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1. 00017B2D Industrial Aftermarket Foreword The Business Division Industrial Aftermarket of the Schaeffler Group Industrial IAM is responsible for replacement parts and service business for end customers and sales partners in all significant industrial sectors On the basis of innovative solutions products and services relating to rolling and plain bearings as wellas intelligent implementation of the Total Cost of Ownership philosophy the Industrial Aftermarket service function offers a comprehensive portfolio that covers all phases in the lifecycle of the rolling bearing The aim is to help customers save on maintenance costs optimise plant availability and avoid unforeseen machine downtime The Schaeffler Group 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 worldwide undergo a comprehensive training programme and are audited regularly This ensures that services throughout the world conform to a uniformly high standard of quality Every request every task is different so the Industrial Aftermarket function offers an individual concept for each customer The quality requirements are strongly influenced by a long history of high precision rolling bearing manufacture The production and provision of all products and services in this catalogue is proven in practice and is secured by a quality mana
2. 14 IS Schaeffler Group Industrial FAG Products Mechanical maintenance Lubrication Condition monitoring Products Mechanical maintenance oii cccccsssessssessssssssssusssssssusssssssusssssssucssesseessecssecsseesnsessecsseessestees 18 Our product range comprises tools forthe mechanical hydraulic and thermal mounting and dismounting of rolling bearings Mechanical tools are used predominantly for smaller bearings Medium sized and large rolling bearings are mainly mounted and dismounted using hydraulic or thermal tools The range is logically rounded off by measurement and inspection devices such as transport tools and gloves Lubrication 2242 66 Rolling bearing greases Arcanol offer the best conditions for achieving reliable durable and cost effective bearing arrangements These greases are designed to give favourable running behaviour of the bearings and thus make an important contribution to preventing premature bearing failure The Arcanol range is graduated such that almost all areas of application can be covered to an optimum extent It includes both standard and special greases Condition monitoring iimmssessessssrerrsssmmssssreersssnsssssrerersssssssssrerrsssssssssererssssssssseernsssssssssssnn 84 Condition monitoring contributes to achieving high availability and long life of machinery and plant FAG products help in planning maintenance work and reducing costs The range includes device
3. Figure 2 Scope of delivery FAG Top Laser INLINE2 00017A9E Actions before alignment If a so called soft foot is present this should be removed before alignment is carried out In this way any increased vibration tend ency and bearing damage due to housing distortion is prevented A soft foot is a machine foot that lifts off the floor when slackened The FAG Top Laser INLINE2 helps to quickly identify and eliminate the soft foot Each individual screw foot 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 computer determines any foot movement The soft foot can then be eliminated using shims 90 IS1 Schaeffler Group Industrial Scope of delivery 1 transceiver including cable 3 m Base device 1 reflector 2 brackets 2 chains 300 mm long 4 posts 115 mm long 1 software 1 case 1 USB adapter Ordering designation LASER INLINE2 All the parts included in the delivery are also available as replace ment parts Comprehensive range A comprehensive range of accessories is available in order to expand of accessories the possible applications of the base device FAG Top Laser INLINE2 see table and Figure 3 The accessories can be ordered as a Set in a handy robust case or as individual parts Accessories Accessories for Scope Designation FAG Top Laser INLINE2 of delivery Quantity Chain 600 mm long 2 LAS
4. Lubricators have the following advantages individually configured precise supply to each bearing position fully automatic maintenance free operation reduced personnel costs compared to manual relubrication different dispensing times can be selected pressure buildup to max 25 bar thereby overcoming any obstructions 76 IS1 Schaeffler Group Industrial Lubricators This automatic lubricator is driven by a chemical system The metal FAG Motion Guard COMPACT housing contains 120 cm of Arcanol rolling bearing grease The dispensing time is determined by the different coloured activation screws see table Activation screws Greases and chain oils can be combined if necessary with the activation screws see table Combination of lubricant and activation screws Activation screws Designation Dispensing time Colour ARCALUB ACTIVE 1M 1 month Yellow ARCALUB ACTIVE 3M 3 months Green ARCALUB ACTIVE 6M 6 months Red ARCALUB ACTIVE 12M 12 months Grey Combination of lubricant and ubricant Activation screw ARCALUB ACTIVE activation screws Arcanol 1 month 3 months 6months 12 months MULTITOP e e e MULTI2 e e e LOAD400 e e e e LOAD1000 e e e e TEMP90 e e e e TEMP120 e e e e TEMP200 e e e e FOOD2 e e e e CHAINOIL e e e Lubricators FAG Motion Guard COMPACT are available individually with an activation screw Other delivery options box containing 10 lubricators without a
5. The mounting and dismounting of rolling bearings and linear guidance systems is shown and practised in thematically oriented modules on the mounting of rolling bearings The mounting training covers a wide range of applications starting from mounting exercises with individual products through to bearing mounting on various assemblies such as gearboxes or rail wheelsets In addition to the training portfolio in the areas of rolling bearing theory and technology as well as mounting the Schaeffler Group also offers modules on condition monitoring These give the training participants an opportunity to acquire and deepen their knowledge of vibration analysis of machinery Our trainers communicate the theoretical principles of vibration monitoring the practical handling of measurement systems and the use of configuration and analysis software The knowledge is embedded by means of practical exercises with the measurement systems Schaeffler Group Industrial IS1 133 Training Training locations The Schaeffler Group has its own training centres worldwide Alternatively we will be pleased to train your employees at your location Training Centre With an area of nearly 500 m2 the Schaeffler Group Training Centre Schweinfurt in Schweinfurt Germany offers state of the art training facilities in the areas of rolling bearing technology and mounting starting with standard training on mounting and progressing to the mounting of large roll
6. Designation Dimensions Recommended for extractor extraction plates Amin dmax PULLER HYD PULLER 3ARM mm mm PULLER TRISECTION 50 i 30 160 PULLER TRISECTION 100 26 100 40 60 80 100 230 PULLER TRISECTION 160 50 160 80 100 120 175 200 310 PULLER TRISECTION 260 90 260 175 200 250 300 430 PULLER TRISECTION 380 140 380 250 300 400 660 Further information For detailed information see TPI WL 80 56 FAG Tools AA for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 31 Product overview Hydraulic mounting and dismounting Hydraulic nuts HYDNUT INJECT2500 INJECT1600 Oil injectors 0001709D 0001798F Hand pumps PUMP1000 0 7L Single stage gt Twin stage PUMP1000 4L PUMP1000 8L PUMP1600 4L PUMP1600 8L PUMP2500 4L PUMP2500 8L For drive up distance PUMP1000 4L CONTROL 000179A4 000179A2 000179C2 32 IS Schaeffler Group Industrial High pressure pumps Hydraulic units Mobile Connectors accessories Adapters and reduction nipples Pump holder Digital manometer PUMP4000 0 2L 0001798E TOOL RAILWAY AGGREGATE PUMP NIPPLE A PUMP NIPPLE B VA N PUMP HOLDER 2 PUMP HOLDER 3 00017903 00017AC5 PUMP2500 0 2L KIT g PUMP ADAPTER A PUMP ADAPTER B 0001799A 00017AA0 PUMP1000
7. Jointed face wrenches Double hook wrenches Double hook wrench sets Mechanical extractors Two arm and three arm extractors Hydraulic pressure tools LOCKNUT FACEPIN 0001799B LOCKNUT DOUBLEHOOK SET PULLER 2ARM SET PULLER 2ARM PULLER 2ARM SEPARATOR PULLER SUPPORT IK 000179E5 00017991 LOCKNUT DOUBLEHOOK PULLER 3ARM 0001799E 0001799F 000179C6 Schaeffler Group Industrial IS1 21 gt Product overview Special bearing extractors Separation and extraction devices Internal extractors Hydraulic extractors Three section extraction plates Mechanical mounting and dismounting PULLER SPECIAL BASIC PULLER SPECIAL 2 iL PULLER BORE SET eT amp PULLER HYD PULLER TRISECTION 00017AD5 00017992 00017994 00017995 PULLER INTERNAL10 100 SET 00017996 PULLER HYD 40 60 80 00017993 22 IS Schaeffler Group Industrial Mechanical mounting and dismounting Features These mechanical tools are designed for the mounting and dismounting of bearings The mounting forces are transmitted by SA the geometrical locking effect Mounting tool sets The mounting tool sets are suitable for the simple mounting of rolling bearings up to 50 mm bore They can also be used for the mounting of sleeves intermediate rings seals and similar parts A mounting tool set contains mounting sleeves made from aluminium
8. Product index Feeler gauge Feeler gauge MOUNTING TOOL Setin sti issisissetsistenionaitisickbem in 20 Heat resistant gloves erserrennennvrnvnnrnvservnnnensesnnnnnssessnnnnnssssnnnne 62 Heat resistant and oil resistant gloves Heating fing Heat conducting paste Induction heating device for workpieces up to 10 kg mass 48 Induction heating device for workpieces up to 20 kg mass 48 Induction heating device for workpieces up to 35 kg mass 48 Induction heating device for workpieces up to 150 kg mass 48 Induction heating device for workpieces up to 300 kg mass 48 Induction heating device for workpieces up to 600 kg mass rsnrrnnnnnrnevnvnnennvanennvnnsvnvanees 48 Induction heating device for workpieces up to 1200 kg mass Electric heating plate u nennen here Electric heating plate en Generator for heating device with medium frequency technology sscesseecesseeesreeseseeees 48 Inductor of the heating device with medium frequency technology csecessecesseeesreeseseeees 48 Hydraulienut eeesasen seitens 32 Oil injectors 1500 hats ein aE s E Teaia 32 Oilinjector 2500 hal ST TD 32 Taper rig gauge n klein ev stubber 56 Shaft alignment device Top Laser INLINE2 sonrnnonnnnnernvnnvenvnnevnen 86 Shim Top Laser SHIM isscsscccsesstesconsssosncoesasscccesesovnssseensscnsvesstaocons 86 Belt pulley alignment device Top Laser SMARTY2 86
9. Mounting and Maintenance of Rolling Bearings Products Services Training SCHAEFFLER GROUP INDUSTRIAL jounting 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 changes Schaeffler Technologies GmbH amp Co KG Issued 2011 March 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 Through its Industrial Service function the Schaeffler Group therefore offers high quality products services and training Figure 1 This catalogue gives an overview of the portfolio Mechanical maintenance Lubrication Condition monitoring Reconditioning Maintenance management The employees of the Schaeffler Group worldwide will be pleased to help you select the ideal products services and training Figure 1 Products Services Training
10. Rolling bearing reconditioning TPI 207 TPI WL 80 72 Reconditioning and Repair of Rolling Bearings WL 80 367 Flyer Maintenance Service on Wheelset Bearings Schaeffler Group Industrial IS1 135 Addresses Germany Schaeffler Technologies GmbH amp Co KG Austria Schaeffler Austria GmbH Postfach 1260 Ferdinand P lzl StraBe 2 97419 Schweinfurt 2560 Berndorf St Veit Georg Sch fer StraBe 30 Tel 43 2672 202 0 97421 Schweinfurt Fax 43 2672 202 10 03 Tel 49 2407 9149 66 info at schaeffler com Fax 49 2407 9149 59 info schaeffler iam com Switzerland HYDREL GmbH www schaeffler iam com Badstrasse 14 Schaeffler Technologies GmbH amp Co KG 8590 Romanshorn Industriestra e 1 3 Tel 41 71 4 66 66 66 91074 Herzogenaurach Fax 41 71 4 66 63 33 Tel 49 91 32 82 0 info ch schaeffler com Fax 49 91 32 82 49 50 R info de schaeffler com Worldwide You will find all the Schaeffler Group s addresses and contacts at www schaeffler com 136 IS1 Schaeffler Group Industrial Notes Schaeffler Group Industrial 151 137 Notes 138 IS1 Schaeffler Group Industrial Schaeffler Group Industrial 151 139 Notes 140 IS1 Schaeffler Group Industrial ee Schaeffler Group Industrial 151 141 Key Notes 142 IS1 Schaeffler Group Industrial f ee Schaeffler Group Industrial 151 143 G MATNR 036908134 0000 IS 1 GB D 2011034 Printed in Germany b
11. Separation and extraction device erroerreov 22 PULLER SPECIAL Special bearing extractors 22 PULLER SPECIAL BASIC Special bearing extractors 22 PULLER SUPPORT Hydraulic pressure tool nnerneeeonneevenneoeonneseneee ee 21 PULLER TRISECTION Three section extraction plate eworerreres 22 PULLER 2ARM Two arm extractors 21 PULLER 2ARM SEPARATOR Two arm extractors 21 PULLER 2ARM SET Two arm extractors 21 PULLER 3ARM Three arm extractOrS s reeereenrnnnerernrrnnsrsnnnrnnsesnnnnnnssssnnnrsesee 21 Schaeffler Group Industrial IS1 9 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 PUMP2500 0 2L KIT PUMP2500 4L PUMP2500 8L PUMP2500 MANO G1 2 PUMP4000 0 2L PUMP ADAPTER A PUMP ADAPTER B PUMP HOLDER 2 PUMP HOLDER 3 PUMP NIPPLE A PUMP NIPPLE B PUMP OIL46 PUMP PIPE PUMP SLEEVE CONNECTOR SMART CHECK SNAP GAUGE SOUND CHECK TACHOMETER TEMP CHECK PLUS TEMP CHECK PRO TOOL RAILWAY AGGREGATE VibroCheck Wear Debris Monitor WiPro s Product index Single stage hand pump Twin stage hand pump emeeneeeeeneneoennnevenneeveneeeent Twin stage hand pump with digital manometer 32 Twin Stage hand pump inne ne seines 32 Digital manometer eeeenseesssnnnnnesssnnnnnnssnnnnnnnsssnnnnnnsnsnnnnnnnnnn 33
12. 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 LI an early stage and the source can be determined In this way it is possible to prevent production shutdowns or secondary damage Further information For detailed information see WL 80 366 Flyer Wear Debris Monitor Enquiries info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 111 Services Services Features Mo ntine uun sans an i E tannin LUD FIC At OJ ces aeg Condition Monit ring auces essen Corrective maintenance e nneoevvnnneooovennnnneoeenenneeeee eee Rolling bearing reconditioning Teehnical comsultancy es tissi vahu keaktets kuna d a sten Maintenance management nenerevennneneooonnnneene ones Schaeffler Group Industrial IS1 113 Features Mounting Mounting services Services The Schaeffler Group 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 pro
13. 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 420 mm The reproducibility of the measurement results is less than 1 um 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 deviation 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 58 IS1 Schaeffler Group Industrial Snap gauges Available snap gauges Ordering example Ordering designation Ordering example Ordering designation 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 Designation Diameter range mm min max SNAP GAUGE 30 60 30 60 SNAP GAUGE 60 100 60 100 SNAP GAUGE 100 150 100 150 SNA
