw connections have been loosened the vertical misalignment is first eliminated by means of shims FAG Top Laser EQUILIGN shows the displacement in real time This means that the user can monitor on the display how the measurement results change as soon as the subassembly is moved Horizontal adjustment is then carrried out until the symbol with the thumb pointing upwards is displayed Once the foot screw connections are tightened the shafts are aligned IS1 107 Alignment Shims Shims FAG Top Laser SHIM are used to eliminate vertical misalign FAG Top Laser SHIM mentor soft feet These shims are made from corrosion resistant alloy steel and are available in seven thicknesses 0 05 mm 0 1 mm 0 2 mm 0 5 mm 0 7 mm 1 mm 2 mm and in four sizes dimension c 15 mm 23 mm 32 mm 44 mm see figure 9 and table page 109 Figure 9 Shim dimensions 00017A47 Scope of delivery Case Basic set 360 shims 20 shims each in 3 sizes dimension c 15 mm 23 mm 32 mm and 6 thicknesses 0 05 mm to 1 mm 1 extraction hook Ordering designation LASER SHIM SET Replacement parts As replacement parts we can supply 10 shims each in one of the 4 sizes and one of the 7 thicknesses stated above Ordering
103. r Technologies Products Condition monitoring Page PIOdUeLOVENI I Wesen 98 Features Belt pulley alignment device Top Laser SMARTY2 99 Belt tension measuring device Top Laser TRUMMY2 101 Shaft alignment device Top Laser EQUILIGN 103 Shims Top Laser SHIM u a 108 Product Overview ossseereerreeereeerrrerrrerrerrrrrrrrrrrrrrrrrrrrrr rer rerr seere veer 110 Features Infrared thermometer Temp Check PLUS 111 Infrared thermometer TempCheck PRO 112 Digital hand tachometer FAG TACHOMETER 114 Sonar device SOUND CHECK aaneen 115 POC ICO VOI Wei 116 Features Monitoring devices offline and online 117 Worldwide SCI ICO sn cncsndaccsasadssncutanocatardesiugestusessenssasandeniseenss 117 Vibration measuring device Detector Ill sssosserserrst 117 Online monitoring system SmartCheck 120 Online monitoring system DTECT X1 5 eeen 121 Online monitoring system WiPro eeen 122 Online monitoring system ProCheck 123 Other online monitoring systems uns ennn venen 123 PIO CUCEOV OIC W ee 124 Features Online monitoring system ProTord aaneen eenn 125 FIO CCTV Were 126 Features Grease sensor GreaSeCheCk ssssseosseossreorrerrrerrrrrrrrrrs 127 Oil sensor Wear Debris Check avonne 128 IS1 97 Product overview Alignm
104. r can also offer support in data logging The company s experts can carry out regular measurements on site Schaeffler Technologies IS1 137 138 IS1 Troubleshooting Services Where malfunctions occur on a machine defects must be detected and rectified very quickly Based on many years of experience with different sectors and applications the Schaeffler diagnosis experts are well versed in such troubleshooting tasks Various types of infor mation are fed into the analysis These include earlier measurement records or repair reports If no measurement records are available the diagnosis experts orient themselves to the specific task through observation perusing the machine documentation and discussions with the machine operators Problems or malfunctions in machine operation often become apparent through changes in vibration behaviour unusual tempera ture patterns or similar phenomena Where the diagnosis experts carry out measurements on the machine themselves the measure ment method is selected as a function of the specific machine and the type of malfunction The Schaeffler diagnosis experts are familiar with all analytical techniques from vibration measurement to torque analysis or endoscopy As a result they can quickly identify malfunc tions and prepare proposed solutions The investigation is closed out by a handover discussion between the diagnosis experts and all relevant employees on site In addition to the re
