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FAG Equipment and Services for the Mounting and Maintenance of Rolling Bearings

For increased operational reliability of rolling bearing arrangements

This catalogue is aimed principallyat maintenance managersresponsible for plants in whichrolling bearings and other rotatingmachine components play a criticalrole in determining the quality ofproducts and processes.

Maintenance managers areresponsible for the maintenanceand production process. They mustbe able to rely every day on thequality of their tools and theexpertise of their service providers.

FAG Industrial Services (F’IS)therefore offers high qualityproducts, services and training.This catalogue gives a completeguide to the range on offer from F’IS.

F’IS employees worldwide will bepleased to help you select the idealproducts, services and training foryour needs.

About this catalogue

1

Hans-Willi Kessler, Bernd Geropp and

Armin KempkesManagement of

FAG Industrial Services

Questions and ideas on this catalogueshould be sent to:

Schaeffler KGPostfach 1260 · 97419 Schweinfurt (Germany)Georg-Schäfer-Strasse 30 · 97421 Schweinfurt (Germany)Service Hotline:Telephone: +49 2407 9149-99E-mail: [email protected]

FAG Industrial Services

FAG Industrial Services GmbH (F’IS),headquartered in Herzogenrathnear Aachen, is an independentcompany that takes responsibilityfor the worldwide service businessof Schaeffler Group Industrialcovering the brands INA and FAG.The goal of F’IS is to helpcustomers to reduce maintenancecosts, optimise plant availabilityand prevent unforeseen machinedowntimes. The services areprovided regardless of the brand of the machine components used.F’IS is therefore the specialistcontact for the maintenance ofrotating components. In order to provide the qualifiedand rapid supply of F’IS products,

services and training to customersworldwide, F’IS has specialistcentres around the world. All F’ISemployees worldwide undergo acomprehensive training programmeand are audited regularly. Thisensures that F’IS services throughoutthe world comply with a uniformlyhigh standard of quality.Since each customer has a differentset of requirements, F’IS offersconcepts individually tailored to thecustomer. The quality requirementsare strongly influenced by a longhistory of high precision rollingbearing manufacture.Each tool, accessory and grease inthis catalogue has been subjectedto intensive testing in practical useand is classified as being of highquality.

FAG Industrial Services – Competence in maintenance

2

The F’IS range

F’IS has undertaken ongoingexpansion of its range in recentyears. It covers products, servicesand training in the areas of

• Mounting/Repair• Lubrication• Alignment• Condition monitoring• Maintenance management

The designation system of the INA and FAG brands has beenharmonised. This catalogue contains,for the first time, the new orderingdesignations, which are currentlyonly valid for Europe. Customersoutside Europe are requested tocontinue using the old orderingdesignations (please see thecomparison on page 109).

Mounting/Repair Lubrication Alignment

Conditionmonitoring

Maintenancemanagement

F’IS – Competence in maintenance

Products

Training

Services

Contents

Products 7

Mounting/Repair 8Lubrication 43Alignment 55Condition monitoring 61Maintenance management 71

Services 73

Mounting/Repair 75Lubrication 79Corrective maintenance 80Condition monitoring 81Maintenance management 86

Training 91

Mounting/Repair 93Lubrication 95Alignment 95Condition monitoring 96Maintenance management 99

Publications 103

Index of FAG products 105

Comparison of ordering designations 109

3

Tools for mounting and dismountingOverview

4

Bearing type Bearingbore

Bearingsize

Deep grooveball bearings

Taperedroller bearings

Angular contactball bearingsSpindle bearings

Barrelroller bearings

Four pointcontact bearings

Sphericalroller bearings

Self-aligning ball bearings

Cylindrical roller bearings

Cylindrical

Cylindrical

Withheating

Mounting

Thrust ball bearings

Angular contact thrust ball bearings

Cylindrical roller thrust bearings

Spherical roller thrust bearings

Self-aligning ball bearingsSelf-aligning ball bearings with adapter sleeve

Barrel roller bearingsBarrel roller bearings with adapter sleeve

Spherical roller bearingsSpherical roller bearings with adapter sleeveSpherical roller bearings with withdrawal sleeve

Adapter sleeve Withdrawal sleeve

Cylindrical

Tapered

Small

Medium

Large

Small

Medium

Large

Small

Medium

Large

Small

Medium

Large

Cylindrical roller bearings, double row Tapered Small

Medium

Large

Needle roller bearings

Withoutheating

5

Withoutheating

Hydraulicmethod

Hydraulicmethod

SymbolsDismounting

Heating plate

Hot air cabinetHeating cabinet

Inductionheating device(coil)

Heating ring

Hammer andmounting sleeve

Mechanical andhydraulic presses

Nut andhook wrench

Nut andmounting screws

End cap

Hydraulic nut

Hammer anddrift

Extraction device

Hydraulic method

Doublehook wrench

Withheating

Oil bath

Inductionheating device

Socket wrench

Products · Mounting/Repair

Mechanical mounting and dismounting 8

Mounting tool sets 8Socket wrenches 9Hook and pin wrenches 9Mechanical extractors 12Hydraulic extractors 15Three-section extraction plates 17

Hydraulic mounting and dismounting 19

Hydraulic nuts 19Mounting Manager 21Overview of pressure generation devices 22Oil injectors 24Hand pump sets 25High pressure pump 26Hydraulic systems and units 27Connectors, accessories 28

Thermal mounting and dismounting 31

Electric heating plates 31Induction heating devices 31Heating rings, heat conducting paste 34Electric induction heating devices 35

Measurement and inspection 36

Feeler gauges 36Taper gauges 36Snap gauge 38Enveloping circle gauges 39

Accessories 40

Transport and mounting tool 40Gloves 41Mounting paste 42Anti-corrosion oil 42

7

FAG mounting tool setsFITTING-TOOL-ALU-10-50 andFITTING-TOOL-STEEL-10-50

FAG mounting tool sets alloweconomical and secure mounting ofrolling bearings up to 50 mm bore.They can also be used to easilymount sleeves, intermediate rings,seals and similar parts.

Where inner or outer rings with atight fit are to be driven onto a shaftor into a housing bore respectively,this can be achieved by applyinghammer blows to an appropriatemounting sleeve. This prevents themounting forces from being trans-mitted through the rolling elementsand raceways, which can lead todamage. The carefully matched FAGprecision parts ensure that theforces are uniformly transmitted tothe side faces of the bearing rings.

Products · Mounting/RepairMechanical mounting and dismountingMounting tool sets

8

The FITTING.TOOL.ALU.SET10-50includes mounting sleeves madefrom aluminium and mounting ringsmade from plastic. The parts areeconomical and easy to use.The steel mounting sleeves andsteel mounting rings in theFITTING.TOOL.STEEL.SET10-50 givelong wear-free operating life. These tools can also be used incombination with workshop powerpresses.

For detailed information, see TPI WL 80-56.

Included in delivery Ordering designationFITTING-TOOL-ALU-10-50 FITTING-TOOL-STEEL-10-50

Mounting rings 33 pieces 33 piecesFor bearing bore 10–50 mm 10–50 mmOutside diameter up to 110 mm 110 mmMounting sleeves 3 pieces 5 piecesHammer, recoilless 1 kg 0,7 kgDimensions of case 440~350~95 mm 370~320~70 mmMass of complete set 4,5 kg 21 kgAlso available as individual parts

FAG mounting tool sets FITTING-TOOL-ALU-10-50 and FITTING-TOOL-STEEL-10-50

FAG socket wrench LOCKNUT-SOCKET…For locknuts KM0 to KM20

Locknuts can be easily tightenedand loosened on shafts, adaptersleeves and extraction sleevesusing FAG socket wrenchesLOCKNUT-SOCKET…They require less space on thecircumference of the nut than hookwrenches and allow the use ofratchets and torque wrenches.For increased reliability, socketwrenches should be secured usinga locking pin and rubber washer.FAG socket wrenches therefore havea hole for the locking pin and agroove for the rubber washer. The locking pin and rubber washerare included in delivery.

Ordering example for FAG socketwrench, suitable for locknut KM5:LOCKNUT-SOCKET-KM5


FAG hook wrenchesLOCKNUT-HOOK…For locknuts KM0 to KM40

FAG hook wrenches of seriesLOCKNUT-HOOK… can be used totighten and loosen locknuts onshafts, adapter sleeves andextraction sleeves.FAG hook wrenches can be used tomount small bearings on taperedshaft seats, adapter sleeves orextraction sleeves.Extraction sleeves can also bedismantled using FAG hook wrenchestogether with the extraction nuts.

Ordering example for FAG hookwrench, suitable for locknutsKM18, KM19, KM20:LOCKNUT-HOOK-KM18-20


Products · Mounting/RepairMechanical mounting and dismountingSocket wrenches and hook wrenches for mounting and dismounting

9

FAG jointed hook wrenchesLOCKNUT-FLEXIHOOK…

For locknuts KM1 to KM36 andprecision locknuts ZM12 to ZM150as well as ZMA15/33 to ZMA100/140

FAG jointed hook wrenches ofseries LOCKNUT-FLEXI-HOOK… canbe used to tighten and loosenlocknuts (precision locknuts) onshafts, adapter sleeves andextraction sleeves if no torquevalue is specified.

The joint allows one hook wrenchof series LOCKNUT-FLEXI-HOOK… to be used for mounting ordismounting locknuts of varioussizes.

Ordering example for FAG jointedhook wrench, suitable for locknutsKM14 to KM24: LOCKNUT-FLEXIHOOK.KM14-24


FAG jointed pin wrenchesLOCKNUT-FLEXIPIN…

For precision locknuts AM15 toAM90

FAG jointed pin wrenches of seriesLOCKNUT-FLEXI-PIN… can be usedto tighten and loosen locknutson shafts if no torque value isspecified.

FAG jointed pin wrenches can beused to mount small bearings ontapered shaft seats.

Tightening is achieved by means ofradially arranged holes.

Ordering example for FAG jointedpin wrench, suitable for locknutsAM35 to AM60:LOCKNUT-FLEXIPIN.AM35-60


Products · Mounting/RepairMechanical mounting and dismountingHook wrenches and pin wrenches for mounting and dismounting

10

FAG jointed face wrenchesLOCKNUT-FACEPIN…

For precision locknuts LNP017 toLNP170

FAG jointed face wrenches of seriesLOCKNUT-FLEXI-PIN… can be usedto tighten and loosen precisionlocknuts on shafts if no torquevalue is specified.

FAG jointed face wrenches can beused to mount small bearings ontapered shaft seats.

Tightening is achieved by means ofaxially arranged holes.

Ordering example for FAG jointedface wrench, suitable for precisionlocknuts LNP017 to LPN025:LOCKNUT-FACEPIN.LNP17-25


FAG double hook wrenchesFor locknuts KM5 to KM13

FAG double hook wrenches areintended for the mounting ofself-aligning ball bearings with atapered bore. They are available askits, sets or individual wrenches.

FAG double hook wrench kitsLOCKNUT-DOUBLEHOOK…-KITinclude a case containing a doublehook wrench, a torque wrench anda user manual. The torque wrench allows a preciselydefined tightening torque to beachieved at the start of themounting operation.

FAG double hook wrench setsLOCKNUT-DOUBLEHOOK…-SETcontain four or five double hookwrenches. The other items in thecase are the same as in the kits.

Individual double hook wrenchesLOCKNUT-DOUBLEHOOK-KM5 toLOCKNUT-DOUBLEHOOK-KM13 arealso available. Each double hookwrench is engraved with the torsionangles for the self-aligning ballbearings to be mounted using thatparticular wrench, so that the slidingdistance and reduction in radialinternal clearance can be preciselyset.


Products · Mounting/RepairMechanical mounting and dismountingHook wrenches and pin wrenches for mounting and dismounting

11

Double hook wrench kits, e. g. LOCKNUT-DOUBLEHOOK-KM5-KIT and LOCKNUT-DOUBLEHOOK-KM13-KIT

Double hook wrench kits LOCKNUT-DOUBLEHOOK-KM5-8-SET and LOCKNUT-DOUBLEHOOK-KM9-13-SET

Double hook wrenches, e. g. LOCKNUT-DOUBLEHOOK-KM5 and LOCKNUT-DOUBLEHOOK-KM13

Mechanical FAG extractorsPowerPull

Mechanical extractors can be usedto dismount small rolling bearingsup to approx. 100 mm bore diameterthat are located with a tight fit on ashaft or in a housing. The bearing can be dismountedwithout damage if the extractor is

in contact with the tightly fittedbearing ring.

In mechanical FAG extractors, theextraction force is normally appliedby means of a threaded spindle. In addition to devices with two,three or four arms and a hydraulicpressure tool, we also offer specialextraction devices.

Products · Mounting/RepairMechanical mounting and dismountingMechanical extractors

12


Note: For the dismounting of largerbearings, hydraulic extractorsshould be used (page 15).

Two-arm extractor 54

• For extraction of complete rollingbearings or tightly fitted innerrings as well as other parts, e.g. gears

• Grip width 80–350 mm, gripdepth 100–250 mm

Available as set (stand with 6 extractors) or individually

Ordering designation:PULLER54-SETPULLER54-100PULLER54-200PULLER54-300PULLER54-400PULLER54-500PULLER54-600

Two-arm bearing extractor 47

• For extraction of complete rollingbearings or tightly fitted innerrings

• Grip width 45 and 90 mm, gripdepth 65 and 100 mm

Ordering designation:PULLER47-100PULLER47-200

Three-arm extractor 52

• For extraction of complete rollingbearings or tightly fitted innerrings

• Grip width 85–640 mm, gripdepth 65–300 mm

Ordering designation:PULLER52-085PULLER52-130PULLER52-230PULLER52-295PULLER52-390PULLER52-640

Hydraulic pressure tool 44

• For loosening of tightly fittedparts in conjunction withmechanical extractors

• Significant reduction in effortthrough generation of an axialforce of 80 or 150kN, with ahydraulic return mechanism onthe larger device

Ordering designation:PULLER44-080PULLER44-150


13

Ball bearing extractor 56

• For extraction of complete radialball bearings

• For tightly fitted outer rings• For bearings without radial access• Three sets with different claws

available

Ordering designation:PULLER56-020-SETPULLER56-120-SETPULLER56-220-SET

Special bearing extractor 64

• For radial bearings (deep grooveball bearings, self-aligning ballbearings as well as cylindricalroller, tapered roller and sphericalroller bearings); please state thebearing manufacturer.

• For tight fit of inner ring or outerring

Ordering example for deep grooveball bearing 6000:Base device PULLER64-400 +collet PULLER64.COLLET-A-6000

Ordering example for tapered roller bearing pair 30203-A in X arrangement:Base device PULLER64-400 +collet PULLER64.COLLET-B-30203A+ collet PULLER64.COLLET-C-30203A

Extraction device 49

• For all rolling bearing types. For extraction of complete rollingbearings or tightly fitted innerrings. The extractor and theseparator device are available infive sizes with grip widths of upto 210 mm.

• Principally for cases in which theinner ring is adjacent to a shoulderon the shaft without extractionslots. Good radial access to thebearing position is required.

Ordering designation:PULLER49-100-060PULLER49-100-075PULLER49-200-115PULLER49-300-150PULLER49-400-210


14

Internal extractor 62

• For deep groove ball bearings andangular contact ball bearings.The internal extractor setcomprises nine extractors andcan be used on bearings with abore of 5 mm up to approx. 70 mm.

• For tightly fitted outer rings.• The inner ring bore must be free.

Ordering designation(nine internal extractors with twocountersupports in a rigid metalcase):PULLER62-SET

The nine internal extractors canalso be ordered individually.

Internal extractor PULLER-INTERNAL10/100-SET

• For standard deep groove ballbearings. The set, containing 6 sets of extraction legs and 2 threaded spindles, can be usedon bores from 10 to 100 mm.

• For tightly fitted outer rings.• No dismantling of shaft.

Ordering designation(six sets of extraction legs and twothreaded spindles in a toolbox):PULLER-INTERNAL10/100-SET

The individual parts can also beordered individually.

Overview of significant advantages

• Safety grip allows pumping whilewearing industrial gloves

• Optimum operating position dueto 360° rotary coupling for pumphandle (separate pump with SPIDER 175 and 400)

• Pressure build-up or reduction by rotation of handle on cut-offvalve

• Pressure control valve preventsoverload

• Parts under mechanical load are made from high qualitychromium-molybdenum steel

• Maximum possible reduction intorsional and frictional forces dueto chromium plated piston madefrom quenched and temperedsteel

• Height of stroke adjustable bymeans of standard adapter

• High load capacity of extractionarms and claws throughmanufacture as single piece

• Simple centring by spring-loadedsteel cone

• “Quick” screw thread for settingof optimum grip depth

• Simple conversion to two-armoperation if insufficient space forthree arms

Products · Mounting/RepairMechanical mounting and dismountingHydraulic extractors

15

Hydraulic FAG extractorsPowerPull SPIDER

The hydraulic FAG extractorsPowerPull SPIDER are used wherehigher extraction forces arerequired. The ten extractor sizes have arange of extraction forces from 40 to 400 kN, covering a very widerange of possible applications.

These devices allow rolling bearings,gears, sleeves and many othershrink fitted parts to be quickly andeasily dismounted. In addition, thelow mass of the extractors meanthat they can be used in anyposition.If necessary, greater grip depth canbe achieved through the use ofextra long extraction arms(available as accessories).

For protection of operators, theextractors SPIDER 40 to 80 have asafety grid. All larger hydraulicextractors are supplied with atransparent, very tough safety cover.The cover can be easily placedaround the workpiece or tool andsecured using velcro strips.


SPIDER 40…80: Hydraulic standard extractor withintegral hand pump

Products · Mounting/RepairMechanical mounting and dismountingHydraulic extractors

16

Compact extractor for extractionforces up to 80 kN, together withsafety grid in rigid case

SPIDER 100…300: Extra strong hydraulic extractorwith integral hand pump

For difficult dismounting work withextraction forces up to 300 kN, withlonger extraction arms on request.With accessories in rigid metal case.

SPIDER 175 + 400: Extra strong hydraulic extractorwith separate hand pump

Extractor for restricted spaces,connected to hand pump by hydraulichose, extraction force up to 400 kN(top of the range model)

Ordering designation Extraction force Grip width Grip depth Stroke MassExtractor kN mm mm mm kg

PULLER-HYD40 40 150 152 55 4,5PULLER-HYD60 60 200 152 (190*) 82 4,9PULLER-HYD80 80 250 190 (229*) 82 6,6* With optional longer extraction arms, replacement parts can be ordered

individually

Ordering designation Extraction force Grip width Grip depth Stroke MassExtractor kN mm mm mm kg

PULLER-HYD100 100 280 182 (220*) 82 5,6PULLER-HYD120 120 305 220 (259*) 82 7,6PULLER-HYD200 200 356 259 (300*) 82 10PULLER-HYD250 250 406 300 (375*) 100 20PULLER-HYD300 300 540 (800*) 375 (405*) 100 25* With optional longer extraction arms, replacement parts can be ordered

individually

Ordering Extraction force Grip width Grip depth Stroke MassdesignationExtractor kN mm mm mm kg

PULLER-HYD175 175 356 229 (300*) 82 15,6PULLER-HYD400 400 800 (1 200*) 405 (635*) 250 49* With optional longer extraction arms, replacement parts can be ordered individually

SPIDER 40…80

SPIDER 100…300

SPIDER 175 + 400

Three-section FAG extraction platesPowerPull PULLER-TRISECTION… for hydraulic and mechanicalextractors

These allow the extraction ofcomplete bearings, tightly fittedinner rings and other components.The load capacity and extractionforce are precisely matched to eachother.

Products · Mounting/RepairMechanical mounting and dismountingThree-section extraction plates

17

Ordering designation Dimensions Mass Recommended forExtraction plate hydraulic extractor mechanical extractor

dmin dmax B SPIDERmm kg

PULLER-TRISECTION-50 12 50 17 0,5 – 52-085/52-130PULLER-TRISECTION-100 26 100 28 2,6 40/60/80/100 52-230PULLER-TRISECTION-160 50 160 33,5 5,8 80/100/120/175/200 52-295PULLER-TRISECTION-260 90 260 46,5 18,4 175/200/250/300 52-390PULLER-TRISECTION-380 140 380 65 50,3 250/300/400 52-640

Three-section FAG extraction plates PowerPull PULLER-TRISECTION...

G

dmin

B

dmax

The SPIDER extraction claws gripdirectly under the screw studs ofthe PULLER-TRISECTION and giveuniform distribution of force. Evenwhere parts are firmly seated, thereis no tilting or bending. The highextraction forces are concentrated,for example, on the bearing innerring. In general, the bearing andshaft remain intact and can beused again.

The PULLER-TRISECTION is field-tested and can be fitted under thebearing with just a few movements.


Where radial internal clearance cannot bemeasured using feeler gauge due to pooraccessibility

With inch size thread to ABMA Standardsfor Mounting Accessories, Section 8,Locknut Series N-00

FAG hydraulic nuts HYDNUT...

Hydraulic nuts HYDNUT... can beused to press parts with a taperedbore onto their tapered seat.Presses are mainly used if thedrive-up forces required cannotbe applied using other devices, e.g. shaft nuts or pressure screws.