14. monitoring Continuous monitoring For production critical machinery continuous monitoring Figure 3 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 the Schaeffler Group offers a wide range of solutions including single channel standalone solutions for smaller equipment medium sized systems with up to 8 channels that can be extended on a modular basis and also complex monitoring systems with up to 2048 sensor channels In addition to giving advice on selecting the right system the Schaeffler Group 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 himself or to enlist the services of the Schaeffler Group for online monitoring Due to the communication options of the monitoring systems remote analysis can be carried out by the experts of the Schaeffler Group Figure 3 Continuous monitoring Schaeffler Group Industrial IS1 117 Services Regular monitoring The failure of so called B or C category plant items not does lead directly to downtime and does not therefore lead to expensive secondary damage For such machine parts offline monitoring is generally recommended
15. Belt tension measuring device Top Laser TRUMMV2 86 8 IS1 Schaeffler Group Industrial Page LOCKNUT DOUBLEHOOK Double hook wrench vea 24 LOCKNUT DOUBLEHOOK SET Double hook wrench set vevenneeooonnnnneeeoenenenee eee 21 LOCKNUT FACEPIN Jointed face wrench ssssececececccccccceeeceeeesssseseeeeeeeeeeeeeeeas 21 LOCKNUT FLEXIHOOK Jointed hook Wrench ccccccccccccececcceeeesssseceeceecceccsceeeeeeeeeees 20 LOCKNUT FLEXIPIN Jointed pin WrenCh esssnnrnnorsnnnrnnnesvnnnrnnnesennnnnnesennnrnnsesennnnseee 20 LOCKNUT HOOK Hook wrench 20 LOCKNUT SOCKET Socket wrenCh mmeeeerneeeeeennnneeeeevenneeeeeenenneene net 20 MGA31 Enveloping circle gauge for external enveloping circle ennrevenneooenaneeeni 56 MGI21 Enveloping circle gauge for internal enveloping circle 56 MGK132 Taper gauge rmreensenerersarssesesssnsnsnnennnsnnnssnssssssssessensnnnnnnnnnnsessenee 56 MGK133 Taper gauge nk seems essen wos 56 ProCheck Online monitoring system ProCheck cessecccsesssneeeeeeetenees 99 ProTorg Online monitoring system ProTorg eeeesaneessnnessssnesssnnensennennennn 108 PULLER BORE SET Internal extractors 22 PULLER HYD Hydraulic extractors 22 PULLER INTERNAL10 100 SET InternalextractOrs mmmemrreronvreronrrrornrrrennrrrennrrrennrerennresenvnsennr 22 PULLER SEPARATOR
16. 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 can rapidly cause an explosion For detailed information see TPI WL 80 69 FAG ProCheck State of the Art Machine Monitoring for Maximum Availability Enquiries info schaeffler iam com 49 2407 9149 66 106 IS 1 Schaeffler Group Industrial Online monitoring system The online monitoring system FAG VibroCheck is used wherever FAG VibroCheck a large number of measurement points must be continuously and A reliably monitored Typical applications can be found in paper plants wire rolling mills cement plants and power stations Through the high predictive accuracy and early identification of forthcoming damage optimum use can be made of planned stop pages and downtimes due to failure can be drastically reduced Parameters monitored FAG VibroCheck allows monitoring using up to 2 048 sensors For the detection of defects such as imbalance and misalignment FAG VibroCheck generates spectrum based parameters that are managed within narrow frequency bands according to speed In addition to vibration signals other process parameters can be p detected such as pt temperature power pressure torque In addition to general parameter monitoring the user has access to an automat
17. there is also the option of temporary measurement carried out by the Schaeffler Group The objective here is to find short term approaches to solutions where unexpected component failure occurs For detailed information see TPI 199 FAG ProTorg Enquiries info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 109 Kar Product overview Monitoring of lubricants Oil sensor Wear Debris Monitor Wear Debris Monitor 000179C7 110 IS1 Schaeffler Group Industrial Monitoring of lubricants Features 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 we in the oil The debris particles that can indicate a failure can be detected in the 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 Oil sensor FAG Wear Debris Monitor is an oil sensor that monitors the number FAG Wear Debris Monitor ofparticlesin the oil and classifies the particles by size and material 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 Monitor can be found 2 for example in gearboxes in raw material extraction plants Bs planetary gearboxes in wind turbines or in ship propulsion systems
18. 115V Available heating plates Designation Dimensions Power at Temperature Device Heating 230 V 50 Hz plate mm mm W 2 min max HEATER PLATE 390X270X56 380X180 1500 50 200 HEATER PLATE 370C 360X 360X170 350X350 2200 100 370 Schaeffler Group Industrial IS1 49 Heating rings Recommended accessories Ordering example Ordering designation Further information Heat conducting paste Ordering example Ordering designation Further information Thermal mounting and dismounting 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 advantageous for the occasional extraction of small and 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 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 Electric heating plate HEATER PLATE 370C Temperature measuring device TEMP CHECK
19. HYD120 XL 120 370 400 240 280 75 PULLER HYD200 XL 200 430 450 275 330 80 PULLER HYD250 XL 250 480 540 315 385 100 PULLER HYD300 XL 300 540 610 375 405 100 Available hydraulic extractors Designation Extraction Grip span Grip depth Stroke with separate hand pump force Standard XL Standard XL length kN mm mm mm mm mm PULLER HYD175 XL 175 360 450 250 305 82 PULLER HYD400 XL 400 580 1000 420 635 100 Further information For detailed information see TPI WL 80 56 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries info schaeffler iam com 49 2407 9149 66 30 IS1 Schaeffler Group Industrial Three section Three section extraction plates PULLER TRISECTION see table extraction plates Can be used with hydraulic and mechanical extractors en 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 extraction forces are concentrated on the bearing inner ring In general the bearing and shaft remain intact and can be used again The extraction plates can be fitted under the bearing with just a few movements Available three section
20. 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 Tools for Thermal Dismounting Enquiries info schaeffler iam 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 Tools for Thermal Dismounting Enquiries info schaeffler iam com 49 2407 9149 66 50 IS1 Schaeffler Group Industrial Induction heating devices Induction heating devices technical data Even large parts can be mounted using the induction heating method It is also suitable for batch mounting of complete bearings inner rings and rotationally symmetrical steel parts such as labyrinth rings roll couplings and bands The induction heating device gives uniform and controlled heating of the parts Non metallic components and the device itself remain cold Once the set temperature is reached the workpiece is aut
21. a further period The same applies to the wheelset bearings of rail vehicles These are among the most heavily loaded of vehicle parts and are subjected to regular maintenance The Schaeffler Group therefore offers operators of all rail vehicles the opportunity to have their wheelset bearings professionally dismounted cleaned and reconditioned The service portfolio of the Schaeffler Group applies to all wheelset bearings as well as cylindrical spherical and tapered roller bearings up to a maximum width of 180 mm and a maximum outside diameter of 425 mm products from all rolling bearing manufacturers all rail vehicles The service comprises professional dismounting cleaning failure analysis and reconditioning of bearings in the Service Centre of the Schaeffler Group identification marking of each individual bearing before dismounting where required documentation for each bearing of all maintenance activities carried out For detailed information see TPI 207 Reconditioning and Repair of Rolling Bearings Enquiries tel info schaeffler iam com 49 9721 91 1919 fax 49 9721 91 3639 Through professional cleaning and reconditioning it is also possible to return larger standard and special rolling bearings to an acceptable functionally secure condition In general the costs of such rolling bearing reconditioning are significantly lower than the costs of a new bearing and delivery times are shorter in most cases In
22. achieving optimum mounting operations the use of modern mounting tools such as heating by means of the versatile medium frequency technique the design and manufacture of special tools 114 IS1 Schaeffler Group Industrial x a N e 5 Figure 1 Mounting services Advantages The mounting services give the following advantages extended bearing life considerable cost reductions less unplanned downtime increased plant availability correct use of rolling bearings Further information Enquiries tel 49 9721 91 3142 fax 49 9721 91 3639 Equipment rental Customers who require special mounting and measuring equipment only infrequently for example in order to carry out repairs can rent these from the Schaeffler Group on a weekly basis for a fee The Schaeffler Group offers rental of the following equipment enveloping circle gauges hydraulic nuts hand pump sets heating devices The devices are checked after each use by the experts of the Schaeffler Group and where necessary returned to full working condition Further information Enquiries tel 49 9721 91 1133 fax 49 9721 91 3809 Service Hotline Tel 49 2407 9149 99 Schaeffler Group Industrial IS1 115 Services Lubrication In more than half of all cases inadequate lubrication is the cause of unplanned machine downtime The life of rotating machine elements can be significantly extended by the use of greases appropriate to th
23. and dismounting of components such as ships propellers For driving hydraulic nuts up to HYDNUT800 1000 Unlimited 50 Mounting and dismounting of rolling bearings In conjunction with a hydraulic nut 1600 Unlimited 80 Mounting and dismounting of rolling bearings Mounting and dismounting of components such as rudder splines and rudder blades 2500 Unlimited 125 Mounting and dismounting of bearings Mounting and dismounting of components such as gears and couplings 4000 Unlimited gt 100 Dismounting of bearings with cylindrical bore For rolling bearings For interference fits with high contact pressure 250 Delivery rate and oil reservoir are small 2500 Unlimited gt 100 Dismounting of bearings with cylindrical bore For interference fits with high contact pressure Delivery rate and oil reservoir are small Schaeffler Group Industrial IS1 37 Features Software Mounting Manager of Mounting methods Measurement the axial drive up distance Measurement of the reduction in radial internal clearance Hydraulic mounting and dismounting Hydraulic tools can be used to apply large forces These tools are therefore particularly suitable for the 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
24. as a more economical option The experts of the Schaeffler Group can assist in identifying the most economically appropriate solution between cost effective continuous monitoring 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 of the normal condition of the machine Deviations can thus be detected For the 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 Diagnosis Centre of the Schaeffler Group Vibration experts will then analyse the data and prepare a diagnosis report Through working with the experts of the Schaeffler Group customers can build up their own know how in analysis If no personnel are available for data logging the Schaeffler Group can also offer support in data logging The company s experts can carry out regular measurements on site Troubleshooting 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 diagnosis experts of the Schaeffler Group are well versed in such troubleshooting tasks Various types of information are fed into the analysis These include e
25. belt tension the belt mass and length must be entered Vibration ofthe belt is then induced The device measures the natural freguency by means of clock pulse light and uses this to determinethe belttension Thistechnigue is less prone to disruptive influences in comparison with measurement sound waves A Do not look into the laser beam or point the laser beam into another Caution person s eyes Scope of delivery Microprocessor Base device probe for direct connection Probe with cable Plastic case hr Ordering designation LASER TRUMMY2 Accessories Calibration device Ordering designation LASER TRUMMY CALI CHECK Schaeffler Group Industrial IS1 89 Alignment Shaft alignment device FAG Top Laser INLINE2 Figure 2 is a PC based alignment system FAG Top Laser INLINE2 for coupled 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 laptop or netbook more precise alignment than with conventional methods rapid simple measurement by means of continuous rotary motion reduced vibration and friction losses longer machine running times usable with conventional laptops with a USB interface optional wireless connection for ease of use without a troublesome tangle of cables A Do not look into the laser beam or point the laser beam into another Caution person s eyes
26. 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 1 table and table page 28 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 gt oo oo gt FG g Designation Grip Grip Dimensions Extraction span depth force w t a b mm mm mm mm kN PULLER 2ARM90 90 100 14 1 18 1 30 PULLER 2ARM130 130 100 14 1 18 1 30 PULLER 2ARM160 160 150 18 1 26 2 50 PULLER 2ARM200 200 150 18 1 26 2 50 PULLER 2ARM250 250 200 20 1 28 2 75 PULLER 2ARM350 350 200 20 1 28 2 75 PULLER 2ARM SEPARATOR45 45 65 245 12 1 10 PULLER 2ARM SEPARATOR90 90 100 2 5 14 1 40 PULLER 2ARM SEPARATOR150 150 150 2 5 28 1 40 Schaeffler Group Industrial IS1 27 Available three arm extractors Hydraulic pressure tool Available pressure tools Special bearing extractors Ordering example Base device Ordering designa
27. 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 of the accessories and tools required The software contains a library with references to publications giving further information and an electronic learning system The software Mounting Manager is available online at www schaeffler iam com Bearings with a tapered bore are mounted either directly on the tapered shaft or journal or by means of an adapter sleeve or withdrawal sleeve on the cylindrical shaft The internal clearance is set either by measurement of the axial drive up distance or by conventional 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
28. monitor the condition of their machinery The support given by the experts of the Schaeffler Group is progressively reduced in stages and the customer s employees use their new knowledge directly in their daily work Company C would like to completely outsource the area of condition diagnosis The Schaeffler Group offers complete packages under which the entire service is provided by the Schaeffler Group 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 example to operators of wind turbines Company D is a plant manufacturer and would like to offer condition monitoring as a service itself In this case the Schaeffler Group acts as a subcontractor for the mostly portable 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 manufacturer The plant manufacturer can thus offer its customers a highly qualified monitoring service without having to establish its own experts Enquiries info schaeffler iam com 49 2407 9149 66 126 IS 1 Schaeffler Group Industrial Maintenance mana gement Maintenance consultancy Figure 8 Phases in a con
