fag equipment and services for the mounting and ... equipment and services for the mounting and...

FAG Equipment and Servicesfor the Mounting and Maintenance of Rolling Bearings

For increased operational reliability of rolling bearing arrangements

A Member of the

Schaeffler Group

This catalogue is aimed principallyat maintenance managers respon-sible for plant in which rollingbearings and other rotating machine components play a criticalrole in determining the quality ofproducts and processes.

Maintenance managers are respon-sible for the maintenance and production process. They must beable to rely every day on the quality of their tools and the expertise 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 fromF’IS.

F’IS employees and their certifiedpartners will be pleased to helpyou select the ideal products, services and training for yourneeds.

About this catalogue

1

Dr.-Ing. Bernd Geropp and Dr.-Ing. Hans-Willi Kessler

Managing Directors ofFAG Industrial Services

Questions and ideas on this catalogueshould be sent to

FAG Kugelfischer AG & Co. oHGPostfach 1260 · D-97419 SchweinfurtGeorg-Schäfer-Straße 30 · D-97421 SchweinfurtService Hotline:Telephone: +49 2407 9149-99E-Mail: [email protected]

The address of the representative responsible for your particular countrycan be found on the last cover page.

FAG Industrial Services

Since the beginning of 2001, FAG Kugelfischer has concentratedits independent service businessthrough FAG Industrial ServicesGmbH (F’IS) based in Herzogenrath,near Aachen. Since the integrationof FAG into the Schaeffler Group,F’IS has undertaken service tasksfor the whole Group.

F’IS is a specialist contact for themaintenance of rotating components. The aim is to helpcustomers save on maintenancecosts, optimise plant availabilityand avoid unforeseen machinedowntime. The services are provided irrespective of the brand of the

machine components used.In order to provide a rapid, competent supply of F’IS products,services and training to customersworldwide, F’IS has Centres ofExcellence around the world. Thesework together with local partnersthat are certified and regularlyaudited by F’IS. Since each customer has a differentset of requirements, F’IS offersconcepts individually tailored to thecustomer. The quality requirementsare strongly influenced by the history, going back more than 100 years, of high precision rollingbearing manufacture at FAG.Each tool, accessory and grease inthis catalogue, has been subjected tointensive testing in practical use andclassified as being of high quality.

FAG Industrial Services – Competence in Maintenance

2

The F’IS range

F’IS has undertaken ongoing expansion of its range in recentyears.

F’IS offers products, services andtraining in the following five areas:

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

Overview(For details, please consult

the contents list)

Mounting/Repair Lubrication Alignment

Conditionmonitoring

Maintenancemanagement

FAG Industrial Services – Competence in Maintenance

Products

Training

Services

Contents

Products 7

Mounting/Repair 8Lubrication 43Alignment 55Condition monitoring 61Maintenance management 69

Services 71


Training 85


Publications 95

Index of FAG products 97

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-sized

Large

Small

Medium-sized

Large

Small

Medium-sized

Large

Small

Medium-sized

Large

Cylindrical roller bearings, double row Tapered Small

Medium-sized

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 pumps 26Hydraulic systems and units 27Connectors, accessories 28

Thermal mounting and dismounting 31

Electric heating plate 31Induction heating devices 31Heating rings, heat conducting paste 34Electric induction heating devices (coils) 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.SET10-50 andFITTING.TOOL.STEEL.SET10-50

FAG fitting tool sets allow economicaland secure mounting of rollingbearings up to 50 mm bore. Theycan also be used to easily mountsleeves, intermediate rings, sealsand 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 to damage. The carefully matched FAG precision parts ensure that the forces are uniformly transmitted tothe side faces of the bearing rings.

Products · Mounting/RepairMechanical mounting and dismountingMounting tool sets

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The FITTING.TOOL.ALU.SET10-50 has mounting sleeves made from aluminium and mounting ringsmade from plastic. The parts areeconomical and easy to use.The steel mounting sleeves andsteel mounting rings in the FITTING.TOOL.STEEL.SET10-50 givelong wear-free operating life. Thesetools can also be used in conjunction with workshop powerpresses.

For detailed information, see TI WL 80-56.

Included in delivery Ordering designationFITTING.TOOL.ALU.SET10-50 FITTING.TOOL.STEEL.SET10-50

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.SET10-50 and FITTING.TOOL.STEEL.SET10-50

FAG socket wrenchesLOCKNUT.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 the circumference 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 thereforehave a hole for the locking pin anda groove for the rubber washer. The locking pin and rubber washerare included in the delivery.

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


FAG hook wrenchesLOCKNUT.HOOK…For locknuts from KM0 and precision locknuts from LNPG017

FAG hook wrenches of seriesLOCKNUT.HOOK… (former FAGdesignation: HN../..) can be usedto tighten and loosen locknuts(precision locknuts) on shafts,adapter sleeves and withdrawalsleeves.FAG hook wrenches can be used to mount small bearings on taperedshaft seats, adapter sleeves orextraction sleeves.Withdrawal sleeves can also bedismounted using FAG hook wrenchestogether with the extraction nuts.

Ordering example for FAG hookwrench, suitable for locknuts KM18,KM19, KM20:LOCKNUT.HOOK.KM18-20(former designation: HN120/130)


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

9

FAG jointed hook wrenchesLOCKNUT.FLEXI-HOOK…

For locknuts KM0 to KM40 and precision locknuts LNPG017 toLNPG200

FAG jointed hook wrenches ofseries LOCKNUT.FLEXI-HOOK… canbe used to tighten and loosen locknuts (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 or dismounting locknuts of varioussizes.

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


FAG jointed pin wrenchesLOCKNUT.FLEXI-PIN…

For precision locknuts AM15 toAM90

FAG jointed pin wrenches ofseries LOCKNUT.FLEXI-PIN… can be used to tighten and loosen locknuts on shafts if no torquevalue is specified.

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.FLEXI-PIN.AM35-60



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FAG jointed face wrenchesLOCKNUT.FACE-PIN…

For precision locknuts LNP017 toLNP170

FAG jointed face wrenches of seriesLOCKNUT.FACE-PIN… can be used to tighten and loosen precision locknuts 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 locknutsLNP017 to LPN025:LOCKNUT.FACE-PIN.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…KIT comprise a case containing a double hook wrench, a torquewrench and a user manual. The torque wrench allows aprecisely defined tightening torqueto be achieved at the start of the mounting operation.

FAG double hook wrench setsLOCKNUT.DOUBLEHOOK…SET (former FAG designations 173556and 173557) contain four or fivedouble hook wrenches. The otheritems in the case are the same asin the kits.

Individual double hook wrenchesLOCKNUT.DOUBLEHOOK.KM5 toLOCKNUT.DOUBLEHOOK.KM13 (former designations DHN5 toDHN13) are also available. Eachdouble hook wrench is engravedwith the torsion angles for the self-aligning ball bearings to bemounted. Thus the sliding distanceand reduction in radial internalclearance can be precisely set.



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Double hook wrench kits, e.g. LOCKNUT.DOUBLEHOOK.KM5.KIT andLOCKNUT.DOUBLEHOOK.KM13.KIT (FAG ordering designations)

Double hook wrench sets LOCKNUT.DOUBLEHOOK.KM5-8.SET and LOCKNUT.DOUBLEHOOK.KM9-13.SET (FAG ordering designations)

Double hook wrenches, e.g. LOCKNUT.DOUBLEHOOK.KM5 and LOCKNUT.DOUBLEHOOK.KM13 (FAG ordering designations)

Mechanical FAG extractorPowerPull

Mechanical extractors can be usedto dismount small rolling bearingsup to approx. 100 mm bore diameter that are located with atight fit on a shaft or in a housing.The bearing can be dismounted without 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, threeor four arms and a hydraulicpressure tool, FAG also offers specialextraction devices.

Products · Mounting/RepairMechanical mounting and dismountingMechanical extractors

12


Note: For dismounting larger bearings,hydraulic extractors should 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, grip depth 100 – 250 mm

Available as set (stand with 6 extractors) or individually

Ordering designation:ABZIEHER54.SETABZIEHER54.100ABZIEHER54.200ABZIEHER54.300ABZIEHER54.400ABZIEHER54.500ABZIEHER54.600

Two-arm bearing extractor 47

• For extraction of complete rollingbearings or tightly fitted innerrings

• Grip width 45 and 90 mm, grip depth 65 and 100 mm

Ordering designation:ABZIEHER47.100ABZIEHER47.200

Three-arm extractor 52

• For extraction of complete rollingbearings or tightly fitted innerrings

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

Ordering designation:ABZIEHER52.085ABZIEHER52.130ABZIEHER52.230ABZIEHER52.295ABZIEHER52.390ABZIEHER52.640

Hydraulic pressure tool 44

• For loosening of tightly fittedparts in conjunction with mechanical extractors

• Significant reduction in the effortrequired due to generation of anaxial force of 80 or 150 kN, with a hydraulic return mechanism onthe larger device

Ordering designation:ABZIEHER44.080ABZIEHER44.150


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:ABZIEHER56.020.SETABZIEHER56.120.SETABZIEHER56.220.SET

Special bearing extractor 64

• For radial bearings (deep grooveball bearings, self-aligning ballbearings as well as cylindricalroller, tapered roller and spherical roller bearings); indicate bearing manufacturer.

• For tight fit of inner ring or outerring

Ordering example for deep groove ball bearing 6000:Base device ABZIEHER64.400 + Pincers ABZIEHER64A.6000

Ordering example for tapered roller bearing pair 30203A in X arrangement:Base device ABZIEHER64.400 + Pincers ABZIEHER64B.30203A +Pincers ABZIEHER64C.30203A

Extraction device 49

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

• Principally for cases in which theinner ring is abutted against ashoulder on the shaft withoutextraction slots. Good radialaccess to the bearing position isrequired.

Ordering designation:ABZIEHER49.100.060ABZIEHER49.100.075ABZIEHER49.200.115ABZIEHER49.300.150ABZIEHER49.400.210


14

Internal extractor 62

• For deep groove ball bearingsand angular contact ballbearings.The internal extractor setcomprises nine extractors andcan be used on bearings with a bore 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):ABZIEHER62.SET

The nine internal extractors canalso be ordered individually.

Internal extractor PULLER.INTERNAL.SET10-100

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

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

Ordering designation(six sets of extraction legs and twothreaded spindles in a toolbox):PULLER.INTERNAL.SET10-100

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

• Stroke travel adjustable by meansof standard adapter

• High load capacity of extractionarms and claws through manufacture 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 extractor PowerPull SPIDER

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

These devices allow rollingbearings, gears, sleeves and manyother shrink fitted parts to bequickly and easily dismounted. Inaddition, the low mass of theextractors allows for use in anyposition.If necessary, greater grip depth can be achieved through the use ofextra long extraction arms(available as accessories).