They are mainly used for:• mounting of rolling bearings with

a tapered bore. The bearings canbe seated directly on a taperedshaft, on an adapter sleeve or anextraction sleeve. If the bearingis located using an extractionsleeve or an adapter sleeve, thehydraulic nut can also be usedfor dismounting.

• mounting of couplings, gears,ships’ propellers etc.


Products · Mounting/RepairHydraulic mounting and dismountingHydraulic nuts

19

Ordering designation Design Main application

HYDNUT50 to HYDNUT200 With metric precision thread to DIN 13 Standardised adapter and extraction sleevesHYDNUT205 to HYDNUT1180 With trapezoidal thread to DIN 13 with metric dimensions

HYDNUT90-INCH to Sleeves with inch dimensionsHYDNUT530-INCH

HYDNUT100-HEAVY to Reinforced design For high mounting forces, HYDNUT900-HEAVY with smooth bore e.g. in shipbuilding

HYDNUT.GAUGE-DISPLACE Displacement gauge for HYDNUT(see also page 20)

FAG hydraulic nuts HYDNUT...

FAG displacement gauge forhydraulic nuts

If the radial internal clearancecannot be measured with a feelergauge due to poor accessibility, theaxial displacement of the bearingcan be measured on the taperedseat. This can be achieved bymeans of a gauge screw mounted tothe end face of the hydraulic nut. If the axial threaded connector holeG. of the hydraulic nut is taken upby the pump, the second axial holecan be used for the displacementgauge. The bearing is first placed in itsstarting position. The oil pressurerequired is dependent on thebearing size and the number ofdisplacement surfaces and is givenin the user manual. A hand pumpset with a manometer must beused, see page 25. The dial gaugeis set to zero and the bearing ismoved by pumping until thespecified drive-up distance isachieved. The user can determine which ofthe metering needles suppliedshould be used from thecomprehensive user manualincluded with each gauge.

Ordering designation: HYDNUT.GAUGE-DISPLACE1 displacement gauge with dial gauge, 6 metering needlesand seals in case


Products · Mounting/RepairHydraulic mounting and dismountingDisplacement gauge for hydraulic nuts

20

FAG Mounting Manager

The FAG computer program MOUNTING MANAGER is a user-friendly aid for ensuring thecorrect mounting of bearings andoffers the following options:• It shows various mechanical and

hydraulic mounting methods• It calculates the data required for

mounting in relation to reductionin radial internal clearance,displacement and start pressure

• It gives useful mounting advice• It generates a list of the

accessories and tools required

Further information on mountingand dismounting of bearings isoffered in the integrated librarycontaining appropriate publications,Technical Information documentsetc. and our electronic learningsystem.

Calculation possibilities for mounting methods:

Bearings with a tapered bore aremounted either directly on thetapered shaft or journal or bymeans of an adapter sleeve orextraction sleeve on the cylindricalshaft. The internal clearance is seteither by conventional means usingfeeler gauges or by means of theaxial displacement.

a) Mounting of bearings withtapered bore by measurement ofthe axial displacement

The bearing is placed in its startingposition on the tapered bearingseat with a hydraulic nut. Therequired starting pressure definedfor each individual bearing is set inthe hydraulic nut by means of thedigital manometer. The dial gaugemounted on the hydraulic nut isused to measure the axial drive-upuntil the final position is reachedon the tapered seat.

This mounting method:• shortens and simplifies mounting

considerably• offers very high security and

accuracy• allows the correct mounting of

sealed bearings

Products · Mounting/RepairHydraulic mounting and dismountingMounting Manager

21

b) Mounting of bearings withtapered bore by measurement ofthe reduction in radial internalclearance

When the bearing is pushed ontothe tapered seat, the inner ring isexpanded and the radial internalclearance is thereby reduced. This reduction in radial internalclearance is valid as a measure ofthe firm seating of the bearing. It ismeasured by means of a feelergauge.

The FAG Mounting Manager isavailable on CD-ROM.

Ordering designation:CD-MM 1.1

Products · Mounting/RepairHydraulic mounting and dismountingOverview of pressure generation devices

22

Pressure deviceOil injector Hand pump set

Single stage Twin stage

INJECT2500 INJECT1600 PUMP1000-0,7L PUMP1000-4L PUMP1600-4L

Oil container volume [l] 0,008 0,027 0,7 4 4

Connector GD/i G: G. G. G.

Max. oil pressure [bar] 2 500 1 600 1 000 1 000 1 600(psi) 36 250 23 200 14 500 14 500 23 200

Application

Max. shaft ø [mm] 80 150 250 Unlimited Unlimited

Overview of pressure generation devices

Mounting anddismounting ofbearings withtapered bore. Press fits up toapprox. 125 N/mm2

contact pressure.

Mounting anddismounting ofbearings withtapered bore. Press fits up toapprox. 80 N/mm2

contact pressure.

Mounting anddismounting ofrolling bearings.Mounting of pressfits up to approx. 50 N/mm2

contact pressure.For drivinghydraulic nuts upto HYDNUT395/HYDNUT300-HEAVY

Mounting anddismounting ofrolling bearings.Mounting ofpress fits up to80 N/mm2

contact pressure,e.g. of rudderspindles andrudder blades

Mounting anddismounting ofrolling bearings.Mounting of pressfits up to approx.50 N/mm2

contact pressure,e.g. of ships’propellers. Fordriving hydraulicnuts up to HYDNUT800

UnlimitedFor rolling bearingsup to d = 250 mm

Compressed air Electric

High pressurepump set

Products · Mounting/RepairHydraulic mounting and dismountingOverview of pressure generation devices

23

Pressure deviceHand pump set High pressure Hydraulic unit

pumpTwin stage

PUMP2500-4L PUMP4000-0,2L PUMP2500-0,2L-KIT AGGREG-P1000-1/P2500-2 AGGREG-E700

Oil container volume [l] 4 0,2 0,2 13 10

Connector G. (direct) G: (direct) G. with high G. G.

pressure hose

Max. oil pressure [bar] 2 500 4 000 2 500 2 500 700(psi) 36 250 58 000 36 250 36 250 10 150

Application

Max. shaft ø [mm] Unlimited Unlimited Unlimited Unlimited

Detailed information on FAG pressure generation devices is given in TPI WL 80-50.

Overview of pressure generation devices

Mounting anddismounting ofbearings.Mounting ofpress fits up toapprox. 125 N/mm2

contact pressure,e.g. of gears andcouplings.

For press fitswith highcontact pressure (> 100 N/mm2).Dismounting ofbearings withcylindrical bore.Flow rate and oilreservoir aresmall.

For press fitswith highcontact pressure(> 100 N/mm2).Dismounting ofbearings withcylindrical bore.Flow rate and oilreservoir aresmall.

For driving largehydraulic nuts upto HYDNUT1180.Mounting oflarge press fits:ship shaftcouplings, ships’propellers,gears, contactpressure up to50 N/mm2.

Mounting ofshaft couplingsand press fits,gears etc. by the hydraulicmethod. Contactpressure up to100 N/mm2.

Max.oil pressure

FAG oil injectors

Oil injectors have a small volumedisplacement; they can be used inthe hydraulic method for thedismounting of rolling bearings andother press fits with direct seatingon tapered shafts, e.g. in machinetools for cylindrical roller bearingsFAG NNU49..-S-K, NN30..-AS-K,N10..-K, N19..-K.

The INJECT2500 can be used forshaft diameters up to 80 mm, theINJECT1600 up to 150 mm.

Products · Mounting/RepairHydraulic mounting and dismountingOil injectors

24

Conventional O rings can be usedas replacement seals: OR6~1,5 (for INJECT2500), OR10~2,0 (for INJECT1600).


Oil injector Valve nipple Connector Oil volume MassW

Ordering designation cm3 bar kg

INJECT2500 INJECT2500.VALVE GD/i 8 2 500 0,91

INJECT1600 INJECT1600.VALVE G: 27 1 600 2,18

The oil injector can be refilled with oil without losses by connecting the valve nipple to the oil injector. In this case, the oil injector is ordered with a valve nipple. Ordering designation for INJECT2500 + INJECT2500.VALVE: INJECT2500-SETOrdering designation for INJECT1600 + INJECT1600.VALVE: INJECT1600-SET

FAG oil injectors

FAG hand pump sets

FAG offers one hand pump set witha single stage pump and three handpump sets with a twin stage pump.The twin stage pumps have a highflow rate in the low pressure range(up to 50 bar) and then switch

automatically to the high pressurestage. This gives a high work rate.Where there is an increased oilrequirement, the twin stage pumpsare available with an 8 litre oilcontainer (suffix 8L).In cases where the type ofinstallation of the adapter or

Products · Mounting/RepairHydraulic mounting and dismountingHand pump sets

25

extraction sleeve requires aseparate oil supply, we can uponrequest supply a two-way valve(suffix D).


Pump Hand pump setBase design With 8 litre With distributor With 8 litre oil container

oil container and distributor

Single stage1 000 bar PUMP1000-0,7L*

Twin stage1 000 bar PUMP1000-4L* PUMP1000-8L* PUMP1000-4L-D PUMP1000-8L-D1 600 bar PUMP1600-4L PUMP1600-8L PUMP1600-4L-D PUMP1600-8L-D2 500 bar PUMP2500-4L PUMP2500-8L PUMP2500-4L-D PUMP2500-8L-D

* The 1 000 bar pumps with one connector are also available with a digital manometer.Ordering example: PUMP1000-0,7L-DIGI

FAG hand pump sets (overview of ordering designations)

PUMP2500-8L-DPUMP1000-0,7L-DIGI

Oil containervolume

Flow rate Max.oil pressure

FAG high pressure pumpPUMP4000-0,2L

The high pressure pump is suitablefor mounting and dismounting ofrolling bearings for shaft diametersup to 250 mm. Since it generatespressures of up to 4 000 bar, thepump can be used to expand heavyshaft couplings and gears by thehydraulic method. The pump isconnected directly or via thick-walled adapters. The high pressure pump can alsobe connected via a pump holder(with or without a manometer) anda 2 m long flexible high pressurehose (maximum permissible oilpressure 2 500 bar). The pumpmust always be operated with amanometer.


Products · Mounting/RepairHydraulic mounting and dismountingHigh pressure pump · High pressure pump sets

26

FAG high pressure pump sets

In order to make it easier to selectthe right device, we supplycomplete sets in storage cases:

FAG high pressure pump setPUMP2500-0,2L-KIT


High pressure pump Connector MassW

Ordering designation l cm3/stroke bar kg

PUMP4000-0,2L G: 0,2 0,3 4 000 3,8comprisingPUMP4000-0,2L.BODY (pump body)PUMP4000-0,2L.TANK (oil container)

FAG high pressure pump PUMP4000-0,2L

Pull rod Oil container Pump body

For width across flats 27 mm

Threaded connector G:

Oil container

High pressure pipe

Manometer Pump holder

Pump body

FAG high pressure pump set PUMP2500-0,2L-KIT with manometer up to 2 500 barIncluded in delivery:1 high pressure pump PUMP4000-0,2L 1 manometer1 pump holder 1 high pressure hose3 reduction nipples 1 storage case

Ordering designation for set: PUMP2500-0,2L-KIT

Max. oilpressure

Motorrating

Oil containervolume(suctionquantity)

Oilvolumeflow

Oil containervolume

Compressed air driven FAG hydraulic unit

The FAG hydraulic unitAGGREG-P1000-1/P2500-2 drivenby compressed air is mobile andcomprises a 13 litre oil containermade from light metal and twopumps (1 000 bar and 2 500 bar). We can supply designs for otheroperating pressures by agreement.The pump (2 500 bar) has twoseparately controllable outputs andis suitable as a pressure device forexpanding shaft couplings and

gears by the hydraulic method. The pump (1 000 bar) can drive ahydraulic nut at the same time. The pump is suitable for press fitswith contact pressures up to 100 N/mm2.

Products · Mounting/RepairHydraulic mounting and dismountingHydraulic systems and units

27

Included in delivery:Base device, ready-to-use, incl. 1 manometer 0 to 1 000 bar, 1 manometer 0 to 2 500 bar, 3 high pressure hoses 2 500 bar, 2 m

Electrically driven FAG hydraulic unit

These units are suitable for drivinglarge hydraulic nuts and mountingof large press fits such as shipshaft couplings, ships’ propellersand gears (contact pressure up to50 N/mm2).Electrical connection: plug, voltage400 V at 50 Hz. Other voltages and frequencies byagreement.

Included in delivery: Base unit, ready-to-use, incl. 1 manometer, 0 to 1 000 bar,

Mobile FAG hydraulic unitfor batch mounting

The mobile unit has a valve-controlled, double direction pressurecylinder (pressure force 700 kN,stroke 215 mm) driven by a motorpump. The height position of the cylindercan be varied between 290 and690 mm by means of a liftingcylinder and rocker. Accessories such as guide bushes,mounting sleeves, traction andpressure spindles and drawing

frames must be ordered accordingto the individual application.When making enquiries or placingorders, information on the bearingtype and power connection as wellas installation drawings (shaft,housing, additional parts) arerequired.This unit is predominantly used forthe mounting and dismounting ofFAG wheelset bearings TAROL(see also publication TPI WL 80-50).

Ordering designation:TOOL-RAILWAY-AGGREGATE

Hydraulic unit Max. oil pressure MassW

Ordering designation l bar kg

AGGREG-P1000-1/P2500-2 13 1 000 or 2 500 40 (without oil)

Compressed air driven FAG hydraulic unit

Hydraulic unit MassW

Ordering designation l l/min bar kW kg

AGGREG-E700 10 0,9 700 1,1 40 (with oil)

Electrically driven FAG hydraulic unit

1 high pressure hose 1 000 bar, 2 m, 1 pressure control valve

FAG adapters and reduction nipples

Adapters and reduction nipples arematched to the threads of highpressure hoses and pressure pipes. Adapters and reduction nipples oftype A (with sealing ring) aresuitable for oil pressures up to 800 bar. Type B (with blade sealing) issuitable for oil pressures up to 2 500 bar.Other adapters and reductionnipples can be supplied byagreement.


Products · Mounting/RepairHydraulic mounting and dismountingConnectors, accessories

28

Type A (with sealing ring) Type B (with blade sealing)

G1

G

G1

G

Reduction nipple G > G1/G < G1

Ordering designation

PUMP.NIPPLE-A-G.-GB/i

PUMP.NIPPLE-B-G.-GB/i

PUMP.NIPPLE-A-G.-G-

PUMP.NIPPLE-B-G.-G-

PUMP.NIPPLE-A-G.-G:

PUMP.NIPPLE-B-G.-G:

PUMP.NIPPLE-A-G.-M14PUMP.NIPPLE-B-G.-M14

PUMP.NIPPLE-A-G.-M18~1,5

PUMP.NIPPLE-A-G3/i-G.

PUMP.NIPPLE-B-G3/i-G.

PUMP.NIPPLE-A-G:-GB/i

PUMP.NIPPLE-B-G:-GB/i

PUMP.NIPPLE-A-G:-G.

PUMP.NIPPLE-B-G:-G.

Reduction nipple

Reduction nipple G > G1/G < G1

Ordering designation

PUMP.NIPPLE-A-G:-G3/i

PUMP.NIPPLE-B-G:-G3/i

PUMP.NIPPLE-A-M18~1,5-G.

PUMP.NIPPLE-A-M18~1,5-G3/i

PUMP.NIPPLE-A-M18~1,5-G:

Reduction nipple

Adapter G1 = GOrdering designation

PUMP.ADAPTER-A-G.

PUMP.ADAPTER-B-G.

PUMP.ADAPTER-A-G3/e

PUMP.ADAPTER-B-G3/e

Adapter


29

FAG pump holders

Pump holder Ordering designation MassW

kg

Without connector PUMP.HOLDER-2for manometer 1,95

With connector G- PUMP.HOLDER.3for manometer 1,95

FAG pump holders

FAG manometers

When selecting a manometer, payattention to the max. operatingpressure.

Manometer Threaded connector Pressure display Diameter Mass≈ W

Ordering designation bar mm kg

PUMP1000.MANO-DIGI G. 0–1 000 73 0,4PUMP1000.MANO-G- G- 0–1 000 100 0,8PUMP1600.MANO-G- G- 0–1 600 100 1,5PUMP2500.MANO-G- G- 0–2 500 160 1,7


FAG manometers


30

FAG high pressure pipes for highpressure pumps, sheathed in PVChose (max. permissible pressure of2 500 bar should be monitored bymanometer)

High pressure pipe Connector MassW

Ordering designation kg

PUMP.PIPE-G. G. 0,6PUMP.PIPE-GD/i GD/i 0,6PUMP.PIPE-G- G- 0,6PUMP.PIPE-G: G: 0,8The connector for the pump holder is G:.For other connectors, a suitable reduction nipple must be used in addition.For detailed information, see TPI WL 80-50.

FAG high pressure pipe

FAG sleeve connectors for adapterand extraction sleeves(up to 800 bar)

(special lengths available byagreement)

Connector Threaded connector MassW

Ordering designation kg

PUMP.SLEEVE-CONNECTOR-M6 M6 0,22PUMP.SLEEVE-CONNECTOR-M8 M8 0,245PUMP.SLEEVE-CONNECTOR-GB/i GB/i 0,285PUMP.SLEEVE-CONNECTOR-G. G. 0,42The connector for the hand pump set is G..For detailed information, see TPI WL 80-50.

FAG sleeve connectors

FAG electric heating plate HEATER-PLATE

The temperature-controlled FAG heating plate HEATER-PLATEcan be used to heat rolling bearings(up to a maximum of 120 °C) orsmall machine components up to 5 kg mass. The removable housing coverprotects the workpieces fromcontaminants and ensures uniformand rapid heating. This inexpensive device ismaintenance-free and easy tohandle.

Dimensions (W~D~H):390~270~156 mmPlate size 380~180 mmPower: max. 1 500 Wat 230 V/50 HzTemperature control:continuously variable from +50 to +200 °CMass: 5,6 kg

Ordering designation:HEATER-PLATE

Ordering designation for versionwith 115 V/60 Hz:HEATER-PLATE-115V

FAG electric heating plate HEATER-PLATE-370C

The HEATER-PLATE-370C is usedprincipally for heating the FAG aluminium heating ringsHEATING-RING (see page 34). It canalso be used for the heating ofrolling bearings. Heating rings are suitable fordismounting the inner rings ofcylindrical roller and needle rollerbearings without ribs and innerrings with one rib. The heatingrings are heated to a temperatureof 200–300 °C. The outsidediameter of the workpieces can beup to max. 350 mm, the mass canbe up to 20 kg.Dimensions (W~D~H):360~360~170 mmPlate size 350~350 mmPower: max. 2 200 W at 230 V/50 HzPower control: 0 to 100 %Temperature control:continuously variable from +100 to +370 °CMass: approx. 13 kg

Ordering designation:HEATER-PLATE-370COrdering designation for 115 V/60 Hz version:upon request

Products · Mounting/RepairThermal mounting and dismountingElectric heating plates · Induction heating devices

31

FAG induction heating devices

Many rolling bearings and otherrotationally symmetrical partsmade from steel have tight fits onthe shaft. In particular, larger partscan be mounted more easily if theyare heated first. Rapid and clean induction heatingis superior to the conventionalmethods. It is therefore particularlysuitable for batch mounting. Heatingis carried out on complete bearings,rings for cylindrical roller or needleroller bearings and rotationallysymmetrical steel parts such aslabyrinth rings, roll couplings, tyres etc.

Advantages• Rapid, energy-efficient operation• Suitable for rolling bearings and

other ring-shaped steel parts• Very safe operation• Environmentally friendly, oil-free

(no disposal required) • Uniform, controlled heating• Easy to use• Automatic demagnetisation• High cost-effectiveness through

selection of the most suitablesize of device for the particularapplication

• Suitable for batch mountingFor the mounting of workpieces upto 300 kg mass, FAG suppliesfive table-top heating devicesPowerTherm HEATER10 to 300suitable for mobile and/orstationary use. For workpieces up to 3 000 kgmass, we recommend the particularlyheavy duty standalone devicesHEATER600, HEATER1200 andHEATER3000.For detailed information, see TPI WL 80-54. FAG heating plate HEATER-PLATE FAG heating plate HEATER-PLATE-370C

Products · Mounting/RepairThermal mounting and dismountingInduction heating devices

32

Heating device HEATER10 HEATER20 HEATER35 HEATER150

Power consumptionmax. 1) 2,3 kVA 3,6 kVA 3,6 kVA 12,8 kVAVoltage/frequency 2) 230 V/50 Hz 230 V/50 Hz 230 V/50 Hz 400 V/50 HzCurrent 10 A 16 A 16 A 32 A

Mass 7 kg 17 kg 31 kg 51 kgLength 230 mm 345 mm 420 mm 505 mmWidth 200 mm 200 mm 260 mm 260 mmHeight 240 mm 240 mm 365 mm 440 mm

Dimension a 65 mm 120 mm 180 mm 210 mmDimension b 95 mm 100 mm 160 mm 210 mm

Ledges (incl.) 20/45/65 mm 20 mm 70 mm 100 mmfor workpieces (graduated supports) 35 mmof min. bore 60 mm

Ledges (accessories) 10 mm 10 mm 15 mm 20 mmfor workpieces 15 mm 15 mm 20 mm 30 mmof min. bore 35 mm 45 mm

45 mm 60 mm60 mm 70 mm

85 mm

1) If lower voltage is used, the power will be reduced.2) Upon request, we can also supply heating devices with other rated voltages and frequencies as well as higher power

ratings.