29. must be specifically ordered to match the bearing Base device for bearings with inside diameter up to 30 mm PULLER SPECIAL BASIC30 Collet for deep groove ball bearing 6000 PULLER SPECIAL A 6000 Collets for pair of tapered roller bearings 30203 A in X arrangement PULLER SPECIAL B 300203A PULLER SPECIAL C 300203A 28 IS1 Schaeffler Group Industrial Internal extractor sets The internal extractor set PULLER BORE see table can be used for the dismounting of small deep groove and angular contact ball on 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 The individual parts can also be ordered individually Available internal extractor sets Designation Diameter range Scope of delivery mm mm 7 min max D al PULLER BORE5 39 SET 5 39 6 internal extractors 1 countersupport 1 impact extractor PULLER BORE40 79 SET 40 79 4 internal extractors 1 countersupport 1 impact extractor PULLER INTERNAL 10 100 SET 10 10 6 extraction legs 2 screw spindles Further information For detailed information see TPI WL 80 56 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries info schaeffler i
30. position A suitable hydraulic 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 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 Hand pump Hydraulic nut Rolling bearing 4 Tapered seat Initial position Start position Drive up distance Final position Figure 1 Mounting of a rolling bearing using PUMP1000 4L CONTROL 00015F9B Scope of delivery Hand pump with digital manometer High pressure hose with coupling sleeve Spacer ring HYDNUT50 to HYDNUT150 Plug in coupling nipple User manual Metal case Ordering designation PUMP1000 4L CONTROL 42 181 Schaeffler Group Industrial High pressure pump Available high pressure pump Ordering designation Available by agreement Further information The high pressure pump see table 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 b
31. 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 38 IS1 Schaeffler Group Industrial Hydraulic nuts Hydraulic nuts HYDNUT see table are used to press components with a tapered bore onto their tapered seat Presses are mainly SA used if the drive up forces required cannot be applied using other accessories e g shaft nuts or pressure SCrews 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 Available hydraulic nuts A Designation Design Application 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 Sleeves with inch HYDNUT530 INCH to ABMA dimensions Standards for Mounting Accessories Section 8 Locknut Series N 00 HYDNUT100 HEAVY to Increased capacity design For hi
32. srrnnrrennrnnnvrrennnnnnvrennrnnsssvnnnnr 68 Multi purpose grease for bearings under normal loads D 62 sensee 68 Multi purpose grease for bearings under normal loads D gt 62 escesccssseeeseeereeeees 68 Special grease for very high speeds high temperatures 70 Special grease for low and high temperatures 70 Special grease for low and high temperatures high speed 70 Special grease for high temperatures high speed 70 Special grease for very high temperatures rrnnnnrrnrnnvnnvnnvnnnnner 70 Special grease for high loads high temperatures oscillating motion veneeee 70 Transport and mounting tool wrwereneeeenreree 62 Vibration measuring device Detector Ill 0enneeeoeennna 98 Vibration measuring device Detector III with automatic measurement point detection 98 Balancing function for Detector III Online monitoring system DTECT X1 s Schaeffler Group Industrial IS1 7 FEELER GAUGE 100 FEELER GAUGE 300 FITTING TOOL ALU 10 50 GLOVE PRO GLOVE PRO CUT HEATING RING HEATING RING PASTE HEATER10 HEATER20 HEATER35 HEATER150 HEATER300 HEATER600 HEATER1200 HEATER PLATE HEATER PLATE 370C HEAT GENERATOR HEAT INDUCTOR HYDNUT INJECT1600 INJECT2500 KLR LASER INLINE2 LASER SHIM LASER SMARTY2 LASER TRUMMY2
33. time Misalignments are presented in degrees the parallelism offset is presented in mm A Do not look into the laser beam or point the laser beam into another Caution person s eyes Figure 1 Electronic target mark 000179B3 Schaeffler Group Industrial IS1 87 Alignment Scope of delivery 1 emitter Base device gt optical target marks attached by magnetism 1 battery 1 lined case Ordering designation LASER SMARTY2 Spare parts Optical target marks attached by magnetism Ordering designation LASER SMARTY2 TARGET Accessories Electronic target marks attached by magnetism Case Ordering designation LASER SMARTY2 TARGET DIGITAL 88 IS1 Schaeffler Group Industrial Belt tension measuring device The robust handy FAG Top Laser TRUMMY 2 is an optical electronic FAG Top Laser TRUMMY2 manual measuring instrument belt tension strand force go 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 can be used in many locations and comprises a cableless measurement probe a measurement probe with a cable for difficult to access locations and a microprocessor that displays relevant measurables for belt tension as a frequency in Hz or force in N The simple and reliable user menu is given in several languages Before measuring the
34. 00 2 20 120 not suitable thickener oi 68 IS1 Schaeffler Group Industrial Continuous Characteristic applications Temperatures Low High Vibra Support Relubri limit friction load tions forseals cation temperature high low facility ec speed speed Low High 80 Ball and roller bearings in rolling mills o construction machinery automotive engineering spinning and grinding spindles 75 Ball bearings up to 62 mm diameter o o o o o in small electric motors agricultural and construction machinery household appliances 75 Ball bearings from 62 mm diameter o o o in large electric motors agricultural and construction machinery ventilators Continuous Characteristic applications Temperatures Low High Vibra Support Relubri limit friction load tions forseals cation temperature high low facility speed speed SE Low High 90 Ball roller and needle roller bearings o linear guidance systems in machine tools 80 Ball and roller bearings in rolling mills o o rail vehicles 80 Ball and roller bearings in mining machinery o o construction machinery wind turbines 80 Ball and roller bearings wind turbines o 80 Ball and roller bearings in mining machinery 0 o construction machinery Schaeffler Group Industrial IS1 69 Grease
35. 00179BC Schaeffler Group Industrial IS1 75 Ja Motion Guard Select Manager Features Software Lubricators Lubrication devices Lubricators and lubrication systems automatically provide bearings with the correct quantity of lubricant 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 bearings For manual relubrication grease guns are suitable The software Motion Guard Select Manager gives the following options assistance in the selection of suitable lubricators definition of dispensing times and relubrication quantities selection of suitable and preferred Arcanol greases management of a lubrication and maintenance plan The software Motion Guard Select Manager is available online at www schaeffler iam com Automatic lubricators convey fresh grease 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 lubricators are matched to the bearing position They have a wide range of applications for example on pumps compressors and fans in conveying equipment machinery etc
36. 72 Product overview Lubrication devices c cccsscscssesesssssscssssessesessescsececseessscessseseeens 74 Features Software Motion Guard Select Managel cccsscssessescescesesseseees 76 kube 76 Lubrication system Motion Guard CONCEPTE 0e 80 Pistol grease guns Service pump for wind turbines eeeerrnrers 81 Grease PUMPS Arie Bunte Heine 82 Schaeffler Group Industrial IS1 67 Multipurpose greases Designation Thickener Base oil Base oil viscosity Consist Operating at 40 C ency temperature mm s NLGI C over incl MULTITOP Lithium Partially ISO VG 68 2 40 140 soap synthetic oil MULTI2 Lithium Mineral ISO VG 68 2 30 120 a soap oil Definition of symbols extremely suitable highly suitable MULTI3 Lithium Mineral ISOVG6s 3 30 120 o suitable soap oil less suitable not suitable Greases for high loads Designation Thickener Base oil Base oil Consist Operating viscosity ency temperature at 40 C mm s NLGI eC over incl LOAD150 Lithium Mineral ISO VG 150 2 20 140 complex oi LOAD220 Mixed Mineral IS0VG 220 1 2 20 140 thickener oi Definition of symbols LOAD400 Mixed Mineral 400 2 20 140 extremely suitable thickener oi highly suitable LOAD460 Aluminium Mineral 400 1 30 130 o suitable complex oi less suitable LOAD1000 Mixed Mineral ISO VG 10
37. 8 PUMP NIPPLE B G1 4 G3 4 PUMP NIPPLE B G3 4 G3 8 PUMP NIPPLE A G1 4 M14 PUMP NIPPLE A M18X1 5 G1 4 PUMP NIPPLE B G1 4 M14 PUMP NIPPLE A M18X1 5 G3 8 PUMP NIPPLE A G1 4 M18X1 5 PUMP NIPPLE A M18X1 5 G3 8 PUMP NIPPLE A G3 8 G1 4 PUMP NIPPLE B G3 8 G1 4 Designation Designation PUMP ADAPTER A G1 4 PUMP ADAPTER A G3 4 PUMP ADAPTER B G1 4 PUMP ADAPTER B G3 4 Schaeffler Group Industrial IS1 45 Hydraulic mounting and dismounting Pump holders Pump holders are available with and without a connector G1 2 for a manometer see table Available pump holders Designation Design PUMP HOLDER 2 Pump holder without connector for manometer PUMP HOLDER 3 Pump holder with connector for manometer Manometers In addition to the manometer with digital display there are three analogue manometers with an indicator see table T When selecting a manometer pay attention to the maximum oil pressure Available manometers Designation Threaded connector Maximum oil pressure mm bar PUMP1000 MANO DIGI Gl 4 1000 PUMP1000 MANO G1 2 61 2 1000 PUMP1000 MANO G1 2 61 2 1600 PUMP1000 MANO G1 2 61 2 2500 High pressure pipes 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 G2 4 For otherthread sizes a reduction nippl
38. CANOL ANTICORROSIONOIL 62 IS1 Schaeffler Group Industrial 00017A45 Accessories Features Accessories are used to assist in the storage transport and mounting of rolling bearings SA Transport and mounting tool 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 spherical 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 A the bearing is suspended bythe tool using the carrying slings and gt a 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 Available tools Designation Bearing outside diameter Mass of tool mm kg over incl BEARING MATE250 450 250 450 6 3 pe BEARING MATE450 650 450 650 6 4 BEARING MATE650 850 650 850 6 5 Ordering example Transport and mounting tool for bearings with inside diameter of 250 mm to 450 mm with 2 sho
39. CT X1 s is a flexible online system for the monitoring of rotating components and elements in the machinery and plant industry Typical applications can be found for example in the 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 This increases the capacity utilisation of machinery and plant The system can be tailored to customer specific requirements by means of the software The base device is available as an 8 channel system The system is suitable for connection of all conventional acceleration speed and travel sensors Due to its compact size and robust housing class IP 67 it is suitable for a wide range of monitoring applications It has standardised connectors allowing easy installation on machinery and plant 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 vibration experts of the Schaeffler Group For detailed information see WL 80 372 flyer FAG DTECT X1 s Enquiries info schaeffler iam com 49 2407 9149 66 104 IS 1 Schaeffler Group Industrial Online monitoring system FAG WiPro s allows online monitoring of wind farms onshore and FAG WiPro s Offshore The system gives earl
40. ER INLINE CHAIN600 Chain 1500 mm long LASER INLINE CHAIN1500 Post 150 mm long LASER INLINE POST150 Post 200 mm long LASER INLINE POST200 Post 250 mm long LASER INLINE POST250 Post 300 mm long LASER INLINE POST300 PTRI RI RI RIN Magnetic holder including 4 posts 150 mm long LASER INLINE MAGNET Accessory set complete 1 LASER INLINE ACCESS SET This contains all the parts listed above Wireless upgrade 1 LASER INLINE2 UPG WI Chain 2 Post 3 Magnetic holder Figure 3 l Accessories N we 000179E7 Schaeffler Group Industrial IS1 91 Alignment Shims Shims FAG Top Laser SHIM are used to eliminate vertical FAG Top Laser SHIM misalignment or 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 4 and table page 93 00017A47 Figure 4 Shim dimensions 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 example 1 10 shims with dimension c 15 mm and 0 2 mm thickness Ordering designa
41. HAMPION 74 Lubricator Motion Guard COMPACT POLAR with grease charge without activation screw Lubricator Motion Guard CHAMPION ccccccccseeseeeeessseeeeeeeeees Drive unit for lubricator Motion Guard CHAMPION LC unit for lubricator Motion Guard CHAMPION 6 IS1 Schaeffler Group Industrial ARCANOL ANTICORROSIONOIL ARCANOL MOUNTINGPASTE ARCANOL BIO2 ARCANOL CLEANM ARCANOL FOOD2 ARCANOL LOAD150 ARCANOL LOAD220 ARCANOL LOAD400 ARCANOL LOAD460 ARCANOL LOAD1000 ARCANOL MULTITOP ARCANOL MULTI2 ARCANOL MULTI3 ARCANOL SPEED2 6 ARCANOL TEMP90 ARCANOL TEMP110 ARCANOL TEMP120 ARCANOL TEMP200 ARCANOL VIB3 BEARING MATE DETECT3 KIT DETECT3 KIT RFID DETECT3 BALANCE KIT DTECTX1 s Anti corrosion oil Mounting paste 2 ersehen iona iaee Special grease for environmentally hazardous applications 70 Special grease for clean room applications 0 70 Special grease for applications with food contact Greases for high loads high speed Greases for high loads high speed Greases for high loads mean Speed ccessssceceeesseeeeeeeeteeee 68 Greases for high loads mean Speed cccssssceceeeesseeeeeeesenees 68 Greases for high loads low speed ereerneenenee 68 Multi purpose grease for high speed high loads high temperatures
42. Industrial Hand pumps Hand pumps have a single stage or twin stage pump with a manometer SA Single stage pump The hand pump PUMP1000 0 7L has an oil container with a volume of 0 7 I The maximum pressure is 1000 bar see table A digital manometer is available as an accessory Available single stage pump Designation Maximum oil pressure bar PUMP1000 0 7L 1000 Twin stage pump The twin stage pumps see 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 il Where there is an increased oil requirement the twin stage pumps are available with a 8 oil container suffix 8L In those cases where the type of installation of the 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 Available twin stage pumps Designation Maximum oil pressure bar n PUMP1000 4L 1000 La PUMP1600 4L 1600 PUMP2500 4L 2500 Schaeffler Group Industrial IS1 41 Hydraulic mounting and dismounting Pump for drive up distance The hand pump PUMP1000 4L CONTROL is particularly suitable as a pressure generation device where rolling bearings are to be driven onto their tapered seat using a hydraulic nut Figure 1 First the bearing is driven smoothly onto the tapered seat as far as the initial
43. MANO DIGI 00017A48 000179BD Schaeffler Group Industrial 151 gt Kun 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 PUMP OIL46 Hydraulic oil 00017AC7 000179C5 34 IS1 Schaeffler Group Industrial Schaeffler Group Industrial IS1 35 Matrix for preselection Type Designation Oil Connector of pressure generation devices container l Oil injector INJECT2500 0 008 G3 8 INJECT1600 0 027 G3 4 Hand pump Single stage PUMP1000 0 7L 0 7 Gl 4 Twin stage PUMP1000 4L 4 61 4 PUMP1000 4L CONTROL 4 61 4 PUMP1600 4L 4 Gl 4 PUMP2500 4L 4 61 4 High pressure pump PUMP4000 0 2L 0 2 G3 4 PUMP2500 0 2L KIT 0 2 G1 4 Hydraulic unit Available by agreement 36 IS1 Schaeffler Group Industrial Maximum oil pressure Maximum shaft diameter Maximum contact pressure in interference fits Application bar mm N mm 2500 80 125 Mounting and dismounting of bearings with tapered bore 1600 150 80 Mounting and dismounting of bearings with tapered bore 1000 250 50 Mounting and dismounting of rolling bearings For driving hydraulic nuts up to HYDNUT395 or HYDNUT300 HEAVY 1000 Unlimited 50 Mounting and dismounting of rolling bearings Mounting