For protection of operators, theextractors SPIDER40 to 80 have asafety grid. All larger hydraulicextractors are supplied with atransparent, very tough safetycover. The cover can be easilyplaced around the workpiece ortool and secured using velcrostrips. For detailed information, see TI WL 80-56.

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 metalcase.

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

Extractor for restricted spaces, connected to hand pump byhydraulic hose, 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* Optionally with longer extraction arms, replacement parts can be ordered individually


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*) 110 20PULLER.HYD300 300 540 (800*) 375 (405*) 110 25* Optionally with longer extraction arms, replacement parts can be ordered individually


PULLER.HYD175 175 356 229 (300*) 82 15,6PULLER.HYD400 400 800 (1200*) 405 (635*) 250 49* Optionally with 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.TRISECTION50 12 50 17 0,5 – 52.085/52.130PULLER.TRISECTION100 26 100 28 2,6 40/60/80/100 52.230PULLER.TRISECTION160 50 160 33,5 5,8 80/100/120/175/200 52.295PULLER.TRISECTION260 90 260 46,5 18,4 175/200/250/300 52.390PULLER.TRISECTION380 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 provideuniform 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 proven inpractical use and can be fittedunder the bearing with just a fewmovements.


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 HYD.NUT..

Hydraulic nuts HYD.NUT.. (formerFAG designation: RKP) can be usedto press parts with a tapered boreonto their tapered seat. Presses aremainly used if the pressing forcesrequired cannot be applied usingother devices, e.g. shaft nuts orpressure screws.

They are mainly used for:the mounting of rolling bearingswith a tapered bore. The bearingscan be seated directly on a taperedshaft, on an adapter sleeve or anextraction sleeve. If the bearing islocated using an extraction sleeveor an adapter sleeve, the hydraulicnut can also be used for dismounting.the mounting of couplings, gears,ships’ propellers etc.


Products · Mounting/RepairHydraulic mounting and dismountingHydraulic nuts

19

Ordering designation Design Main application

HYD.NUT50 to HYD.NUT200 With metric precision thread to DIN 13 Standardised adapter and withdrawal sleevesHYD.NUT205 to HYD.NUT1180 With trapezoidal thread to DIN 13 with metric dimensions

HYD.NUT90INCH to Sleeves with inch dimensionsHYD.NUT530INCH

HYD.NUT100HEAVY to Reinforced design For high mounting forces,HYD.NUT900HEAVY with smooth bore e.g. in shipbuilding

HYD.NUT.DISPLACE.GAUGE Displacement gauge for HYD.NUT(see also page 20)

FAG hydraulic nuts HYD.NUT..

FAG displacement distance gaugefor hydraulic nuts

If the radial internal clearance cannot be measured with a feelergauge due to poor accessibility, the axial displacement of thebearing on the tapered seat can be measured. This can be achievedby means of a gauge screw mounted to the end face of thehydraulic nut. If the axial threaded connector hole G. of the hydraulic nutis taken up by the pump, thesecond axial hole can be used forthe displacement distance gauge. 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 the specified displacement is achieved. The user can determine which of the metering needles suppliedshould be used from the comprehensive user manualincluded with each gauge.

Ordering designation: HYD.NUT.DISPLACE.GAUGE(former FAG designation: RKP.MG)1 displacement distance gauge withdial gauge, 6 metering needles andseals in case


Products · Mounting/RepairHydraulic mounting and dismountingFAG displacement distance 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 withtapered bore and offers the followingoptions:• 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• and 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 Informationdocuments etc. and the RollingBearing Learning System (WLS).

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 with tapered bore by measurement ofthe axial displacement

The bearing is placed in its startingposition on the tapered bearing seatwith a hydraulic nut. The requiredstarting pressure defined for eachindividual bearing is set in thehydraulic nut by means of the digitalmanometer. The dial gauge mountedon the hydraulic nut is used to measure the axial displacement untilthe final position is reached on thetapered seat.

This mounting method:• gives considerably shorter and

simpler mounting• 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 with taperedbore by measurement of thereduction in radial internal clearance

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 of the firm seating of the bearing. It is measured by means of a feelergauge.

The FAG Mounting Manager isavailable on CD-ROM.

Ordering designation:CD-MM 1.0

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

22

Pressure deviceOil injector Hand pump set

Single stage Twin stage

OILINJECTOR1600 OILINJECTOR2500 PUMP1000.0,7L PUMP1000.4L PUMP1600.4L

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

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

Max. oil pressure [bar] 1600 2500 1000 1000 1600(psi) 23200 36250 14500 14500 23200

Application

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

Overview of pressure generation devices

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

contact pressure.

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

contact pressure.

Mounting anddismounting ofrolling bearings.Mounting ofpress fits up toapprox. 50 N/mm2

contact pressure. For drivinghydraulic nuts upto HYD.NUT395/HYD.NUT300HEAVY


contact pressure,e.g. of rudder spindles andrudder blades.


contact pressure,e.g. of ships’propellers. Fordriving hydraulicnuts up toHYD.NUT800

Unlimited forrolling bearingsup to d= 250 mm

Compres-sed 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.SET AGGREGATE.P1000/2500 AGGREGATE.E700

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

G. with highConnector G. (direct) G: (direct) pressure hose G. G.

Max. oil pressure [bar] 2500 4000 2500 2500 700(psi) 36250 58000 36250 36250 10150

Application

Max. shaft ø [mm] Unlimited Unlimited Unlimited Unlimited

Overview of pressure generation devices

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

contact pressure,e.g. of gears and couplings.

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

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

For driving largehydraulic nuts upto HYD.NUT1180.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 flow rate;they can be used in the hydraulicmethod for the dismounting of rolling bearings and other pressfits with direct seating on taperedshafts, e.g. in machine tools forFAG cylindrical roller bearingsNNU49SK, NN30ASK, N10K, N19K.

The OILINJECTOR2500 can be usedfor shaft diameters up to 80 mm, the OILINJECTOR1600 up to 150 mm.

Products · Mounting/RepairHydraulic mounting and dismountingOil injectors

24

Conventional O rings can be usedas replacement seals: OR6~1,5 (for OILINJECTOR2500),OR10~2,0 (for OILINJECTOR1600).


Oil injector Valve nipple Connector Oil volume MassW

GOrdering designation cm3 bar kg

OILINJECTOR2500 OILINJECTOR2500.VALVE GD/i 8 2500 0,91(107640) (107642)

OILINJECTOR1600 OILINJECTOR1600.VALVE G: 27 1600 2,18(107641) (107643)

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 OILINJECTOR2500 + OILINJECTOR2500.VALVE: OILINJECTOR2500.SET,Ordering designation for OILINJECTOR1600 + OILINJECTOR1600.VALVE: OILINJECTOR1600.SET

FAG oil injectors

FAG hand pump sets

FAG offers a hand pump set with asingle 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 generates a high workrate. Where there is an increasedoil requirement, the twin stagepumps are available with an 8 litreoil container (suffix .8L).For those cases in which the typeof installation of the adapter or

Products · Mounting/RepairHydraulic mounting and dismountingHand pump sets

25

extraction sleeve requires a separate oil supply, FAG suppliesupon request 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 stage1000 bar PUMP1000.0,7L*

Twin stage1000 bar PUMP1000.4L* PUMP1000.8L* PUMP1000.4L.D PUMP1000.8L.D1600 bar PUMP1600.4L PUMP1600.8L PUMP1600.4L.D PUMP1600.8L.D2500 bar PUMP2500.4L PUMP2500.8L PUMP2500.4L.D PUMP2500.8L.D

* The 1000 bar pumps with one connector are also available with a digital manometer.Ordering example: PUMP1000.0,7L.DIGI

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 up to 4000 bar, thepump can be used to expand heavyshaft couplings and gears bythe hydraulic method. The pump is connected directly or via thick-walled adapters. The high pressure pump can alsobe connected via a pump holder(with or without a manometer) anda 2 metre flexible high pressurehose (permissible oil pressure2500 bar). The pump must alwaysbe operated with a manometer.


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, FAG suppliescomplete sets in storage cases.

FAG high pressure pump setPUMP2500.0,2L.SET


High pressure pump Connector MassW

Ordering designation l cm2/stroke bar kg

PUMP4000.0,2L*) G: 0,2 0,3 4000 3,8comprisingPUMP4000.0,2L.BODY (pump body)PUMP4000.0,2L.TANK (oil container)*) formerly 120109

FAG high pressure pump PUMP4000.0,2L

Pull rod Oil container Pump body

for across flats 27 mm

Connector thread G:

Oil container

High pressure pipe

Manometer Pump holder

Pump body

FAG high pressure pump set PUMP2500.0,2L.SET with manometer up to 2500 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.SET

Max. oilpressure

Motorrating

Oil containervolume(suctionquantity)

Oilvolumeflow

Oil containervolume

Compressed air driven FAG hydraulic unit

The compressed air driven FAG hydraulic unitAGGREGATE.P1000/2500 is mobileand comprises a 13 litre oil containermade from light metal and twopumps (1000 bar and 2500 bar). FAG supplies designs for other operating pressures by agreement.The 2500 bar pump has two separately controllable outputsand is suitable as a pressure devicefor expanding shaft couplings

and gears by the hydraulic method. The 1000 bar pump can charge ahydraulic nut at the same time. Thepump is suitable for press fits withcontact pressures up to 100 N/mm2.

Products · Mounting/RepairHydraulic mounting and dismountingHydraulic systems and units

27

Included in delivery:Base unit, ready-to-use, incl. 1 manometer, 0 to 1000 bar, 1 manometer 0 to 2500 bar, 3 high pressure hoses, 2500 bar, 2 metres

Electrically driven FAG hydraulic unit

These units are suitable for charging large hydraulic nuts andmounting of large press fits such as ship shaft couplings, ships’ propellers and gears (contactpressure up to 50 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 1000 bar,

Mobile FAG hydraulic unitfor batch mounting

The mobile unit has a valve-con-trolled, double direction pressurecylinder (pressure force 700 kN,stroke 215 mm) driven by a motorpump. The height position of thecylinder can be varied between 290 and 690 mm by means of a lifting cylinder and rocker. Accessories such as guide bushes,mounting sleeves, traction andpressure spindles and drawingframes must be ordered according

to 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 principally used for themounting and dismounting ofFAG TAROL wheelset bearings(see also FAG TI WL 80-50).