Overview of induction heating devices

a

b

33

Heating device HEATER300 3) HEATER600 HEATER1200 HEATER3000

Power consumptionmax. 1) 12,8 kVA 25 kVA 40 kVA 100 kVAVoltage/frequency 2) 400 V/50 Hz 400 V/50 Hz 400 V/50 Hz 400 V/50 HzCurrent 32 A 63 A 100 A 250 A

Mass 75 kg (+25 kg) 3) 350 kg 850 kg 1 800 kgLength 870 mm 1 100 mm 1 500 mm 2 500 mmWidth 300 mm 850 mm 1 100 mm 1 500 mmHeight 580 mm 1 250 mm 1 400 mm 1 800 mm

(900 mm) 3)

Dimension a 330 mm 430 mm 700 mm 700 mmDimension b 260 mm 400 mm 450 mm 800 mm

Ledges (incl.) 115 mm 145 mm 215 mm 285 mmfor workpiecesof min. bore

Ledges (accessories) 30 mm 45 mm 85 mm 145 mm for workpieces 45 mm 60 mm 115 mm 215 mmof min. bore 60 mm 70 mm 145 mm

70 mm 85 mm85 mm 100 mm

100 mm 115 mm130 mm

3) Convertible to a mobile version by adding HEATER300.TROLLEY

Overview of induction heating devices

a

b

FAG heating rings

Heating rings are suitable fordismounting the inner rings ofcylindrical roller and needle rollerbearings without ribs and innerrings with one rib. Heating rings areparticularly advantageous for theoccasional extraction of small andmedium-sized bearing rings(bore diameter 50 to 200 mm).Depending on the size of the ring,heating takes between 5 and 30 seconds.The heating rings are made fromlight metal. They have a radial slot.They are easy to handle due to theheat-insulated handles.

Heating rings are heated tobetween 200 and 300 °C by meansof an electric heating plate. Thecylindrical outside surface of thebearing inner ring must be coatedwith a silicone-free heat conductingpaste (HEATING-RING.PASTE). This gives optimum heat transfer.The heating ring is then slid overthe inner ring to be extracted.

The bearing ring must be removedfrom the heating ring immediatelyafter extraction in order to preventoverheating.Each bearing size requires a specificheating ring. By agreement, we cansupply these heating rings madefrom a special aluminium alloy. In order to prepare a quotation, werequire the following information:1. Bearing designation or ring

dimensions,2. Drawing of mounting position

stating fits.3. Approximate number of parts

to be extracted per day

Recommended FAG accessories

• Electric heating plate fortemperatures up to 370 °CHEATING-PLATE-370C

• Temperature gauge TEMP-CHECK-CONTACT(see page 62)

• Gloves GLOVE2• Heat conducting paste (see below)

HEATING.RING.PASTE-20ML(20 ml included in delivery)

Products · Mounting/RepairThermal mounting and dismountingHeating rings · Heat conducting paste

34

Ordering examples for heatingrings

HEATING-RING-320E(for inner ring of cylindrical rollerbearing NU320-E, NJ320-E etc.)HEATING-RING-2317E(for inner ring of cylindrical rollerbearing NU2317-E, NJ2317-E etc.)

For detailed information, see TPI WL 80-58Expected to be available from July 2007

FAG heat conducting pasteHEATING-RING.PASTE

The silicone-free heat conductingpaste HEATING.RING.PASTE is usedas an aid in the dismounting ofbearing inner rings by means ofheating rings. The cylindrical outside surface ofthe bearing inner ring is coatedwith the heat conducting pastebefore extraction in order toachieve optimum heat transfer fromthe heating ring to the bearinginner ring.

Ordering designation(expendable syringe containing 20 ml silicone-free heat conductingpaste):HEATING-RING.PASTE-20ML

For detailed information, see TPI WL 80-58Expected to be available from July 2007

Electric induction heating devices

Electric induction heating devicesare suitable for the dismounting ofinner rings on medium-sized andlarge cylindrical roller and needleroller bearings (bore diameter 90 mm and larger). They can also be used to heatlabyrinth rings, couplings, ring rollsand other rotationally symmetricalparts.

Heating devices with low voltage

This design comprises an inductioncoil and a transformer. The coil runs on harmless lowvoltage and is water-cooled. Thisallows continuous heating, which isparticularly suitable for batchmounting. Due to the lightweightconstruction, these devices areeasy to handle. Each bearing size requires a specificcoil.The coil is connected to a mobiletransformer that can be designedfor any mains voltage. The voltagefor the coil is adjustable between20 and 40 V.The transformers for the inductioncoils are available from FAG in sixdifferent power steps. The largest transformer and thecorresponding coil can be used toheat inner rings up to a maximummass of 1 200 kg to the requireddismounting temperature of80...120 °C (maximum mass of600 kg for couplings).

Ordering example for bearing innerrings 120~150~144 mm:COIL152X145-LOW (coil)COIL.TRAFO-45KVA-400V-50HZ(transformer)

Products · Mounting/RepairThermal mounting and dismountingElectric induction heating devices

35

Heating devices with mains voltage

In addition to coils for low voltage,FAG also supplies coils for mainsvoltage (with a switch box or footswitch). This economical alternativewithout water cooling is used forsporadic dismounting (where batchdismounting is not required).

Heating device for low voltage with transformerfor dismounting of the inner rings of cylindricalroller bearings

Information required for quotation

FAG induction heating devices arealways produced as one-off items.In order to prepare a quotation, werequire the following information: 1. Exact designation of the bearing

or dimensions of the parts to beextracted

2. Width of the intermediate ring, if present

3. The mains voltage and frequencypresent at the mounting location

For detailed information, see TPI WL 80-58Expected to be available from July2007

Heating device for low voltage with mains volt-age for dismounting of the inner rings ofcylindrical roller bearings

FAG feeler gaugesFEELER-GAUGE-100 and FEELER-GAUGE-300

Feeler gauges are used to measurethe radial internal clearance,especially for mounting on tapered

Products · Mounting/RepairMeasurement and inspectionFeeler gauges · Taper gauges

36

shaft seats and on adapter andextraction sleeves.

Taper gauges

When a bearing with a tapered boreis seated directly on the shaft, thetapered bearing seat must be

precisely machined so that the fitsurfaces match precisely. We supply various gauges formeasuring the taper. Most bearingswith a tapered bore have a

FAG taper ring gauge

The simplest means of measuringtapered shaft seats on smallbearings is the taper ring gauge. By application of inking material, it can be determined whether theshaft and ring gauge match;corrections are made until the ringgauge is in contact over its wholewidth. The inner rings of thebearings are not suitable as ringgauges because their walls are toothin and could be damaged. Wesupply taper ring gauges for taperdiameters from 30 to 240 mm.

Ordering designation (example):KLR20Taper ring gauge for bearings of100 mm bore, e.g. for double rowcylindrical roller bearingsNN3020-AS-K or NNU4920-S-K.

taper 1:12. Only spherical rollerbearings of series 240 and 241have a taper 1:30.

Taper ring gauge Taperdiameter

Ordering designation mm

KLR06...KLR48 30...240

FAG taper ring gauge

Ordering designation Feeler length Feeler thicknessmm mm

FEELER-GAUGE-100 100 0,03 0,08 0,140,04 0,09 0,160,05 0,10 0,180,06 0,12 0,200,07

FEELER-GAUGE-300 300 0,03 0,12 0,200,04 0,13 0,250,05 0,14 0,300,06 0,15 0,350,07 0,16 0,400,08 0,17 0,450,09 0,18 0,500,10 0,19

FAG feeler gauges FEELER-GAUGE-100 and FEELER-GAUGE-300

FAG feeler gauges FEELER-GAUGE-100 andFEELER-GAUGE-300

FAG taper gauge MGK 9205for the inspection of large taperedshaft studs (taper 1:12 or 1:30)

Measurement principle of tapergauge MGK 9205: When measuringtapered studs of large diameter, a master can be used in which theupper and lower edge form anangle, the taper angle of the stud = 2 α. If the upper edge ofthe master is parallel with the linediametrically opposed to the master, the taper angle isacceptable.

A further requirement is that thetaper is in a defined ratio to areference surface, e.g. to the sideface of a roll barrel.

FAG taper gauges MGK 9205 areavailable in several sizes.The delivery of individual gauges,and also of complete sets, alwaysincludes two magnets. Deliveryalso includes belts for fixing thegauge in positions other than onthe upper side of the stud.

Ordering examples for gauge sets(each with two saddles and fivemasters): MGK9205-12.SET (taper 1:12)MGK9205-30.SET (taper 1:30)See also TI WL 80-70.

Products · Mounting/RepairMeasurement and inspectionTaper gauges

37

FAG taper gauge MGK 133for external tapers 1:12 and 1:30and 27 to 205 mm taper diameter.

The taper gauge MGK 133 rests onthe taper with four hardened andpolished support pins. The positionof the gauge on the taper isdefined by these pins and onestop. The stop can be attached toeither the front or back of thegauge. The gauge contains twomovable measuring brackets, oneof which is in contact with the

smaller taper diameter while theother, at a fixed distance, is incontact with the larger taperdiameter.

The deviation of the taper diameterfrom the nominal value is displayedin both measurement planes by aprecision indicator.

The reproducibility of the measure-ment results is less than 1 μm. The gauge is set using a gaugetaper (available by agreement).

FAG taper gauge MGK 9205


Products · Mounting/RepairMeasurement and inspectionTaper gauges · Snap gauge

38

FAG snap gauge SNAP-GAUGE-…/…for inspecting the diameter ofcylindrical shafts and workpiecesof all types, directly on themachine tool and for setting theenveloping circle gauge MGA 21(see page 39).

The actual dimension of theworkpiece can be determinedprecisely. The snap gauge functions as acomparator gauge. Its setting ischecked using shims. We supplythe shims required for eachdiameter.

Ordering example for shaft diameter 120 mm:SNAP-GAUGE-100/150(snap gauge)SNAP-GAUGE.MASTER120(shim) FAG snap gauge

FAG taper gauge MGK 132for external tapers with 0° to 6°taper angle and 90 to 510 mmtaper diameter.

With the taper gauge MGK 132, thereproducibility of the measurementresults is within 1 μm. The MGK132 rests on the workpiecewith four hardened, ground andlapped ledges. The ledges form anangle of 90°. A stop on the front orrear precisely defines the positionof the gauge.Between the support ledges, themeasurement slide runs on

preloaded roller bearings. A dialgauge fixed in the housing actsagainst the measurement slide andindicates the deviation of the taperdiameter from the nominal value. A precision indicator is fixed to themeasurement slide. Its blade-shapedtip is in contact with the workpieceand measures the deviation of thetaper from the nominal value. Thegauge is set using a gauge taper(available by agreement).


Measurementrange

Ordering designation mm

SNAP-GAUGE-30/60 30–60 SNAP-GAUGE-60/100 60–100 SNAP-GAUGE-100/150 100–150 SNAP-GAUGE-150/200 150–200 SNAP-GAUGE-200/250 200–250 SNAP-GAUGE-250/300 250–300

Available snap gauges

Products · Mounting/RepairMeasurement and inspectionEnveloping circle gauges

39

FAG enveloping circle gauge MGA 21for setting the radial internalclearance of cylindrical roller bear-ings NNU4920-K to NNU4964-K andNNU4920 to NNU4964.

Bearings of bore diameter 100 to320 mm have removable innerrings.In the FAG enveloping circle gaugeMGI 21, the internal envelopingcircle of the roller and cageassembly is measured by twohardened and precision groundsurfaces, one of which is movable.After mounting of the outer ring,the gauge is set to the internalenveloping circle of the roller and

cage assembly. This dimension ismeasured using a snap gauge, forexample the SNAP-GAUGE…/… (see page 38).It is then possible to set the innerring to the diameter that gives therequired radial internal clearance. Bearings with a tapered bore areslid onto the tapered seat of theshaft.For bearings with a cylindrical bore,preground inner rings are used(suffix F12) and finish ground tothe required raceway diameter.

Ordering example for NNU4920:MGI21-4920

FAG enveloping circle gauge MGA 31for setting the radial internalclearance of cylindrical rollerbearings NN3006-K to NN3038-Kand N1006-K to N1048-K.

Bearings with a tapered bore haveremovable outer rings.The gauge is used to precisely setthe radial internal clearance orpreload of cylindrical rollerbearings. The raceway diameter of themounted outer ring is measuredusing a conventional internalgauge. This dimension is transferred

to the two hardened and precisionground measuring surfaces of theenveloping circle gauge. The tapered shaft with thepremounted inner ring and rollerand cage assembly can then beinserted in the gauge. The shaft ismoved axially by the hydraulicmethod until the precision indicatorof the enveloping circle gaugeshows the required radial internalclearance or preload.

Ordering example for NN3006-K:MGA31-3006

FAG enveloping circle gauge MGA 31 for settingthe radial internal clearance of cylindrical rollerbearings with removable outer ring

FAG enveloping circle gauge MGI 21 for settingthe radial internal clearance or preload ofcylindrical roller bearings with removable innerring

Transport andmounting tool

FAG transport and mounting tool

BEARING.MATE is an accessory forthe secure, rapid and easy handlingof medium-sized and large rollingbearings. It can also be used wherebearings are heated prior tomounting.

The tool comprises two handlesand two steel strips. Turning thehandles clamps the steel stripsfirmly on the outer ring of therolling bearing. The compactpackaging also includes twobrackets. These are used onspherical roller bearings and self-aligning ball bearings in orderto prevent tilting of the inner rings.The tool and bearing is carriedeither by two people or a crane. If two carrying slings are used, therolling bearing can be rotated toany position when transported bycrane. During heating on aninduction heating device, the toolremains mounted on the bearing.The steel strips expand uniformlywith the bearing. Optimum tensionis thus maintained.The three sizes of tool are matchedto different bearing outsidediameters, see table below.

Accessories

Long brackets to prevent tilting ofself-aligning bearing inner rings(2 pieces)Ordering designation:BEARING-MATE.LOCKBAR270

Carrying sling, 1 m long (2 pieces)BEARING-MATE.SLING-1M

Products · Mounting/RepairAccessoriesTransport and mounting tool

40

Replacement parts

Short brackets to prevent tilting ofself-aligning bearing inner rings(2 pieces)Ordering designation:BEARING-MATE.LOCKBAR170

Pack of spare partsBEARING-MATE.SERVICE-KIT

Ordering designation Bearing outside diameter Bearing mass Operating temperature Tool massmin. max. max. max.mm kg °C kg

BEARING-MATE250-450 250 450 500 160 6,3BEARING-MATE450-650 450 650 500 160 6,4BEARING-MATE650-850 650 850 500 160 6,5

FAG transport and mounting tool

Heat-resistant FAG gloves GLOVE1

Heat-resistant FAG gloves areparticularly suitable for the handlingof heated rolling bearings or otherparts in mounting or dismounting.The outside comprises ruggedpolyester and can withstandtemperatures up to 150 °C. Theinside is made from comfortablecotton.

The principal characteristics are:

• resistant up to 150 °C• lint-free• asbestos-free• comfortable• cut-resistant

Ordering designation:GLOVE1

Products · Mounting/RepairAccessoriesGloves

41

Heat-resistant and oil-resistantFAG gloves GLOVE2

Heat-resistant and oil-resistantFAG gloves are particularly suitablefor the handling of heated andlubricated rolling bearings inmounting or dismounting.

Their principal characteristicsderive from the multiple layerconstruction comprising differentfibres.

The principal characteristics are:

• resistant up to 250 °C• non-flammable• heat-resistant even when damp• authorised for protection against

mechanical (DIN EN 388) andthermal (DIN EN 407) influences

• cotton-free• cut-resistant

Ordering designation:GLOVE2

Products · Mounting/RepairAccessoriesMounting paste · Anti-corrosion oil

42

FAG mounting paste

This mounting and multi-purposepaste has proven valuableparticularly for the mounting ofrolling bearings. It facilitates thesliding of bearing rings andprevents stick-slip, scoring, wearand fretting corrosion. It also givesgood protection against corrosion.It is pale in colour and does notcause contamination.The mounting paste is applied in avery thin layer so that the metallicsheen turns matt.The permissible operatingtemperature range is between –30 °C and 150 °C.

The paste is resistant to water,water vapour and many alkalineand acidic media.

Available in:70 g tubes250 g tubes400 g cartridges1 kg cans

Ordering designation:ARCANOL-MOUNTINGPASTE-70GARCANOL-MOUNTINGPASTE-250GARCANOL-MOUNTINGPASTE-400GARCANOL-MOUNTINGPASTE-1KG

FAG anti-corrosion oil

The anti-corrosion oil is suitableparticularly for unpacked rollingbearings. It can also be sprayed onbright metal surfaces of devices,machines and machine elementsto give long term anti-corrosionprotection when stored indoors.It is not generally necessary towash anti-corrosion oil out ofrolling bearings since it gives neutralbehaviour towards all conventionalrolling bearing greases and oils.

It can be easily and effectivelyremoved using alkaline solventsand neutral cleaning agents.

Available in:0,4 litre spray can with ozone-safepropellant CO2

Ordering designation:ARCANOL-ANTICORROSIONOIL-400G

Products · Lubrication

Lubricants 44

Arcanol rolling bearing greases 44

Lubrication systems 48

Motion Guard SELECT MANAGER 48Motion Guard COMPACT 49Motion Guard CHAMPION 51Motion Guard CONCEPT6 52Metering devices 53Grease gun 53

43

Special rolling bearing greases likeArcanol at first glance cost a littlemore than standard greases. Butthey are worth the price. For withArcanol you can buy some extrasecurity, since Schaeffler KG carriesout selection tests, provides qualityassurance and gives practice-basedlubrication recommendations.Bearings that fail prematurely dueto incorrect grease selection,together with all the unpleasantand expensive consequences, areincreasingly a thing of the past.

In co-operation with renownedlubricant manufacturers, we havefor many years developed lubricatinggreases that are particularly suitablefor rolling bearings. However,before a new grease is included inthe Arcanol range, it must pass aseries of stringent tests in theSchaeffler lubricant laboratory.

The greases are tested thoroughly.On our lubricant test rigs FE8 (DIN 51819) and FE9 (DIN 51821),the greases are tested in rollingbearings to find out how theyimprove service life and reducefriction and wear. Only the bestgreases are then selected to undergothe subsequent tests undersimulated field conditions in farmore complicated rolling bearingtest rigs. If the results meet therequirements of the stringentFAG specifications, the greases areincluded in the Arcanol range. They thus receive the Arcanol sealof quality.In addition, we test every singlebatch to ensure the uniform qualityof the product. It is only after thegrease has passed this final testthat it is allowed to be filled intocontainers labelled Arcanol. Therange is structured such that thesegreases cover nearly all fields ofapplication in an optimum manner.

Products · LubricationLubricantsArcanol rolling bearing greases

44

The overview on pages 46/47 showschemical-physical data, fields ofapplication and the conditions forwhich these greases are suitable.The selection of a suitable greaseis considerably facilitated by theelectronic INA/FAG rolling bearingcatalogue.

• More than 80% of all rollingbearings are lubricated withgrease

• Incorrect lubrication causes morethan 40% of all cases of rollingbearing damage

• Users therefore need lubricantsand lubrication recommendationsthat they can rely on

• Arcanol rolling bearing greasesensure that a bearing can beused to its full capacity– long service life– good running behaviour– high operational reliability

Mixed friction Speed

Rela

tive

ser

vice

life

Lubr

icat

ion

inte

rvalArcanol

Standard grease

Arcanol

Standard grease

Products · LubricationLubricantsArcanol rolling bearing greases · Container sizes · Ordering examples

45

Arcanol 20 g 70 g 250 g 400 g 1 kg 5 kg 10 kg 25 kg 50 kg 180 kggrease tube tube tube cartridge can bucket bucket hobbock hobbock drum

MULTITOP – – • • • • • • – •MULTI2 • – • • • • • • – •MULTI3 – – • • • • • • – •

LOAD150 – – – • • – • – – –LOAD220 – – – – • – • • – •LOAD400 – – – • • • • • • •LOAD1000 – – – – – • – • – •

TEMP90 • – – • • • – • – •TEMP110 – – – • • – – – • –TEMP120 – – – – • • – • – –TEMP200 – • – – • – – – – –

SPEED2,6 – – • – • – – • – –VIB3 – – – • • • – • • –BIO2 – – – • • – • • – •FOOD2 – – – • • – • • – •

Other container sizes available by agreement.