44. Manometer 34 Twin stage hand pump 32 Twin stage hand pump 32 Manometer cen sdscescenedfesecestcvedenceedsspicnseScesetenteceoesunts 34 High pressure PUMP AT 33 Twin stage hand pump 32 Twin stage hand pump 32 Manometer areas NN 34 High pressure PUM Pues nee aa seen 33 Adapter 33 Adapter 33 Pump holder 33 Pump holder 33 Adapter and reduction nipple rarnnreronnvnnrvnrnnvenvnnervenssrnrnssvnr 33 Adapter and reduction nipple rssnnrerovnvnnrvnrnnennvnnervenssnrnssvnr 33 Hydraulic oil 34 High pressure pipe 34 Sleeve c nnect r SAS 34 Online monitoring system SmartCheck rrronnnnnrnnrnnvnnrnsvnvnnsee 98 Snap 35 197 4 AAA AL TD 56 Sonar device 94 Digital hand tachometer 94 Temperature measuring device TempCheck PLUS 94 Temperature measuring device TempCheck PRO 94 Mobile hydraulic unit for batch mounting of TAROL bearings eeernee 33 Online monitoring system VibroCheck emnennre 99 Oil sensor Wear Debris Monitor eeerreres 110 Online monitoring system WiPro S eeverneeoeeenennee 98 10 1S1 Schaeffler Group Industrial Schaeffler Group Industrial IS1 11 Products Mechanical maintenance Lubrication Condition monitoring 00017B04 Services 00017AF2 Training 00017B16 Appendix Publications Addresses 000174DA
45. P 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 Snap gauge for shaft diameter 120 mm SNAP GAUGE 100 150 Shim for shaft diameter 120 mm SNAP GAUGE MASTER120 Schaeffler Group Industrial IS1 59 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 to MGI21 For cylindrical roller bearings NNU4920 K NNU4948 K with separable inner ring NNU4920 NNU4948 MGA31 For cylindrical roller bearings NN3006 K NNU3048 K with separable outer ring N1006 K N1048 K 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 measuremen
46. 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 Ordering designation SOUND CHECK Schaeffler Group Industrial IS1 97 Product overview Vibration diagnosis Vibration measuring device DETECT3 KIT DETECT3 KIT RFID DETECT3 BALANCE KIT Detector III ert oe 000179B8 Online monitoring system SMART CHECK SmartCheck 00017465 Online monitoring system DTECTX1s DTECT X1 s 000179BF Online monitoring system wiPros WiPro s 000179BE 98 IS1 Schaeffler Group Industrial Online monitoring system ProCheck ProCheck 000179B9 Online monitoring system VibroCheck i HNADAAGA ODENSE Schaeffler Group Industrial IS1 99 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 unpl
47. am com 49 2407 9149 66 Schaeffler Group Industrial IS1 29 Mechanical mounting and dismounting Hydraulic extractors The hydraulic extractors see tables are used where higher extraction 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 lever or separate pump Available hydraulic extractors Gen Designation Extraction Grip span Grip depth Stroke with integral hand pump force Standard XL Standard XL kN mm mm mm mm mm PULLER HYD40 40 260 165 55 PULLER HYD60 XL 60 260 260 165 195 82 PULLER HYD80 XL 80 355 380 210 240 75 PULLER HYD100 XL 100 310 340 195 250 75 PULLER
48. and mounting rings made from plastic An error frequently made during mounting is to transmit the 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 A to an appropriate mounting sleeve The carefully matched precision a parts ensure that the forces are uniformly transmitted to the side faces of the bearing rings Scope of delivery 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 Recoilless hammer mass 1 kg Case Ordering designation FITTING TOOL ALU 10 50 i Also available as individual parts LT Further information For detailed information see TPI WL 80 56 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 23 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 of the nut than hook wrenches and allow the use of ratchets and torque wrenches For increased reliability socket wrenches should be secured using a locking pin and rubb
49. and the knowledge on site Due to the wide portfolio of services from the Schaeffler Group it is possible to weave together the right package of training and services from the Schaeffler Group 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 experts of the Schaeffler Group 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 the company in the use of the systems and accompany them while making the initial steps In difficult cases assistance can be requested from the experts of the Schaeffler Group These will help in the analysis and formulation of measures Schaeffler Group Industrial IS1 125 Example 2 Teaching Example 3 Outsourcing Example 4 Offering a service Further information Services Company B would like to build up its own knowledge in the field of condition diagnosis Condition diagnosis is a complex subject Building up knowledge therefore takes time In such cases the Schaeffler Group offers a two year programme after which even customers without prior knowledge can themselves
50. anned downtime is reduced Monitoring devices In the field of offline monitoring devices regular monitoring offline and online the Schaeffler Group offers FAG Detector III The online monitoring systems continuous measurement include FAG SmartCheck FAG DTECT X1 s FAG WiPro s FAG ProCheck and FAG VibroCheck 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 Group Industrial 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 III 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 it is completed The device evaluates the measurement results and presents the results with self explanatory symbols on the device display Figure 1 Value OK Prealarm 3 Main alarm Figure 1 S
51. arlier 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 appar ent through changes in vibration behaviour unusual temperature patterns or similar phenomena Where the diagnosis experts carry out measurements on the machine themselves the measurement method is selected as a function of the specific machine and the type of malfunction The diagnosis experts of the Schaeffler Group are familiar with all analytical techniques from vibration measurement to torque analysis or endoscopy As a result they can quickly identify malfunctions 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 results of the investigation the recommended countermeasures are discussed in particular 118 IS1 Schaeffler Group Industrial Vibration measurements In many areas relating to rolling bearings vibration measurements are the standard method for detecting problems The vibration expert can assess the condition of the machine without the need for any dismounting work A large proportion of possible causes of damage can thus be detected and assessed with little work Modal analysis Modal analys
52. ctivation screws The exception here is lubricators with TEMP200 which are packed individually For examples of available lubricators see table Available lubricators Designation Lubricant Activation screw Scope examples Atcanol of delivery ARCALUB MULTITOP MULTITOP Not included 10 lubricators in delivery ARCALUB TEMP90 TEMP90 Not included 10 lubricators in delivery ARCALUB MULTITOP 1M MULTITOP 1 for 1 month 1 lubricator ARCALUB MULTI2 3M MULTI2 1 for 3 months 1 lubricator ARCALUB MULTITOP 6M MULTITOP 1 for 6 months 1 lubricator ARCALUB LOAD400 12M LOAD400 1 for 12 months 1 lubricator Schaeffler Group Industrial IS1 77 Lubricators Motion Guard COMPACT variant CLEAR Activation screws Ordering example Ordering designation Lubricators Motion Guard COMPACT variant POLAR Dispensing time Ordering example Ordering designation Ordering example Ordering designation Lubrication devices The variant CLEAR ofthe lubricator is suitable for explosion protected and corrosion inducing humidity areas The transparent plastic housing can be used at ambient temperatures from 0 C to 40 C It is filled with 100 cm of lubricant The variant CLEAR is available with the same lubricants as the standard design see table Combination of lubricant and activation screws page 77 Lubricators COMPACT of the variant CLEAR are supplied in a box of 10 pieces The appropriate activation screws w
53. d 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 current 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 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 and analysed there by the operator or external service providers such as the vibration experts of the Schaeffler Group 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 info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 103 Online monitoring system FAG DTECT X1 s Versatile system Remote monitoring Further information Vibration diagnosis FAG DTE
54. dered according to the individual application TOOL RAILWAY AXLE When making enquiries or placing orders information on the bearing types and power connection as well as installation drawings shaft housing additional parts are required 00017A51 TOOL RAILWAY AGGREGATE For detailed information see TPI 195 FAG Pressure Generation Devices Enquiries info schaeffler iam com 49 2407 9149 66 44 IS1 Schaeffler Group Industrial Connectors accessories Adapters and reduction nipples Type A Type B Figure 3 Adapters and reduction nipples Available adapters and reduction nipples Available adapters 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 see Figure 3 and tables Adapters and reduction nipples of type A with sealing ring are suitable for oil pressures up to 800 bar Figure 3 Type B with blade sealing is suitable for oil pressures up to 2 500 bar Figure 3 LLL Varm z Designation Designation PUMP NIPPLE A G1 4 G1 8 PUMP NIPPLE A G3 4 G1 8 PUMP NIPPLE B G1 4 G1 8 PUMP NIPPLE B G3 4 G1 8 PUMP NIPPLE A G1 4 G1 2 PUMP NIPPLE A G3 4 G1 4 PUMP NIPPLE B G1 4 G1 2 PUMP NIPPLE B G3 4 G1 4 PUMP NIPPLE A G1 4 G3 4 PUMP NIPPLE A G3 4 G3
55. e can be used T Check the oil pressure using a manometer Ordering example High pressure pipe with a connector G1 4 on the consumer device side Ordering designation PUMP PIPE G1 4 46 IS1 Schaeffler Group Industrial Sleeve connectors Sleeve connectors can be used at pressures up to 800 bar The connector to the pump holder is G1 4 The connector to AA the consumer device is available in the sizes M6 M8 G1 g and G1 4 For otherthread sizes a reduction nipple can be used H Check the oil pressure using a manometer Ordering example Sleeve connector with a connector G1 g on the consumer device side Ordering designation PUMP SLEEVE CONNECTOR G1 8 Hydraulic oil The hydraulic oil is a zinc free high performance hydraulic oil for use in the mounting and dismounting of bearings For refilling the hydraulic oil is available in containers holding 1 I 5 I and 201 gt a Ordering example 5 l hydraulic oil in a canister Ordering designation PUMP OIL46 5L Further information For detailed information see TPI WL 80 56 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 47 Product overview Thermal mounting and dismounting Electric heating plates HEATER PLATE HEATER PLATE 370C 00017999 00017A5A Heating rings HEATING RING HEATING RING PASTE Heat conducting paste 00017A5D 00017997 Induction heati
56. e different operating and environmental conditions as well as the definition of and adherence to lubrication intervals and quantities Services Services relating to lubrication Figure 2 include the selection of lubricants and lubrication systems the lubrication of bearing positions the preparation of lubrication and maintenance plans lubrication point management consultancy on lubricants lubricant investigations and tests Advantages The lubrication service of the Schaeffler Group 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 Figure 2 Lubrication as a service 116 IS1 Schaeffler Group Industrial Condition Monitoring The malfunction free and optimised operation of complex machinery and plant can only be achieved by means of condition based maintenance The Schaeffler Group uses vibration diagnosis as a preferred method here This method makes it possible to detect damage in machinery at a very early stage This means that for example damaged components can be replaced as part of planned downtime Unscheduled downtime is avoided 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
57. e or by means of a 400 g cartridge The cartridge must correspond 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 Available lever grease guns Designation Maximum Delivery quantity delivery pressure per stroke bar cm ARCA GREASE GUN 800 2 Available reinforced hoses Designation Length Connector mm LAA ARCA GREASE GUN HOOK ON HOSE 300 Cylindrical lubrication nipple with head 16 mm to DIN 3404 ARCA GREASE GUN HOSE 300 Taper type lubrication nipple to DIN 71412 Schaeffler Group Industrial IS1 83 FAG Condition monitoring Product overview Features Product overview Features Product overview Features Product overview Features Product overview Features Condition monitoring Page Alignment uses sen senken einen 86 Belt pu
58. e used to expand and mount heavy shaft couplings and gears by means of the hydraulic method The high pressure pump can 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 2 500 bar Always operate the pump together with a manometer Designation Connector Oil container Delivery volume Maximum capacity per stroke oil pressure l cm bar PUMP4000 0 2L G3 4 0 2 0 3 4000 PUMP4000 0 2L Hydraulic units driven by pneumatic and electric means are available by agreement For detailed information see TPI 195 FAG Pressure Generation Devices Enquiries info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 43 Mobile hydraulic unit Figure 2 Mobile hydraulic unit Ordering designation Further information Hydraulic mounting and dismounting The mobile hydraulic unit Figure 2 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 Guide bushes mounting sleeves traction and pressure spindles drawing frames and other tool sets must be or
59. ement and inspection FEELER GAUGE 100 FEELER GAUGE 300 000179A9 MGK133 000179BA SNAP GAUGE 00017947 MGI21 000179A5 KLR MGK132 000179BB MGA31 000179A6 56 IS1 Schaeffler Group Industrial Features Feeler gauges Available feeler gauges Taper ring gauges and taper gauges Taper ring gauges Ordering example Ordering designation Measurement and inspection 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 Feeler thickness length mm mm FEELER GAUGE 100 100 0 03 0 08 0 14 0 04 0 09 0 16 0 05 0 1 0 18 0 06 0 12 0 2 0 07 FEELER GAUGE 300 300 0 03 0 12 0 2 0 04 0 13 0 25 0 05 0 14 0 3 0 06 0 15 0 35 0 07 0 16 0 4 0 08 0 17 0 45 0 09 0 18 0 5 0 1 0 19 These gauges are used to inspect tapered bearing seats in production 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 determ
60. er 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 delivery Socket wrenches are available in sizes suitable for locknuts KMO to KM20 Other sizes and special solutions are available by agreement Socket wrench Locking pin Rubber washer Socket wrench suitable for locknut KM5 LOCKNUT SOCKET KM5 Special sizes available by agreement For detailed information see TPI WL 80 56 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries info schaeffler iam com 49 2407 9149 66 24 IS1 Schaeffler Group Industrial Hook and pin wrenches These wrenches can be used for the mounting and dismounting of small bearings on shaft seats adapter sleeves or withdrawal en sleeves Hook wrenches 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 KM40 Other sizes available by agreement Ordering example Hook wrench suitable for locknuts KM18 KM19 and KM20 Ordering designation LOCKNUT HOOK KM18 20 Hook wrenches can also be ordered as a Set Special sizes available by agreement A Jointed hook wrenches 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 fo