Ordering designation:TAROL.MOUNTING.AGGREGATE(MHU.TAROL)

Hydraulic unit Max. Massoil pressure W

Ordering designation l bar kg

AGGREGATE.P1000/2500 13 1000 or 2500 40 (without oil)

Compressed air driven FAG hydraulic unit

Hydraulic unit MassW

Ordering designation l l/min bar kW kg

AGGREGATE.E700 10 0,9 700 1,1 40 (with oil)

Electrically driven FAG hydraulic unit

1 high pressure hose, 1000 bar, 2 metres,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) are suitable for oil pressures up to 800 bar. Type B (with blade sealing) issuitable for oil pressures up to2500 bar.Other adapters and reduction nipples 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 holder

Pump holder Ordering designation MassW

kg

Without connector PUMP.HOLDER.2for manometer (118543/2) 1,95

With connector G- PUMP.HOLDER.3for manometer (118543/2A) 1,95

FAG pump holder

FAG manometers

When selecting a manometer, pay attention to the max. operatingpressure.

Manometer Connector thread Pressure display Diameter Mass(Former ordering designation) ≈ W

Ordering designation bar mm kg

PUMP1000.MANO.DIGI – G. 0 – 1000 73 0,4PUMP1000.MANO.G- (124830) G- 0 – 1000 100 0,8PUMP1600.MANO.G- (130594) G- 0 – 1600 100 1,5PUMP2500.MANO.G- (133315) G- 0 – 2500 160 1,7


FAG manometers


30

FAG high pressure pipes for highpressure pumps, sheathed in PVC hose (max. permissible pressure of2500 bar should be monitored by manometer)

High pressure pipe Consumer collector Mass(Former ordering designation) W

Ordering designation kg

PUMP.PIPE.G. (164641) G. 0,6PUMP.PIPE.GD/i (123076) GD/i 0,6PUMP.PIPE.G- (128167) G- 0,6PUMP.PIPE.G: (120386) G: 0,8The connector for the pump holder is G:.For other consumer collectors, a suitable reduction nipple must be used in addition.For detailed information, see TI WL 80-50.

FAG high pressure pipes

FAG sleeve connectorsfor adapter and extraction sleeves(up to 800 bar)

(special lengths available by agreement)

Connector Connector thread Mass(Former ordering designation) W

Ordering designation kg

PUMP.SLEEVE.CONNECTOR.M6 (118549A-M6) M6 0,22PUMP.SLEEVE.CONNECTOR.M8 (118549A-M8) M8 0,245PUMP.SLEEVE.CONNECTOR.GB/i (118549A-GB/i) GB/i 0,285PUMP.SLEEVE.CONNECTOR.G. (118549A-G.) G. 0,42The connector for the hand pump set is G..For detailed information, see TI WL 80-50.

FAG sleeve connectors

FAG electric heating plate HEATER.PLATE

Where tight fits are to be achievedon cylindrical bearing seats, it isadvisable to heat bearings formounting. Sufficient expansion canbe achieved at 80 to 100 °C. When heating the bearings, the temperature must be preciselymonitored, for example by usingthe FAG temperature measuring instrument TEMP.MG. It must notunder any circumstances rise above120 °C, in order to prevent changesto the structure and hardness.Rolling bearings can be heated on a temperature-controlled FAG heating plate HEATER.PLATE. The bearing must be covered withsheet metal and turned over several times in order to ensureuniform heating.The heating plates can be used toheat not only rolling bearings(maximum temperature 120 °C!) butalso labyrinth rings, shrink fit ringsand sealing rings.

Dimensions (B~T~H):390~270~156 mmPower: max. 1500 Wat 230 V/50 Hz *Temperature control: continuously variable from 50 to 200 °C

Ordering designation:HEATER.PLATE

* Also available with 115 V/60 Hz

For detailed information see TI WL 80-54.

By agreement, FAG also suppliesheating plates for heating partsup to 300 °C. This design is used,for example, for heating FAG aluminium heating rings(see page 34).

Products · Mounting/RepairThermal mounting and dismountingElectric heating plate · 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 (rolling bearingsmust not be heated to more than120 °C). Rapid and clean induction heatingis superior to the conventionalmethods. It is therefore particularlysuitable for batch mounting. The devices can be used for heating complete bearings, ringsfor cylindrical roller or needle roller 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• Extremely 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

For the mounting of workpieces upto 300 kg mass, FAG supplies fivetable-top heating devices Power-Therm HEATER10 to 300 suitable for mobile and/or stationary use. For workpieces up to 3000 kg mass,we recommend the heavy dutystandalone devices AWG25, AWG40and AWG100.For detailed information, see TI WL 80-54.

Heating deviceHEATER10 HEATER20 HEATER35 HEATER150

Power consumptionmax. 2,2 kVA 3,5 kVA 3,5 kVA 12,8 kVAVoltage/frequency* 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 360 mm 440 mm

Ledges 10~10~25 mm 14~14~200 mm 50~50~280 mm 70~70~350 mm(included in delivery) 30~30~40 mm 25~25~200 mm

46~40~55 mm 40~40~200 mm

Clear width 65 mm 120 mm 180 mm 210 mmClear height 120 mm 100 mm 160 mm 215 mm

Accessory ledges 7~7~105 mm 7~7~200 mm 10~10~280 mm 14~14~350 mm10~10~105 mm 10~10~200 mm 14~14~280 mm 20~20~350 mm

30~30~200 mm 25~25~280 mm 30~30~350 mm30~30~280 mm 40~40~350 mm40~40~280 mm 50~50~350 mm

60~60~350 mm

Rolling bearing / workpieceMin. bore** 15 mm 20 (10) mm 70 (15) mm 100 (20) mmMax. width 65 mm 120 mm 180 mm 210 mmMax. mass 10 kg 20 kg 35 kg 150 kg (horizontal only)

Products · Mounting/RepairThermal mounting and dismountingInduction heating devices

32

* FAG also supplies induction heating devices for other voltages and frequencies.

** Values in brackets refer to accessory ledges

Overview of induction heating devices

Heating deviceHEATER300 *** AWG25 AWG40 AWG100

Power consumptionmax. 12,8 kVA 25 kVA 40 kVA 100 kVAVoltage/frequency* 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 125 kg 350 kg 600 kg 2000 kgLength 700 mm 1280 mm 1800 mm 3000 mmWidth 500 mm 500 mm 600 mm 1000 mmHeight 900 mm 1250 mm 1400 mm 1800 mm

Ledges 80~80~490 mm 100~100~700 mm 150~150~850 mm 200~200~1300 mm(included in delivery)

Clear width 390 mm 390 mm 600 mm 800 mmClear height 300 mm 430 mm 450 mm 800 mm

Accessory ledges 20~20~490 mm 30~30~700 mm 60~60~850 mm 100~100~1300 mm30~30~490 mm 40~40~700 mm 80~80~850 mm 150~150~1300 mm40~40~490 mm 60~60~700 mm 100~100~850 mm50~50~490 mm 80~80~700 mm60~60~490 mm70~70~490 mm

Rolling bearing / workpieceMin. bore** 115 (30) mm 145 (45) mm 220 (85) mm 290 (145) mmMax. width 390 mm 390 mm 600 mm 800 mmMax. mass 300 kg (horizontal only) 600 kg 1200 kg 3000 kg

Products · Mounting/RepairThermal mounting and dismountingInduction heating devices

33

FAG also supplies special heating devices witheven higher power ratings for very heavy

*** HEATER300 can be converted to a mobileunit. Ordering designation for the trolleyrequired: HEATER300.TROLLEY

Overview of induction heating devices

workpieces or for automation in special processoperations.

FAG heating rings

Heating rings are suitable for dismounting the inner ringsof cylindrical roller and needle rollerbearings without ribs and inner ringswith one rib. Heating rings are particularly advantageous for theoccasional extraction of small andmedium-sized bearing rings (borediameter 50 to 200 mm). Dependingon the size of the ring, heating takesbetween 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 to between 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). Thisprovides optimum heat transfer. Thebearing ring must be removed fromthe heating ring immediately

after extraction in order to preventoverheating.Each bearing size requires a specialheating ring. By agreement, FAG supplies these heating rings madefrom a special aluminium alloy. Inorder 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 tobe extracted per day

Recommended FAG accessories

• Electric heating plate for temperatures up to 300 °C(by agreement)

• Temperature measuring instrument TEMP.MG (see page 62)

• Gloves HANDSCHUH2• Heat conducting paste

(see below) HEATING.RING.PASTE(20 ml included in delivery)

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

34

Ordering examplesfor heating rings

HEATING.RING320E(for the inner ring of a cylindricalroller bearing NU320E, NJ320E etc.)HEATING.RING2317E(for the inner ring of a cylindricalroller bearing NU2317E, NJ2317Eetc.)


FAG heat conducting paste HEATING.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 to achieve optimum heat transfer from

the heating ring to the bearinginner ring.

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


Electric induction heating devices(coils)

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 safe low voltageand is water-cooled. This allows continuous heating,which is particularly suitable forbatch mounting. Due to the lightweight construction, thesedevices are easy to handle. Each bearing size requiresa special coil.The coil is connected to a mobiletransformer that can be designedfor any mains voltage. The voltagefor the coil is adjustable to a valuebetween 20 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 1200 kg to the requireddismounting temperature of80 ... 120 °C (in the case ofcouplings, the maximum mass is600 kg).

Ordering example for bearing innerrings 120~150~144 mm:COIL152/145LOW.1 (coil)COIL.TRANSFORMER45.400V.50HZ(transformer)

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).

Products · Mounting/RepairThermal mounting and dismountingElectric induction heating devices (coils)

35

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, ifavailable

3. The mains voltage and frequency present at the mounting location


Heating device for low voltage with transformer for dismounting the innerrings of cylindrical roller bearings

FAG feeler gauges FEELER.GAUGE100and FEELER.GAUGE300

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, the tapered bearing seat must be

precisely machined such that thefit surfaces match precisely. FAG supplies various gauges formeasuring the taper. Most bearingswith a tapered bore have a

FAG taper ring gauge

The simplest means of measuringtapered shaft seats of small bearingsis the taper ring gauge. By applicationof bluing material, it can be deter-mined whether the shaft and ringgauge match. Corrections are madeuntil the ring gauge fits the shaft overits whole width. The inner rings of thebearings are not suitable as ring gauges because their walls are toothin and could be damaged. FAG supplies taper ring gauges fortaper diameters from 30 to 240 mm.

Ordering designation (example):KLR20Taper ring gauge for bearings of100 mm bore, e.g. for double row cylindrical roller bearings NN3020ASKor NNU4920SK.