105. s ofthe balancing process are also transferred to the Trendline software for evaluation IS1 118 Schaeffler Technologies Ordering examples Scope of delivery Base device Ordering designation Scope of delivery Device with automatic measurement point detection Ordering designation Scope of delivery Upgrade level with balancing function Ordering designation Accessories Further information Schaeffler Technologies The vibration measuring device FAG Detector Ill is available in two variants with the balancing function available for ordering in an upgraded version 1 base device with rechargeable battery 1 accelerometer attached by magnetism and sensor cable 1 infrared temperature sensor 1 charger with worldwide compatibility 1 PC data cable serial and USB 1 user manual 1 protective bag with holder for temperature sensor 1 free of charge PC software Trendline 1 case DETECT3 KIT As DETECT3 KIT 1 RFID reader integrated 5 RFID tags for identifying the measurement point DETECT3 KIT RFID 1 accelerometer attached by magnetism and sensor cable 1 trigger sensor optical 1 trigger sensor induction 1 reflex mark for trigger sensor 1 cable for trigger sensor 10 m 1 magnetic holder for trigger sensor 1 extension for magnetic holder A 1 balance 1 dongle for activation of balancing function 1 case DETECT3 BALANCE KIT Sensor extension cables 5 m or 15 m long are available by agreement
106. s that wish to change to the concept of condition based maintenance are supported by Schaeffler with training attendance during the introductory phase ongoing advice during the period of use and service contracts In condition oriented maintenance machinery and plant no longer undergo maintenance work on the basis of failures or times but on their assessed condition In partnership with the customer the Schaeffler advisory experts prepare plans that give recommen dations for action on the basis of the results of condition monitoring These recommendations result in targeted maintenance measures and thus to reduced costs Services are not off the peg products and the requirements vary according to the machine and the knowledge on site Due to the wide portfolio of Schaeffler services local certified Schaeffler employees can weave together the right package of Schaeffler training and services together with in house activities The scope is enormous and dependent on the prior knowledge and usable work capability as well as the requirements for quality of monitoring The following four examples show the extent of the scope and how widely service concepts can vary Starting from the customer require ments the Schaeffler experts prepare a concept to meet the needs and assist in its implementation Company A has employees with experience in the field of condition diagnosis In this case it is sufficient to instruct the employees of t
107. sseccsecceecccsecceeceesceeeeceeeeceeees 32 Twin stage hand pump with digital Manometer 32 Twin Stage mand PUMP sister eta 32 Bieital manomeler erlag 33 INVIGT O gg KE KS sirener ort beast reses dei E 34 Twinstage hand PUM Darni NNA 32 Twin Stage hand PUMP sserssersrerrrrrrerrrerrrerrrersrrersrrerrrrrrrrrrs 32 Manometer nennen a EE 34 Nipple for rapid push fit couplings annen 33 Socket for rapid push fit COUPlINZS ssssersssrrsssersrrrrrrrerrrrrs 33 High pressure pump warren nennen 33 Iwnstase hand DUMP eisen 32 Twin stage hand pUMPp sssesssseesseeesssesssecesseeessscossecesseeesssessse 32 Manometer 34 FIISh pressite pump seen eek 33 Adap Est a a ee a Teen EEO RE 33 PuUmMB Holder 22 33 Pamp holder neigen 33 Adapter and reduction nipple seessersserssrrrrrrrsrrrerrrerrrrrrrrr 33 High pressure pipe seen 34 SlEEVEEONNEELD ist Sosane danstaal beenen edrat 34 Online monitoring system SmartCheck vere 116 snap saugen eelde beun ANANAS NANA ARN 66 SOMNAT IV ee euere 110 Bigitallhand tachomeler iisunisiinskearenn 110 Temperature measuring device TempCheck PLUS 110 Temperature measuring device TempCheck PRO 110 Mobile hydraulic unit for batch mounting of TAROL bearings 33 Oil sensor Wear Debris Check u es 126 IS1 11 67 61000 39468000 70061000 Products Mounting 0001934A Products Lu
108. st 300 mm long Magnetic holder including 2 posts 150 mm long Scope of Designation delivery Quantity LASER CHAIN600 SET LASER CHAIN1500 SET LASER POST150 SET LASER POST200 SET LASER POST250 SET LASER POST300 SET 1 LASER BRACKET MAGNET IS1 105 106 IS1 Accessories set 1 Chains 600 mm 2 Chains 1500 mm 3 Posts 150 mm 4 Posts 200 mm 5 Posts 250 mm 6 Posts 300 mm 7 Magnetic holder Case Figure 7 Accessories set Alignment Description Chain 600 mm long LASER ACCESS SET Chain 1500 mm long 2 Post 150 mm long Post 200 mm long A Post 250 mm long 4 Post 300 mm long Magnetic holder including 2 posts 2 150 mm long Case 1 00019C90 Schaeffler Technologies