61. et The Schaeffler Group service covers both complete solutions in the form of CMMS implementation as well as individual modules for the following areas Systems integration Through the implementation of interfaces for example to ERP Enterprise Resource Planning systems the CMMS is integrated in the IT environment of a company This allows holistic assessment and data analyses in a complete system so that redundant data maintenance and multiple inputting of data can be avoided Process operations are standardised and optimised and the exchange of information across departments is improved Mobile solutions The use of electronic checklists on a handheld PC enables data to be collected during inspection The data determined and checked for consistency are transferred via a workshop PC to the CMMS data base Damage can thus be notified and processed without delay The mobile system facilitates a computer aided maintenance process and eliminates manual order processing using paper forms Data quality and analysis options are increased by the use of standardised coding Creation and expansion The integration of reports into the CMMS gives an authoritative of the reporting system reporting system that offers versatile possibilities for data analysis and representation Typical applications in this field include evaluation and failure analyses with multi stage reports stock and master data lists as well as internal and external business pape
62. for monitoring 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 FAG ProTorg can be used to detect signals such as torque elongation force pressure temperature and displacement changes 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 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 The versatile application possibilities covered by FAG ProTorg require precise definition of the parameters to be monitored when configuring the hardware and software Each system thus represents an individual solution The Schaeffler Group accompanies the customer throughout the project phase Following system configuration by the Schaeffler Group the user receives intensive training that equips him to use the system independently Upon customer request the experts of the Schaeffler Group can undertake evaluation of the measurement data If a permanent installation is not required
63. g corrosion It also gives protection against corrosion The operating temperature range is between 30 C and 150 C The paste is resistant to water water vapour and many alkaline and acidic media Designation Container 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 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 Spray can containing 0 4 ARCANOL ANTICORROSIONOIL 400G Schaeffler Group Industrial IS1 65 FAG Lubrication Lubrication Page Matrix Multipurpose greases c ccccscsesessssecsscseseesssescseseseseescscseseseseees 68 Greases f r high lOAdS ssecsecssceeseescg cerieirar 68 Greases for wide temperature ranges n srrers 70 Special grease Sunissa eens iron Ene uA EE UE EARS KOA SENEESE EEDE 70 Features Rolling bearing greases Arcanol sccssessceseessessceseesseessesseseennes
64. g pads and additional RFID tags are available by agreement Further information For detailed information see TPI WL 80 64 FAG Detector IIl The Solution for Monitoring and Balancing or www FAG Detectorlll com Enquiries info schaeffler iam com 49 2407 9149 66 102 IS1 Schaeffler Group Industrial Online monitoring system FAG SmartCheck is a compact innovative modular online measur FAG SmartCheck ing system for continuous monitoring of machinery and process A 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 Plug and play system 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 a patented independent teaching mode that identifies the alarm thresholds Parameters monitore
65. ge Selection of software based on the catalogue of requirements Preparation of a thorough data model Specification of interfaces between software packages Specification of the necessary hardware Improvement of reporting system Performance figure system Automated printed measurables reports for management Electronic reporting via the Internet Benchmarking against partner companies Sustainability In order to maintain the optimisation of costs and benefits achieved of the developed solutions in the long term regular assessments are carried out after the implementation phase These measures are carried out by the customer while the Schaeffler Group stands ready as a neutral partner Maintenance controlling can be carried out through extension of the reporting system by means of systems of maintenance relevant performance figure and benchmarking projects Maintenance controlling should be regularly inspected It is only in this way that its authoritativeness and influence on the process can be ensured 128 IS1 Schaeffler Group Industrial Computerised maintenance In the field of computerised maintenance management systems management systems CMMS the Schaeffler Group draws on its sound technical knowledge to offer analysis of customer specific requirements independent of the manufacturer The experts of the Schaeffler Group implement a CMMS optimised for the customer This is based on standard software packages available in the mark
66. gement system certified to ISO 9001 2008 Contents Page PROCUGHIN COX A fen SA MA 6 Products nae n tnesin ange 15 Mechanical maintenance eesesssssssssssssseceressssssssssssseecsecerees 18 00 03 47 119 mnes A E 66 Condition monitoring csesssssseccececcccceeeseseeesersnseeeeeees 84 SEMICeSuads keen ene 112 Training veale katsele EE E RE EE E 130 Appendix P blications snsc an eeina a EEE 135 Addresses Aussen aeeai E NESER vao RoS 136 Schaeffler Group Industrial IS1 5 ARCA GREASE GUN ARCA PUMP ARCA PUMP BARRELL ARCA PUMP BARRELL GUN METER ARCA PUMP WIND SERVICE KIT ARCALUB ARCALUB ACTIVE ARCALUB CLEAR ARCALUB C6 ARCALUB C6 LC ARCALUB POLAR ARCALUB LC KIT ARCALUB DRIVE ARCALUB LC Product index Lever grease gun Grease dispensing unit rreerreseneeeeeneneeenneesonnee ent 75 Drum Pumps tencHRHRRBEhReR 75 Pistoligre se gun arosbansenessgslennanenenschhense 74 Service pump for wind turbines renarnrenernenevnrnnnenvenenvnnssvvensnn 75 Lubricator Motion Guard COMPACT with grease charge without activation screw 74 Activation screw for lubricator Motion Guard COMPACT eessnnnnvnverevnnnnnnvsennnnrser 74 Lubricator Motion Guard COMPACT CLEAR with grease charge without activation screw 74 Multi point lubrication system CONCEPT6 With CUNT 4er sehen 74 LC unit with grease charge for lubricator C
67. gh mounting forces HYDNUT900 HEAVY with smooth bore for example A in shipbuilding fu Further information For detailed information see TPI 196 FAG Hydraulic Nuts Enquiries info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 39 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 Oilinjectors Oil injectors have only a small delivery volume see table They are suitable for the dismounting of rolling bearings and other press fits with direct seating on tapered shafts 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 Designation Connector Oil Maximum For shaft Oil injector Valve nipple volume oil pressure diameters p up to cm bar mm INJECT2500 INJECT2500 VALVE G2 g 8 2500 80 INJECT1600 INJECT1600 VALVE G 4 27 1600 150 Oil injectors and valve nipples can also be ordered as a set Ordering example Oil injector with maximum oil pressure of 1600 bar Ordering designation INJECT1600 Ordering example Oil injector with maximum oil pressure of 2 500 bar forset Valve nipple Ordering designation INJECT2500 SET 40 IS1 Schaeffler Group
68. gressing through maintenance to the reconditioning of rolling bearings During the operational phase the experts of the Schaeffler Group provide support through services in the fields of condition monitor ing 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 training and consultancy portfolio of the Schaeffler Group In this way customers benefit from the expertise of a leading supplier of rolling and plain bearings The industrial service experts of the Schaeffler Group offer mounting services for rolling bearings that are applicable across industrial sectors They have detailed knowledge and extensive experience in all industrial sectors The mounting personnel in the Industrial Service function of the Schaeffler Group are trained and skilled personnel who can provide reliable rapid and competent assistance The mounting services are provided either at the customer s location or in the workshop facilities of the Schaeffler Group The mounting services Figure 1 page 115 include the mounting and dismounting of rolling bearings of all types approval inspection of adjacent parts shafts and housings measurement and production inspection of tapered shaft seats together with provision of the necessary measuring equipment maintenance and inspection of bearing arrangements troubleshooting on problem bearings support in
69. hort heating times control of heating according to time and temperature automatic demagnetisation flexible and rigid 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 54 181 Schaeffler Group Industrial Figure 4 In order to rationalise work the inductor is wrapped around a subframe Application Data required in enquiries 00017A56 Examples of the use of medium frequency technology include heating of bearings for mounting and dismounting batch dismounting of bearing inner rings and labyrinth rings for example in the case of wheelset bearings in rail vehicles F Figure 3 page 54 ar 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 Ordering information Bearing dimensions if possible with drawings Representation of the adjacent construction Data on the fit conditions Description of the mounting process and its frequency Power supply data Ambient conditions Your address Schaeffler Group Industrial IS1 55 Product overview Feeler gauges Taper ring gauges Taper gauges Snap gauges Enveloping circle gauges Measur
70. ic rule based expert system The system can monitor up to 20 components per sensor This allows monitoring of all rolling bearing types and tooth meshes in the vicinity of a sensor in relation to the occurrence of component specific frequency windows Remote monitoring Defects and damage can be detected on the machine 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 vibration experts of the Schaeffler Group Customer specific solutions The display which is individually tailored to the customer s require ments gives a user interface that allows a rapid overview of the condition of the plant Depending on the complexity of the plant this display can be arranged on several levels Other online Other monitoring systems for the requirements of specific sectors monitoring systems are available by agreement Schaeffler Group Industrial IS1 107 Product overview Monitoring of components Online monitoring system ProTorg ProTorg 108 IS1 Schaeffler Group Industrial Features Online monitoring system FAG ProTorg Function Customer specific solutions Troubleshooting Further information Monitoring of components Online monitoring systems of this type are used for estimating the remaining life of heavily loaded components as well as for process monitoring The online monitoring system FAG ProTorg is suitable
71. igure 3 page 54 The rigid design is particularly suitable for batch applications The flexible design of inductor can be wound around the components Figure 2 The flexible inductor can also be used with subframes Figure 4 page 55 to rationalise repetitive work Overall this gives a wide range of applications see table 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 55 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 construction sites for wind turbines or for other large components that are difficult to transport 00017A53 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 Schaeffler Group Industrial IS1 53 Rigid inductor in the dismounting of wheelset bearings 00017988 Thermal mounting and dismounting 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 s
72. individual cases customers may also receive the same warranty on the reconditioned bearing as on a new bearing For detailed information see TPI 207 Reconditioning and Repair of Rolling Bearings Enquiries info schaeffler iam com tel 49 202 293 2226 fax 49 202 293 2437 124 151 Schaeffler Group Industrial Technical consultancy Condition oriented maintenance Service concepts for plant manufacturers and operators Example 1 Instruction Companies that wish to change to the concept of condition based maintenance are supported by the Schaeffler Group with training attendance during the introductory phase ongoing advice during the period of use and service contracts Furthermore the Schaeffler Group offers support in the introduction and adaptation of Computerised Maintenance Management Systems CMMS These systems help to improve transparency of the services and costs involved in maintenance 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 advisory experts of the Schaeffler Group prepare plans that give recommendations 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 shelf products and the requirements vary according to the machine
73. ine 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 for example double row cylindrical roller bearings NN3020 AS K KLR NN3020 Schaeffler Group Industrial IS1 57 Taper gauge for tapers1 12 and 1 30 Ordering designation Taper gauge for taper angle 0 to 6 Ordering designation Measurement 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
74. ing and dismounting Designation Dimensions in mm Length Width Height a b HEATER10 230 200 240 65 95 HEATER20 345 200 240 120 100 HEATER35 420 260 365 180 160 HEATER150 505 260 440 210 210 HEATER300 870 300 580 900 330 260 HEATER600 1100 850 1250 430 400 HEATER1200 1500 1100 1400 700 450 1 Height with trolley HEATER300 TROLLEY 00017A00 Designation Ledges for workpieces with bore diameter in mm Supplied Available accessory min min HEATER10 15 30 45 10 HEATER20 20 35 60 10 15 45 HEATER35 70 15 20 35 45 60 HEATER150 100 20 30 45 60 70 85 HEATER300 115 30 45 60 70 85 100 HEATER600 145 45 60 70 85 100 115 130 HEATER1200 25 85 115 145 For detailed information see TPI 200 FAG Heating Devices PowerTherm for Mounting of Rolling Bearings Enquiries info schaeffler iam com 49 2407 9149 66 52 181 Schaeffler Group Industrial Induction units with medium frequency technology Figure 2 The flexible inductor can be wrapped around the component Versatile in application The FAG heating device with medium frequency technology gives rapid simple and effective heating of medium sized to large rolling AA 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 2 or rigid design F
75. ing bearing arrangements With the aid of mounting tables and training islands with large rolling bearing arrangements typical of industry the participants can practice dealing with bearings and tools in an environment representative of actual conditions and under skilled instruction and deepen their know ledge of mounting work Quality assurance Through continuous market monitoring and exchange of experience the Schaeffler Group is in a position to continuously improve its training courses What is particularly important to us are the ideas and suggestions that we receive through feedback from our training participants Certification of the INA and FAG Technical Training Centres to ISO 9001 2008 underlines our continuous aspiration to increasing quality Training courses The standard programme of training courses is sufficient in most standard and individual cases to achieve acquisition of the knowledge necessary for day to day work Upon customer request the Schaeffler Group also offers individually tailored training courses In these cases customers can themselves define the key components of the content The standard training programme for the areas of rolling bearing technology and mounting as well as condition monitoring is already comprehensive an excerpt is shown in table Excerpt from the training portfolio of the Schaeffler Group Training courses Rolling bearing Basic training Rolling bearing technology techn