Arcanol rolling bearing greases · Container sizes

Ordering example Description

ARCANOL-MULTITOP-5KG FAG rolling bearing grease Arcanol MULTITOP in 5 kg bucketARCANOL-MULTI2-20G FAG rolling bearing grease Arcanol MULTI2 in 20 g tube (50 pieces)ARCANOL-MULTI3-25KG FAG rolling bearing grease Arcanol MULTI3 in 25 kg hobbock

ARCANOL-LOAD150-10KG FAG rolling bearing grease LOAD150 in 10 kg bucketARCANOL-LOAD220-180KG FAG rolling bearing grease Arcanol LOAD220 in 180 kg drumARCANOL-LOAD400-400G FAG rolling bearing grease Arcanol LOAD400 in 400 g cartridge (10 pieces)ARCANOL-LOAD1000-5KG FAG rolling bearing grease Arcanol LOAD1000 in 5 kg bucket

ARCANOL-TEMP90-1KG FAG rolling bearing grease Arcanol TEMP90 in 1 kg canARCANOL-TEMP110-400G FAG rolling bearing grease Arcanol TEMP110 in 400 g cartridgeARCANOL-TEMP120-25KG FAG rolling bearing grease Arcanol TEMP120 in 25 kg hobbockARCANOL-TEMP200-70G FAG rolling bearing grease Arcanol TEMP200 in 70 g tube

ARCANOL-SPEED2,6-250G FAG rolling bearing grease Arcanol SPEED2,6 in 250 g tube (10 pieces)ARCANOL-VIB3-25KG FAG rolling bearing grease Arcanol VIB3 in 25 kg hobbockARCANOL-BIO2-1KG FAG rolling bearing grease Arcanol BIO2 in 1 kg canARCANOL-FOOD2-10KG FAG rolling bearing grease Arcanol FOOD2 in 10 kg bucket

Arcanol rolling bearing greases · Ordering examples

ArcanolMULTITOP MULTI2 MULTI3 LOAD150 LOAD220 LOAD400 LOAD1000

Products · LubricationLubricantsArcanol rolling bearing greases · Selection table

46

Overview of Arcanol rolling bearing greases

DIN 51825

Thickener

Base oil

Base oil viscosity at 40 °C[mm2/s]

Consistency (NLGI class)

Operating temperature [°C]

Long term limit temperature [°C]

Characteristicareas of application forArcanol rolling bearing greases

Low temperatures

High temperatures

Low friction,high speeds

High loads,low speeds

Vibrations

Support forseals

Relubrication facility

KP2N-20

Lithium/

calcium soap

with EP additives

Mineral oil

ISO VG

1000

2

–20...+140

80

Special grease

for ball and

roller bearings

in

mining

machinery,

construction

machinery,

preferably

under shock

loads and large

bearings

at

very high loads,

moderate

temperatures,

low speeds

ο

ο

––

++

+

+

+

KP2N-20

Lithium/

calcium soap

with EP additives

Mineral oil

400

2

–25...+140

80

Special grease

for ball and

roller bearings

in

mining

machinery,

construction

machinery,

wind turbines

at

very high loads,

moderate

temperatures,

moderate speeds

–

ο

–

++

+

+

+

KP2N-20

Lithium

complex soap

with EP additives

Mineral oil

ISO VG

150

2

–20...+140

95

Special grease

for ball, roller

and needle roller

bearings, linear

guidance systems

in

machine tools

at

high loads, with

wide speed

range, swivel

movements

ο

ο

–

++

+

+

+

KP2N-20

Lithium/

calcium soap

with EP additives

Mineral oil

ISO VG

220

2

–20...+140

80

Special grease

for ball and

roller bearings

in

rolling mill

plant,

rail vehicles

at

high loads, with

wide speed

range, high

humidity

ο

ο

–

++

+

+

+

K3N-30

Lithium soap

Mineral oil

80

3

–30...+140

75

Universal grease

for ball bearings

D > 62 mm

in

large

electric motors,

agricultural and

construction

machinery,

fans

+

ο

ο

ο

+

+

+

K2N-30

Lithium soap

Mineral oil

ISO VG

100

2

–30...+140

75

Universal grease

for ball bearings

D ≤ 62 mm

in

small

electric motors,

agricultural and

construction

machinery,

household

appliances

+

ο

ο

ο

ο

ο

++

KP2N-40

Lithium soap

with EP additives

Mineral oil+ester

85

2

–40...+150

80

Universal grease

for ball and

roller bearings

in

rolling mills,

construction

machinery,

automotive engi-

neering, spinning

and grinding

spindles

at

increased

speeds,

high loads,

low and high

temperatures

++

ο

+

+

+

ο

++

ISO VG = ++ highly suitable ο suitable – less suitable

ISO viscosity group + very suitable –– not suitable

TEMP90 TEMP110 TEMP120 TEMP200 SPEED2,6 VIB3 BIO2 FOOD2

47

KP2P-40

Calcium

polycarbamide

with EP additives

PAO oil

130

2

–40...+160

90

Special grease

for ball and

roller bearings

in

couplings,

electric motors,

automotive

engineering

at

high

temperatures,

high loads

++

+

ο

ο

ο

ο

ο

KE2P-40

Lithium

complex soap

Ester oil

ISO VG

150

2

–40...+160

110

Special grease

for ball and

roller bearings

in

electrical

equipment,

automotive

engineering

at

high

temperatures,

high speeds

++

++

+

ο

ο

ο

ο

KP3N-30

Lithium

complex soap

with EP additives

Mineral oil

170

3

–30...+150

90

Special grease

for ball and

roller bearings

in

blade adjusters

in rotors for

wind turbines,

packaging

machinery,

rail vehicles

at

high

temperatures,

high loads,

with oscillating

motion

+

+

–

+

++

ο

–

KFK2U-40

PTFE

Fluoro polyether oil

400

2

–40...+260

200

Special grease

for ball and

roller bearings

in

track rollers

in baking

machinery,

piston pins

in compressors,

kiln trucks,

chemical plant

at

very high

temperatures,

in chemically

aggressive

environment

++

++

––

+

–

ο

ο

KE3K-50

Polycarbamide

PAO/ester oil

ISO VG

22

2–3

–50...+120

80

Special grease

for ball bearings

in

machine tools,

instruments

at

very high speeds,

low temperatures

++

ο

++

––

–

ο

+

KPHC2R-30

Polycarbamide

with EP additives

PAO/ester oil

ISO VG

460

2

–35...+180

120

Special grease

for ball and

roller bearings

in

continuous

casting plant

at

high

temperatures,

high loads

+

++

–

++

ο

ο

ο

KPE2K-30

Lithium/

calcium soap

Ester oil

58

2

–30...+120

80

Special grease

for ball and

roller bearings

in

environmentally

hazardous

applications

+

ο

ο

ο

ο

ο

+

KPF2K-30

Aluminium

complex soap

White oil

192

2

–30...+120

70

Special grease

for ball and

roller bearings

in

applications

with food

contact;

H1 to USDA

+

–

ο

ο

ο

ο

++

Automatic FAG lubricatorsMotion Guard

Reliable and economical lubricationfor a long bearing life

Rolling bearings are reliablemachine components that give a long operating life. The mostfrequent cause of failure isinadequate or incorrect lubrication.Approximately 90% of all bearingsare lubricated with grease. Providinga reliable supply of suitable greaseis therefore particularly important.

If an automatic lubricator is usedfor controlled relubrication, asufficient quantity of fresh greaseis continuously supplied to thecontact points of the rolling bearing.

This results in a significant increasein bearing life. These reliable,economical devices give extendedlubrication and maintenanceintervals and also prevent under-supply or oversupply of grease.

Plant downtime and maintenancecosts are reduced as a result. Thesparing and environmentallyfriendly use of lubricants contributeto higher cost-efficiency.

FAG Motion Guard lubricators areindividually matched to the bearinglocation and eliminate the need forcostly central lubrication systems.They have a wide range ofapplications, for example onpumps, compressors and fans, inconveying equipment, vehicles etc.

The single point lubrication systemsMotion Guard COMPACT can beused to dispense eight of theArcanol greases described onpages 46 to 47, while CHAMPIONcan dispense all these greases.Motion Guard CONCEPT6 is used as asingle point or multi-point lubricationsystem with thirteen Arcanolgreases.

Products · LubricationLubrication systemsMotion Guard · Motion Guard SELECT MANAGER

48

Advantages of lubricators

• Individually configured, precisesupply to each bearing positionimmediately after initial operation

• Fully automatic, maintenance-freeoperation

• Savings on personnel costscompared to manual relubrication

• Various dispensing times can beselected (1, 3, 6 or 12 months; forCONCEPT6: 1 day to 24 months)

• No risk of confusion orcontamination of lubricants

• Pressure build-up to 4 bar (COMPACT),to 5 bar (CHAMPION) or to 25 bar (CONCEPT6), thus overcoming any obstructions

• Suitable for connection to theFAG monitoring system Easy Check

• Comprehensive range ofaccessories

Motion Guard SELECT MANAGER

The software Motion Guard SELECT MANAGER Version 2.0allows:• selection of lubricators• definition of dispensing times

and relubrication quantities• selection of suitable/preferred

Arcanol greases• management of a lubrication and

maintenance plan

Detailed information on FAG automatic lubricators is givenin publication WL 81 122.

FAG lubricator Motion Guard COMPACT

This automatic lubricator iselectrochemically driven. Theelectrolyte is environmentallyfriendly citric acid.The metal housing is filled with 120 cm3 of FAG Arcanol rollingbearing grease.The dispensing time is determinedby the different coloured activationscrews.Automatic lubricators Motion GuardCOMPACT are available with suitablelubricants as standard in packs of10 containers.

Ordering examples:

ARCALUB-LOAD400(filled with LOAD400, pack of10 containers without activationscrew)

ARCALUB-TEMP90(filled with TEMP90, pack of10 containers without activationscrew)

COMPACT lubricators filled withArcanol MULTITOP and MULTI2 arealso available in single packsincluding activation screws, whilethose with TEMP200 are onlysupplied in single packs withactivation screws.

Ordering examples:

ARCALUB-MULTITOP-1M(filled with MULTITOP, includingactivation screw for 1 month)

ARCALUB-MULTI2-3M(filled with MULTI2, includingactivation screw for 3 months)

ARCALUB-MULTITOP-6M(filled with MULTITOP, includingactivation screw for 6 months)

ARCALUB-TEMP200-12M(filled with TEMP200, includingactivation screw for 12 months)

Products · LubricationLubrication systemsMotion Guard COMPACT · Lubricators and activation screws

49

Activation screws

Ordering designations (10 pieces):

ARCALUB.ACTIVE-1Mfor 1 month (yellow)

ARCALUB.ACTIVE-3Mfor 3 months (green)

ARCALUB.ACTIVE-6Mfor 6 months (red)

ARCALUB.ACTIVE-12Mfor 12 months (grey)(12M cannot be used for MULTITOPand MULTI2)

Suitable Arcanol greases, chain oilsand activation screws

1M 3M 6M 12M

MULTITOP • • •MULTI2 • • •LOAD400 • • • •LOAD1000 • • • •TEMP90 • • • •TEMP120 • • • •TEMP200 • • • •FOOD2 • • • •CHAINOIL • • • •

Arcanol

ARCALUB-TEMP200-6M

Variant CLEAR

The variant CLEAR of the lubricatorMotion Guard COMPACT is suitablefor explosion-protected andcorrosion-inducing humidity areas.The lubricator can be used atoperating temperatures from 0 to+40°C. The upper temperature limitis determined by the transparentplastic housing with a volume of100 cm3.

Ordering example:

ARCALUB-CLEAR-FOOD2(filled with FOOD2, pack of10 containers without activationscrew)

In addition to FOOD2, seven otherArcanol grease grades as listed forCOMPACT on page 49, as well aschain oil can be used.

The special activation screws forthe variant CLEAR with dispensingtimes of 1, 3 or 6 months areoffered separately.

Ordering designation (10 pieces):

ARCALUB.ACTIVE-CLEAR-1MARCALUB.ACTIVE-CLEAR-3MARCALUB.ACTIVE-CLEAR-6M

Products · LubricationLubrication systemsMotion Guard COMPACT · Variants CLEAR and POLAR

50

Variant POLAR

The variant POLAR of the lubricatorMotion Guard COMPACT is designedfor operation in temperatures from–25 °C to +10 °C. The metal housingis filled with 120 cm3 of Arcanolrolling bearing grease MULTITOP (it is only available with this grease).

Ordering designation:

ARCALUB-POLAR-MULTITOP(filled with MULTITOP, pack of10 containers without activationscrew)

For the dispensing time as a functionof the actual temperature present,see the following table.

The black activation screw must beordered separately.

Ordering designation (10 pieces):ARCALUB.ACTIVE-POLAR

Temperature Dispensing time

+10 °C 1 week± 0 °C 2 weeks–10 °C 6 weeks–20 °C 14 weeks–25 °C 26 weeks

Variant POLAR

FAG lubricatorsMotion Guard CHAMPION

The automatic lubricator Motion Guard CHAMPION iselectromechanically driven.The robust, electronically controlledgeared motor can be used morethan once. It allows the dispensingtimes to be adjusted depending onthe temperature and to 1, 3, 6 or12 months. It is battery poweredand the battery set is replacedwhenever the cartridge is changed.

Ordering designation:ARCALUB.DRIVE

Special drive units are available asaccessories for machine-controlledoperation in explosion hazardareas.

The lubricator Motion Guard CHAMPION is suitable for all theArcanol rolling bearing greasesdescribed on page 46–47 as wellas chain oil. Filled LC (LubricantCartridge) units with a dispensingvolume of 60, 120 and 250 cm3 areavailable and are screwed onto thedrive unit. Once the LC unit isempty, it cannot be refilled.

Ordering examples(one battery set is included in thedelivery):

ARCALUB.LC60-MULTITOP(filled with MULTITOP, 60 cm3)ARCALUB.LC120-LOAD400(filled with LOAD400, 120 cm3)ARCALUB.LC250-VIB3(filled with VIB3, 250 cm3)

The complete lubricator, comprisinga drive unit, LC unit and batteryset, is connected to the lubricationpoint by means of an adapter orhose.

Ordering designations:ARCALUB.ADAPTER

ARCALUB.TUBE(3 m hose with connectors)

Products · LubricationLubrication systemsMotion Guard CHAMPION · Lubricator drives, LC units, sets and accessories

51

FAG lubricator setsMotion Guard CHAMPION

The automatic lubricator MotionGuard CHAMPION in sizes 120 and250 cm3 and filled with ArcanolMULTITOP is offered as a completelubricator set. The sets comprise:

• a drive unit• an adapter• an LC unit with battery set

Ordering designations:ARCALUB.LC120-MULTITOP-KITARCALUB.LC250-MULTITOP-KIT

The lubricator CHAMPION has onlybeen tested in conjunction withArcanol lubricants.

By agreement, FAG also suppliesthe lubricator CHAMPION withspecial fillings.

Accessories for Motion Guard COMPACT and CHAMPION

The Motion Guard product range issupplemented by a comprehensiverange of accessories. For detailedinformation, see publication WL 81 122.

FAG lubrication system Motion Guard CONCEPT6

This single-point and multi-pointlubrication system can supply upto six lubrication points withlubricant constantly, precisely andregardless of temperature. Thedispensing times can be adjustedto between 1 day and 24 monthsand LC units are available in sizes250 and 500 cm3.

FAG starter kitsMotion Guard CONCEPT6

The starter kits are premounted ona retaining plate and form the basisfor the multi-point lubricationsystem Motion Guard CONCEPT6.

The geared motor in the MP-6 ispowered and controlled by thedrive unit.

Products · LubricationLubrication systemsMotion Guard CONCEPT6

52

Variant CONTROL

The variant CONTROL of thelubricator CONCEPT6 is controlledby the machine, i.e. lubricant isonly dispensed while the machineis running. We also supply starterkits for the variant CONTROL as abasis for multi-point lubricationsystems.

Ordering designation:ARCALUB-C6-CONTROL-250-KITARCALUB-C6-CONTROL-500-KIT

The patented distribution systemMP-6 allows independent supply ofbetween two and six lubricationpoints.

Lubricant is distributed independentof its consistency or solid particlecontent. If the distributor identifiesan obstruction in an individualoutlet, this is indicated on thedisplay of the drive unit. The otheroutlets continue to be supplied.

Ordering designations:ARCALUB-C6-250-KITARCALUB-C6-500-KIT

Only the following must be orderedspecially: hose and connectors forthe lubrication point and LC unitsin sizes 250 cm3 and 500 cm3.

LC units are available with the 13 suitable Arcanol grease grades(see page 46–47, except for MULTI3and VIB3).

Ordering examples:ARCALUB-C6.LC250-MULTITOPARCALUB-C6.LC250-LOAD400ARCALUB-C6.LC500-SPEED2,6ARCALUB-C6.LC500-TEMP200

By agreement, we supply LC unitswith other greases whose suitabilityhas been checked.

For single-point lubrication, theparts required are orderedindividually from the range ofaccessories.

For detailed information, seepublication WL 81 122.

FAG grease metering devices

These devices are used for themetered greasing of rolling bearings.The metering range is between 10 and 133 cm3. Larger meteringranges can also be achieved byoperating the device several times.By means of a pneumatically driven,double direction piston pump, themedium is conveyed directly fromthe grease container (25 kg or 180 kg) via the metering valve tothe application point.

The grease metering device comprises:• a cover• a piston• a metering valve• a hose connecting the pump and

valve• a 2,5 m hose• a grease gun

Technical data:

Pump ratio: 10 : 1Delivery quantity: 400 cm3/minMetering range: 10–133 cm3

Ordering designations:ARCA-PUMP-25ARCA-PUMP-180

Products · LubricationLubrication systemsGrease metering devices · Grease gun

53

FAG grease gun with reinforced hose

In difficult operating conditions oraggressive environments, rollingbearings must be frequentlyrelubricated via lubrication nipples.With the FAG grease gun and thematching reinforced hose, thisoperation can be carried out easily,cleanly and quickly. The partscomply with DIN 1283.

Grease gun

Container diameter 56 mmTotal length of gun 390 mmDelivery quantity 2 cm3/strokePressure max. 800 bar

The gun can either be filled withbulk grease or fitted with a cartridgeto DIN 1284.

• 500 cm3 container volume withbulk grease or

• 400 g cartridge to DIN 1284(diameter 53,5 mm, length 235 mm)

Connector thread GB/i

Mass approx. 1,5 kg

Ordering designation: ARCA.GREASE-GUN

Reinforced hose

Length 300 mmConnector thread GB/i

Fitted with hydraulic grip couplingfor taper type lubrication nipple toDIN 71412

In place of the hydraulic gripcoupling, slide couplings for flatlubrication nipples to DIN 3404 orother nozzles can be connected.These connectors are availablefrom normal trade outlets.

Ordering designation:ARCA-GREASE-GUN.HOSE

A hose with a connector forcylindrical nipples to DIN 3404 isoptionally available.

Ordering designation:ARCA-GREASE-GUN.HOOK-ON-HOSE

ARCA-PUMP-180

ARCA-GREASE-GUN withARCA-GREASE-GUN.HOSE andARCA-GREASE-GUN.HOOK-ON-HOSE

Belt and chain drives 56

Belt pulley alignment device 56Belt tension measuring device 57

Shaft couplings 58

Shaft alignment device 58

Accessories for alignment 60

Shims 60

Products · Alignment

55

FAG belt pulley alignment deviceTop-Laser SMARTY2

Top-Laser SMARTY2 is an economicalmeasuring device for the alignmentof belt pulleys and chain sprockets.Through the use of this device, thewear of belt drives, bearings andseals is reduced. Less vibration isgenerated and the running timeand reliability of the machinery isincreased.

Features and advantages:• Parallelism and misalignment of

both pulleys displayed• Significantly quicker and more

precise than conventionalmethods

• Suitable for both horizontally andvertically mounted machinery

• Only one person required foralignment

• Also suitable for non-magneticsprockets or pulleys

The measuring device can bemounted in just a few seconds. Thelaser beam can be clearly seen onthe target marks. Once the laserbeam is adjusted to coincide withthe slots in the target marks, themachine is correctly aligned. The target marks are available in

Products · AlignmentBelt and chain drivesBelt pulley alignment device

56

optical and digital form. In the caseof the digital target mark, adjustmentvalues are shown in the displayin real time. Misalignments arepresented in degrees and theparallelism offset in mm. Since the measuring instrument isso light, the emitter and targetmarks can be easily attached tonon-magnetic drive pulleys using astrong, double-sided adhesive tape.

Ordering designation and scope ofdelivery:

Complete laser measuring deviceincl. 2 optical target marks, 2 batteries and user manual inpadded case:LASER-SMARTY2

Replacement part:1 optical magnetic target markLASER-SMARTY2.TARGETAccessories:1 digital magnetic target markLASER-SMARTY2.TARGET-DIGITAL


B

A

BA

FAG belt tension measuring deviceTop-Laser TRUMMY2

The robust, handy Top-LaserTRUMMY2 is an optical-electronicinstrument for measuring andsetting optimum belt tension(strand force). Optimum belt tension, like precisealignment of the belt pulleys(see Top-Laser SMARTY2, page 56),is an essential precondition forachieving the maximum possiblelife of the belt drive. There is alsoless wear of the drive components,energy costs are reduced and cost-effectiveness is increased.The user-friendly Top-LaserTRUMMY2 can be used in manylocations and comprises a cablelessmeasurement probe, a measurement

probe with a cable for difficultto access locations and amicroprocessor that indicatesrelevant measurables for belt tensioneither as frequency [Hz] or force[N]. By means of an impulse (forexample by striking the stationarybelt), the tensioned belt is excitedto natural vibration. The individualstatic natural frequency thusgenerated is measured withinseconds by the TRUMMY2 sensorusing clock pulse light and displayed.In order to calculate the strand forceof the belt drive, the belt massand length are entered in themicrocomputer before measurement.TRUMMY2 uses these to calculatethe strand force, which is thencompared with the specifiednominal value.