Alignment 1 Display of actual condition 2 Foot screw connection 3 Direction of vertical displacement 4 Direction of horizontal displacement Schaeffler Technologies Figure 8 Alignment Before alignment is carried out any soft foot must be eliminated FAG Top Laser EQUILIGN clearly indicates the soft foot Each individ ual foot screw connection is loosened and the device is monitored to see if it displays any changes between the foot screwed firmly into place and the loosened foot The soft foot can then be eliminated using shims This eliminates any tendency towards vibration and bearing damage as a result of housing deformation During measure ment at least three positions are a
109. stant gloves are particularly suitable for the handling of heated rolling bearings or other heated components in mounting and dismounting The gloves are cut resistant and durable Gloves GLOVE PRO are resistant up to 150 C GLOVE PRO Ifthe main priority is protection of hands against high temperatures the heat insulating gloves GLOVE PRO TEMP are suitable They com prise several layers are cotton free oil resistant and suitable for temperatures up to 200 C The gloves are non flammable and are also heat resistant even when damp They are authorised in accor dance with DIN EN 388 for mechanical influences and in accordance with DIN EN 407 for thermal influences GLOVE PRO TEMP Ifthe main priority is not only good protection against high tempera tures but also protection against burrs and edges the particularly cut resistant gloves GLOVE PRO CUT are suitable They comprise several layers are oil resistant and suitable for temperatures up to 250 C The gloves are non flammable and are also heat resistant even when damp They are authorised in accordance with DIN EN 388 for mechanical influences and in accordance with DIN EN 407 for thermal influences GLOVE PRO CUT Schaeffler Technologies Mounting paste The mounting paste see table facilitates the sliding of bearing rings and prevents stick slip effects scoring wear and fretting corrosion It also gives protection against corrosion The operating temperature rang
110. subcontractor for the mostly port able monitoring systems as a trainer to the service employees of the plant manufacturer and as an expert team The expert team always moves into action when machines show sets of characteristics that cannot be clearly assessed by the employees of the plant manufac turer The plant manufacturer can thus offer its customers a highly qualified monitoring service without having to establish its own experts Further information Enquiries industrial services schaeffler com 49 2407 9149 66 Schaeffler Technologies IS1 147 148 IS1 TCO approach Services The Schaeffler approach to reducing total costs TCO Total Cost of Ownership is a practically based concept for plant operators MRO and plant manufacturers OEM The aim is to reduce operating costs associated with rolling bearings and increase plant availability on a continuing basis The costs incurred are objectively and measurably compared with the benefits to be accrued by means of appropriate parameters Inthe case of MRO Schaeffler works as a partner with employees from production and maintenance facilities to optimise and conserve the value of the plant With the user Schaeffler works on specifically named problems and submits technical approaches to solutions Furthermore Schaeffler provides proposals for cost reductions that are based on experience within specific sectors and spanning different sectors This analysis covers plant co
111. sults of the investigation the recommended countermeasures are discussed in particular Schaeffler Technologies 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 measurement points are defined The machine is then specifically excited to vibration using an impulse hammer Based on parallel measurement of the excitation and resulting machine vibrations at the various measure ment 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 determination of natural frequencies or resonance frequencies Due to design related factors such as mass and rigidity each machine has one or more natural frequencies If the speed of the motor in a machine is within the range of a natural frequency extreme vibrations may occur in the machine With the aid of modal analysis the Schaeffler vibration experts can submit recommendations for design improvements to the machine detection of the soft spot in a machine If a high level of vibration occurs during initial operation or after a technical modification of a machine this may be due to a so called soft spot This