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.GAUGE100 100 0,03 0,08 0,140,04 0,09 0,160,05 0,10 0,180,06 0,12 0,200,07

FEELER.GAUGE300 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.GAUGE100 and FEELER.GAUGE300

FAG feeler gauges FEELER.GAUGE100 and FEELER.GAUGE300

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 an angle, the taper angle of thestud = 2 α. If the upper edge ofthe master is parallel to the line diametrically opposed to the master, the taper angle isacceptable.

It is further required that the taperis in a defined ratio to a datum surface, e.g. to the side face of aroll 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 five masters): 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 bolts. The position of the gauge on the taperis defined by these bolts and onestop. The stop can be attached toeither the front or back of the gauge. The gauge contains twomovable measuring brackets, oneof which is in contact with thesmaller taper diameter while the

other, at a fixed distance, is in contact with the larger taper diameter.

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

The reproducibility of the measurement results is less than 1 µm. The gauge is set using a gauge taper (available byagreement).

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 the machine tool and for setting theenveloping circle gauge MGI 21(see page 39)

The actual dimension of the workpiece can be determined precisely. The snap gauge functions asa comparator gauge. Its setting ischecked using shims. FAG supplies the shims required foreach diameter.

Ordering examplefor shaft diameter 120 mm:SNAP.GAUGE100-150(snap gauge)SNAP.GAUGE.MASTER.DISK120(shim) FAG snap gauge

FAG taper gauge MGK 132for external tapers with 0° to 6°taper angle and 90 to 510 mm taperdiameter

With the taper gauge MGK 132, thereproducibility of the measurementresults is within 1 µm. The MGK 132 rests on the work-piece with four hardened, groundand lapped ledges. The ledgesform an angle of 90°. A stop on thefront or rear precisely defines theposition of 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-shaped tip is in contact with theworkpiece and measures the deviation of the taper from thenominal value. The gauge is setusing a gauge taper (available byagreement).


RangeOrdering designation mm

SNAP.GAUGE30-60 30–60 SNAP.GAUGE60-100 60–100 SNAP.GAUGE100-150 100–150 SNAP.GAUGE150-200 150–200 SNAP.GAUGE200-250 200–250 SNAP.GAUGE250-300 250–300

Available snap gauges

Products · Mounting/RepairMeasurement and inspectionEnveloping circle gauges

39

FAG enveloping circle gauge MGI 21for setting the radial internalclearance of cylindrical rollerbearings NNU4920K to NNU4964Kand NNU4920 to NNU4964

Bearings of bore diameter 100 to320 mm have removable innerrings.In the FAG enveloping circle gaugeMGI 21, the internal enveloping circle of the roller and cage assembly is measured by two hardened and precision ground surfaces, one of which is movable.After mounting of the outer ring,the gauge is set to the internalenveloping circle of the roller and

cage assembly. This dimension ismeasured using a snap gauge, forexample the SNAP.GAUGE…-… (seepage 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) that are finish groundto the required raceway diameter.

Ordering example for NNU4920:MGI21.4920

FAG enveloping circle gauge MGI 31for setting the radial internalclearance of cylindrical rollerbearings NN3006K to NN3038K andN1006K to N1048K

Bearings with a tapered bore haveremovable outer rings.The gauge is used to precisely setthe radial internal clearance or preload of the cylindrical rollerbearings. The raceway diameter of the mounted 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 the premounted inner ring and rollerand cage assembly can then beinserted in the gauge. The shaft ismoved axially by the hydraulicmethod until the precision indicatorshows the required radial internalclearance or preload.

Ordering example for NN3006K:MGA31.3006

FAG enveloping circle gauge MGA 31 for setting radial internal clearance of cylindricalroller bearings with removable inner ring

FAG enveloping circle gauge MGI 21 for settingradial internal clearance or preload of cylin-drical roller bearings with removable inner ring

Transport andmounting tool

FAG transport and mounting tool

BEARING.MATE from FAG is anaccessory for the secure, rapid andeasy handling of medium-sized andlarge rolling bearings. It can alsobe used where bearings are heatedprior to mounting. The tool comprises two handlesand two steel strips. Turning the handles clamps thesteel strips firmly on the outer ringof the rolling bearing. The compact packaging also includes two brackets. These areused on spherical roller bearingsand self-aligning ball bearings inorder to prevent tilting of the innerrings.The tool and bearing are carried either by two people or a crane. If two carrying slings are used, the rolling bearing can be rotatedto any position when transportedby crane. 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 tool sizes are matched todifferent bearing outside diameters, see table below.

Accessories

Long brackets to prevent tilting of self-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 Workpiece massmin. max. max. max.mm kg °C kg

BEARING.MATE250-450 250 450 500 120 6,3BEARING.MATE450-650 450 650 500 120 6,4BEARING.MATE650-850 650 850 500 120 6,5

FAG transport and mounting tool

Heat-resistant FAG glovesHANDSCHUH1

Heat-resistant FAG gloves are particularly suitable for the handling of heated rolling bearingsor other parts in mounting or dismounting.The outside comprises rugged polyester and can withstand temperatures 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 designationHANDSCHUH1

Products · Mounting/RepairAccessoriesGloves

41

Heat-resistant and oil-resistantFAG gloves FAG HANDSCHUH2

Heat-resistant and oil-resistant FAGgloves are particularly suitable forthe handling of heated rollingbearings or other parts in mountingor dismounting.

Their principal characteristicsderive from the multiple layer construction comprising differentfibres.

The principal characteristics are:

• Resistant up to 250 °C• Non-flammable• Heat-resistant even when damp• Authorised for use with

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

• Cotton-free• Cut-resistant

Ordering designationHANDSCHUH2

Products · Mounting/RepairAccessoriesMounting paste · Anti-corrosion oil

42

FAG mounting paste

This mounting and multi-purposepaste has proven valuable particularly for the mounting ofrolling bearings. It facilitates thesliding of bearing rings and prevents 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 a very thin layer such that the metallic sheen turns matt.The paste can be used attemperatures between –30 °C and

150 °C. It is resistant to water, steam and many alkaline and acidagents.

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

Ordering designation:ARCA.MOUNTINGPASTE.70GARCA.MOUNTINGPASTE.250GARCA.MOUNTINGPASTE.400GARCA.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 elements togive long term anti-corrosion protection when stored indoors.It is not generally necessary towash anti-corrosion oil out ofrolling bearings since it behavesneutrally 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:ARCA.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 52Grease dosing devices 53Grease gun 53

43

Special rolling bearing greases likeArcanol at first glance cost a littlemore than standard greases. But theyare worth the price. For with Arcanolyou can buy some extra safety as FAGselects only the best from a numberof good greases in a series of tests,provides quality assurance and giveslubrication recommendations.Bearings which fail prematurelybecause they were lubricated withthe wrong grease, with all theunpleasant and expensive consequences, increasingly belong tothe past.

In co-operation with renowned lubricant manufacturers, we have formany years developed lubricatinggreases that are particularly suitablefor rolling bearings. However, beforea new grease is included in the Arcanol programme, it has to pass aseries of stringent tests in the FAGlubricant lab.

The greases are tested thoroughly.On our lubricant test rigs FE8 (DIN51819) and FE9 (DIN 51821), thegreases are tested in rolling bearingsto find out how they improve servicelife and reduce friction and wear.Only the best greases are subjectedto the following tests under simulated field conditions in far morecomplicated rolling bearing test rigs.If the results meet the requirementsof the stringent FAG specifications,the greases are included in the Arcanol programme. Thus theyreceive the Arcanol seal of quality.

In addition, we test every singlebatch to ensure the uniform qualityof the product. It is only after thegrease has passed this final test thatit is allowed to be filled into containers labelled Arcanol. The programme consists of fourteengreases which cover nearly all fieldsof application 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 grease isconsiderably facilitated by the electronic INA/FAG rolling bearingcatalogue.

• More than 80% of all rollingbearings are lubricated with grease

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

• Therefore users need lubricantsand lubrication recommendationswhich they can rely on.

• Arcanol rolling bearing greasesensure that a bearing can be usedto its full capacity– long service life– good running behaviour– very safe operation

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

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

LOAD220 • • • •LOAD400 • • • • • • •LOAD1000 • • •

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

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

Other container sizes by agreement.

Arcanol rolling bearing greases · Container sizes

Ordering designation Description

ARCA.GREASE.MULTI2.20G FAG rolling bearing grease Arcanol MULTI2 in 20 g tube (50 pieces)ARCA.GREASE.TEMP200.70G FAG rolling bearing grease Arcanol TEMP200 in 70 g tubeARCA.GREASE.SPEED2,6.250G FAG Rolling bearing grease Arcanol SPEED2,6 in 250 g tube (10 pieces)

ARCA.GREASE.LOAD400.400G FAG rolling bearing grease Arcanol LOAD400 in 400 g cartridge (10 pieces)ARCA.GREASE.BIO2.1KG FAG rolling bearing grease Arcanol BIO2 in 1 kg canARCA.GREASE.MULTITOP.5KG FAG rolling bearing grease Arcanol MULTITOP in 5 kg bucket

ARCA.GREASE.FOOD2.10KG FAG rolling bearing grease Arcanol FOOD2 in 10 kg bucketARCA.GREASE.MULTI3.25KG FAG rolling bearing grease Arcanol MULTI3 in 25 kg hobbockARCA.GREASE.LOAD220.180KG FAG rolling bearing grease Arcanol LOAD220 in 180 kg drum

Arcanol rolling bearing greases · Ordering examples

ArcanolMULTITOP MULTI2 MULTI3 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 temp. limit [°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 soapwith EP additives

Mineral oil

ISO VG1000

2

–20...+140

80

Special greasefor ball androller bearings

inminingmachinery,constructionmachinery,preferablyundershock loadsand in largebearings

undervery high loads,moderatetemperatures,low speeds

οο

––

+++

++

KP2N-20


Mineral oil

400

2

–25...+140

80


inminingmachinery,constructionmachinery

under very high loads,moderatetemperatures,moderatespeeds

–ο

–

+++

++

KP2N-20


Mineral oil

ISO VG220

2

–20...+140

80


inrolling millequipment,railvehicles

under high loads,with wide speedrange,high humidity

οο

–

+++

++

K3N-30

Lithium soap

Mineral oil

80

3

–30...+140

75

Universal greasefor ball bearingsD > 62 mm

inlargeelectric motors,agricultural andconstructionmachinery,fans

+ο

ο

ο+

++

K2N-30

Lithium soap

Mineral oil

ISO VG100

2

–30...+140

75

Universal greasefor ball bearingsD ≤ 62 mm

insmallelectric motors,agricultural andconstructionmachinery,householdappliances

+ο

ο

οο

ο++

KP2N-40

Lithium soapwith EP additives

Mineral oil+ester

85

2

–40...+150

80

Universal greasefor ball androller bearings

inrolling mills,constructionmachinery,automotive engineering,spinning andgrinding spindles

underincreasedspeeds,high loads,low and hightemperatures

++ο

+

++

ο++

ISO VG = ++ extremely suitable ο suitable – less suitableISO viscosity group + very suitable –– not suitable