76. is 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 measurement 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 vibration experts of the Schaeffler Group can submit recommendations for design improvements to the machine detection of the soft spot in a machine Ifa 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 is defined as a rigidity problem often caused by a poor quality connection between two machine parts for example at a screw connection Fo
77. ith dispensing times of 1 3 or 6 months must be ordered separately in units of 10 pieces see table Designation Dispensing time Colour ARCALUB ACTIVE CLEAR 1M 1 month Yellow ARCALUB ACTIVE CLEAR 3M 3 months Green ARCALUB ACTIVE CLEAR 6M 6 months Red 10 lubricators COMPACT variant CLEAR filled with Arcanol FOOD2 ARCALUB CLEAR FOOD2 The variant POLAR of the lubricator has a metal housing and can be used at temperatures from 25 C to 10 C The variant POLAR of the lubricator is available only with 120 cm Arcanol MULTITOP There is only a black activation screw and the dispensing time is dependent on the temperature see table The lubricator COMPACT of the variant POLAR is supplied in a box of 10 pieces without activation screws The black activation screws must be ordered separately in units of 10 pieces Temperature Dispensing time C 10 1 week 0 2 weeks 10 6 weeks 20 14 weeks 25 26 weeks 6 months 10 lubricators COMPACT variant POLAR filled with Arcanol MULTITOP ARCALUB POLAR MULTITOP 10 activation screws ARCALUB ACTIVE POLAR 78 IS1 Schaeffler Group Industrial Lubricator This lubricator comprises a drive unit an LC unit Lubricant FAG Motion Guard CHAMPION Cartridge containing lubricant and a battery set It is connected to SA the lubrication point by means of a support adapter or a hose see table A battery driven geared motor allows dispensing
78. l counter that displays the lubricant quantity in grams The specific mass of the lubricant can be set ARCA PUMP BARREL GUN METER These service pumps see table are particularly suitable for the 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 The greases Arcanol LOAD400 LOAD460 and MULTIPTOP in 12 5 kg buckets can be used for filling Available service pumps Designation Maximum Delivery rate for wind turbines delivery pressure bar cm min ARCA PUMP WIND SERVICE KIT 200 280 Schaeffler Group Industrial IS1 81 Lubrication devices Grease pumps Grease pumps are driven by pneumatic electrical or manual means Grease dispensing units Grease dispensing units ARCA PUMP see 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 device 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
79. lley alignment device Top Laser SMARTY2 87 Belt tension measuring device Top Laser TRUMMY2 89 Shaft alignment device Top Laser INLINE2 sc eeesseeesseeeeees 90 Shims Top Laser SHIM errnrennnvnnvnrnnnnnrnevnvnnsvnvensenrnsvnvnnssnvensvener 92 Checking the operating condition venerneeneeer 94 Infrared thermometer FAG TempCheck PLUS emeee 95 Infrared thermometer FAG TempCheck Pro rrsnnnnnsnnrnnnnnvanennrene 96 Digital hand tachometer evveeneovevnnennoooeenenneeeoeeneneee 97 Sonar device SOUND CHECK 97 Vibration didgn siS s csessecsbesssseeaedesaescoecvnssasaccecssessuned rennen 98 Detector Ill SmartEhecku ungane etic ik i cdinevin ragen 103 DTECTX1 5 WiPro S neuen Bracheckar nn ee eek ee VibroCheck Monitoring of components venenneneeenenneeneennnnnee 108 PROUT OF Gi vist sedecdevuen E E S A E TET 109 Monitoring of lubricants srororrennnrnnnrrrnnrnnnnrrnnnrnnnervnnnrnesesvnnren 110 Wear Debris MOMItOn ss scissccvsacsconcoctseseancacsssseacsacstasectasngeccecdees 111 Schaeffler Group Industrial IS1 85 Product overview Alignment Belt pulley alignment device LASER SMARTY2 LASER TRUMMY2 Top Laser SMARTY2 Belt tension measuring device Top Laser TRUMMY2 000179B1 000179B2 Shaft alignment device Top Laser INLINE2 Shims Top Laser SHIM LASER SHIM 0001798D 86 IS1 Schaeffler G
80. lubrication system can supply up to six different lubrication points precisely and irrespective of temperature The dispensing times can be adjusted from 1 day up to 24 months and LC units are available in the sizes 250 cm and 500 cm The starter kits are premounted on a retaining plate and form the basis forthe multi point lubrication system Motion Guard CONCEPTS The distribution system MP 6 allows the independent supply of between two and six lubrication points The geared motor in the distribution system is powered and controlled by the drive unit Lubricant is distributed independent of its consistency or solid particle content If the distributor identifies an obstruction in an individual outlet this is indicated on the display of the drive unit The other outlets continue to be supplied with lubricant In the variant CONTROL of the lubricator CONCEPT6 the lubricator is controlled by the machine Lubricant is only dispensed while the machine is running We also supply starter kits for this variant as a basis for multi point lubrication systems For single point lubrication the parts required are ordered individually from the range of accessories The hose and connectors for the lubrication points as well as the LC units must be ordered separately see table page 81 The lubrica tion system is available in four designs see table Designation Features ARCALUB C6 250 KIT Control by lubricator For LC unit
81. ly available Balancing Kit is required This makes it possible to not only detect but also eliminate imbalances The results of the balancing process are also transferred to the Trendline software for evaluation Schaeffler Group Industrial IS1 101 Vibration diagnosis Ordering examples The vibration measuring device FAG Detector III is available in two variants with the balancing function available for ordering in an upgraded version Scope of delivery Base device with rechargeable battery Base device Accelerometer attached by magnetism Infrared temperature sensor Charger with worldwide compatibility PC data cable serial and USB User manual Protective bag with holder for temperature sensor Trendline PC software free of charge Case Ordering designation DETECT3 KIT Scope of delivery As DTECT3 KIT i A Device RFID reader integrated with automatic measurement 5 RFID tags point detection Ordering designation DETECT3 KIT RFID Scope of delivery Accelerometer attached by magnetism and sensor cable Upgrade level Trigger sensor optical and induction with balancing function s i Reflective mark for trigger sensor Balance Magnetic holder for trigger sensor Extension for magnetic holder Cable for trigger sensor 10 m Dongle for activation of balancing function Case Ordering designation DETECT3 BALANCE KIT Accessories Sensor extension cables 5 m or 15 m long are available by agreement The charging dock mountin
82. n defects can thus be detected in the initial operation phase These defects include misalignment of motors pumps or fans as well as incorrect electrical connections in switch cabinets The experts of the Schaeffler Group 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 over the period of the warranty their removal and the secondary damage may incur considerable costs and downtime Further information Enquiries info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 121 Services Corrective maintenance Once a machine problem has been diagnosed it should be elim inated as quickly as possible Two of the most frequent problems namely imbalance in pumps and fans as well as misalignment of machine components to each other can be corrected directly by the experts of the Schaeffler Group Balancing Imbalance is one of the most frequent defects that lead to unexpected failure of rotating machine elements Correct balancing gives a decisive increase in the life of rotating machine parts This increases the productivity and availability of the machine The experts of the Schaeffler Group reduce to a normal level the imbalance that occurs for example due to contamination wear and repairs They can detect and eliminate the causes on machinery operating at a
83. nd Dismounting of Rolling Bearings TPI 195 TPI WL 80 50 FAG Pressure Generation Devices TPI 196 TPI WL 80 57 FAG Hydraulic Nuts TPI 180 FAG Tools for Thermal Dismounting TPI 200 TPI WL 80 54 FAG Heating Devices PowerTherm for Mounting of Rolling Bearings WL 80 100 Mounting and Dismounting of Rolling Bearings WL 80 376 Flyer FAG Medium Frequency Heating Device WL 80 369 Service flyer Bearing Heating Using Medium frequency Heating Device Technology WL 82 102 E Rolling Bearing Damage Lubrication TPI 168 Arcanol Rolling Bearing Greases TPI 176 WL 81115 Lubrication of Rolling Bearings WL 80 346 FAG Motion Guard the Intelligent Lubricators Condition monitoring TPI WL 80 64 FAG Detector III The Solution for Monitoring and Balancing TPI WL 80 67 FAG VibroCheck Online Monitoring System for Heavy Industry TPI WL 80 69 FAG ProCheck State ofthe Art Machine Monitoring for Maximum Availability WL80 363 Flyer FAG ProCheck Ex TPI 182 TPI WL 80 55 FAG Alignment Tools Top Laser SMARTY2 TRUMMY2 INLINE2 SHIM TPI 199 FAG ProTorg WL 80 365 Flyer FAG ProTorq TPI 214 FAG SmartCheck WL 80 375 Flyer FAG SmartCheck WL 80 366 Flyer FAG Wear Debris Monitor WL 80 372 Flyer FAG DTECT X1 s WL 80 373 Flyer FAG WiPro s WL 80 377 Flyer FAG Temperature Measuring Devices WL 80 368 Service flyer Thermography WL 80 374 Service flyer Endoscopy
84. ng devices HEATER 10 20 35 150 300 HEATER600 HEATER1200 000179FE 00017A4B Medium frequency devices HEAT GENERATOR HEAT GENERATOR HEAT INDUCTOR HEAT INDUCTOR P 00017A5E 48 IS1 Schaeffler Group Industrial Thermal mounting and dismounting Features Devices for thermal mounting and dismounting 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 These devices include electric heating plates heating rings and induction heating devices with either mains frequency or medium frequency operation 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 H 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 for the heating of heating rings HEATING RING Heating plates HEATER PLATE are also available as a version with 115 V 60 Hz suffix
85. ning 1 kg ARCANOL TEMP110 400G Arcanol TEMP110 Cartridge containing 400 g ARCANOL TEMP120 25KG Arcanol TEMP120 Hobbock containing 25 kg ARCANOL TEMP200 70G Arcanol TEMP200 Tube containing 70 g ARCANOL SPEED2 6 250G Arcanol SPEED2 6 10 tubes each containing 250 g ARCANOL VIB3 25KG Arcanol VIB3 Hobbock containing 25 kg ARCANOL BIO2 1KG Arcanol BIO2 Can containing 1 kg ARCANOL FOOD2 12 5KG Arcanol FOOD2 Bucket containing 12 5 kg ARCANOL CLEAN M 400G Arcanol CLEAN M Tube containing 400 g For detailed information see TPI 168 Arcanol Rolling Bearing Greases Enquiries info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 73 SA Product overview Lubricators Motion Guard COMPACT Motion Guard CHAMPION Lubrication systems Pistol grease guns Lubrication devices ARCALUB ARCALUB CLEAR ARCALUB POLAR 0001797F ARCALUB DRIVE 000179B0 ARCALUB C6 000179AA ARCA PUMP BARRELL GUN METER ARCALUB ACTIVE 3 Ro 6 000179AD ARCALUB LC 000179AC ARCALUB C6 LC 000179AB 00017AC3 74 IS1 Schaeffler Group Industrial Service pumps for wind turbines Grease pumps Grease dispensing units Drum pumps Lever grease guns ARCA PUMP WIND SERVICE KIT ARCA PUMP 000179A3 ARCA GREASE GUN x 000179B4 00017A4D ARCA PUMP BARRELL 0
86. ology and mounting Basic training Mounting of rotary bearings Basic training Mounting of rolling bearings in gearboxes Practical training Mounting of rolling bearings using large rolling bearings Linear Products and applications Basic training Mounting of linear bearings Rolling bearing failures Identifying causes Optimising operation Maintenance of main spindle bearings Condition FAG SmartCheck Introductory product training monitoring FAG SmartCheck Advanced product training Software Administrator FAG ProCheck FAG DTECT X1 and X1 s FAG Detector Ill Beginners training FAG Detector III Principles of vibration analysis FAG Detector III Machine diagnosis FAG Detector Ill Balancing Special training Training completely oriented to the application Further information Detailed information can be found at on the Internet www schaeffler iam com or www fag com or www ina com in the menu Services Training Courses 134 IS1 Schaeffler Group Industrial Publications FAG Ordering designation Title New Old for comparison purposes only General formula FIS001 u Smart Performance Program TPI 177 Optimising Processes in the Paper Industry WL 80 601 Optimising Processes in the Steel Industry Fitting TPIWL 80 56 FAG Tools for Mechanical Mounting a
87. om 49 2407 9149 66 Schaeffler Group Industrial IS1 93 Product overview Checking the operating condition Temperature measuring device TEMP CHECK PLUS TEMP CHECK PRO TempCheck PLUS TempCheck PRO OP Sco nr 000179C1 VV 00017AD2 Digitalhand tachometer TACHOMETER SOUND CHECK TACHOMETER Sonar device SOUND CHECK 000179AE 000179B7 94 IS1 Schaeffler Group Industrial Checking the operating condition Features These devices can be used to manually check the following parameters of rolling bearing arrangements temperature speed and SA noise Infrared thermometer The infrared thermometer FAG TempCheck PLUS is suitable FAG TempCheck PLUS for the 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 a glass optics for precise non contact temperature measurement a small measurement spot of 13 mm ata distance of up to 140 mm measurement spot size corresponds to 20 1 distance measurement spot size at distance of more than 140 mm rapid precise temperature measurement over a tem
88. omatically demagnetised The heating device HEATER10 is a portable table top device It is supplied with a carry case HEATER20 is also portable and is supplied in a case The devices HEATER35 and HEATER150 are also designed as table top devices The heating device HEATER300 can be used as a table top device It can also be placed on the trolley HEATER300 TROLLEY The higher power rating standalone devices HEATER600 and HEATER1200 can be used for the heating of workpieces up to 1200 kg The technical data for the heating devices and the ledges are compiled in the table page 51 Figure 1 page 52 and the tables page 52 Designation Maximum Rated Fre Current Mass power voltage quency consumption consumption kVA V Hz A kg HEATER10 2 3 230 50 10 7 HEATER20 3 6 230 50 16 11974 HEATER35 3 6 230 50 16 31 HEATER150 12 8 400 50 32 51 HEATER300 12 8 400 50 32 75 25 HEATER600 25 400 50 63 350 HEATER1200 40 400 50 100 850 D If lower voltage is used the power will be reduced 2 Heating devices with other rated voltages and frequencies and with higher power ratings are available on request 3 Convertible to a mobile version by means of HEATER300 TROLLEY Schaeffler Group Industrial IS1 51 AM Induction heating devices technical data continued Figure 1 Dimensions a and b Induction heating devices ledges Further information Thermal mount
89. perature range of 32 C to 530 C degree of emission adjustable to material low mass 150 g USB interface te report software simple to use low purchase costs A Do not look into the laser beam or point the laser beam into another Caution person s eyes Scope of delivery Measuring device Base device Battery Wrist strap Adapter for camera tripod Carry case Protective rubber slip cover User manual Report software Case Ordering designation TEMP CHECK PLUS For further information For detailed information see publication WL 80 377 FAG Temperature Measuring Devices Enquiries info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 95 Checking the operating condition Infrared thermometer The infrared thermometer FAG TempCheck PRO is suitable for FAG TempCheck PRO the thermal monitoring of machine components and fluids Temperatures 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