112. the manufacturer s specifications The work is then documented Figure Alignment Further information Enquiries industrial services schaeffler com 49 2407 9149 66 142 IS1 Schaeffler Technologies Rolling bearing reconditioning Itis often the case that new rolling bearings are fitted although the existing bearings could be restored to as new condition by means of appropriate reconditioning In many cases reconditioning of rolling bearings is significantly more cost effective than using new bearings Figure 8 1 Before reconditioning 2 After reconditioning Figure 8 Rolling bearing raceway and rollers before and after reconditioning Advantages Reconditioning is carried out irrespective of manufacturer and is thus not restricted to products of Schaeffler Technologies Before reconditioning the condition of the bearings can be assessed on site in consultation with experts from the Global Technology Network The advantages for the customer are as follows reductions in life cycle costs LCC Life Cycle Costs increases in operating life savings in material and energy costs reductions in inventory costs high flexibility through short lead times feedback on the characteristics and frequencies of damage Quality Schaeffler performs reconditioning of rolling bearings to uniform standards throughout the world All sites apply identical processes and guidelines Schaeffler rolling bearings are processed in accordanc
113. tion system are as follows suitable for oil and grease up to NLGI 3 supply of up to eight lubrication points supply of set lubricant quantity independent oftemperature reliable piston pump as delivery pump reduced personnel costs compared to manual relubrication favourable price performance ratio operating temperature from 20 C to 70 C individual lubrication intervals and lubricant quantities can be set low operating voltage of DC 24 V pressure build up to 70 bar coupling with machine operation possible can be controlled via an external control system 90 IS1 Schaeffler Technologies Available lubrication systems CONCEPT8 Available LC units Further information Schaeffler Technologies Designation CONCEPT8 1P CONCEPT8 2P CONCEPT8 3P CONCEPT8 4P CONCEPT8 1P LIN CONCEPT8 2P LIN CONCEPT8 3P LIN CONCEPT8 4P LIN LIN for linear applications CC with internal heating facility OIL oil version Designation ARCALUB C8 LC800 MULTITOP ARCALUB C8 LC800 MULTI2 ARCALUB C8 LC800 MULTI3 ARCALUB C8 LC800 LOAD150 ARCALUB C8 LC800 LOAD220 ARCALUB C8 LC800 LOAD400 ARCALUB C8 LC800 LOAD460 ARCALUB C8 LC800 LOAD1000 LC units are also available by agreement with other greases or with oils CONCEPT8 1P CC CONCEPT8 2P CC CONCEPT8 3P CC CONCEPT8 4P CC CONCEPT8 1P OIL CONCEPT8 2P OIL CONCEPT8 3P OIL CONCEPT8 4P OIL ARCALUB C8 LC800 TEMP90 ARCALUB C8 LC800 TEMP110 ARCALUB C8 LC800 TEMP120 ARCALUB C8 LC800 TEMP
114. tool Schaeffler Technologies LOCKNUT FACEPIN 0001799B LOCKNUT DOUBLEHOOK SET PULLER 2ARM PULLER 2ARM SEPARATOR 000190B3 PULLER 3ARM 000179C6 LOCKNUT DOUBLEHOOK PULLER 2ARM SET PULLER SUPPORT IS1 0008AAB3 00089FDE 00019328 00017991 19 we Product overview Mechanical mounting and dismounting Special bearing extractors PULLER SPECIAL BASIC PULLER SPECIAL CUSTOM Separation and extraction devices PULLER SPECIAL 00017AD5 0008AABC Internal extractors PULLER BORE SET PULLER INTERNAL10 100 SET di FG Hydraulic extractors PULLER HYD PULLER HYD175 PULLER HYD400 00019290 00019292 0008AAC5 Three section PULLER TRISECTION extraction plates DAN 20 IS1 Schaeffler Technologies 00017995 Features Mounting tool sets Scope of delivery Ordering designation Further information Schaeffler Technologies Mechanical mounting and dismounting These mechanical tools are designed for the mounting and dismounting of bearings The mounting forces are transmitted by the form fit effect The mountingtool sets are suitable forthe simple mounting ofrolling bearings up to 50 mm bore They can also be used forthe mounting of sleeves intermediate rings seals and similar parts A mounting tool set contains mounting sleeves made from aluminium and mounting rings made from plastic An error frequently made during mounting is to transmit t