Products · AlignmentBelt and chain drivesBelt tension measuring device

57

In comparison with systemsoperating for example by soundwaves, this new measurementtechnique using clock pulse lightis clearly superior, since themeasurement result cannot bedistorted by disruptive influences.The simple and reliable userinstructions are given in severallanguages.

Ordering designation:Laser measuring device in plasticcase:LASER-TRUMMY2


FAG shaft alignment device Top-Laser INLINE

The FAG Top-Laser INLINE is a PC-based alignment system forcoupled shafts in motors, pumps,ventilators and gearboxes (withrolling bearings).

Operating benefits:• Simple to mount• Error-free handling even by

untrained personnel due toautomatic measurement andpositioning process

• More precise alignment than withconventional methods

• Rapid measurement due tocontinuous rotary motion

• Reduced vibration and frictionlosses

• Longer machine running times• Usable with conventional laptops

Included in delivery: 1 transceiver

(incl. 3 m cable)1 reflector2 brackets2 chains (300 mm)4 posts (115 mm)1 software1 case1 serial PC card

All the parts included in the deliveryare also available as replacementparts.

Ordering designation:Complete Top-Laser INLINE: LASER-INLINE

Actions before alignment

Before any alignment operation,any tilting foot (machine foot thatlifts off the floor when slackened)should be removed in order toprevent increased vibration tendencyand bearing damage due to housingdistortion.

Products · AlignmentShaft couplingsShaft alignment device

58

The Top-Laser INLINE helps toquickly identify and eliminate theso-called soft foot. It is onlynecessary to loosen each individualscrew foot connection. The computerdetermines any foot movement. The tilting foot can then beeliminated using shims.

Case PC card Software

Post

Chain Bracket Transceiver

Cable

Reflector

Included in delivery

Accessories

The possible applications of theLASER-INLINE basic device can beexpanded with the aid of acomprehensive range of accessories(see table). The accessories can beordered as a set in a handy, robustcase or – individually compiled –as individual parts.


Products · AlignmentShaft couplingsShaft alignment device

59

Accessories for LASER-INLINE Ordering designation

Accessory set, complete 1 piece LASER-INLINE.ACCESS-SET

Chain, 600 mm long 2 pieces LASER-INLINE.CHAIN600Chain, 1 500 mm long 2 pieces LASER-INLINE.CHAIN1500

Post, 150 mm long 4 pieces LASER-INLINE.POST150Post, 200 mm long 4 pieces LASER-INLINE.POST200Post, 250 mm long 4 pieces LASER-INLINE.POST250Post, 300 mm long 4 pieces LASER-INLINE.POST300

Magnetic holder 2 pieces LASER-INLINE.MAGNET

Accessory case, empty 1 piece LASER-INLINE.CASE-ACCESSORIES

Accessories for LASER-INLINE

C

B

A

FAG shims Top-Laser SHIM

Top-Laser SHIMs are used toeliminate any vertical misalignmentdetected using the FAG Top-Laserdevices. These shims are availablein seven thickness values (0,05;0,10; 0,20; 0,50; 0,70; 1,00; 2,00 mm) and four sizes(dimension C = 15, 23, 32 or 44 mm).

Composition of setThe practical case contains 20 shimseach of 3 sizes (C = 15, 23 and 32 mm) and 6 thickness values(0,05 to 1,0 mm), i.e. a total of360 shims, together with oneextraction hook.

Ordering designation:LASER.SHIM-SET

Individual or replacement parts

As replacement parts, we supply10 shims each of one of the 4 sizesand one of the 7 thickness valuesstated above.

Ordering examples:

10 shims of dimension C = 15 mmand 0,20 mm thickness:LASER.SHIM15X0,20

10 shims of dimension C = 44 mmand 0,10 mm thickness:LASER.SHIM44X0,10


Products · AlignmentAccessoriesShims

60

Ordering designation Dimensions Total quantity MassSet A B C Thickness of shimsFAG mm kg

LASER.SHIM-SET 55 50 15 0,05–1,0 360 6,775 70 23 0,05–1,090 80 32 0,05–1,0

LASER.SHIM-SET

Ordering designation Dimensions Total quantity MassIndividual or A B C Thickness of shimsreplacement partsFAG mm g

LASER.SHIM15X… 55 50 15 0,05–2,0 10 each 11–440LASER.SHIM23X… 75 70 23 0,05–2,0 10 each 21–840LASER.SHIM32X… 90 80 32 0,05–2,0 10 each 29–1 160LASER.SHIM44X… 125 105 44 0,05–2,0 10 each 53–2 100

LASER.SHIMs Individual or replacement parts

Products · Condition monitoring

Operating condition 62

Temperature measuring devices 62Digital hand tachometer 63Sonar device 64

Vibration diagnosis 65

Detector II 65Detector III 66Easy Check 67Easy Check Online 67DTECT X1 67WiPro 68VibroCheck 69ProCheck 70

61

FAG infrared thermometerTempCheck PLUS

The FAG infrared thermometerTempCheck PLUS measures theinfrared radiation emitted by anobject and uses this to calculatethe surface temperature. Thecontact-free measurement makes itpossible to easily determine thetemperature of difficult to reach ormoving objects. The device is very light (it weighsonly 150 g) and can be takenpractically anywhere it is needed.The FAG infrared thermometerTempCheck PLUS can measuretemperatures in a range between–32°C and +530 °C. It has highprecision glass optics for accuratecontact-free temperature measure-ment. It is suitable for monitoringthe temperature of components of amachine.

Overview of the advantages ofTempCheck PLUS:• Rapid and precise temperature

measurement• State of the art infrared

temperature measurementtechnology

• Simple to use• Reduction of unplanned

downtime• Low purchase cost

Ordering designation and scope ofdelivery: TEMP-CHECK-PLUS(measuring device with battery,strap, user manual and carry case)

Caution

Do not look into the laser beam. Donot point the laser beam into otherpeople’s eyes.

Products · Condition monitoring Operating conditionTemperature measuring devices

62

FAG temperature measuring device TempCheck CONTACT

This handy device has a displayrange from –60 °C to +1 000 °C. The surface temperatue sensorTEMP-CHECK-CONTACT.SENSOR has a measurement range from –60 °C to +300 °C.

The device is suitable for measuringthe temperature of• rolling bearings, housings and

lubrication systems for operationalmonitoring

• heated rolling bearings and jointsduring mounting

The microprocessor-controlledmeasuring device has a single linedisplay. The touch keyboard has

the following switching functions:• On/Off• Hold

(hold the measurement value inthe display)

Ordering designation and scope ofdelivery:TEMP-CHECK-CONTACT(measuring device with sensorTEMP-CHECK-CONTACT.SENSOR andservice case)

FAG temperature sensor asreplacement part(can be ordered individually):Rapid reaction surface sensorOrdering designation: TEMP-CHECK-CONTACT.SENSOR

FAG temperature sensor as accessory(can be ordered individually, formeasuring the temperature of fluids,lubricants etc.): Immersion/insertion sensorOrdering designation: TEMP-CHECK-CONTACT.SENSOR-IMMERSION


FAG digital hand tachometerTACHOMETER

The speed counter is suitable fortwo types of operation:• Direct speed measurement using

an adapter, track wheel andmeasurement stylus

• Non-contact optical speedmeasurement using a reflectivemark

Direct speed measurement

For direct speed measurement, thesupplied adapter must be fitted.

Through contact with the component,the rubber stylus measures thespeed or the surface speed isdetermined in conjunction with atrack wheel.

Non-contact speed measurement

For non-contact measurement, areflective mark is applied to themachine part to be measured. Thismark is detected by photoelectricmeans using visible red light. The device displays the speed inrevolutions per minute.

Products · Condition monitoring Operating conditionDigital hand tachometer

63

Ordering designation:TACHOMETER

Included in delivery:• Digital hand tachometer• Adapter for direct measurement

1:1• Track wheel, 6 inch• Rubber stylus• 10 reflective marks• User manual• Case

Replacement parts

10 reflective marksOrdering designation: TACHOMETER.MARKS-REFLEX

FAG sonar device SOUND-CHECK

The sonar detector can be used tocheck rolling bearing noise veryeasily, quickly and reliably.Changes in noise due to wear,pitting formation or distortion ofthe bearing can be detected at anearly stage if regular inspection iscarried out. In this way, unforeseenoperational downtimes and moresignificant machine damage can beprevented. The device is used inthe same way as a doctor’sstethoscope.

The tips of the earpiece are placedin the ear canals to provideinsulation against backgroundnoise. The insulating grip is heldlike a pencil between index fingerand thumb and the sensor isplaced firmly on the part to bemeasured. If a noise is heard, thesensor is moved until its volumereaches a maximum.

Ordering designation:SOUND-CHECK

Products · Condition monitoring Operating conditionSonar device

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Condition monitoring byvibration diagnosis

Vibration diagnosis is the mostreliable method for identifyingmachine damage at an early stage.Imbalance and misalignmentdefects can be detected accurately,as well as rolling bearing damageand gear tooth defects. For thisarea, we therefore offer acomprehensive product portfolio,ranging from simple vibrationmonitors to complex monitoringsystems with a large number ofmeasuring points. FAG vibrationmeasuring devices help to planmaintenance work, extend bearinglife, reduce costs and increaseplant availability.

In the field of offline monitoringdevices, we offer Detector II andDetector III. The online monitoring devicesinclude products from theeconomical Easy Check range, thedigital vibration monitors DTECT X1and WiPro as well as the onlinemonitoring systems VibroCheck andProCheck.For all these devices and on allaspects of condition monitoring,F’IS offers a worldwide service –from the F’IS Customer Hotline tocustomer-specific service contracts.In order to achieve optimumnetworking, all online systems haveversatile communication options asstandard.

FAG Detector II

Detector II is a portable vibrationmeasuring device and data collectorin one. Using this economicaldevice is straightforward and easyto learn. It weighs approx. 450 gand is highly suitable for monitoringextensive plants where measurementrounds involving large distancesmust be covered. Detector II picks upvibration signals at predeterminedmeasuring points and calculatesthe effective values for vibrationrate and acceleration. It can beused to monitor machine vibrationsin accordance with ISO 10816 aswell as the rolling bearing conditionusing the demodulated signaldetection method. Temperatures canalso be measured by non-contactmeans using an infrared sensor.The data collected by the deviceare transferred to a computer. They are then evaluated, analysedand presented in graphic form withthe aid of the software Trendline.Any incipient damage can thus bedetected at an early stage. DetectorII can also be used by personnelwho have no experience ofvibration measurement. A veryuseful feature in this respect is the“e-mail button”. This allows thecollected data to be sent to an

Products · Condition monitoring Vibration diagnosisDetector II

65

external diagnosis expert for furtheranalysis.

Included in delivery:• Basic device with rechargeable

battery• Acceleration sensor with magnetic

foot• Temperature sensor• Power pack• PC data cable• User manual• Protective bag with holder for

temperature sensor• PC software Trendline• Case• USB serial adapter

Accessories:• Second attachable bag for holding

acceleration sensor• Sensor extension cables for

lengths of 5 m and 15 m areavailable on request

Ordering designation:DETECT2-1MB-KIT

For detailed information, seeTPI WL 80-62.Please direct enquiries to:[email protected]

FAG Detector II

FAG Detector III

Detector III is based on thesuccessful Detector II. The proven,simple operating concept wasretained and supplemented by alarge number of new functionalities.In addition to vibration measure-ment, contact-free temperaturemeasurement and data collection,the system is now also capable ofcarrying out static and dynamicbalancing tasks. As a result,imbalance can not only be detectedbut easily and efficiently eliminated.For this purpose, the optionallyavailable Balancing Kit is required.With the aid of the softwareinstalled on the system, the user is guided through the balancingprocedure step by step.The results of the balancingprocedure as well as the vibrationmeasurement are transferred to thesoftware FAG Trendline where theyare analysed and evaluated. Thecompletely revised F’IS Vieweroffers the user a large number offunctions that make data analysisconsiderably easier. In particular,the newly integrated bearingdatabase containing approx. 20 000 bearings from variousmanufacturers gives more simpleand more efficient analysis of themeasured data. As a result, it isvery easy to compare the measureddata with possible damagefrequencies. A completely new feature is theoptional functionality of automaticdetection of measuring points.* RFID tags are applied at themeasuring points and are thusdetected automatically by thesystem. This contributes not onlyto prevention of errors but also tooptimisation of measuring time.

Further highlights of the system: • an expanded memory capacity,

allowing storage of up to 1 600measurement points and at thesame time up to 270 time signals

• the speed measurement function• and the revised report generator

system

Ordering designation:DETECT3-KITIncluded in delivery:• Basic device with rechargeable

battery• Acceleration sensor with magnetic

foot• Temperature sensor• Charger• PC data cable (serial/USB)• User manual• Protective bag with holder for

temperature sensor• PC software Trendline• Case

Ordering designation:DETECT3-KIT-RFIDIncluded in delivery:• As DTECT3-KIT• RFID reader (integrated)• RFID tags

Products · Condition monitoring Vibration diagnosisDetector III

66

Ordering designation:DETECT3.BALANCE-KITIncluded in delivery:• Acceleration sensor with magnetic

foot and sensor cable• Trigger sensor (optical and

inductive) • Scales• Magnetic holder for trigger sensor• Extension for magnetic holder• Cable for trigger sensor

(length 10 m)• Reflective mark for trigger sensor• Dongle for activation of balancing

function• Case

Accessories• Sensor extension cables for

lengths of 5 m and 15 m areavailable on request.

• Further RFID tags are available onrequest

*This functionality is not yetavailable worldwide.

Please direct any enquiries to:[email protected] detailed information, see TPI WL 80-64.

FAG Detector III and Balancing Kit

67

FAG EASY Check series

The FAG Easy Check devices areeconomical vibration monitors forpermanent monitoring of criticalmachinery in plants with constantoperating conditions, e.g. pumps,fans, electric motors etc. Since Easy Check vibration monitorsare easy to mount and operate,they can also be used withoutdifficulty by employees who have noknowledge of condition monitoring.The devices monitor vibration inaccordance with ISO 10816, thecondition of rolling bearings withthe aid of the demodulated signalmethod and the temperature at thebearing locations.The use of Easy Check devices cancontribute to a considerable costreduction as arising damage isdetected at an early stage and thenecessary work can be integratedinto maintenance planning.

FAG Easy Check basic device

FAG Easy Check is a standalonedevice that is powered by a batteryand is applied directly to the criticalmachine. The vibration monitordraws attention to any problem bymeans of LEDs (traffic light function).

The status of the LEDs on the EasyCheck must be checked at regularintervals.

Ordering designation:EASY-CHECK

FAG Easy Check Online

In contrast to the basic device, FAG Easy Check Online has anexternal power supply. Additionalalarm outputs for vibration andtemperature offer the possibility ofpresenting alarm conditions on acontrol station or traffic lightdevice. This eliminates the need for regular inspections and allowsthe monitoring of difficult to access locations. Using the input, FAG Easy Check Online can beadministered remotely, e.g. forresetting the alarms, starting thelearning phase or activating ameasurement cycle.

Ordering designation:EASY-CHECK-ONLINE

Products · Condition monitoring Vibration diagnosisEasy Check · DTECT X1


FAG DTECT X1

DTECT X1 allows early detection ofdamage by selective frequencyvibration monitoring based onindividually adjustable frequencybands. By means of the selectivefrequency method, specificallyselected machine parts can bemonitored. DTECT X1 hascharacteristics that would normallyonly be found on significantly moreexpensive systems. The system is variable and can be speciallymatched to the requirements of theapplication. The basic device isavailable with 2 channels, 4 channels or as an 8 channelsystem with an external multiplexer.All conventional acceleration,speed and travel sensors can beattached. It is possible to recordprocess variables such as speed,

FAG Easy Check basic device FAG Easy Check Online FAG DTECT X1

temperature, torque and pressure.The signal collected by the sensoris broken down into its frequencycomponents by means of Fast FourierTransformation (FFT). It is thuspossible to monitor amplitudeswithin fixed, very narrow frequencybands for specified limit valuesand trigger an alarm. If necessary,the remote monitoring function canbe used to monitor machines withoutthe need for a diagnosis expert onsite. Any changes are automaticallynotified via telecommunicationsystems (fixed line, mobile or GSMmodem) to the operating company,plant manufacturer or serviceprovider regardless of where thesystem is located throughout theworld. Stored and current data canbe remotely retrieved and analysedby the FAG Diagnosis Centre.


FAG WiPro

WiPro is a cost-effective onlinemonitoring system for the condition-based maintenance of windturbines.The system, certified by the AZT(Allianz Zentrum für Technik), canmonitor not only the drive train(main bearing, gearbox, coupling,generator) but also vibrations inthe tower. If required, otherinformation such as rotor bladespeeds or oil quality can beintegrated in the conditionmonitoring. WiPro is equipped witha signal processor and evaluates allmeasurement signals in the nacelleitself. Due to the intelligent linkingof expert knowledge with informationfrom the turbine, it is possible tokeep the transfer data volume verysmall. This is particularly importantwhere a large number of turbinesare to be monitored on a permanentbasis, allowing transfer dataquantities to be kept to a minimum.Due to the different communication

Products · Condition monitoring Vibration diagnosisDTECT X1 · WiPro

68

FAG WiPro

options, an appropriate solutioncan be found for any wind farm.With WiPro, the operator is keptinformed at all times of thecondition of the most importantcomponents. This gives a high levelof investment security and activemachine protection. The modular concept of the WiProsystem allows all types of windturbines to be retrofitted with thesystem. Any wind farm can benetworked using the WiPro system,whether the turbines are connectedusing copper cables, fibre optics,ISDN or analogue lines or even ifno telephone connection at all ispresent.

For detailed information, seeTI WL 80-66.Please direct enquiries to:[email protected]

69

For detailed information, see TPI WL 80-67.Please direct enquiries to:[email protected]

Products · Condition monitoring Vibration diagnosisVibroCheck

FAG VibroCheck

FAG VibroCheck

The online monitoring systemVibroCheck is ideally used wherevera large number of measuring points must be continuously andreliably monitored, such as inrolling mills, paper factories orpower stations. In its most extendedconfiguration, up to 2 048 sensorscan be integrated in the system. For the detection of defects such as imbalance and misalignment,VibroCheck generates spectrum-based parameters that are managedwithin narrow frequency bandsaccording to speed. In addition togeneral parameter monitoring, theuser has available an automatic,rule-based expert system that canmonitor up to 20 components persensor. This allows monitoring ofall rolling bearing types and toothmeshes in the vicinity of a sensorin relation to the occurrence ofcomponent-specific frequencywindows. In addition to vibrationsignals, other process parameterssuch as temperature, power,pressure, torque etc. can also bedetected. By remote access, the data can alsobe analysed by external serviceproviders or CM experts at otherlocations.The display, which is individuallytailored to the customer’s require-ments, gives a user interface thatallows a rapid overview of thecondition of the plant. Dependingon the complexity of the plant, thisdisplay can be arranged on severallevels. Through the high predictiveaccuracy and early identification offorthcoming damage, optimum usecan be made of planned stoppagesand downtimes due to failure canbe drastically reduced.

70

Products · Condition monitoring Vibration diagnosisProCheck

FAG ProCheck

ProCheck is the latest generation ofmodular concept online monitoringsystems. Together with the newlydeveloped software, the systemrepresents a high performancesolution for preventing unplanneddowntime and increasing reliability. The device records vibration data,process parameters and operatingdata, assesses these data andprovides the customer withauthoritative and reliableinformation on the condition ofhis equipment.The system is available in severalconfiguration levels, can beexpanded at any time and can beflexibly adapted to the growingrequirements of the industrialenvironment. The customer canstart with 4 monitoring channelsand progressively expand the systemup to 16 channels. He also has theoption of correlating a large number

of analogue and digital input andoutput signals to his vibration data.These signals also allow simplecommunication with higher levelsystems such as process controlsystems. Data can thus be easilyexchanged or made available.For monitoring of complex systems,ProCheck uses methods andtechniques established in themarket such as frequency-selectiveparameters, demodulated signaldetection and trend monitoring.

Potential machine defects in complexunits can be reliably identified bymonitoring vibration in combinationwith other process parameters suchas temperature. Counteractivemeasures can then be introduced ingood time. Due to its flexibility,scalability and extremely robustdesign, this system is destined foruse in all industrial segments. Thesystem has almost no limits,whether it is used in steelworks,

paper machinery or cement plants.This is aided by its extremelycompact and robust design,together with its ATEX and ULapprovals.


Further online monitoring systems

Further online monitoring systemsfor the requirements of specificsectors are available on request.

FAG ProCheck

CMMS Interface 72

Products · Maintenance management

71

CMMS Interface

With the CMMS* Interface, F’ISoffers an intelligent link betweenvibration measurement/analysisand the Computerized MaintenanceManagement System MAXIMO®. By means of a software module, theportable FAG vibration measuringdevice Detector and its softwareTrendline is linked to theComputerized MaintenanceManagement System MAXIMO®.In addition to the advantages ofthe two systems in themselves, thelink created by the CMMS Interfacegenerates the following synergyeffects:

• Central storage of diagnostic andmaintenance data

• Redundancy-free administrationof master data

• Fully automatic generation ofcurrent routes for Detector

• Updating of follow-up orders inMAXIMO® in an alarm situation

• Build up a measurement valuehistory in MAXIMO®

Please direct enquiries to:[email protected]

* Computerized MaintenanceManagement System

Products · Maintenance managementCMMS Interface

72

Services

73

Services relating to rolling bearings

Mounting/Repair 75

Mounting service 75Reconditioning of rolling bearings 76Equipment rental 78

Lubrication 79

Corrective maintenance 80

Balancing 80Alignment 80

Condition monitoring 81

Continuous measurement (online) 81Regular measurement (offline) 81Troubleshooting 82Technical consultancy 84

Maintenance management

Maintenance consultancy 86

Computerized Maintenance Management System 88

F’IS defines itself as an independentfull service supplier and covers thecomplete range of services relatingto the life cycle of a rolling bearing:from mounting, through maintenanceto reconditioning of rolling bearings.