TEMP90 TEMP110 TEMP120 TEMP200 SPEED2,6 VIB3 BIO2 FOOD2

Products · LubricationLubricantsArcanol rolling bearing greases · Selection table

47

KP2P-40

Calciumpolycarbamidewith EP additives

PAO oil

130

2

–40...+160

90


incouplings,electric motors,automotive engineering

underhightemperatures,highloads

+++

ο

οο

οο

KE2P-40

Lithiumcomplex soap

Ester oil

ISO VG150

2

–40...+160

110


inelectricalequipmentautomotive engineering

underhightemperatures,highspeeds

++++

+

οο

οο

KP3N-30

Lithiumcomplex soapwith EP additives

Mineral oil

170

3

–30...+150

90


inblade adjustersin rotors forwind powerplant,packagingmachinery

underhightemperatures,highloads,oscillatingmotion

++

–

+++

ο–

KFK2U-40

PTFE

Fluoro polyether oil

400

2

–40...+260

200


intrack rollersin baking machinery,piston pinsin compressors,kiln trucks,chemical plant

undervery hightemperatures,in chemicallyaggressiveenvironments

++++

––

+–

οο

KE3K-50

Polycarbamide

PAO/ester oil

ISO VG22

2–3

–50...+120

80

Special greasefor ball bearings

inmachinetools,instruments

undervery highspeeds,lowtemperatures

++ο

++

–––

ο+

KPHC2R-30

Polycarbamidewith EP additives

PAO/ester oil

ISO VG460

2

–35...+180

120


incontinuouscasting plant

underhightemperatures,highloads

+++

–

++ο

οο

KPE2K-30

Lithium/calcium soap

Ester oil

58

2

–30..+120

80


inenvironmentallyhazardousapplications

+ο

ο

οο

ο+

KPF2K-30

Aluminiumcomplex soap

White oil

192

2

–30..+120

70


inapplicationswith food con-tact;H1 to USDA

+–

ο

οο

ο++

FAG automatic lubricatorsMotion Guard

Reliable and economicallubrication for a long bearing life

Rolling bearings are reliable machine components that give along operating life. The mostfrequent cause of failure isinadequate or incorrect lubrication.Approximately 90 % of all bearingsare lubricated with grease. Providing a reliable supply ofsuitable grease is therefore particularly important.

If an automatic lubricator is usedfor controlled relubrication, a sufficient quantity of fresh greaseis continuously supplied to thecontact points of the rollingbearing.

This results in a significantincrease in bearing life. These reliable, economical devices giveextended lubrication and maintenance intervals and also

prevent undersupply or oversupplyof grease. As a result, plant downtimeand maintenance costs are reduced.The sparing 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 on pumps,compressors and fans, in conveyingequipment, vehicles etc.

The single point lubrication systems Motion Guard COMPACTand CHAMPION can be used to dispense eight or all 14 Arcanolgreases described on pages 46 to47. Motion Guard CONCEPT6 is usedas a single point or multi-pointlubrication system with twelveArcanol greases.

Products · LubricationLubrication systemsMotion Guard · Motion Guard SELECT MANAGER

48

Advantages of the lubricators

• Individually configured, precisesupply to each bearing positionimmediately after initialoperation

• 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 or contamination of lubricants

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

• Suitable for connection to theFAG monitoring system EasyCheck

• Comprehensive range ofaccessories

Motion Guard SELECT MANAGER

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• maintenance of a lubrication and

maintenance plan

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

FAG lubricatorsMotion Guard COMPACT

This automatic lubricator iselectrochemically driven. The electrolyte 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 suitable lubricants in standardpacks of 10 containers.

Ordering examples:

ARCA.LUB.LOAD400(filled with LOAD400, pack of 10 containers without activation screw)

ARCA.LUB.TEMP90(filled with TEMP90, pack of 10 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 with activation screws.

Ordering examples:

ARCA.LUB.MULTITOP.1M(filled with MULTITOP, includingactivation screw for 1 month)

ARCA.LUB.MULTI2.3M(filled with MULTI2, including activation screw for 3 months)

ARCA.LUB.MULTITOP.6M(filled with MULTITOP, includingactivation screw for 6 months)

ARCA.LUB.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):

ARCA.LUB.ACTIVE.1Mfor 1 month (yellow)

ARCA.LUB.ACTIVE.3Mfor 3 months (green)

ARCA.LUB.ACTIVE.6Mfor 6 months (red)

ARCA.LUB.ACTIVE.12Mfor 12 months (grey)(12M cannot be used for MULTITOP and MULTI2!)

Suitable Arcanol greases, chain oilsand activation screws

1M 3M 6M 12M

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

Arcanol

ARCA.LUB.TEMP200.6M

Version CLEAR

The CLEAR version of the lubricatorMotion Guard COMPACT is suitablefor explosion-protected and corrosion-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:

ARCA.LUB.FOOD2.CLEAR(filled with FOOD2, pack of 10 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 for the CLEAR version with dispensingtimes of 1, 3 or 6 months are offered separately.

Ordering designation (10 pieces):

ARCA.LUB.ACTIVE.CLEAR.1MARCA.LUB.ACTIVE.CLEAR.3MARCA.LUB.ACTIVE.CLEAR.6M

Products · LubricationLubrication systemsMotion Guard COMPACT · Versions CLEAR and POLAR

50

Version POLAR

The POLAR version 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 (itis only available with this grease).

Ordering designation:

ARCA.LUB.MULTITOP.POLAR(filled with MULTITOP, pack of 10containers without activationscrew)

For the dispensing time as a function of the actual temperature,see the following table.

The black activation screw must beordered separately. Ordering designation (10 pieces):ARCA.LUB.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

Version POLAR

FAG lubricator Motion Guard CHAMPION

The automatic lubricator MotionGuard CHAMPION iselectromechanically driven.The robust, electronically controlledgeared motor can be used more thanonce. It allows the dispensing timesto be adjusted depending on thetemperature and to 1, 3, 6 or 12months. It is battery powered andthe battery set is replaced wheneverthe cartridge is changed.

Ordering designation:ARCA.LUB.DRIVE

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

The lubricator Motion Guard CHAMPION is suitable for all theArcanol rolling bearing greasesdescribed on page 46-47 as well aschain 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):

ARCA.LUB.MULTITOP.LC60(filled with MULTITOP, 60 cm3)ARCA.LUB.LOAD400.LC120(filled with LOAD400, 120 cm3)ARCA.LUB.VIB3.LC250(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:ARCA.LUB.ADAPTER

ARCA.LUB.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:ARCA.LUB.MULTITOP.LC120.SETARCA.LUB.MULTITOP.LC250.SET

The lubricator CHAMPION has onlybeen tested in conjunction withArcanol lubricants. Empty LC unitsfor one-off filling are available inthe three sizes 60, 120 and 250 cm3, but should only be usedafter consulting FAG.

Ordering designations:ARCA.LUB.EMPTY.LC60ARCA.LUB.EMPTY.LC120ARCA.LUB.EMPTY.LC250

By agreement, FAG also suppliesthe lubricator CHAMPION with special filling specifications.

Accessories for Motion Guard COMPACT and CHAMPION

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

FAG lubrication system Motion Guard CONCEPT6

This single and multi-pointlubrication system can supply upto six lubrication points with lubricant constantly, precisely andirrespective of temperature. Thedispensing times can be adjustedto any time between 1 day and 24months and LC units are availablein sizes 250 and 500 cm3.

FAG starter kitsMotion Guard CONCEPT6

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

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

Products · LubricationLubrication systemsMotion Guard CONCEPT6

52

Version CONTROL

The CONTROL version of the lubricator CONCEPT6 is controlledby the machine, i.e. lubricant isonly dispensed while the machineis running. FAG also suppliesstarter kits for the CONTROL versionas a basis for multi-pointlubrication systems.

Ordering designation:ARCA.LUB.C6-CONTROL-250.KITARCA.LUB.C6-CONTROL-500.KIT

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

Lubricant is distributed independent of its consistency orsolid particle content. If the distributor identifies anobstruction in an individual outlet,this is indicated on the display ofthe drive unit. The other outletscontinue to be supplied.

Ordering designations:ARCA.LUB.C6-250.KITARCA.LUB.C6-500.KIT

Only the following items must beordered separately: hose and connectors for the lubrication pointand filled LC units in sizes 250 cm3

and 500 cm3.

LC units are available with the 12suitable Arcanol grease grades (seepage 46-47, except for MULTI3 andVIB3).

Ordering examples:ARCA.LUB.MULTITOP.C6-250ARCA.LUB.LOAD400.C6-250ARCA.LUB.SPEED2,6.C6-500ARCA.LUB.TEMP200.C6-500

By agreement, FAG supplies LCunits with other greases whose suitability has been checked.

For single point lubrication, theparts required are ordered individually from the range ofaccessories.

For detailed information, see publication WL 81 122.

FAG grease dosing devices

These devices supply rollingbearings with accurately dosedgrease quantities within a range of10 to 133 cm3. If larger grease volumes are required, the device canbe actuated several times.With a pneumatically driven, double-acting piston pump the grease is fedvia the dosing valve directly from itscontainer (25 kg or 180 kg) to thearea to be lubricated.

The grease dosing device consists of:• a cap• a piston• a dosing valve• a connecting tube between pump

and valve• a tube, 2.5 m long• a grease gun

Technical data:

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

Ordering designations:ARCA.PUMP25ARCA.PUMP180

Products · LubricationLubrication systemsGrease dosing devices · Grease gun

53

FAG grease gun with armoured tube

Under difficult operating conditionsor rough environmental conditionsrolling bearings frequently have to be relubricated via lubrication nipples. Relubrication is easy, cleanand swift if an FAG grease gun withan armoured tube is used. These parts meet the requirements ofDIN 1283.

Grease gun

Diameter of container 56 mmTotal length of gun 390 mmDelivery 2 cm3/strokePressure max. 800 bar

The grease gun can be refilled either with bulk grease or with acartridge in accordance with DIN 1284.

• 500 cm3 of bulk grease or• 400 g cartridge according to

DIN 1284 (diameter 53.5 mm, length 235 mm)

Connection thread GB/i

Mass approx. 1.5 kg

Ordering designation: ARCA.GREASE-GUN

Armoured tube

Length 300 mmConnection thread GB/i

Equipped with a hydraulic gripcoupling for a hydraulic-type lubricating nipple according to DIN 71412

Instead of this hydraulic coupling it is also possible to connectsliding couplings for button headlubricating nipples in accordancewith DIN 3404 or other connectionpieces. These connection piecescan be purchased from specialisedretailers.