90. r work Reports can be prepared quickly and easily Due to their stand ardised form they fulfil the requirements involved in certification Other services relating to CMMS The Schaeffler Group also offers the following services in this area release and database platform changeover CMMS modifications and expansion functions data analysis and corrective data maintenance implementation of automated processes training of personnel to user and administrator level Schaeffler Group Industrial IS1 129 Training Product overview Features Training Page Training doa steecseesses E E vet vaielda US t 132 Target STOUPS AAA Str cture sesssnne Training locations Quality assurance Training courses standard and individual cssssssersseeeeeee 134 Schaeffler Group Industrial IS1 131 Product overview Training Rolling bearing technology Training example Mounting of rolling bearings Training example Machinery monitoring Training example X life PUMP1000 0 7L DIGI Detector III 132 IS1 Schaeffler Group Industrial Training Features The Schaeffler Group training courses communicate comprehensive knowledge on rolling bearings linear guidance systems and plain bearings In order to achieve a long life for rolling bearings plain bearings and linear guidance systems correct mounting and dismounting as well as correct selection of lubrication mounting tools and me
91. r 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 Group Industrial IS1 119 Services Torque and force measurements With torque measurement the Schaeffler Group offers a service that can be used to estimate the remaining life of drive components In addition production processes can be monitored and optimised In contrast to vibration measurement FAG ProTorg can be used to monitor values that act on the structural elements These include moments forces and other physical units where changes can be detected at scanning rates of less than 1 kHz Monitoring of torque including those cases where it is in addition to vibration measurement is always appropriate where drive elements must be protected against overload or the physical value torque plays an important role in production Typical areas of use include steel and aluminium paper oil and gas raw material extraction and processing wind power and pulp and paper Endoscopy Digital optical endoscopes can be used to examine the interior of a machine Figure 4 to determine the extent of damage The images can be stored as a digital photograph or video and forms the basis of diagnosis by the expe
92. r bearing arrangement engineering The Arcanol rolling bearing greases offer very good preconditions 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 and testing systems Arcanol rolling bearing greases have superior characteristics in all areas compared to normal greases Figure 1 1 00017A41 72 IS1 Schaeffler Group Industrial Available greases examples For further information Designation Rolling bearing grease Container ARCANOL MULTITOP 5KG Arcanol MULTITOP Bucket containing 5 kg ARCANOL MULTI2 20G Arcanol MULTI2 50 tubes each containing 20 g ARCANOL MULTI3 25KG Arcanol MULTI3 Hobbock containing 25 kg ARCANOL LOAD150 12 5KG Arcanol LOAD150 Bucket containing 12 5 kg ARCANOL LOAD220 180KG Arcanol LOAD220 Drum containing 180 kg ARCANOL LOAD400 400G Arcanol LOAD400 10 cartridges each containing 400 g ARCANOL LOAD460 1KG Arcanol LOAD460 Bucket containing 1 kg ARCANOL LOAD1000 5KG Arcanol LOAD1000 Bucket containing 5 kg ARCANOL TEMP90 1KG Arcanol TEMP90 Can contai
93. r locknuts KM1 to KM36 Other sizes available by agreement Ordering example Jointed hook wrench suitable for locknuts KM14 to KM24 Ordering designation LOCKNUT FLEXIHOOK KM14 24 Jointed pin wrenches The jointed pin wrench LOCKNUT FLEXIPIN is hooked into radially arranged holes in the nut Jointed pin wrenches are available in sizes suitable La for locknuts AM15 to AM90 Other sizes available by agreement Ordering example Jointed pin wrench suitable for precision locknuts AM35 to AM60 Ordering designation LOCKNUT FLEXIPIN AM35 60 Jointed face wrenches The jointed face wrench LOCKNUT FACEPIN is hooked into axially arranged holes in the nut Jointed pin wrenches are available in sizes suitable for precision locknuts LPNO17 to LPN170 Other sizes available by agreement Ordering example Jointed face wrench suitable for precision locknuts LPN017 to LPN170 Ordering designation LOCKNUT FLEXIPIN LPN17 25 Schaeffler Group Industrial IS1 25 Double hook wrenches Ordering example for individual wrench Ordering designation Ordering example Ordering designation Scope of delivery of double hook wrench set Ordering example Ordering designation Ordering example Ordering designation Further information Mechanical mounting and dismounting Double hook wrenches LOCKNUT DOUBLEHOOK are intended for the mounting of self aligning ball bearings with a tapered bore They are available as kits sets or individual wrenche
94. ring Explosion protected variant Further information Vibration diagnosis FAG ProCheck is an online monitoring system It can be used to 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 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 Due to its extremely robust and compact design this system is ideally suited for use in almost all industrial segments The system can be used in steelworks paper machinery cement plants or in the oil and gas industry 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 vibration experts of the Schaeffler Group An explosion protected version of FAG ProCheck is available by
95. rnnnnennoeeeeneeeenennnenana siss 45 Thermal mounting and dismounting wwweree 48 Electric heating plates esseneosnnnenennosnenensennenevernnenennesnennsesesnsenene 49 Heating TIMES cs tees avas er eee kee basser aire tes 50 Heat conducting paste i55555456nw406051 0809 t oaase v svsv hsseevnav nasv v 50 Induction heating devices essnnrrvnrernnnnennrrnnnnrensennunneensennnnnseeene 51 Induction units with medium frequency technology 53 Measurement and inSpection cccsssccccesssnceeceesesneeecessseeeees 56 Feelergauges n n nennen 57 Taper ring gauges and taper gauges reenreenr 57 Snap gauges Enveloping circle gauges vevernoooovovennenooenanneoooon venna eee 60 ATcessorleSu nanumsnersimskensasnannanuetendilnndte 62 Transport and mounting tool GIOVE Skannere eee seuss Mounting Paste a5 ee a aa E ea 65 ANtitCOMOSION Ollsssssiscadscsseseascosiessscissecdsecsiebacweadesassseascascusaaseesesd 65 Schaeffler Group Industrial IS1 19 Product overview Mechanical mounting and dismounting Mounting tool sets _FITTING TOOL ALU 10 50 N Socket wrenches LOCKNUT SOCKET w Hook and pin wrenches LOCKNUT HOOK Hook wrenches 00017940 000179B6 000179C4 Jointed hook wrenches LOCKNUT FLEXIHOOK LOCKNUT FLEXIPIN Jointed pin wrenches 0001799D 0001799C 20 IS1 Schaeffler Group Industrial
96. rollers before and after reconditioning Advantages The advantages for the customer are as follows longer useful life due to high quality maintenance work short downtime periods due to swift implementation of the maintenance process little mounting work since the wheelset bearings are returned in a condition ready for mounting reduced maintenance costs due to preventive maintenance Reconditioning levels Before reconditioning the bearing is dismounted cleaned and examined The processing steps required are established and a proposal is prepared Levels of rolling bearing reconditioning see table Level I to Level IV Processing steps Level Il III IV Removal of fretting corrosion H H H E Polishing of raceways H Regrinding of raceways H H Manufacture of rolling elements H Replacement of cage H H Replacement or rework of rolling bearing rings Assembly H H H Preservation or greasing H H E Packing H E Despatch H a E Schaeffler Group Industrial IS1 123 Standard bearings up to 425 mm outside diameter and wheelset bearings for rail vehicles Further information Large rolling bearings of outside diameter greater than 425 mm Further information Services In particular bearings with smaller dimensions are regularly replaced during maintenance work although they could be reconditioned with little work and then used for
97. roup Industrial Alignment Features These products assist in the alignment of shafts and belt pulleys and the checking of belt tension Belt pulley alignment device FAG Top Laser SMARTY2 is a line laser for the alignment of belt FAG Top Laser SMARTY2 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 device can also be used on non magnetic sprockets or pulleys Due to the low mass the emitter and target marks can be easily attached to non magnetic drive pulleys using strong double sided adhesive tape 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 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
98. rt brackets Ordering designation BEARING MATE250 450 Schaeffler Group Industrial IS1 63 Accessories brackets Ordering designation Accessories carrying slings Ordering designation Accessories pack of small parts Ordering designation Gloves Resistant up to 150 C Ordering designation Resistant up to 250 C 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 resistant 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 Gloves GLOVE PRO CUT comprise several layers are oil resistant and are 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 to mechanical influences and in accordance with DIN EN 407 to thermal influences GLOVE PRO CUT 64 IS1 Schaeffler Group Industrial Mounting paste Available mounting pastes Anti corrosion oil Ordering example Ordering designation The mounting paste see table facilitates the sliding of bearing rings and prevents stick slip effects scoring wear and frettin
99. rts of the Schaeffler Group The condition of individual components such as rolling bearings or gear teeth can be assessed If the bearings inspected are products of Schaeffler Technologies GmbH amp Co KG the customer also has access to the knowledge of the application engineers of the Schaeffler Group These experts will prepare a detailed damage analysis and submit proposals for improvement Figure 4 Endoscopy 120 IS1 Schaeffler Group Industrial Thermography Thermography is one of the most important non destructive diagnostic techniques Figure 5 Many technical problems manifest themselves in the form of heat generation which can be detected with the aid of a high resolution infrared camera The major advantage of 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 electrical connections in switch cabinets rolling bearing arrangements in motors and fans thermal linings in cement kilns 86 5 C 80 60 40 20 Figure 5 3 Thermography FLIR systems 14 1 C 5 Approval inspection of new plant The combination of different diagnostic techniques enables the experts of the Schaeffler Group to carry out assessment of new plant irrespective of the manufacturer Frequently occurring installatio
100. s A Desig Thickener Base oil Base oil viscosity Consist Operating for wide temperature ranges nation at 40 C ency temperature mm s NLGI C over incl TEMP90 Mixed Synthetic ISO VG 100 2 30 140 thickener oi TEMP110 Lithium Synthetic ISO VG 68 43 40 160 oo complex oi Definition of symbols TEMP120 Polycar Synthetic ISO VG 460 2 30 180 extremely suitable bamide oi highly suitable TEMP200 PTFE Fluor ISO VG 220 460 2 30 250 o suitable idated less suitable polyether not suitable e Special greases Symbol Thickener Base oil Base oil viscosity Consist Operating at 40 C ency temperature mm s NLGI C over incl SPEED2 6 Lithium Synthetic ISO VG 22 213 30 120 complex oi VIB3 Lithium Mineral 2 ISO VG 150 3 30 150 complex oi BIO2 Mixed Synthetic ISO VG 55 2 30 120 thickener oi Definition ofsymbols Foop2 Alumin White 150 VG 100 2 30 120 extremely suitable ium oi highly suitable complex o suitable CLEAN M Polycar Synthetic 1SO VG 100 2 40 200 less suitable bamide oi not suitable 70 IS1 Schaeffler Group Industrial Continuous Characteristic areas of application Temperatures Low High Vibra Support Relubri limit friction load tions forseals ca
101. s The double hook wrench kits and 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 KM5 to KM8 and for locknuts KM9 to KM13 Each double hook wrench is engraved with the torsion angles for the appropriate self aligning ball bearings The drive up distance and reduction in radial internal clearance can therefore be precisely set Double hook wrench suitable for locknut KM7 LOCKNUT DOUBLEHOOK KM7 Double hook wrench kit suitable for locknut KM5 LOCKNUT DOUBLEHOOK KM5 KIT Several double hook wrenches Torgue wrench User manual Case 4 double hook wrenches suitable for locknuts KM5 to KM8 LOCKNUT DOUBLEHOOK KM5 8 SET 5 double hook wrenches suitable for locknuts KM9 to KM13 LOCKNUT DOUBLEHOOK KM9 13 SET For detailed information see TPI WL 80 56 FAG Tools for Mechanical Mounting and Dismounting of Rolling Bearings Enquiries info schaeffler iam com 49 2407 9149 66 26 IS1 Schaeffler Group Industrial Mechanical extractors Two arm and three arm extractors Figure 1 Dimensions of the gripper Available two arm extractors Mechanical extractors can be used to dismantle small and medium sized rolling bearings that are located with a tight fit on a shaft or in a housing The bearing can be dismantled without damage if the
102. s forthe alignment of shafts and belt pulleys Temperature measuring and sonar devices make it possible to check the operating condition An important element of the range comprises measuring systems that monitor vibration torque and lubricants 16 IS1 Schaeffler Group Industrial Schaeffler Group Industrial IS 1 17 FAG Mechanical maintenance Product overview Features Product overview Matrix Features Product overview Features Product overview Features Product overview Features Mechanical maintenance Page Mechanical mounting and dismounting were 20 MOUNTING tool sets es 23 Socket wrenches Hook and pin wrenches rssnnenannvnnnnnrnnvnnvnnenvnnnsnvanennvansvnvenssnvensen 25 Mechanical extractors reronnrrnnrrennnrenvenenrnnerennnnrnnesennnnrenssnnnnnser 27 Hydraulic extractors esceenae sn stein en 30 Three section extraction plates srnnnnrrnrnnnonrnrvnnnnsvnvnnsnnrnssnnnnee 31 Hydraulic mounting and dismounting ueneesseeesssnnneenesnennnnnene 32 Matrix for preselection of pressure generation devices 36 Software Mounting Manager 0vemrneeeonennneoeeennnee 38 Hydraulic nuts Pressure generation devices eerernneneeenenneoeoennennee ee 40 Mobile hydraulic unit eesernnnrnnvrrvnnnrnvnrennnrnnnevennnnnensvsnnrnesssnnnnsen 44 Connectors accessorieS 0nrrrr
103. s personnel structure tasks and responsibilities machine utilisation commercial and production measurables technical characteristics of the processes utilisation of IT and measurement systems maintenance strategies knowledge management measurables systems relevant to maintenance co operation between departments The consultancy experts evaluate the information obtained and place it within an overall context Anonymous data from other companies and sectors are also drawn upon for comparison As requested the results are prepared for the management and plant level Schaeffler Group Industrial IS1 127 Services Concepts and implementation The concepts prepared by the consultancy experts of the Schaeffler Group with the customer are aligned to the situation and objectives of the customer There are no standard processes that are imposed on the customer Each customer is given individual treatment The concepts prepared are implemented in partnership We apply for example the following approaches to achieving solutions Maintenance strategy ABC analysis of plant stock in relation to priorities TCO Total Cost of Ownership LCC Life Cycle Cost TPM Total Productive Maintenance Condition oriented maintenance Introduction concept for CMMS Software selection Master data structures Strategy for recurring maintenance and inspection tasks Specification and implementation of interfaces Inclusion of old data IT linka