During the operational phase, F’IS experts provide supportthrough services in the field ofcondition monitoring and correctivemaintenance. Companies that wishto build up their knowledge in theareas of rolling bearings andcondition monitoring have accessto the F’IS training and consultancy

Services · Services relating to rolling bearings

74

portfolio. Through the associationwith the Schaeffler Group, customersalso benefit from the expertise of aleading supplier of rolling and plainbearings.

Detailed information on theindividual services is given on the following pages.

Services relating to rolling bearingsReconditioning of

rolling bearings

Rolling bearing technology/design

Corrective maintenance

Technicalconsultancy

Conditionmonitoring

Lubrication

Customer training

Mounting

Materials, coatings Tribology

75

Mounting service

The F’IS Mounting Team offersmounting services for rollingbearings across market sectors. Wehave extensive experience, forexample, in railways, raw materialmining and processing, steel andaluminium, wind power, paper, oiland gas etc.

The F’IS mounting personnel arespecially trained and will providereliable and rapid assistance.The mounting services are providedeither at the customer’s location orin the F’IS workshop facilities.

The mounting service includes:• mounting and dismounting of

rolling bearings of all types• approval inspection of adjacent

parts (shafts and housings)• maintenance and inspection of

bearing arrangements• defect analysis on bearing

arrangements not runningsatisfactorily

• advice on rationalisation ofmounting operations

• design and manufacture ofspecial tools

Operating benefits:• extended bearing life• considerable cost reductions• less unplanned downtime• increased plant availability• improved awareness among

employees of the correct handlingof rolling bearings

Services · Services relating to rolling bearingsMounting/RepairMounting service

Please direct enquiries about theservices described to:

Schaeffler KGTel. +49 9721 91-3142 or -2573Fax +49 9721 91-3809

76

Reconditioning of rollingbearings

Wheelset bearings for railwayvehicles and standard bearings upto 425 mm outside diameter

Wheelset bearings for railwayvehicles are among the mostheavily loaded vehicle parts. Theirlife can be increased significantlyby appropriate and regularmaintenance. F’IS therefore offersoperators of all railway vehicles theopportunity to have their wheelsetbearings professionally dismantled,cleaned and reconditioned.Customers thus benefit from the in-depth knowledge in the field ofrolling bearings that is only availablefrom a bearing manufacturer. Thetechnical expertise of F’IS employeesguarantees the highest quality inmaintenance and the achievementof maximum bearing life.

The F’IS service offer applies to:• all wheelset bearings and

cylindrical, spherical and taperedroller bearings up to a maximumwidth of 180 mm and a maximumoutside diameter of 425 mm

• products from all rolling bearingmanufacturers

• all railway vehicles

The service includes:• professional dismounting,

cleaning and reconditioning ofrailway wheelset bearings at theF’IS Service Center in Schweinfurt(Germany)

• identification marking of eachindividual bearing beforedismounting

• if required, bearing-specificdocumentation of all maintenanceactivities carried out

Services · Services relating to rolling bearingsMounting/RepairReconditioning of rolling bearings

Operating benefits:• longer life of railway wheelset

bearings due to high qualitymaintenance work

• short downtime periods due toswift implementation of themaintenance process

• minimal mounting work, since thewheelset bearings are returned ina condition ready for mounting

• reduced maintenance costs dueto preventive maintenance

Please direct enquiries about theservices described to:

Schaeffler KGGeorg-Schäfer-Strasse 3097421 Schweinfurt (Germany)Tel. +49 9721 91-1919Fax +49 9721 91-3809

For detailed information, see TPI WL 80-72Expected to be available from June 2007

Large rolling bearings of outsidediameter >>425 mm

The statements on wheelset bearingsand standard bearings up to anoutside diameter of 425 mm canalso be applied to larger standardand special rolling bearings. Withinthe framework of maintenanceactivities, rolling bearings are stillreplaced for reasons of safety thatcould be restored to an acceptableand functional condition throughappropriate cleaning andreconditioning. In general, thecosts of such reconditioning aresignificantly lower than the costs ofa new bearing – with shorter deliverytimes in most cases. In individualcases, customers may also receive the same warranty on thereconditioned bearing as on a newbearing.

The F’IS experts repair all types ofrolling bearings such as cylindricalroller bearings, spherical rollerbearings, tapered roller bearingsetc.

They first carry out a damagediagnosis on the basis of which itis decided whether repair is viableand which level of reconditioning isrequired on the rolling bearing.

For detailed information, see WL 80 151.

Please direct enquiries to:

Schaeffler KGMettmanner Strasse 7942115 Wuppertal (Germany)Tel. +49 202 293-2226Fax +49 202 293-2437

Services · Services relating to rolling bearingsMounting/RepairReconditioning of rolling bearings

77

Overview of the individual stages in reconditioning of rolling bearings

Assessment –Inspection

Dismounting

Washing

Examination

Definition ofrepair operations

Preparation ofproposal

Level I – Requalifying

Measurement

Mounting

Preservation,greasing ifappropriate

Packaging, longterm packaging ifappropriate

Despatch

Level II – Refurbishment

Polishing ofraceways

Removal offretting corrosion

Mounting



Despatch

Level III – Remanufacturing

E.g.

Regrinding ofraceways

Manufacture of newrolling elements

Replacement ofcage if appropriate

Removal of frettingcorrosion

Mounting



Despatch

Level IV – RemanufacturingPlus

E.g.

Regrinding ofraceways

Manufacture ofinner ring withnew borediameter

Redimensioningof internalclearance

Manufacture ofnew rollingelements

Replacementof cage ifappropriate

Removal offretting corrosion

Mounting



Despatch

Equipment rental

Customers who require specialmounting and measuring equipmentonly occasionally, for example inorder to carry out repairs, can rentthese from F’IS on a weekly basisfor a fee.

FAG Industrial Services primarilyrents• taper gauges• enveloping circle gauges• hydraulic nuts• hand pump sets• heating devices

The equipment is stored at ourmounting workshop and its functionis checked and maintained by ourmounting specialists.

Please direct enquiries about thisservice to

Schaeffler KGTel. +49 9721 91-1133Service Hotline:Tel. +49 2407 9149-99

Services · Services relating to rolling bearingsMounting/RepairEquipment rental

78

Services · Services relating to rolling bearingsLubrication

79

Lubrication as a service

In more than half of all cases,inadequate lubrication is the causeof unplanned machine downtime.

The use of suitable greasesfor different operating andenvironmental conditions as well asknow-how in when, how frequentlyand with what quantities bearingsshould be lubricated, makes itpossible to significantly extend thelife of rotating machine elements.

Specialised employees offer theirservice across market sectors andhave special experience, forexample in the areas of railway/transport, power transmission,steel and aluminium, paper, windpower, agriculture and forestry, thefood and delicacies industry aswell as mining and processingtechnologies. F’IS services includethe selection and installation oflubricants and lubrication systems,the lubrication of bearing positions,the preparation of lubrication andmaintenance plans, lubricationpoint management, lubricationconsultancy and lubricantinvestigations and tests.

A comprehensive selection of highquality FAG Arcanol greases speciallytested and selected for use inrolling bearings is available. Theconsistent quality of Arcanollubricants is ensured by ongoinginvestigation on special test rigs.The use of names that are easilyremembered and matched to theapplication allows rapid greaseselection. The F’IS team also dealswith special requirements such asrapidly biodegradable greases andgreases for use in the food industry,

on the basis of ongoing innovation.

FAG Arcanol rolling bearing greasesare also suitable for use in FAG automatic lubricators MotionGuard.

The software Motion Guard SELECTMANAGER Version 2.0 allows:• selection of lubricators• definition of dispensing times

and relubrication quantities• selection of suitable/preferred

Arcanol greases• management of a lubrication and

maintenance plan

Use of the F’IS lubrication servicecan prevent the failure of rotatingmachine parts and increaseproductivity while reducinglubrication costs.

Services · Services relating to rolling bearingsCorrective maintenanceBalancing · Alignment

80

Corrective maintenance

Once a machine problem has beendiagnosed, it should be eliminatedas quickly as possible. Two of themost frequent problems – imbalancein pumps and fans as well asmachine components incorrectlyaligned to each other – can becorrected directly by F’IS.

Balancing

Imbalance is one of the mainsources of malfunctions that leadto unexpected failure of machineelements. Correct balancing gives adecisive increase in the life ofrotating machine parts. Thisincreases the productivity andplant availability. The F’IS expertsreduce the increased vibration thatoccurs due to contamination, wear,repairs etc. to a normal level. Theydetect and eliminate the causes ofimbalances on machines at speedsof 40 to 10 000 rpm such aspumps, ventilators, compressors,turbines, motors etc. Irrespective ofthe sector, F’IS offers not only adetailed analysis of the reasons forthe malfunction but also theremoval of imbalances in any levelof adjustment.

Alignment

Many of the standard pieces ofequipment used in industrialfacilities are composed of severalcomponents, for example anelectric motor and pump/fan. Afterinstallation, repair or overhaul, thecomponents of such machines mustbe aligned with each other. If this is carried out incorrectly ornot at all, it results in high loadsbeing placed on the bearings aswell as increased energy demandand wear.The methods and tools for machinealignment have changed in recentyears: away from demanding andinaccurate methods using a dial

gauge and straight edge to laseralignment systems. These arehighly accurate and effective.In addition to service products inthis area (see page 55), F’IS alsooffers alignment of machinery as aservice. Where necessary, the F’IS service technician will take thenecessary laser alignment systemto the customer and carry outalignment of the machine inaccordance with the manufacturer’sspecifications. Successfulcompletion of the work is thendocumented.


Services · Services relating to rolling bearingsCondition monitoringContinuous measurement · Regular measurement

81

Condition monitoring

The malfunction-free and optimisedoperation of complex machineryand systems can only be achieved by means of condition-basedmaintenance. The key method used by F’IS incondition-based maintenance isvibration diagnosis. This methodmakes it possible to detect incipientdamage in machinery at a very earlystage. The customer can thus takea proactive rather than a reactiveapproach. For example, damagedcomponents can be replaced aspart of planned downtime. Aboveall, vibration diagnosis helps toavoid unplanned downtime andexpensive secondary damage, toincrease productivity and improveavailability. Dependng on the type of machineand its importance for the productionprocess, different methods areused in condition monitoring:continuous monitoring (online) andregular monitoring (offline).

Continuous measurement(online)

In the case of production-criticalmachinery, permanent monitoringby means of vibration diagnosis isindispensable in many cases.Access at any time to preciseinformation on the condition of themachine offers the only effectiveprotection against unplanneddowntime and expensive productionbreakdowns as well as preventingsecondary damage. For this reason,online monitoring generally paysfor itself over a period of a fewmonths. Depending on the area ofapplication, F’IS offers a wide

range of solutions, includingstandalone solutions for smalleraggregates, medium-sized systemswith up to 8 channels that can beextended on a modular basis andalso complex monitoring systemswith up to 2 048 sensors. In addition to giving expert advicein selecting the right system, F’ISalso implements plant monitoring.This includes not only hardwareselection but also systemconfiguration and, if necessary, its integration into existing systems.Depending on know-how, thecustomer can either carry out plantmonitoring himself or enlist the F’IS monitoring service. The F’ISmonitoring systems have e-servicefunctionality, allowing externalmonitoring by F’IS experts underfavourable terms.

For such machine parts, the moreeconomical offline monitoring isgenerally recommended. In thiscase, costs and benefits are in anoptimum ratio. In offline monitoring, machinery isexamined and assessed by vibrationanalysis at regular intervals, forexample every 4 weeks. Thisregularity gives more in-depthknowledge of the normal conditionof the machine, allowing deviationsto be easily detected. Whenpreparing the offline monitoringconcept, the selection of measuringpoints and monitoring accessoriesas well as the definition of themeasurement interval play adecisive role. It is not absolutelyessential to have expertise on site.In the case of irregularities inmeasurements and trend analysis,F’IS offers the e-service. At thebush of a button, all relevant dataare exported from the database andsent by e-mail to the F’IS DiagnosisCentre, where it is subjected toexpert analysis. The customerpromptly receives easilyunderstandable and authoritativediagnosis reports by e-mail.

Regular measurement(offline)

The failure of individual machinesis not always critical for production.The failure of so-called “B” or “C”category plant items does not leaddirectly to downtimes and thereforedoes not induce expensivesecondary damage.

Through close teamwork with theF’IS experts, the customer soonacquires excellent analyticalknow-how. F’IS also offers support in dataacquisition and carries out regularon-site measurements if thecustomer’s internal personnelcannot be made available.

Troubleshooting

If malfunctions or other problemsoccur on a machine, a detaileddefect analysis must be quicklycarried out. This can be likedetective work. Based on manyyears’ experience in different sectorsand applications, the F’IS diagnosisexperts are well versed in suchtroubleshooting tasks. Their analysisincorporates various information,for example from visual observation,examination of the machinedocumentation and discussionswith machine operators. Problems or malfunctions inmachine operation often becomeapparent through changes invibration behaviour, unusualtemperature patterns or similarphenomena. The F’IS experts there-fore also carry out measurementson the machine. The measurementmethods used will depend on theparticular application. The F’ISexperts are familiar with allmeasurement techniques, fromvibration measurement to torqueanalysis or endoscopy. As a result,they can quickly identifymalfunctions and prepare proposedsolutions. It is important to F’IS that customersare in a position to interpret theresults of investigations correctly inorder to introduce the correct

countermeasures. At completion ofan investigation, F’IS thereforeholds a handover meeting with allrelevant employees of the customerto discuss not only the results ofthe investigation but also therecommended counteractivemeasures.

Vibration measurements

Detecting problems by usingvibration analysis is the state of theart method in the field of troubleshooting. Like a doctor with astethoscope, the vibration expertcan assess the condition of themachine without the need for anydismantling. A large proportion ofpossible causes of damage canthus be detected and assessedwith little work.

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Modal analysis

Modal analysis is a particular formof vibration diagnosis. This methoddoes not examine individualcomponents of a machine but themachine as a whole. The aim is todetermine the overall vibrationbehaviour of the machine. A modelof the machine is created on thecomputer and a large number ofmeasuring points are defined. The machine is then specificallyexcited using an impulse hammer.Based on parallel measurement ofthe excitation and resultingmachine vibrations at the variousmeasuring points, a vibrationmodel of the machine can bedetermined by the computer andpresented in three dimensions.

Modal analysis has a wide varietyof possible applications: • Determination of natural

frequencies or resonancefrequenciesEach machine has one or morenatural frequencies that aredetermined by its design (massand rigidity). If a machine is runin such a way that excitation (e.g.the speed of the motor) occurs inthe region of a natural frequency,extreme vibration of the machinecan occur. Based on the results ofmodal analysis, our experts cansubmit recommendations fordesign improvements to themachine.

• Detection of a “soft point” of amachine If a high level of vibration occursat initial operation or after atechnical modification of amachine, this may be due to a“soft point”. This is defined as arigidity problem, often caused by

a poor quality connectionbetween two machine parts(for example a screw connection).For analysis, the measurementsare used to produce an animationshowing the movements of themachine. Showing the movementof the individual machine parts inrelation to each other quicklyleads to identification of the“soft point” of the machine. A discussion can then be held toprepare proposals for improvingthe design of the machine.

Torque/force measurements

If damage accumulates at aparticular point in the system, adesign problem may be surmised.Overloading of shafts or bearingpositions that were not taken intoconsideration in the design of themachine can be detected by meansof torque or force measurementsand taken into consideration in animproved structure of the machine. Depending on the application,temporary installations or fixedinstallations can be used. Inparticular, continuous torquemeasurement carried out directlyon rotating shafts is highlydemanding on a technical level: the measurement data must betransferred from the rotating shaftand the contact-free supply of energymust be provided. Implementingthe long term installation of suchtelemetry systems under industrialconditions requires considerableexperience, which the F’IS expertshave gained over many years.

Endoscopy

If damage has been detected, forexample, but the component cannotbe replaced in the short term forproduction reasons, the preciseextent of the damage can bedetermined using endoscopy. Theinterior of the machine is examinedusing digital optical endoscopes.The images are stored in the formof digital photographs or videosand are used as the basis ofdiagnosis by F’IS experts. Individualcomponents such as rolling bearingsor gear teeth can then be easilyassessed. If the bearings inspectedare Schaeffler KG products, thecustomer also has access to theknowledge of Schaeffler applicationengineers. They will prepare adetailed damage analysis andsubmit well-qualified proposals forimprovement. This is an advantagethat clearly demonstrates thebenefits of obtaining products andservices from a single source.

Thermography

Thermography is one of the mostimportant non-destructive diagnostictechniques. Many technicalproblems manifest themselves inthe form of heat generation, whichcan be detected with the aid of ahigh resolution infrared camera.The major advantage of thermo-graphy is the rapid, non-contactcollection of temperature data.Simultaneous recording of a digital,optical image allows preciseallocation of the temperaturegradients to visible features onsite.

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There is a wide range of objects thatcan be examined by this method: it extends from assessment ofelectrical connections in switchcabinets, through rolling bearingarrangements in motors and fans,to thermal linings in cement works.

Approval inspection of a new plant

The combination of differentdiagnostic techniques enablesF’IS to carry out an assessment ofa new plant regardless of themanufacturer. Frequently occurringinstallation errors such as defectivealignment of motors and pumps/fansto each other or incorrect electricalconnections in switch cabinets canthus be detected in the initialoperation phase and their correctionrequired by the plant manufacturer.If such defects remain undetectedover the period of the warranty,their removal and the secondarydamage may cause considerablecosts and downtime. As part of the new plant approvalinspection, F’IS checks the mostcommon problems and records theactual status. Where necessary,corrective measures can then berequired of the plant manufactureror operator in good time.

© FLIR Systems

Technical consultancy

In addition to providing services,consultancy is one of the mainactivities of F’IS. Companies that wish to change tothe concept of condition-basedmaintenance are supported by F’ISwith initial training, attendanceduring the introductory phase,expert backup and customisedservice contracts. Furthermore, F’IS offers support inthe introduction and adaptation ofmaintenance planning and controlsystems (CMMS). These systemshelp to improve transparency of theservices and costs involved inmaintenance (see page 88).

Introduction of condition-basedmaintenance

Many customers intend to converttheir maintenance activities whollyor partly to a condition-basedmaintenance strategy in the comingyears. Maintenance of machineryand plant will no longer be basedon failures or times but on theirassessed condition. The aim of theF’IS consultants is to find the perfectbalance between the costs andbenefits of condition assessment.Many years of experience incondition monitoring and main-tenance planning give an optimumbasis here, which allows recom-mendations on methods andproducts for condition monitoringto be made after a soundly-basedanalysis of the critical plant andmachinery. In partnership with thecustomer, plans are prepared thatgenerate recommended activitities

for the maintenance personnelderived from the results of conditionmonitoring. Ultimately, it are theserecommendations and not alarmmessages that lead to targetedmaintenance activities and thus tocost savings.

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• “Customer A has employeeswith experience in the field ofcondition monitoring”In such a case, it is sufficent toinstruct the employees in handlingthe systems and accompany themwhile making the initial steps.Furthermore, F’IS acts as a teamof experts that can be called inon difficult cases and support thecustomer in the analysis andformulation of activities.

• “Customer B would like to buildup its knowledge in the field ofcondition monitoring”The field of condition monitoringis a complex subject; building upknowledge will therefore takesome time. For such cases, F’ISoffers a 2 year programme, afterwhich even customers withoutprior knowledge can themselvesmonitor the condition of theirmachinery. The support given byF’IS is progressively reduced invarious steps and the customer’semployees use their newknowledge directly in their dailywork.

• “Customer C wishes to completelyoutsource the area of conditionmonitoring” F’IS offers complete packages inwhich the entire service isprovided by F’IS. This begins withthe initial operation of systemsand progresses throughcontinuous monitoring to completeleasing of the hardware, so thatno initial costs are incurred bythe customer. Such monitoringpackages are very attractive, forexample to customers in the windpower industry.

Service concepts for plantmanufacturers and operators

Services are not volume products –the needs and requirements varyfrom customer to customer – so theservice concept must be tailored asa result.Due to the wide range of servicesF’IS can offer its customers, it ispossible to customise the rightpackage of training and servicestogether with the activities carriedout by the customer himself. The scope is enormous anddepends on the prior knowledgeand usable work capability of thecustomer as well as the requirementsfor quality of monitoring. Someselected examples should help toclarify this:

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Services · Services relating to rolling bearingsCondition monitoringTechnical consultancy

• “Customer D is a plantmanufacturer and wishes to offer condition monitoring as aservice itself”In this case, F’IS acts as asubcontractor of mostly portablemonitoring systems, a trainer ofthe service employees of theplant manufacturer and as anexpert team that can always becalled upon to assist when mattersarise that cannot be clearlyassessed by the employees of theplant manufacturer. The plantmanufacturer can thus offer itscustomers a highly qualifiedmonitoring service without havingto establish its own experts.