Ordering designation:ARCA.GREASE-GUN.HOSE

ARCA.PUMP180

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 SMARTY

Top-Laser SMARTY 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 areincreased.

Features and advantages:• Displays parallelism and

misalignment of both pulleys• 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 be mounted in just a few seconds. Thelaser beam can be clearly seen onthe target marks. When the laserbeam coincides with the slits in thetarget marks as a result of adjust-ment, the machine is correctlyaligned.

Products · AlignmentBelt and chain drivesBelt pulley alignment device

56

Due to the low mass of the measuring device, the transmitterand target marks can be fixed tonon-magnetic drive pulleys using astrong, double-sided adhesivestrip.

Ordering designationComplete laser measuring deviceincl.2 target marks,2 batteries and user manual in padded case:LASER.SMARTY

Replacement part1 magnetic target markLASER.SMARTY.TARGET


B

A

BA

FAG belt tension measuring deviceTop-Laser TRUMMY

The robust, handy Top-Laser TRUMMY is an optical-electronicinstrument for measuring and setting optimum belt tension(strand force).

Optimum belt tension, like precisealignment of the belt pulleys(see Top-Laser SMARTY, page 56), is an essential precondition for achieving 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-Laser TRUMMY can be used in many

locations and comprises a measure-ment probe and a microprocessorthat indicates relevant measurablesfor belt tension either as frequency[Hz] or force [N]. By means of animpulse (for example by strikingthe stationary belt), the tensionedbelt is excited to natural vibration.The individual static naturalfrequency thus generated ismeasured within seconds by theTRUMMY sensor using clock pulselight and displayed. In order to calculate the strand force of thebelt drive, the belt mass and lengthare entered in the microcomputerbefore measurement. TRUMMY usesthese data to calculate the strandforce, which is then compared withthe specified nominal 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 the measurement result cannot be distorted by disruptive influences.The simple and secure user instructions are given in severallanguages.

Ordering designationLaser measuring device in plasticcase:LASER.TRUMMY


FAG shaft alignment device Top-Laser INLINE

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

Advantages:• Simple to use• Error-free handling even by

untrained personnel due to automatic measurement andpositioning process

• More precise alignment than withconventional methods

• Rapid measurement due to continuous rotary motion

• Reduced vibration and frictionlosses

• Longer machine running times• Usable with conventional laptops• Suitable for use in combination

with Bearing Analyser

Included in delivery1 transmitter/receiver

(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 delivery are also available asreplacement parts.

Ordering designationComplete 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 to prevent increased vibration tendency and bearing damage dueto housing distortion.

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 computer determines any footmovement. The tilt foot can then beeliminated using shims.

Case Serial PC card Software

Post

Chain Bracket Transmitter/receiver

Cable

Reflector

Included in delivery

Accessories

The possible applications of thebasic device LASER.INLINE areexpanded by a comprehensive range of accessories (see table).The accessories can be ordered as a set in a handy, robust case or – individually compiled – asindividual 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, 1500 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.ACCESS.SUITCASE

Accessories for LASER.INLINE

C

B

A

FAG shims Top-Laser SHIMS

Top-Laser SHIMS are used to eliminate 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 handy case contains 20 shimseach in 3 sizes (C = 15, 23 and 32 mm)and 6 thickness values (0,05 to 1,0 mm), i.e. a total of 360 shims,together with one extraction hook.

Ordering designation:LASER.SHIMS.SET

Individual or replacement parts

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

Ordering examples:

10 shims in dimension C = 15 mmand 0,20 mm thickness:LASER.SHIMS15.0,20

10 shims in dimension C = 44 mmand 0,10 mm thickness:LASER.SHIMS44.0,10


Products · AlignmentAccessoriesShims

60

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

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

LASER.SHIMS.SET

Ordering designation Dimensions Total quantity MassIndividual or replacement parts A B C Thickness ShimsFAG mm g

LASER.SHIMS15… 55 50 15 0,05 – 2,0 10 each 11 – 440LASER.SHIMS23… 75 70 23 0,05 – 2,0 10 each 21 – 840LASER.SHIMS32… 90 80 32 0,05 – 2,0 10 each 29 – 1160LASER.SHIMS44… 125 105 44 0,05 – 2,0 10 each 53 – 2100

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 65Bearing Analyser 65Easy Check 66Easy Check Online 66DTECT X1 66WiPro 67Screen Saver 68VibroCheck 68

61

FAG infrared thermometer TempCheck PLUS

The FAG infrared thermometerTempCheck PLUS measures theinfrared radiation emitted by anobject and uses this to calculatethe surface temperature. The contact-free measurement makesit possible to easily determine thetemperature of difficult to reach ormoving objects. The device is very light (it weighsonly 150 g) and can be taken practically anywhere it is needed.The FAG infrared thermometerTempCheck PLUS can measure temperatures in a range between –32 °C and +530 °C. It has a highprecision glass optic for accuratecontact-free temperature measure-ment. It is suitable for monitoringthe temperature of rolling bearingsand other components.

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)

Safety warning

Do not look into the laser beam orpoint it in other people’s eyes.

Products · Condition monitoringOperating conditionTemperature measuring devices

62

FAG temperature measuring deviceTEMP.MG

This handy device has a displayrange of –60 to +1000 °C. The surface temperature sensorTEMP.MG.F, included in the delivery, has a measurement rangeof –60 to +300 °C.

The device is suitable for measuring the temperature of• rolling bearings, housings

and lubrication systems for operational monitoring

• heated rolling bearings and jointsduring mounting

The microprocessor-controlled measuring device has a single linedisplay. The touch keyboard has

the following switching functions:• On/off• Hold (hold the measurement

value in the display)

Ordering designation and scope ofdelivery:TEMP.MG(measuring device with sensorTEMP.MG.F and service case)

FAG temperature sensor asreplacement part(can be ordered individually):Rapid reaction surface sensorOrdering designation: TEMP.MG.F

FAG temperature sensor as accessory(can be ordered individually, for measuring the temperature offluids, lubricants etc.): Immersion/insertion sensor Ordering designation: TEMP.MG.TF


FAG digital hand tachometerTACHOMETER

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

using an adapter, track wheeland measuring tips

• Non-contact optical speed measurement using reflectivemark

Direct speed measurement

For direct speed measurement, thesupplied adapter must be fitted.

Through contact with the component,the rubber stylus measures theturning speed or determines thesurface speed in conjunction with a track 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 monitoringOperating conditionDigital hand tachometer

63

Ordering designation:TACHOMETERContents: Digital hand tachometer

Adapter for direct1:1 measurementTrack wheel 1/10 m Track wheel 6 inchRubber stylus10 reflective marksUser manualCase

Replacement parts

10 reflective marksOrdering designation: TACHOMETER.REFLEX.MARKS

FAG sonar detector 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 atan early stage if regular inspectionis carried out. In this way, unexpected interruptions in operation and more seriousmachine damage can be avoided.The device is used in the same wayas a doctor’s stethoscope.

The tips of the earpiece are placedin the ear canals to provide insulation against background noise. 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 monitoringOperating conditionSonar device

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Condition monitoring byvibration diagnosis

Vibration diagnosis is the mostreliable method for identifyingmachine damage at an early stage.Balance and misalignment defectscan be detected accurately, as wellas rolling bearing damage and geartooth defects. In this field, F’ISoffers a comprehensive productrange from simple vibration monitors to complexmonitoring systems with a largenumber of measurement points.FAG vibration measuring deviceshelp to plan maintenance work,extend bearing life, reduce costsand increase plant availability.

In the field of offline monitoringdevices, FAG offers Detector II andBearing Analyser III. The online monitoring devicesinclude products from theeconomical Easy Check range, thedigital vibration monitors DTECT X1, WiPro and Screen Saver as well asthe online monitoring system VibroCheck.

FAG Detector II

Detector II is a portable vibrationmeasuring device and data collectorin one. Using this economicaldevice is straightforward and easy to learn. It weighs approx. 450 g and is highly suitable for monitoring extensive plant wherelarge distances must be covered.Detector II picks up vibration signals at predetermined measure-ment points and calculates theeffective values for vibration rateand acceleration. It can be used tomonitor machine vibrations in

accordance with ISO 10816 as wellas the rolling bearing conditionusing envelope signal processing.Temperatures can also be measured by non-contact meansusing an infrared sensor. The datacollected by the device are transferred to a computer. They are then evaluated, analysedand presented in diagrammaticform with the aid of the software Trendline. Any incipient damagecan thus be detected at an earlystage. Detector II can also be usedby personnel who have no experience of vibration measure-ment. A very useful feature in thisrespect is the “E-Mail button”. Thisallows the collected data to be sentto an external diagnosis expert forfurther analysis.

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

Products · Condition monitoringVibration diagnosisDetector II · Bearing Analyser III

65

FAG Bearing Analyser III

Bearing Analyser III is a multi-channelvibration analysis device. The device is suitable for reliable earlydiagnosis of damage as well as fortroubleshooting on machines. BearingAnalyser III can be used for detailedanalysis of complex machinery andplant as well as multi-stage gearboxesand rolling mills. The Bearing Analysercomprises a laptop, the BA III softwareand a docking station that isconnected to the laptop via a data acquisition card. The signals collectedare transferred to the laptop and evaluated by the Bearing Analyser software. Bearing Analyser III alsooffers the option of continuous datarecording. The automatic diagnosissystem can, together with the integrated database, identify typicalpatterns of machine damage in thevibration signal and alert the user viathe inbuilt traffic light function. In this way, damage can be detectedand analysed independently of the absolute level of the signal power.


FAG Detector II

FAG Bearing Analyser III

FAG Easy Check series

The FAG Easy Check devices areeconomical vibration monitors forpermanent monitoring of criticalmachinery in plant with constantoperating conditions, e.g. pumps,fans, electric motors etc.Since Easy Check vibration monitors are easy to mount andoperate, they can also be used byemployees who have no knowledgeof condition monitoring. The devices monitor vibration inaccordance with ISO 10816, thecondition of rolling bearings withthe aid of envelope signalprocessing and the temperature atthe bearing locations.The use of Easy Check devices cancontribute to a considerable costreduction since incipient damage isdetected at an early stage and thenecessary work can be integratedinto maintenance planning.

FAG Easy Check

FAG Easy Check is a standalonedevice that is powered by a batteryand applied directly to the criticalmachine. The vibration monitor

draws attention to any problem bymeans of LEDs (traffic lightfunction). The status of the LEDs onthe Easy Check must be checked atregular intervals.