104. s containing 250 cm ARCALUB C6 CONTROL 250 KIT Control by machine For LC units containing 250 cm ARCALUB C6 500 KIT Control by lubricator For LC units containing 500 cm ARCALUB C6 CONTROL 500 KIT Control by machine For LC units containing 500 cm 80 IS1 Schaeffler Group Industrial Available LC units Further information Pistol grease guns Ordering designation Service pumps for wind turbines Designation with 250 cm 500 cm ARCALUB C6 LC250 MULTITOP ARCALUB C6 LC500 MULTITOP ARCALUB C6 LC250 MULTI2 ARCALUB C6 LC500 MULTI2 ARCALUB C6 LC250 LOAD150 ARCALUB C6 LC500 LOAD150 ARCALUB C6 LC250 LOAD220 ARCALUB C6 LC500 LOAD220 ARCALUB C6 LC250 LOAD400 ARCALUB C6 LC500 LOAD400 ARCALUB C6 LC250 LOAD1000 ARCALUB C6 LC500 LOAD1000 ARCALUB C6 LC250 TEMP90 ARCALUB C6 LC500 TEMP90 ARCALUB C6 LC250 TEMP110 ARCALUB C6 LC500 TEMP110 ARCALUB C6 LC250 TEMP120 ARCALUB C6 LC500 TEMP120 ARCALUB C6 LC250 TEMP200 ARCALUB C6 LC500 TEMP200 ARCALUB C6 LC250 SPEED2 6 ARCALUB C6 LC50 SPEED2 6 ARCALUB C6 LC250 B102 ARCALUB C6 LC500 BI02 ARCALUB C6 LC250 FOOD2 ARCALUB C6 LC500 FOOD2 LC units are also available by agreement with other greases For detailed information see WL 80 346 FAG Motion Guard The Intelligent Lubricators Enquiries info schaeffler iam com 49 2407 9149 66 Pistol grease guns have a 4 digit digita
105. speed of 40 min to 10000 min Typical examples of such machines include pumps ventilators compressors turbines and motors The Schaeffler Group 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 comp onents of such machines must be aligned with each other Figure 6 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 the Schaeffler Group alignment of machinery as a service Where necessary the service technicians of the Schaeffler Group will take the necessary laser alignment system to the customer and carry out alignment of the machine in accordance with the manufacturer s specifications The work is then documented Figure 6 Alignment Further information Enquiries info schaeffler iam com 49 2407 9149 66 122 IS1 Schaeffler Group Industrial Rolling bearing reconditioning During maintenance work many bearings are replaced even though they have not yet reached the limits of their performance capacity Reconditioning of rolling bearings may represent an economically attractive alternative here Figure 7 Before reconditioning After reconditioning Figure 7 Rolling bearing raceway and
106. sultancy process Analyses The Schaeffler Group offers consultancy in order to make maintenance more transparent and efficient as well as services relating to computerised maintenance management systems Maintenance consultancy by the Schaeffler Group helps to make costs more transparent and design maintenance more effectively In this case the experts of the Schaeffler Group move beyond classi cal consultancy and place the emphasis on technical perspectives Figure 8 The consultancy process starts with a comprehensive analysis of processes Building on this base the experts prepare improvement concepts with the aim of integrating individual solutions within an overall solution During and after implementation the experts of the Schaeffler Group support the customer by means of comprehensive services from system installation through system modification to the support provided by the Schaeffler Group beyond the project phase Implementation CMMS IT network Diagnostic system Reporting Concepts Maintenance strategy Condition diagnosis Reporting CMMS introduction Key Performance Indicator KPI Analyses Maintenance analysis Malfunction analysis IT benefit analysis Materials management Knowledge management 00017AC9 The experts of the Schaeffler Group hold discussions on site with employees and analyse the available documents The analysis considers subjects including business processes cost
107. t 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 MGI31 is used to measure with separable outer rings by means of two hardened and precision ground surfaces the external enveloping circle of the roller and cage assembly The gauge is set to the raceway diameter of the mounted outer ring This dimension is determined using 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 60 IS1 Schaeffler Group Industrial Schaeffler Group Industrial IS1 61 Product overview Accessories Transport and mounting tool BEARING MATE ey Gloves GLOVE PRO GLOVE PRO CUT 000179A1 00017A42 K an gt Mounting paste ARCANOL MOUNTINGPASTE 00017A44 E otf Anti corrosion oil AR
108. thods are of decisive importance The necessary technical knowledge is provided by training courses on these subjects Other courses show how the condition of bearings can be monitored during operation The interpretation of vibration measurements is also covered in the teaching Target groups 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 Structure The starting point in the training program is the same for all participants The first stage is product oriented training that covers the types designations and preferred applications as well as the bearing arrangement systems This is followed by modules covering rolling bearing theory as well as selected applications Rolling bearing theory conveys the necessary knowledge on subjects such as bearing clearance load distribution in the bearing rating life or lubrication This knowledge is important in order that bearings can achieve the calculated life and do not fail prematurely Workshops 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
109. times of 1 3 6 or 12 months irrespective of the temperature The drive unit can be used again The battery set is replaced each time the LC unit is changed LC units are available with 60 cm 120 cm and 250 cm dispensing volumes with a battery set included in each case The lubricator Motion Guard CHAMPION is suitable for all Arcanol lubricants as well as chain oil Special fillings and drive units for machine controlled operation are available by agreement Available accessories Designation Lubricant Quantity Scope of delivery cm ARCALUB DRIVE Drive unit ARCALUB LC60 MULTITOP MULTITOP 60 LC unit with battery set ARCALUB LC120 LOAD400 LOAD400 120 LC unit with battery set ARCALUB LC250 VIB3 VIB3 250 LC unit with battery set ARCALUB ADAPTER Support adapter ARCALUB TUBE Hose with two POD connectors 3 m long RO Lubricator set The lubricator is available with the grease MULTITOP as a set FAG Motion Guard CHAMPION Aset comprises a drive unit support adapter and LC unit with battery set The LC units in the set can contain 120 cm or 250 cm of grease Ordering example Lubricator set filled with 120 cm MULTITOP Ordering designation ARCALUB LC120 MULTITOP KIT Schaeffler Group Industrial IS1 79 Lubrication system Motion Guard CONCEPT6 Starter kits Variant CONTROL Available designs Available lubricators CONCEPT6 Lubrication devices This single point and multi point
110. tion LASER SHIM15X0 20 Ordering example 2 10 shims with dimension c 44 mm and 0 1 mm thickness Ordering designation LASER SHIM44X0 10 92 IS1 Schaeffler Group Industrial Available shims Designation Mass Dimensions in mm m a b c Thick g ness LASER SHIM15X0 05 11 55 50 15 0 05 LASER SHIM15X0 10 22 55 50 15 0 1 LASER SHIM15X0 50 44 55 50 15 0 5 LASER SHIM15X0 50 110 55 50 15 0 5 LASER SHIM15X0 70 154 55 50 15 0 7 LASER SHIM15X1 00 220 55 50 15 1 LASER SHIM15X2 00 440 55 50 15 2 LASER SHIM23X0 05 21 75 70 23 0 05 LASER SHIM23X0 10 42 75 70 23 0 1 LASER SHIM23X0 20 84 75 70 23 0 2 LASER SHIM23X0 50 210 75 70 23 0 5 LASER SHIM23X0 70 294 75 70 23 0 7 LASER SHIM23X0 00 420 75 70 23 1 LASER SHIM23X0 00 840 75 70 23 2 LASER SHIM32X0 05 29 90 80 32 0 05 LASER SHIM32X0 10 58 90 80 BP 0 1 LASER SHIM32X0 20 116 90 80 32 0 2 LASER SHIM32X0 50 290 90 80 32 0 5 LASER SHIM32X0 70 406 90 80 32 0 7 LASER SHIM32X0 00 580 90 80 2P il LASER SHIM32X0 00 1160 90 80 32 2 LASER SHIM44X0 05 53 125 105 44 0 05 LASER SHIM44X0 10 106 125 105 44 0 1 LASER SHIM44X0 20 212 125 105 44 0 2 LASER SHIM44X0 50 530 125 105 44 0 5 LASER SHIM44X0 70 742 125 105 44 0 7 LASER SHIM44X0 00 1050 125 105 44 1 LASER SHIM44X0 00 2120 125 105 44 2 Further information For further information on FAG alignment devices see TPI 182 FAG Alignment Tools Top Laser SMARTY2 TRUMMY2 INLINE2 SHIM Enquiries info schaeffler iam c
111. tion Ordering example Collet Ordering designation Ordering example Collets Ordering designation Mechanical mounting and dismounting Designation Grip Grip Dimensions Extraction span depth a b force mm mm mm mm kN PULLER 3ARM160 130 105 14 1 15 1 40 PULLER 3ARM230 230 150 19 1 22 1 100 PULLER 3ARM310 295 235 19 1 22 1 100 PULLER 3ARM430 390 270 20 2 30 2 150 PULLER 3ARM660 640 300 22 2 34 2 150 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 Designation Axial force Minimum Maximum spindle diameter torque kN mm Nm PULLER SUPPORT80 80 M22 25 PULLER SUPPORT150 150 M30 50 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 and four point contact bearings The special bearing extractor comprises the base device and a collet 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
112. tion temperature high low facility SIE speed speed Low High 90 Ball and roller bearings in couplings o o o o o electric motors automotive engineering 110 Ball and roller bearings in electrical o o o o o equipment automotive engineering 120 Ball and roller bearings in continuous o o o casting plant 200 Ball and roller bearings o o o in guide rollers in baking machinery piston pins in compressors kiln trucks chemical plant Continuous Characteristic applications Temperatures Low High Vibra Support Relubri limit friction load tions forseals cation temperature high low facility XC speed speed Low High 80 Ball bearings in machine tools instrument o o engineering 90 Ball and roller bearings in blade adjusters in wind turbine rotors packaging machinery rail vehicles 80 Ball and roller bearings o o o o o in environmentally hazardous applications 70 Ball and roller bearings o o o o in applications with food contact 90 Ball roller and needle roller bearings o o o o as well as linear guidance systems in clean room applications Schaeffler Group Industrial IS1 71 Features Rolling bearing greases Arcanol L rating life n speed R mixed friction t lubrication interval Normal grease Figure 1 Characteristics of lubricants Lubricants The lubricants available from the Schaeffler Group are designed and tested fo
113. to measurement 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 of 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 measurement 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 A Do not look into the laser beam or point the laser beam into another Caution person s eyes Scope of delivery Measuring device Base device Battery Wrist strap Adapter for camera tripod Carry case Protective rubber slip cover Immersion sensor for temperature measurement of fluids Surface temperature sensor User manual Report software Case Ordering designation TEMP CHECK PRO For further information For detailed information see publication WL 80 377 FAG Temperature Measuring Devices Enquiries info schaeffler iam com 49 2407 9149 66 96 IS1 Schaeffler Group Industrial Digital hand tachometer The speed counter is suitable for two
114. types of operation FAG TACHOMETER direct speed measurement using an adapter track wheel and SA measurement stylus non contact optical speed measurement using a reflective mark Direct speed measurement 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 Non contact speed measurement For non contact measurement a reflective mark is applied to the machine part to be measured This mark is detected by photoelectric means using visible red light The device displays the speed in gt revolutions per minute Scope of delivery 1 digital hand tachometer Base device 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 han Ordering designation TACHOMETER Replacement parts 10 reflective marks Ordering designation TACHOMETER MARKS REFLEX Sonar device The sonar detector can be used to check rolling bearing noise very FAG SOUND CHECK easily quickly and reliably Changes in noise due to wear pitting formation or distortion of the bearing can be detected at an early stage if regular inspection is carried out In this way unforeseen operational stoppages and more significant machine damage can be prevented
115. via the metering valve to the application point A grease dispensing unit comprises a cover a piston a metering valve a hose connecting the pump and valve a hose 2 5 m long a metering pistol Available grease dispensing units Designation Pump Delivery rate Metering range Suitable ratio for container sizes cm min cm kg min max ARCA PUMP 25 10 1 400 10 133 25 ARCA PUMP 180 10 1 400 10 133 100 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 Pump Delivery rate Air cons Suitable ratio at 6 bar umption for container sizes g min l min kg ARCA PUMP BARREL 25 S 70 1 1100 150 1922925 ARCA PUMP BARREL 50 S 70 1 1100 150 50 ARCA PUMP BARREL 180 S 70 1 1100 150 180 The following accessories are available for the drum pumps drum cover dust coven follower plate high pressure delivery hoses and pistol grease guns 82 IS1 Schaeffler Group Industrial Lever grease gun and The lever grease gun see table can be used to manually relubricate reinforced hose rolling bearings via lubrication nipples en The container on the lever grease gun can be filled with 500 g loose greas
116. y and reliably detection of possible AP 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 Versatile system FAG WiPro sis 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 Certification The system is certified by Germanischer Lloyd Remote monitoring 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 vibration experts of the Schaeffler Group Further information For detailed information see WL 80 373 flyer FAG WiPro s pe Enquiries info schaeffler iam com 49 2407 9149 66 Schaeffler Group Industrial IS1 105 Online monitoring system FAG ProCheck Parameters monitored Versatile system Remote monito
117. y hofmann Schaeffler Technologies GmbH 8 Co KG Postfach 1260 97419 Schweinfurt Georg Sch fer StraBe 30 97421 Schweinfurt Germany Internet www schaeffler iam com E mail info schaeffler iam com Phone 49 2407 9149 66 Fax 49 2407 9149 59 Notes 144 IS1 Schaeffler Group Industrial
118. ymbols in the device display 00017A6A 100 IS1 Schaeffler Group Industrial Analysis software Automatic detection of measurement points Further information Balancing function 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 of tools for data evaluation The integrated rolling bearing database containing approximately 20 000 bearings from various manufacturers facilitates easier and more efficient analysis of the measured data Since the damage frequencies can be incorporated in the measurement 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 Ill identifies the measurement points by means of RFID tags on the machinery With the proven FAG Detector III mobile vibration and temperature monitoring is thus quicker simpler and more reliable The functionality of automatic measurement point detection is not available worldwide Please direct enquiries to info schaeffler iam com A further special feature of FAG Detector Ill is the balancing function For this purpose the optional

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