These four examples show howcustomised service concepts canvary. Based on individual customerrequirements, F’IS prepares aconcept to meet the needs andassists in its implementation.

Please direct enquiries about theservices described to:[email protected]

Services · Maintenance managementMaintenance consultancy

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Maintenance consultancy

Maintenance consultancy by F’IShelps to make costs more transparentand design maintenance moreeffective. Therefore it is based onclassical consulting but with astrong technical focus.

Consulting starts with a comprehen-sive analysis of the relevantprocesses. On this base the F’ISteam prepares customer-specificimprovement concepts to integrate

individual solutions to an overallsolution. F’IS offers support duringthe implementation phase and aspart of a partnership in followingproject phases.

Analyses

The F’IS team analyses the actualsituation by carrying out workshopswith employees and investigatingthe available documents. Theanalysis considers subjectsincluding:

• business processes, costs,personnel structure, tasks/responsibilities, machineutilisation

• commercial and production KPIs• technical support for processes• utilisation of IT and condition

monitoring systems• maintenance strategies• knowledge management

• maintenance KPIs• co-operation between

departments

Based on their experience, the F’ISconsultants can evaluate theinformation obtained and place itwithin an overall context. Anonymousdata from other companies andsectors are also drawn upon forcomparison. As requested by thecustomer, the results are presentedat a management and/or plant level.

Analyses

Maintenance analysis Damage analysis

IT benefit analysis Materials management Knowledge management

Concepts

Maintenance strategy Condition monitoring

Reporting CMMS KPI

Implementation

CMMS IT network

Diagnostic system Reporting

Controlling

Phases in a consultancyprocess

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Concepts and implementation

The concepts are prepared by F’ISconsultants together with thecustomer and are focused on thesituation and vision of the customer.Each customer gets an individualsolution. The concepts are implemented in partnership withthe customer.

Maintenance strategy:

• ABC analysis of plant stock• TCO

(Total Cost of Ownership)• LCC

(Life Cycle Cost)• TPM

(Total Productive Maintenance)• Condition-based maintenance

(see page 84)

Implementation concept for aCMMS:

• Software selection• Master data structures• Strategy for recurring maintenance

and inspection tasks• Specification and implementation

of interfaces• Transfer of old data

IT network:

• Selection of software based onrequired attributes

• Development of a thorough datamodel

• Specification of interfaces• Specification of the necessary

hardware

Improvement of reporting system:

• Creation of KPIs• Automatical reports• Electronic reporting via the

Internet• Benchmarks with partner

companies

Care of concepts

In order to keep the optimisationof costs and benefits achieved inthe long term, regular assessmentsare carried out after the implemen-tation phase. These assessmentsare made by the customer himselfand the support of the F’ISconsultants as a neutral partner.Maintenance controlling can bemanaged by an extended reportingsystem, KPIs and benchmarks. It isimportant to check permanently themaintenance controlling processitself with the focus on itsexpressiveness and efficiency.

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CMMS

In the section of ComputerizedMaintenance Management Systems(CMMS), F’IS experts apply theirprofound technical knowledge tooffer analysis of customer-specificrequirements. This service isindependent of the software system.Even by using a standard software,which is available on the market,F’IS can configure and optimise thissoftware on the purpose of thecustomer. The F’IS service covers both completesolutions in the form of CMMSimplementation as well as individualmodules for the following areas:

Systems integration

CMMS is incorporated in the IT environment of the company bythe implementation of interfaces,for example to ERP (EnterpriseResource Planning) systems. Thisallows holistic assessment and dataanalyses in a complete system, sothat redundant data administrationand multiple data input can beavoided. Process operations arestandardised and optimised.

The exchange of information acrossdepartments is improved.

Mobile solutions

The use of electronic checklists on a handheld PC enables the datacollection during an inspection.The processing and feedback offailures can then take place withongoing acquisition. The datadetermined and checked forconsistency are transferred via aworkshop PC to the CMMS database.

The mobile system avoids most ofmanual data input. Data qualityand analysis potential areincreased through the use ofstandardised coding.

Establishment/expansion of thereporting system

The integration of reports into theCMMS offers versatile possibilitiesfor data analysis and representation.Typical applications in this fieldinclude evaluation and failureanalyses with multi-stage reports,stock and master data lists as wellas internal and external businesspaperwork. Reports can be generatedquickly and easily. Quality ofinformation is improved byelectronic completion of forms. The use of standardised reportsconforms to the requirements ofcertification.

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Services · Maintenance managementCMMS

Further services for CMMS

• Release and database platformchangeover

• CMMS modifications andexpansion functions

• Data analysis and corrective dataadministration

• Implementation of automatedprocesses

• Training of your personnel to userand administrator level


Training

91

Overview 92

Training descriptions 93

Mounting/Repair 93Lubrication 95Alignment 95Condition Monitoring 96Maintenance management 99

Training aids 100

F’IS offers, in relation to the productand service range, both standardtraining and customer-specifictraining. The individual training unitsare based on a modular conceptwith the result that customers cancompile their own customised

training course on the basis ofthese training components. Aftersuccessfully attending the training,each attendee receives a certificate.The training courses are offeredboth at Schaeffler Group locationsand also on site at our customers.

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92

The current training offer includingdates for the standard trainingcourses can be found atwww.fis-services.com in the sectionTraining.

Overview of F’IS training courses Training formatTraining module Standard Individual

Mounting and repairBasic training: Rolling bearing technology • •Product training: Mounting tools •Basic training: Spindle bearing technology • •Rolling bearing maintenance for railway vehicle maintenance personnel(general) • •Rolling bearing maintenance for TAROL bearings •

LubricationProduct training: FAG lubrication systems Motion Guard •Product training: FAG Arcanol lubricants •

AlignmentProduct training: FAG Top-Laser TRUMMY2, SMARTY2 and INLINE •

Condition MonitoringProduct training: FAG Detector III Basic •Product training: FAG Detector III Balancing •Product training: FAG Detector III Advanced •Product training: FAG Administrator 4.0 •Product training: FAG DTECT X1 (with Administrator 4.0) •Product training: FAG ProCheck (with Administrator 4.0) •Product training: FAG VibroCheck: Installation (hardware) •Product training: FAG VibroCheck: Application (software) •Product training: FAG DTECT X1 (with Administrator 3.8) •Product training: FAG Detector II •

Maintenance managementUser training for implemented CMMS •CMMS administrator training •

More detailed information on the individual training courses can be found on the following pages.

Overview of F’IS training courses

Mounting/Repair

Basic training: Rolling bearingtechnology

Training content: This trainingcommunicates basic knowledge onrolling bearings and their use. Ourrolling bearing experts will explaintypes, characteristics anddesignations of rolling bearings. In the practically-based part of thetraining, correct mounting anddismounting will be communicated.Rolling bearing failures will bediscussed, together with theirsymptoms and causes.

Target group: The course is aimedat head foremen, foremen andmounting personnel frommaintenance shops and interestedemployees. No special knowledgeis required.

Training objective: The participantswill learn the correct andprofessional handling of rollingbearings and gain basic knowledgeof mounting and dismounting.

Duration: 1–2 days

Product training: Mounting tools

Training content: This trainingfocuses on various tools for thecorrect mounting and dismountingof rolling bearings. Particularemphasis is placed on the correctuse of tools on a day-to-day basis.The content of customer-specifictraining is always agreed with thecustomer.


Training objective: The participantswill learn the correct handling ofmounting and dismounting toolsthat they use day to day.

Duration: By agreement

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93

Basic training: Spindle bearingtechnology

Training content: In this training,the participants will acquire basicknowledge of spindle bearings andtheir use. Our spindle bearingexperts will explain the types,characteristics and designations ofspindle bearings. In the practically-based part of the training, correctmounting and dismounting of spindlebearings will be communicated.Specific spindle bearing failureswill be discussed.


Training objective: The participantswill gain basic knowledge of spindlebearings and their mounting, dis-mounting and maintenance.

Duration: 1 day

Rolling bearing maintenance for railway vehicle maintenancepersonnel (general)

Training content: This trainingcovers the maintenance of wheelsetbearings based on cylindrical andtapered roller bearings. Rollingbearing experts from railwayapplication engineering willcommunicate current knowledge onthe bearings and their application.Experienced setting supervisorswill pass on their knowledgeconcerning manual work for rollingbearing maintenance and showcorrect handling using selecteddemonstration items.

Target group: The course is aimedat head foremen, foremen andmounting personnel from railwayvehicle maintenance workshops.

Training objective: The courseparticipants will receive practicalguidance on the maintenance ofwheelset bearings based on simplecylindrical and tapered rollerbearings.

Duration: 1–2,5 days

Rolling bearing maintenance forTAROL bearings

Training content: The subject ofthis training is the maintenance ofTAROL wheelset bearings. Thesedouble row tapered roller bearingunits are adjusted, greased andsealed on both sides. Rollingbearing experts from railwayapplication engineering willcommunicate current knowledge onthe bearings and their application.Experienced setting supervisorswill pass on their knowledgeconcerning manual work for themaintenance of TAROL bearings and

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94

show the particular aspects of thismaintenance using selecteddemonstration items.

Target group: The course is aimedat head foremen, foremen andmounting personnel from railwayvehicle maintenance workshops.

Training objective: The course willenable the participants to carry outmaintenance of TAROL bearingsindependently.

Duration: 1 day(by agreement only)

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Lubrication

Product training:FAG lubrication systemsMotion Guard

Training content: This trainingcovers the FAG lubrication systems“Motion Guard” in relation tofunctionality, possible applications,usage and handling. The focus ison the safe handling and boundaryoperating conditions of the FAG lubrication systems.


Training objective: Following thecourse, the participants will beable to correctly select and use thevarious products in the lubricationsystem “Motion Guard” to ensurethat unplanned machine downtimedue to defective lubrication isavoided.


Product training:FAG Arcanol lubricants

Training content: In this training,the participants will acquire furtherknowledge of the FAG lubricantfamily “Arcanol” in relation topossible applications, usage andhandling. It will be shown howselection of the correct lubricantcan increase the performancecapacity and life of rolling bearings.


Training objective: Following thecourse, the participants will beable to select the correct grease for their particular application.


Training · Training descriptionsLubrication · Alignment

Alignment

Product training: FAG Top-Laser SMARTY2, TRUMMY2 and INLINE

Training content: This coursecommunicates well-foundedknowledge on the alignment ofbelt drives and shafts and themeasurement of belt tension. Thefunctionality, possible applicationsand handling of the measuringsystems Top-Laser TRUMMY2,SMARTY2 and INLINE are explained.The focus is on the safe handlingand boundary operating conditionsof the measurement systems.


Training objective: Following thecourse, the participants will beable to carry out the requiredalignment work using the measuringsystems.


Product training: FAG Detector III Balancing

Training content: The course coversin particular the subject of balancingusing the FAG Detector III in theoryand practice and is aimed atparticipants who have completedthe course “FAG Detector III Basic”and now wish to learn about usingthe “Balancing Kit”. The participantwill learn to use the device safelyand independently carry outbalancing operations with the FAG Detector III.

Target group: The course is aimedat participants who are alreadyfamiliar with use of the Detector III.Participants must have previouslyattended the product trainingcourse “FAG Detector III Basic”.

Training objective: The participantswill learn how to safely use the FAG Detector III during a balancingprocedure.

Duration: 1 day

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Training · Training descriptionsCondition Monitoring

Condition Monitoring

Product training: FAG Detector III Basic

Training content: This trainingconveys basic knowledge both ofvibration theory and vibrationmonitoring as well as the handlingof the measuring system FAG Detector III. The courseparticipants will receive anoverview of the functionality,possible applications, configurationand handling of the measuringsystem.


Training objective: The participantscan subsequently detect simplemachine defects by means of trendanalyses and determine the causeon the basis of the time signal andspectrum.

Duration: 3 days

Product training: FAG Detector III Advanced

Training content: Building on thetraining “FAG Detector III Basic”,this course goes into greater detail on the theory of vibrationexamination and monitoring coveredin the aforementioned course. Thiscourse comprehensively coversspecial subjects such as thesymptomatic form of individualmachine defects. Aspects relatingto the condition monitoring ofindividual machine parts will bediscussed in detail in relation todefects and problems andreconstructed in some cases usingpractical exercises.

Target group: This course is aimedin particular at technicians andengineers working in maintenanceas well as interested employeeswho have already attended thecourse “FAG Detector III Basic” orhave at least one year’s experiencein the use of measuring systems.

Training objective: After the training,the participant should be in aposition to identify the symptomaticform of individual machine defectsand determine their cause.

Duration: 2 days


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Product training: FAG Administrator 4.0

Training content: This training isconcerned with the installation andindividual modules of the softwareFAG Administrator 4.0. The focus ison the function of the individualmodules and the use of the DataViewer – a special analysis tool.The principles of communicationtechnologies are also presented.

Target group: The course is aimedin particular at participants whohave already attended the trainingunits “FAG Detector III Basic/Advanced”. Alternatively, at leastone year’s practical experience with an offline or online vibrationmeasuring system is required.

Training objective: After the training,the participant can securely installthe software and is familiar withthe function of the individualmodules.

Duration: 2 days

Product training: FAG DTECT X1*(with Administrator 4.0)

Training content: On the basis ofthe training units “FAG Detector IIIBasic/Advanced” and “FAG Administrator 4.0”, thiscourse gives well-founded knowledgeon the online measuring system“FAG DTECT X1” in relation tofunctionality, possible applications,usage and handling. In particular,the versatile possible configurationsof the system are communicatedintensively in practical usage.

Target group: The course is aimed in particular at technicians andengineers working in maintenanceas well as interested employees.Participants must have previouslyattended the product trainingcourse “FAG Administrator 4.0”.

Training objective: Following thecourse, the participants will beable to identify machine defectsand damage in detail based ontrend analysis using the measuringsystem by remote diagnosis andonline.

Duration: 2 days

* Also usable for FAG WiPro.

Product training: FAG ProCheck(with Administrator 4.0)

Training content: In this training,the participant will learn to applythe knowledge acquired in thetraining unit “FAG Administrator4.0” to the online measuring systemFAG ProCheck. The focus is onconfiguration and independentpreparation, implementation andevaluation of a measurementprocess using examples.

Target group: The course is aimed in particular at technicians andengineers working in maintenanceas well as interested employees.Participants must have previouslyattended the product trainingcourse “FAG Administrator 4.0”.

Training objective: Followingattendance at this course, theparticipant should be in a positionto configure the measuring systemFAG ProCheck and independentlyprepare, implement and evaluatemeasurement processes.

Duration: 2 days

Product training: FAG VibroCheck: Application (software)*

Training content: The knowledgeacquired in the course “Detector IIIAdvanced” on vibration analysiswill be expanded and deepened onthe measuring system VibroCheck.The focus will be on monitoringconfiguration of the measuringsystem “FAG VibroCheck” andevaluation of the recordedmeasurement data.

Target group: This course is aimedat persons who have alreadyattended the training “Detector IIIAdvanced” or have at least oneyear’s experience in the use ofmeasuring systems and wish to add to this the specifics concerningthe measuring system “FAG VibroCheck”.

Training objective: Following thecourse, the participants will be ableto work correctly with the onlinemeasuring system VibroCheck. The focus of the training is onconfiguration. The course participantcan subsequently visualise themachine using the VC software andanalyse trend data, time signalsand frequency spectra. He canassess and interpret parameter andexpert alarms and handle the alarmlogbook.

Duration: 2 days

* Please note that the producttraining courses FAG VibroCheck:Installation (hardware) and FAG VibroCheck: Application(software) are only bookable as asingle package (total duration: 4 days).


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Product training: FAG VibroCheck: Installation (hardware)*

Training content: The coursecommunicates knowledge on theuse of the VibroCheck (VC) hardware.The focus is on the interactionbetween the VC hardware andsoftware (e.g. in hardware tests,sensor tests). The participant willlearn to use terminal and circuitplans so he can independentlyundertake extension of the VC hardware.

Target group: This course is intendedin particular for those persons whoare responsible for the installationand maintenance of the measuringsystem “FAG VibroCheck”. Importantpreconditions are therefore PC andWindows knowledge as well asknowledge of electrical installationwork.

Training objective: After thecourse, the participants should bein a position to independentlymaintain the measuring system inrelation to hardware extension and troubleshooting as well asindependently carry out hardwareand software installations.

Duration: 2 days

Product training: FAG DTECT X1**(with Administrator 3.8)

Training content: On the basis ofthe training unit “FAG Detector IIIBasic”, this course gives well-founded knowledge both onvibration diagnosis as well asthe online measuring system “FAG DTECT X1” in relation tofunctionality, possible applications,usage and handling. In particular,the versatile possible configurationsof the system are communicatedintensively in practical usage. In addition, the principles ofcommunication technology forteleservice are presented.

Target group: The course is aimed in particular at technicians andengineers working in maintenanceas well as interested employees.

Training objective: Following thecourse, the participants will beable to identify machine defectsand damage in detail based onfrequency analysis using themeasuring system by remotediagnosis and online.

Duration: 4 days(by agreement only)

** Also usable for FAG WiPro.

Maintenance management

User training for implemented CMMS

Training content: This course focuseson the established ComputerizedMaintenance Management System(CMMS) on the customers site. Thecontent is defined in relation to theparticipants upon customer request.

Target group: The course is aimed at persons who have to operate the CMMS in their company. No specialknowledge is required.

Training objective: The participantswill learn how to use CMMS in acorrect way and why it is important toenter the specified information intothe system. They will also learn howto find certain information in thesystem, which is needed in the daily work.


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CMMS administrator training

Training content: This trainingcovers the support and administrationof the CMMS. The content can be defined in relation to theparticipants upon customer requestand taken from the areas ofdatabase management, Internettechnology, server support andauthorisation concepts.

Target group: The course is aimed at system administrators and keyusers.

Training objective: The participantswill learn about independent supportand administration of a CMMS.


Schaeffler Technical Training Centre, Hirschaid

Product training: FAG Detector II

Training content: In this course,soundly-based knowledge will becommunicated on the measuringsystem “FAG Detector II” in relation to functionality, possibleapplications, usage and handling.

Target group: The course is aimed in particular at technicians andengineers working in maintenanceas well as interested employees.No special knowledge is required.

Training objective: The participantwill then be able to identifymachine defects and damage based on trend analysis using themeasuring system.


Rolling bearing mounting cabinetand mounting sets: Basic course for vocational training

There is plenty of literature availableon the the correct mounting ofbearings. However, there is ageneral lack of parts on whichapprentices can practise in aspractical a sense as possible. Thetrainers from the Schaeffler trainingworkshops have therefore compileda basic course.The aim of this rolling bearingcourse is to communicate knowledgeon the selection of the correctbearing, correct mounting anddismounting and the maintenanceof bearing positions. It is thereforedivided into two parts. A theoreticalpart covers the basic knowledge ofrolling bearing technology, whilethe practical part covers the basicskills involved in mounting anddismounting.In the theoretical part, particularattention is paid to combiningtechnical drawing, technicalcalculation and technical theory inone learning unit. The practical partuses exemplary simplified mating

parts (shafts, housings) on whichthe mounting and dismounting ofcommon types of bearings can bepractised with the aid of mechanicalor hydraulic devices.The content is composed of smallerlearning stages and does not gobeyond the degree of difficulty thatis currently required in vocationaltraining. Building on this basic course, otherassemblies such as gearboxes,pumps, spindles, road vehiclewheels etc. can be prepared fortraining.

Handbook 1 (Theoretical part)

• Technical theory• Technical calculation• Technical drawing

Handbook 2 (Practical part)

• Mounting of bearings withcylindrical bore

• Mounting of bearings withtapered bore

• Hydraulic method• Exercises on shafts and housings

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Technical data

Mounting cabinet: Dimensions 1 135~710~380 mmMass (including contents) 94 kgDesigned for 10 mounting exercises:on 5 shaftson 2 housingson 3 shafts and housingsSmallest shaft diameter: 15 mmLargest shaft diameter: 55 mm

Ordering designation (mounting cabinet with contentsand mounting bracket): TRAINING-CABINET-MOD-1A-D

Further demonstration modelsfor training are always available on request. Please contact:[email protected]

101

Mounting sets 2 und 3The trainer can use the FAGmounting sets 2 and 3 – individualexercises from the FAG mountingcabinet - to demonstrate themounting and dismounting of

rolling bearings during teaching orhave the apprentices carry theseout. The shaft and housing partscan be clamped in a vice formounting.

Training · Training aids

Mounting set 1Mounting set 1 is an additionalexercise to the FAG mounting cabinetand facilitates the mounting of aself-aligning ball bearing in ahousing.