FAG Easy Check Online

In contrast to the base 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 forregular inspections and allows themonitoring of difficult to accesslocations. Using the input, FAGEasy Check Online can be administered remotely, for example, for resetting the alarms,starting the learning phase or activating a measurement cycle.

Products · Condition monitoringVibration diagnosisEasy Check · DTECT X1

66

FAG DTECT X1

DTECT X1 allows early detection of damage by selective frequencyvibration monitoring based on individually adjustable frequencybands. By means of the selectivefrequency method, specificallyselected machine parts can bemonitored. DTECT X1 has charac-teristics that would normally onlybe found on significantly moreexpensive systems. The system isvariable and can be speciallymatched to the requirements of theapplication. The base device isavailable with 2 channels, 4 channels or as an 8 channelsystem with an external multiplexer.All conventional acceleration,velocity and displacement sensorscan be attached. It is possible torecord process variables such asspeed, temperature, torque andpressure. The signal collected bythe sensor is broken down into itsfrequency components by means ofFast Fourier Transformation (FFT).

For detailed information, seeTI WL 80-68.Please direct enquiries to:[email protected] Easy Check

FAG Easy Check Online

FAG DTECT X1

It is thus possible to monitoramplitudes within fixed, very nar-row frequency bands for specifiedlimit values and trigger an alarm. If necessary, the remote monitoringfunction can be used to monitormachines without the need for adiagnosis expert on site. Anychanges are automatically notifiedvia telecommunication systems(fixed line, mobile or GSM modem)to the operator, plant manufactureror service provider irrespective ofwhere the system is located throughout the world. Stored andcurrent data can be remotelyretrieved and analysed by the FAG Diagnosis Centre.


FAG WiPro

WiPro is a cost-effective onlinemonitoring system for the condition-based maintenance ofwind turbines.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, other information such as rotor bladespeeds or oil quality can be integrated in the conditionmonitoring. WiPro is equipped witha signal processor and evaluates allmeasurement signals in the nacelleitself. Due to the intelligent linkingof expert knowledge with information from the turbine, it ispossible to keep the transfer datavolume very small. This isparticularly important where a largenumber of turbines are to be monitored on a permanent basis,allowing transfer data quantities tobe kept to a minimum. Due to thedifferent communication options,an appropriate solution can befound for any wind farm.

Products · Condition monitoringVibration diagnosisDTECT X1 · WiPro

67

FAG WiPro

With WiPro, the operator is keptinformed at all times of the condition of the most importantcomponents. This means a highlevel of investment security andactive machine protection. The modular concept of WiPro systems allows all types of wind turbines to be retrofitted with thesystem. Any wind farm can be networked using the WiPro system,whether the turbines are connectedusing copper cables, fibre optics,ISDN or analogue lines or even if notelephone connection is present atall.


station or machine controller. Thedata stored in the monitoring unitcan be downloaded offline byemployees or sent online via variouscommunication channels such asmodem, GSM, TCP/IP etc. to a remote computer for further evaluation and monitoring.


FAG VibroCheck

The online monitoring systemVibroCheck is ideally used wherevera large number of measurementpoints must be continuously andreliably monitored, such as in rolling mills, paper factories orpower stations. In its mostexpanded form, up to 2048 sensorscan be integrated in the system.For the detection of defects such asimbalance and misalignment,VibroCheck generates spectrum-based parameters that are managed within narrow frequencybands according to speed. In addition to general parametermonitoring, the user has availablean automatic, rule-based expertsystem that can monitor up to 20 components per sensor. Thisallows monitoring of all rollingbearing types and tooth meshesin the vicinity of a sensor in relationto the occurrence of component-specific frequency windows. Inaddition to vibration signals, otherprocess parameters such astemperature, power, pressure, torque etc. can also be processed. Through remote access, the datacan also be analysed by external

service providers or CM experts atother locations.The display, which is individuallytailored to the customer’s require-ments, gives a user interface thatallows rapid overview of the condition 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.


Products · Condition monitoringVibration diagnosisScreen Saver · VibroCheck

68

FAG VibroCheck

FAG Screen Saver

Screen Saver is a vibration measuringsystem for use on vibrating screensthat is matched to the roughenvironmental conditions of thematerials processing industry(mining, cement industry etc.). Since the system detects incipientdamage at an early stage, maintenance measures can be planned and unforeseen downtimecan be avoided. Vibrating screensor vibratory conveyors are often keycomponents in materials processing.Their continuous functional capabilityis therefore very important.Depending on the type of screen,replacement can cost between 20 000 and 150 000 €. Downtimecosts, depending on the productionsite involved, can run up to 13 000 €per hour. Thanks to a special filter technique, the system can differentiatebetween vibrations caused by theprocess itself and those that aregenerated by defective components(gearboxes, bearings, loose partsetc.). The current monitoring statuscan be viewed both on the monitoring unit (traffic light system)and transmitted to the control

FAG Screen Saver

CMMS*Interface 70

Products · Maintenance management

69

CMMS*Interface

With the CMMS*Interface, F’ISoffers an intelligent link betweenvibration measurement/analysisand the maintenance managementsystem MAXIMO®. By means of a software module, the portable FAG vibration measuringdevice Detector II and its Trendlinesoftware is linked to the 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 II

• Automatic generation/updating of follow-up orders in MAXIMO®

in an alarm situation• Generation of a measurement

value history in MAXIMO®

Please direct enquiries to:[email protected]

Products · Maintenance managementCMMS*Interface

70

Services

71

Mounting/Repair 72

Mounting service 72Repair service 73Equipment rental 74Railway wheelset bearing maintenance 75

Lubrication 76

Alignment 77

Condition Monitoring 78

Troubleshooting 78Balancing 78Service contract 79Online monitoring 79Offline monitoring 79Measurement concepts 80Remote diagnosis 80

Maintenance management 81

Maintenance consultancy 81Maintenance planningand control systems 83

Mounting service

The F’IS Mounting Team offersmounting services for rollingbearings across market sectors. We have extensive experience, for example, in railways, mining,steel and aluminium, wind power,paper etc.

The F’IS mounting personnel arespecially trained and will providereliable assistance, with a rapidresponse where necessary.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 running satisfactorily

• advice on rationalisation ofmounting operations

• design and manufacture ofspecial tools

The advantages include:• extended bearing life• considerable cost reductions• less unplanned downtime• increased plant availability• improved awareness among

employees of the correct handlingof rolling bearings

Please direct enquiries about the services described to

FAG Kugelfischer AG & Co. oHGTel. +49 9721 91-3142 or -2573Fax +49 9721 91-3809

Services · Mounting/RepairMounting service

72

Repair service for largerolling bearings

During the maintenance ofmachinery and plant, many rollingbearings are taken out of serviceand replaced by new ones as a precaution. This exaggerated safety-awareness blocks any appreciationof the potential cost savings. Thefact is that reconditioned bearingsgenerally have the same performance as new ones. The F’IS experts repair all types of rollingbearings such as cylindrical rollerbearings, spherical roller bearings,tapered roller bearings etc.The F’IS experts carry out a damagediagnosis that costs between 100,— € and 500,— €. On this basis,a decision is made as to whetherrepair is viable or not.

For detailed information, seepublication WL 80 151 DA.

Please direct enquiries to:

FAG Industrial ServicesMettmanner Straße 7942115 WuppertalTelephone +49 202 2932-227Fax +49 202 2932-437E-Mail: [email protected]

Services · Mounting/RepairRepair service

73

Cylindrical roller bearing back-up roller for Sendzimir rolling mills

Roundness measurement

Checking of roller seats

Outer ring grinding Mounting of a large bearing

Sensing trace for a spherical roller bearinginner ring

Equipment rental

Customers who require specialmounting and measuring equipment only infrequently, for example in order to carry outrepairs, can rent these from FAG on a weekly basis for a fee.

FAG mainly offers for rent• taper gauges• enveloping circle gauges• hydraulic nuts• hand pump sets• heating devices

The equipment is stored at ourmounting workshop and itsfunction is checked and maintainedby our mounting specialists.

Please direct enquiries about thisservice to

FAG Kugelfischer AG & Co. oHGTel. +49 9721 913142Service Hotline:Tel. +49 2407 914999

Services · Mounting/RepairEquipment rental

74

Railway wheelset bearingmaintenance

Wheelset bearings for railwayvehicles are among the mostheavily loaded vehicle parts. Theirlife can be increased significantlyby appropriate and regular maintenance. F’IS therefore offersoperators of all railway vehicles theopportunity to have their wheelsetbearings professionally dismounted,cleaned and reconditioned. Customers can thus benefit fromthe high quality maintenance measures and technical expertiseof the F’IS employees in the Reconditioning Team.

The F’IS service offer applies to:• all cylindrical, spherical and

tapered roller bearings up to a maximum width of 180 mm anda maximum outside diameter of 420 mm

• products from all rolling bearingmanufacturers

• all railway vehicles

The service includes:• professional dismounting,

cleaning and reconditioning of wheelset bearings at the F’IS Service Center in Schweinfurt

• marking of each individualbearing before dismounting

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

The advantages include:• longer life of railway wheelset

bearings due to high qualitymaintenance work

• marking of each individualbearing for cleaning and reconditioning. If required, this provides bearing-specificdocumentation of allmaintenance work carried out

• return of the wheelset bearingready for mounting after completion of the maintenancework

• short downtimes due to swiftimplementation of the maintenance process; the emphasis in all maintenance operations is on precision and care

• reduced maintenance costs dueto preventive maintenance

Please direct enquiries about theservices described to

FAG Kugelfischer AG & Co. oHGTel. +49 9721 91-3142 or -2573Fax +49 9721 91-3809

Services · Mounting/RepairRailway wheelset bearing maintenance

75

Lubrication as a service

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

The use of suitable greases for different operating and environmental conditions as wellas know-how of when, how frequently and with what quantitiesbearings should be lubricated,make it possible to significantlyextend the life of rotating machineelements.

Specialised employees offer their service across market sectorsand have special experience, for example, in the areas ofrailways/transport, power trans-mission, steel and aluminium,paper, wind power, agriculture andforestry, the food and delicaciesindustry as well as mining andextractive equipment. F’IS servicesinclude the selection and installation of lubricants and lubrication systems, the lubricationof bearing positions, the preparationof lubrication and maintenanceplans, lubrication point management,lubrication consultancy andlubricant investigations and tests.

A comprehensive selection of highquality FAG greases Arcanolspecially tested and selected foruse in rolling bearings is available.The consistent 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 and

greases for use in the food industry, on the basis of ongoinginnovation.

FAG rolling bearing greases Arcanolare also suitable for use in FAG automatic lubricatorsMotion Guard.