115. topped up or replaced in good time before damage occurs The grease sensor has a diameter of 5 mm and is inserted in a hole in the housing as close as possible to the rolling bearing The sensor is positioned in the lubricant This grease sensor optically measures the water content turbidity thermal and mechanical wear and the grease temperature directly in the bearing arrangement This information is transferred by cable to the evaluation unit A gure 7 The evaluation unit generates an analogue signal that gives the user information rapidly and easily on the condition of the grease 00019DD2 In the past bearings were regreased as a function of time The grease quantities and lubrication intervals were calculated numerically If the grease sensor is used regreasing can be carried out as a function of condition The grease sensor facilitates lubrication appropriate to needs lower lubricant costs prevention of unplanned downtime lower maintenance costs lower equipment costs For detailed information see TPI 234 FAG GreaseCheck Enquiries industrial services schaeffler com 49 2407 9149 66 IS1 127 128 Oil sensor FAG Wear Debris Check IS1 Further information Monitoring of lubricants Oil sensors of this type can be used to determine wear at an early stage in heavily loaded industrial gearboxes on the basis of particles in the oil The debris particles that can indicate a failure can be detected in the
116. uc tion sites for wind turbines or for other large components that are difficult to transport Figure 1 The flexible inductor can be wrapped around the component 00017A53 Schaeffler Technologies IS1 63 Thermal mounting and dismounting medium frequency technology F lt Q N U 00 Oo oOo Oo Figure 2 Rigid inductor inthe dismounting of labyrinth rings Versatile in application Workpieces Inner rings of cylindrical roller bearings Machine supports Labyrinth rings Gears Couplings Rotationally symmetrical steel parts Ring rolls Housings Medium sized to very large bearings Advantages The advantages of the heating device with medium frequency technology are as follows suitable for mounting suitable for dismounting operating frequency from 10 kHz to 25 kHz efficiency of the generator higher than 90 low energy requirements short heating times control of heating according to time and temperature automatic demagnetisation flexible and fixed inductors available suitable for use either inside or outside component lower mains connection power than heating devices with mains frequency almost silent air cooled system 64 181 Schaeffler Technologies 0008A070 Figure 3 Rigid inductor inthe dismounting of wheelset bearings Application Examples of the use of medium frequency technology include heating of bearings for mounting and dismounting batch dismounting of bearing inner r
117. ymbols soap extremely suitable TEMP120 Poly Partially 400 2 30 180 highly suitable carbamide synthetic oil 0 2 o suitable TEMP200 PTFE Fluoridated 55 30 250 less suitable polyether oil not suitable Special greases Designation Thickener Base oil Base oil Consis Operating viscosity at 40 C tency temperature NLGI mm s oc rom Je SPEED2 6 Lithium Synthetic oil 25 2 3 40 120 complex soap VIB3 Lithium Mineral oil 170 3 30 150 complex soap Bio2 Lithium Synthetic oil 55 2 30 120 calcium soap FooD2 Aluminium Synthetic oil 150 2 30 120 Lok complex Definition of symbols soap extremely suitable CLEAN M Poly Ester 103 2 30 180 highly suitable carbamide o suitable less suitable MOTION2 Lithium Synthetic oil 50 2 40 130 not suitable soap 82 IS1 Schaeffler Technologies ment automotive engineering 120 Ball and roller bearings in continuous casting plant paper machinery 200 Ball and roller bearings in guide rollers in baking machinery kiln trucks and chemical plant piston pins in compressors Continuous Characteristic applications Temperatures Low Vibra Support Relubri limit friction tions forseals cation temperature high facility 26 Low High 90 Ball and roller bearings in couplings electric motors automotive engineering 110 Ball and roller bearings in electrical equip a o PB

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