Mounting set 1:Plummer block housingSuitable for the following exercises:• Checking the bearing position• Mounting of adapter sleeve and

bearing• Mounting as locating bearing• Mounting as non-locating bearing• Mounting as through shaft• Mounting in housing closed on

one side• Dismounting of bearing and

adapter sleeveOrdering designation: TRAINING-CABINET-MOD-1B

Mounting set 2:Shaft with housingSuitable for the following exercises:• Selection of fits• Checking the bearing positions• Mounting the bearing on the

shaft• Axial location of the bearing• Mounting of the rotary shaft seal• Assembly (locating bearing)• Dismounting using extractor

Ordering designation: TRAINING-CABINET-MOD-2

Mounting set 3:Hydraulic mountingSuitable for the following exercises:• Mounting with the aid of pressure

screws• Mounting using a hydraulic nut• Setting and checking the radial

internal clearance• Axial location using a locknut and

tab washer• Dismounting using an oil injector

Ordering designation: TRAINING-CABINET-MOD-3

Training videos:

1 ~ 1 of rolling bearingsThe film is particularly suitable for communicating initial basicknowledge on rolling bearings. Itpresents all types of bearings andhighlights their characteristicsfeatures.Ordering designation: TRAINING-VIDEO-201-D

Mounting and dismounting ofrolling bearingsThe film explains the most important

rules of mounting in simple picturesand text. Cardinal mistakes arenamed in simple unambiguousterms. It is clearly shown, step bystep, how various bearings are tobe correctly mounted.Ordering designation: TRAINING-VIDEO-202-D

Hydraulic method for mounting and dismounting of large rollingbearingsThe film shows, using simulatedand real scenes, all the commonmethods and devices in hydraulic

mounting: pumps, hydraulic nuts,special extraction devices, adapterand extraction sleeves. It is alsodemonstrated what must be paidattention in the case of tapered orcylindrical shaft seats, and how theradial internal clearance or axialdisplacement should be correctlymeasured so that the mountedparts have the correct seating onthe shaft.Ordering designation: TRAINING-VIDEO-203-D

Publications · Index of FAG products ·Comparison of ordering designations

103

Publications 104

Index of FAG products 105

Comparison of ordering designations 109

Publications

WL 80 100 Mounting of rolling bearingsWL 80 102 Hydraulic method for mounting and dismounting of rolling bearingsWL 80 134 FAG video on the mounting and dismounting of rolling bearingsWL 80 135 FAG video on the hydraulic method for the mounting and dismounting of rolling bearingsWL 80 151 Repair service for large rolling bearingsWL 81 115 Lubrication of rolling bearingsWL 81 116 Arcanol · Grease tested for use in rolling bearingsWL 81 122 FAG lubricator Motion GuardWL 82 102 Rolling bearing damage

Technical Information/Product Information

TI WL 80-14 Mounting and dismounting of spherical roller bearings with tapered boreTI WL 80-38 Mounting of self-aligning ball bearings using adapter sleevesTPI WL 80-50 FAG pressure generatorsTPI WL 80-54 FAG heating devices PowerThermTPI WL 80-55 FAG alignment toolsTPI WL 80-56 FAG tools for mechanical mounting and dismounting of rolling bearingsTPI WL 80-57 FAG hydraulic nutsTPI WL 80-58 FAG tools for thermal dismountingTPI WL 80-62 FAG Detector II – the “mobile phone” among data collectorsTPI WL 80-64 FAG Detector III – the solution for monitoring and balancingTPI WL 80-65 Monitoring of plant and machinery –

FAG online system DTECT X1TI WL 80-66 FAG WiPro – Wind Turbine ProtectionTI WL 80-67 FAG VibroCheck online monitoring system for heavy industryTPI WL 80-68 FAG Easy Check · FAG Easy Check OnlineTPI WL 80-69 FAG ProCheck – state of the art machinery monitoring for maximum availabilityTI WL 80-70 Measurement and dimensioning of tapered studs using the FAG taper gauge MGK9205TPI WL 80-71 Training courses:

Rolling bearings and condition monitoring – For beginners and advanced studentsTPI WL 80-72 Reconditioning and repair of rolling bearings

CD-ROMs

CD Medias 4.2 Electronic INA/FAG rolling bearing catalogueCD – MGSM 2.0 FAG Motion Guard Select ManagerCD – MM 1.1 FAG Mounting Manager

Publications

104

Index of FAG products

105

Ordering designation Product Page


AGGREG-E700 Electrically driven hydraulic unit 27AGGREG-P1000-1/P2500-2 Compressed air driven hydraulic unit 27

ARCA-GREASE-GUN Arcanol grease gun 53ARCA-GREASE-GUN.HOSE Arcanol reinforced hose 53

ARCA-PUMP-25 (~180) Grease metering device for 25 (180) kg grease container 53

ARCALUB-… Lubricator COMPACT with grease charge, without activation screw 49ARCALUB-CLEAR-… Lubricator COMPACT CLEAR with grease charge, without activation screw 50

ARCALUB.ACTIVE-1M (~3M, ~6M, ~12M) Activation screw for lubricator Motion Guard COMPACT 49ARCALUB.ACTIVE-CLEAR-1M (~3M, ~6M) Activation screw for lubricator Motion Guard COMPACT CLEAR 50ARCALUB.ACTIVE-POLAR Activation screw for lubricator Motion Guard COMPACT POLAR 50

ARCALUB.LC60-… (~LC120-…, ~LC250-…) LC unit with 60 (120, 250) cm3 of grease for lubricator CHAMPION 51ARCALUB.LC120-...-KIT (~LC250-…-KIT) Lubricator kit CHAMPION with LC unit 120 (250) cm3 51

ARCALUB-C6-250-KIT (~500-KIT) Multi-point lubrication system CONCEPT6 with LC unit 250 (500) cm3 52ARCALUB-C6-CONTROL-250-KIT (~500-KIT) Multi-point lubrication system CONCEPT6, (machine controlled) with LC unit 52

ARCANOL-ANTICORROSIONOIL-400G Spray can containing Arcanol anti-corrosion oil 42

ARCANOL-BIO2-... Special grease for environmentally hazardous applications 47ARCANOL-FOOD2-... Special grease for applications with food contact 47ARCANOL-LOAD150-... Special grease for high loads, large speed range 46ARCANOL-LOAD220-... Special grease for high loads, large speed range 46ARCANOL-LOAD400-... Special grease for very high loads, moderate speeds 46ARCANOL-LOAD1000-... Special grease for very high loads, low speeds 46ARCANOL-MULTITOP-... Universal grease for high speeds, high loads, high temperatures 46ARCANOL-MULTI2-... Universal grease for bearings under normal loads (D <_ 62 mm) 46ARCANOL-MULTI3-... Universal grease for bearings under normal loads (D > 62 mm) 46ARCANOL-SPEED2,6-... Special grease for very high speeds, low temperatures 47ARCANOL-TEMP90-... Special grease for low and high temperatures 47ARCANOL-TEMP110-... Special grease for low and high temperatures, high speeds 47ARCANOL-TEMP120-... Special grease for high temperatures, high loads 47ARCANOL-TEMP200-... Special grease for very high temperatures 47ARCANOL-VIB3-... Special grease for high loads, high temperatures, oscillating motion 47

ARCANOL-MOUNTINGPASTE-… Arcanol mounting paste 42

BEARING-MATE250-450 (~450-650; ~650-850) Transport and mounting tool for rolling bearings of outside diameter250–450 mm (450–650 mm; 650–850 mm) 40


106

COIL…X…-LOW.. Coil for electric induction heating device with low voltage 35COIL.TRAFO-... Single phase dry transformer for heating device with low voltage 35

DETECT2-1MB-KIT Detector II 65DETECT3-KIT Detector III 66

EASY-CHECK Easy Check 67EASY-CHECK-ONLINE Easy Check Online 67

FEELER-GAUGE-100 (~300) Feeler gauges, 100 (300) mm long, 13 (23) blade 36

FITTING-TOOL-ALU-10-50 Mounting tool set (aluminium) for rolling bearings of bore diameter 10–50 mm 8FITTING-TOOL-STEEL-10-50 Mounting tool set (steel) for rolling bearings of bore diameter 10–50 mm 8

GLOVE1 (~2) Heat-resistant (heat-resistant and oil-resistant) gloves 41

HEATER10 Induction heating device for workpieces up to 10 kg mass 32HEATER20 Induction heating device for workpieces up to 20 kg mass 32HEATER35 Induction heating device for workpieces up to 35 kg mass 32HEATER150 Induction heating device for workpieces up to 150 kg mass 32HEATER300 Induction heating device for workpieces up to 300 kg mass 33HEATER600 Induction heating device for workpieces up to 600 kg mass 33HEATER1200 Induction heating device for workpieces up to 1200 kg mass 33HEATER3000 Induction heating device for workpieces up to 3 000 kg mass 33

HEATER-PLATE Heating plate (1500 W) 31HEATER-PLATE-370C Heating plate (2 200 W) 31

HEATING-RING-... Heating ring for inner ring of cylindrical roller bearing or needle roller bearing 34HEATING-RING.PASTE-20ML Heat conducting paste (20 ml disposable syringe) 34

HYDNUT… Hydraulic nut with metric internal thread 19HYDNUT…-HEAVY Hydraulic nut, reinforced design with smooth bore 19HYDNUT…-INCH Hydraulic nut with inch size internal thread 19HYDNUT.GAUGE-DISPLACE Displacement gauge for HYDNUT 20

INJECT1600 (~2500) Oil injector 1600 bar (2 500 bar) 24INJECT1600.VALVE (~2500.VALVE) Valve nipple for oil injector 1600 bar (2 500 bar) 24INJECT1600-SET (~2500-SET) Set comprising oil injector 1600 bar (2 500 bar) and valve nipple 24

KLR… Taper ring gauge 36




107

LASER-INLINE Shaft alignment device 58LASER-SMARTY2 Belt pulley alignment device 56LASER-TRUMMY2 Belt tension measuring device 57LASER.SHIM..X… Shims for Top-Laser alignment devices 60

LOCKNUT-DOUBLEHOOK-KM.. Double hook wrench for locknut KM.. 11LOCKNUT-DOUBLEHOOK-KM…-KIT Double hook wrench kit for locknut KM.. 11LOCKNUT-DOUBLEHOOK-KM..-..-SET Double hook wrench set (for locknuts KM5–KM8 / KM9–KM13) 11

LOCKNUT-FACEPIN-… Jointed face wrench for precision locknut LNP… 10LOCKNUT-FLEXIHOOK-… Jointed hook wrench for locknut KM.. or precision locknut ZM(A).. 10LOCKNUT-FLEXIPIN-… Jointed pin wrench for precision locknut AM.. 10

LOCKNUT-HOOK-KM... Hook wrench for locknut KM.. 9

LOCKNUT-SOCKET-KM... Socket wrench for locknut KM.. 9

MGA31-… Enveloping circle gauge for outer enveloping circle 39MGI21-… Enveloping circle gauge for inner enveloping circle 39

MGK132 (~133) Taper gauge for ø 90...510 mm (27…205 mm) 38MGK9205-12.SET (~30.SET) Taper gauge set for large studs, taper 1:12 (1:30) 37

PULLER... Mechanical extractor for small bearings 12PULLER-HYD… Hydraulic extractor 15

PULLER-INTERNAL10/100-SET Internal extractor set (for bearings of bore diameter 10 to 100 mm) 14PULLER-TRISECTION-… Three-section extraction plate for hydraulic and mechanical extractors 17

PUMP1000-…L (~1600-…L, ~2500-…L) Hand pump and accessories 25

PUMP2500-0,2L-KIT High pressure pump set (2 500 bar) 26

PUMP4000-0,2L High pressure pump (4 000 bar) and accessories 26

PUMP.ADAPTER-A-…(~B-...) Pressure device accessory, adapter 28

PUMP.HOLDER-2 (~3) Pump holder without (with) manometer connector 29

PUMP….MANO-G1/2 Manometer 29PUMP….MANO-DIGI Digital manometer 29PUMP.NIPPLE-A-…(~B-...) Pressure device accessory, reduction nipple 28PUMP.PIPE-… Pressure device accessory, high pressure hose 30




108



PUMP.SLEEVE-CONNECTOR-… Pressure device accessory, sleeve connector for hand pumps 30

SNAP-GAUGE-…/… Snap gauge 38SNAP-GAUGE.MASTER... Master disc for snap gauge 38

SOUND-CHECK Polyscope sonar device 64

TACHOMETER Digital hand tachometer 63

TEMP-CHECK-CONTACT Temperature measuring device, contact type 62

TEMP-CHECK-PLUS Infrared temperature measuring device, contact-free 62

TOOL-RAILWAY-AGGREGATE Mobile hydraulic unit for batch mounting of TAROL bearings 27

TRAINING-CABINET-MOD-1A-D (~E, ~F, ~NL) Mounting cabinet with contents and mounting bracket for basic course in German (English, French, Dutch) 100

TRAINING-CABINET-MOD-1B (~2, ~3) Training case with rolling bearing, mounting tool, … 101

TRAINING-VIDEO-201-D (E) 1~1 of rolling bearings in German (English) 101TRAINING-VIDEO-202-D (E) Mounting and dismounting of rolling bearings in German (English) 101TRAINING-VIDEO-203-D (E) Hydraulic method for mounting and dismounting in German (English) 101

Comparison of ordering designations

109

Ordering designation for Europe Ordering designation for countries outside Europe


AGGREG-E700 AGGREGATE.E700AGGREG-P1000-1/P2500-2 AGGREGATE.P1000/2500

ARCA-GREASE-GUN ARCA.GREASE-GUNARCA-GREASE-GUN.HOSE ARCA.GREASE-GUN.HOSE

ARCA-PUMP-25 (~180) ARCA.PUMP.25 (~180)

ARCALUB-… ARCA.LUB. …ARCALUB-CLEAR-… ARCA.LUB. ….CLEAR

ARCALUB.ACTIVE-1M (~3M, ~6M, ~12M) ARCA.LUB.ACTIVE.1M (~3M, ~6M, ~12M)ARCALUB.ACTIVE-CLEAR-1M (~3M, ~6M) ARCA.LUB.ACTIVE.CLEAR.1M (~3M, ~6M)ARCALUB.ACTIVE-POLAR ARCA.LUB.ACTIVE.POLAR

ARCALUB.LC60-… (~LC120-…, ~LC250-…) ARCA.LUB. ... .LC60 (~LC120, ~LC250)ARCALUB.LC120-...-KIT (~LC250-…-KIT) ARCA.LUB. ... .LC120.SET (~LC250.SET)

ARCALUB-C6-250-KIT (~500-KIT) ARCA.LUB.C6-250.KIT (~500.KIT)ARCALUB-C6-CONTROL-250-KIT (~500-KIT) ARCA.LUB.C6-CONTROL-250.KIT (~500.KIT)

ARCANOL-ANTICORROSIONOIL-400G ARCA.ANTICORROSIONOIL.400G

ARCANOL-BIO2-... ARCA.GREASE.BIO2...ARCANOL-FOOD2-... ARCA.GREASE.FOOD2...ARCANOL-LOAD150-... ARCA.GREASE.LOAD150...ARCANOL-LOAD220-... ARCA.GREASE.LOAD220...ARCANOL-LOAD400-... ARCA.GREASE.LOAD400...ARCANOL-LOAD1000-... ARCA.GREASE.LOAD1000...ARCANOL-MULTITOP-... ARCA.GREASE.MULTITOP...ARCANOL-MULTI2-... ARCA.GREASE.MULTI2...ARCANOL-MULTI3-... ARCA.GREASE.MULTI3...ARCANOL-SPEED2,6-... ARCA.GREASE.SPEED2,6...ARCANOL-TEMP90-... ARCA.GREASE.TEMP90...ARCANOL-TEMP110-... ARCA.GREASE.TEMP110...ARCANOL-TEMP120-... ARCA.GREASE.TEMP120...ARCANOL-TEMP200-... ARCA.GREASE.TEMP200...ARCANOL-VIB3-... ARCA.GREASE.VIB3...

ARCANOL-MOUNTINGPASTE-… ARCA.MOUNTINGPASTE...

BEARING-MATE250-450 (~450-650; ~650-850) BEARING.MATE250-450 (~450-650; ~650-850)

110




COIL…X…-LOW.. COIL…/…LOW..COIL.TRAFO-... COIL.TRANSFORMER...

DETECT2-1MB-KIT FIS.DETECTORII.SET.1MBDETECT3-KIT FIS.DETECTORIII.KIT

EASY-CHECK FIS.EASYCHECK.V1EASY-CHECK-ONLINE FIS.EASYCHECK.ONLINE.SET

FEELER-GAUGE-100 (~300) FEELER.GAUGE100 (~300)

FITTING-TOOL-ALU-10-50 FITTING.TOOL.ALU.SET10-50FITTING-TOOL-STEEL-10-50 FITTING.TOOL.STEEL.SET10-50

GLOVE1 (~2) HANDSCHUH1 (~2)

HEATER10 HEATER10HEATER20 HEATER20HEATER35 HEATER35HEATER150 HEATER150HEATER300 HEATER300HEATER600 HEATER600HEATER1200 HEATER1200HEATER3000 HEATER3000

HEATER-PLATE HEATER.PLATEHEATER-PLATE-370C HEATER.PLATE.370C

HEATING-RING-... HEATING.RING...HEATING-RING.PASTE-20ML HEATING.RING.PASTE.20ML

HYDNUT… HYD.NUT…HYDNUT…-HEAVY HYD.NUT…HEAVYHYDNUT…-INCH HYD.NUT…INCHHYDNUT.GAUGE-DISPLACE HYD.NUT.DISPLACE.GAUGE

INJECT1600 (~2500) OILINJECTOR1600 (~2500)INJECT1600.VALVE (~2500.VALVE) OILINJECTOR….VALVEINJECT1600-SET (~2500-SET) OILINJECTOR….SET

KLR… KLR…

111




LASER-INLINE LASER.INLINELASER-SMARTY2 LASER.SMARTY2LASER-TRUMMY2 LASER.TRUMMY2LASER.SHIM..X… LASER.SHIMS...

LOCKNUT-DOUBLEHOOK-KM.. LOCKNUT.DOUBLEHOOK.KM...LOCKNUT-DOUBLEHOOK-KM…-KIT LOCKNUT.DOUBLEHOOK.KM...KITLOCKNUT-DOUBLEHOOK-KM..-..-SET LOCKNUT.DOUBLEHOOK.KM...SET

LOCKNUT-FACEPIN-… LOCKNUT.FACE-PIN…LOCKNUT-FLEXIHOOK-… LOCKNUT.FLEXI-HOOK…LOCKNUT-FLEXIPIN-… LOCKNUT.FLEXI-PIN…

LOCKNUT-HOOK-KM... LOCKNUT.HOOK.KM...

LOCKNUT-SOCKET-KM... LOCKNUT.SOCKET.KM...

MGA31-… MGA31MGI21-… MGI21MGK132 (~133) MGK132 (~133)MGK9205-12.SET (~30.SET) MGK9205.12.SET (~30.SET)

PULLER... ABZIEHER...PULLER-HYD… PULLER.HYD…

PULLER-INTERNAL10/100-SET PULLER.INTERNAL.SET10-100PULLER-TRISECTION-… PULLER.TRISECTION...

PUMP1000-…L (~1600-…L, ~2500-…L) PUMP1000…L (~1600…L, ~2500…L)

PUMP2500-0,2L-KIT PUMP2500.0,2L.SET

PUMP4000-0,2L PUMP4000.0,2L

PUMP.ADAPTER-A-…(~B-...) PUMP.ADAPTER.A.…(~B....)

PUMP.HOLDER-2 (~3) PUMP.HOLDER.2 (~3)

PUMP….MANO-G1/2 PUMP….MANO.G1/2PUMP….MANO-DIGI PUMP….MANO.DIGIPUMP.NIPPLE-A-…(~B-...) PUMP.NIPPLE.A.…(~B....)PUMP.PIPE-… PUMP.PIPE.…

112




PUMP.SLEEVE-CONNECTOR-… PUMP.SLEEVE.CONNECTOR.…

SNAP-GAUGE-…/… SNAP.GAUGE…-…SNAP-GAUGE.MASTER... SNAP.GAUGE.MASTER.DISK

SOUND-CHECK SOUND.CHECK

TACHOMETER TACHOMETER

TEMP-CHECK-CONTACT TEMP.MG

TEMP-CHECK-PLUS TEMP.CHECK.PLUS

TOOL-RAILWAY-AGGREGATE TAROL.MOUNTING.AGGREGATE

TRAINING-CABINET-MOD-1A-D (~E, ~F, ~NL) MOUNTING.CABINET.D (~E, ~F, ~NL)TRAINING-CABINET-MOD-1B (~2, ~3) MOUNTING.CABINET.SET3 (~SET1, ~SET2)

TRAINING-VIDEO-201-D (E) VIDEOFILM201D (E)TRAINING-VIDEO-202-D (E) VIDEOFILM202D (E)TRAINING-VIDEO-203-D (E) VIDEOFILM203D (E)

00/0

4/07

Pri

nted

in G

erm

any

byD

ruck

haus

WEP

PERT

Gm

bH Every care has been taken to ensure the

correctness of the information contained in

this publication but no liability can be

accepted for any errors or omissions.

We reserve the right to make technical

changes.

© Schaeffler KG · 2007, April

This publication or parts thereof may not

be reproduced without our permission.

WL 80 250/3 EA

Schaeffler KG

Postfach 1260

97419 Schweinfurt (Germany)

Georg-Schäfer-Strasse 30

97421 Schweinfurt (Germany)

Service Hotline:

Phone +49 2407 9149-99

Fax +49 2407 9149-59

E-Mail [email protected]

Internet www.fis-services.com

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