Services · Lubrication

76

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• operation of a lubrication and

maintenance plan

Use of the F’IS lubrication service can prevent the failure of rotating machine partsand increase productivity while reducing lubrication costs.

Alignment

Incorrect alignment of belts andshafts are among the most commoncauses of unplanned machinedowntime.

Correct alignment considerablyincreases the life of rotating machine parts. The highly qualifiedF’IS employees are able to reduceto a minimum the increased vibration levels that are induced by deformations in the shafts, machine bodies, foundations etc.They position drive componentssuch as motors, couplings, gearboxes etc. such that the driveoperates with as little wear aspossible.

The F’IS experts locate and eliminate misalignmentson machines using two or more coupled shafts and belts. In addition to detailed analysis ofcauses, the F’IS service includesalignment of belts and shafts onpumps, ventilators, compressors,electrical machinery etc. as well asthe detection and correction ofpositional deviations in belts andshafts using F’IS vibration andlaser measurement devices. F’IS also offers various measuring devices that can be used personally to align defective elements.

With the aid of the F’IS alignmentservice, you can avoid unplannedmachine downtime due to misalignment. You thereby consi-derably increase plant availabilitywhile reducing your maintenancecosts.

For detailed information, seepublication WL 80 316


Services · Alignment

77

Condition Monitoring

The failure-free and optimised operation of complex machineryand plant can only be achieved by means of condition-based maintenance. The key method used by F’IS incondition-based maintenance isvibration diagnosis. This methodmakes it possible to detectincipient damage in machinery at avery early stage. The customer isthus able to act rather than havingto react. For example, damagedcomponents can be replaced aspart of planned downtime. In particular, vibration diagnosishelps to avoid unplanned down-time and expensive consequentialdamage, increase productivity andimprove plant availability. F’IS offers a comprehensive and flexible range of services in the field of condition-based maintenance.

For detailed information, seepublication WL 80 315 DA.

Troubleshooting

If malfunctions or other problemsoccur on a machine, a detaileddefect analysis must be carried outas soon as possible. This can belikened to detective work. Based onmany years experience in differentsectors and applications, the F’ISdiagnosis experts are well versedin such troubleshooting tasks.Their analysis incorporates variousinformation, for example from visual observation, examination of the machine documentation anddiscussions with machine operators. Problems or malfunctions in machine operation often becomeapparent through changes in vibration behaviour, unusualtemperature patterns or similarphenomena. The F’IS expertstherefore also carry out measure-ments on the machine. The measurement methods usedwill depend on the particular application. The F’IS experts arefamiliar with all measurementtechniques, from vibration measurement to torque analysis orendoscopy. As a result, they canquickly identify malfunctions andprepare possible solutions.

Endoscopy

If damage has been detected butthe component cannot be replacedin the short term for productionreasons, the precise extent of thedamage can be determined usingendoscopy. The interior of the machine isexamined using digital videoendoscopes. Based on theirknowledge and experience, the F’IS diagnosis experts can precisely

Services · Condition MonitoringTroubleshooting · Balancing

78

assess the condition of individualcomponents such as rollingbearings and gear teeth.

Force and torque measurement

If damage accumulates at aparticular point in the plant, a design problem may be surmised. Overloading of bearing positionsthat was not taken into consider-ation in the design of the plant canbe detected with the aid of forceand torque and incorporated in animproved plant structure.

Balancing

Imbalance is one of the main sources of malfunctions that leadto unexpected failure of machineelements. Correct balancing givesa decisive increase in the life ofrotating machine parts. This increasesthe productivity and plantavailability. The F’IS experts reduceto a normal level the increasedvibration that occurs due tocontamination, wear, repairs, etc.They detect and eliminate thecauses of imbalances on machinesat speeds of 1 to 100 000 rpm suchas pumps, ventilators, compressors,turbines, motors etc. Irrespective ofthe sector, F’IS offers not only a detailed analysis of the reasons forthe malfunction but also the removal of imbalances in any planeof adjustment. If necessary, variousF’IS analysis devices can be usedto prepare further diagnoses.

For detailed information, seepublication WL 80 317.


Service contract

In order to fulfil the wide range ofcustomer requests and needs, F’IS offers customer-specific servicecontracts. Once the initial situationhas been determined (customerinterest, customer objectives etc.),F’IS submits a proposal for partner-ship over an extended period.Everything is possible: from training and support plans to buildup know-how in vibration diagnosisaccording to a precisely definedplan, to contracts for completemonitoring of bearing conditions. It is also possible to set up an individual online area for servicecustomers (with login via the F’IS website). Information on the current monitoring status can thenbe obtained at any time. The costsfor service contracts vary accordingto their composition.

Online monitoring

In the case of production-criticalmachinery, permanent monitoring bymeans of vibration diagnosis isindispensable in many cases. Accessat any time to precise information onthe condition of the machine offers

uniquely effective protection againstunplanned downtime and expensiveproduction stoppages. If there isalso a risk of consequential damage,an online monitoring system pays foritself in just a few months. Depending on the area of appli-cation, F’IS offers a wide range ofsolutions, including standalonesolutions for smaller equipment,medium-sized systems with up to 8 channels that can be extended ona modular basis and also complexmonitoring systems with up to 2048 sensors. In addition to giving expert advice in selecting the right system, F’ISalso implements plant monitoring.This includes not only hardwareselection but also systemconfiguration and, if necessary, itsintegration into existing systems.Depending on know-how, thecustomer can either carry out plantmonitoring himself or enlist the F’IS monitoring service. All of theF’IS monitoring systems have e-service functionality, allowingexternal monitoring by F’IS expertsunder favourable terms.

Services · Condition MonitoringService contract · Online monitoring · Offline monitoring

79

Offline monitoring

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 stoppages and does nottherefore bring expensive consequential damage. 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 byvibration analysis at regular inter-vals, for example every 4 weeks.This regularity gives more in-depthknowledge of the normal conditionof the machine, allowing deviationsto be easily detected. When preparing the offline monitoringconcept, the selection of measure-ment points and monitoring accessories as well as the definitionof the measurement interval play adecisive role.It is not absolutely essential tohave expertise on site. In the caseof irregularities in measurementsand trend analyses, F’IS offers thee-service. At the push of a button,all relevant data are exported from

the database and sent by e-mail tothe F’IS diagnosis centre, where itis subjected to expert analysis. Thecustomer is promptly sent easilyunderstandable and authoritativediagnosis reports by e-mail. Basedon teamwork with the F’IS experts,excellent analytical know-how issoon achieved. F’IS also offerssupport in data acquisition andcarries out regular on-site measurements if the customer’sinternal personnel cannot be madeavailable.

Measurement concepts

If the decision is made in favour ofcondition-based maintenance, theimportant concept phase begins.The aim is to reduce maintenanceoutlay and increase machine availability. A comprehensive cost/benefit analysis shows the optimum monitoring strategy foreach area and gives an overview of the requirements for the equipment to be used.Numerous parameters influence theselection of the systems to beused, such as the importance ofthe machine for the productionflow, the consequential damagethat may occur and the value of the

machine. The F’IS consultancy teamtakes sufficient time to clarify withthe customer all the existing questions. A plan is jointly drawnup for the introduction or the improvement of existing vibrationmonitoring systems. In particular,the distinction between online andoffline monitoring has a majorinfluence on the monitoring qualityas well as on the costs ofmonitoring.

Remote diagnosis

Due to modern communicationtechnology and the e-servicefunctionality of F’IS products, F’IS is able to remotely monitor practically any plant, such asoffshore wind turbines. From theF’IS diagnosis centre, the F’ISexperts can access the customer’smonitoring systems at any time andview the current status of the plant.The F’IS systems diagnose anydeviation from the normal conditionand forward the diagnosisautomatically via mobile, telephoneline or Internet connection to theF’IS diagnosis centre. In suchcases, the expert team isautomatically informed and canquickly prepare an in-depth

Services · Condition MonitoringOffline monitoring · Measurement concepts · Remote diagnosis

80

analysis. Depending on the urgency,different stages of the agreed escalation plan are put into action. Thus the customer isprovided in a short space of timewith the important information onthe condition of the plant and anyrecommended counteractive measures.

81

Maintenance consultancy

Maintenance consultancy byF’IS helps to make costs moretransparent and design maintenancemore effectively. The F’IS teammoves beyond classical consultancyand places the emphasis ontechnical perspectives.

The consultancy process starts witha comprehensive analysis of therelevant processes. Building onthis base, the F’IS team prepares

customer-specific improvementconcepts with the aim ofintegrating individual solutionswithin an overall solution. F’IS provides support not onlyduring the implementation phasebut also with an ongoing partnership.

Services · Maintenance managementMaintenance consultancy

Analyses

The F’IS team holds discussions withemployees on site and analyses theavailable documents. The analysisincludes subjects such as:

• business processes, costs, personnel structure, tasks/ responsibilities, machine utilisation

• commercial and production measurables

• technical support for processes• utilisation of IT and measurement

systems• maintenance strategies

• knowledge management• measurables systems relevant to

maintenance• co-operation between departments

Thanks to their experience, the F’IS consultants are in a position to evaluate the information obtainedand place it into the overall context.Anonymous data from other companies and sectors are also takeninto account for comparison. As requested by the customer, theresults are presented at a management and/or plant level.

Analyses

Maintenance analysis Failure analysis

IT benefit analysis Materials management Knowledge management

Concepts

Maintenance strategy Condition diagnosis

Reporting IPS system installation Key performance indicators

Implementation

IPS system IT linkage

Diagnostic system Reporting

Controlling

Phases in a consultancy process

82

Concepts and implementation

The concepts prepared by F’ISconsultants with the customer arealigned to the situation and visionof the customer. There are no standard processes that areimposed on the customer. Each customer is given individualtreatment. The concepts preparedare implemented in partnershipwith the customer.

Maintenance strategy:

• ABC analysis of plant stock inrelation to priorities

• RCM (Reliability Centered Maintenance)

• FMEA (Failure Mode and EffectsAnalysis)

• Condition-oriented maintenance

Introduction concept for a Computerized MaintenanceManagement System (CMMS):

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

and inspection tasks• Specification and implementation

of interfaces• Inclusion of old data

IT linkage:

• Selection of software based onthe catalogue of requirements

• Preparation of a thorough datamodel

• Specification of interfacesbetween software packages

• Specification of the necessaryhardware

Plant monitoring concepts:

• Analysis of plant weak points• Selection of appropriate

monitoring points• Definition of limit values• Definition of suitable monitoring

methods• Selection of suitable technology

Improvement of reporting system:

• Key performance indicator systems

• Automated printed key performance indicatorsreports for management

• Electronic reporting via the Internet

• Benchmarking against partnercompanies

Services · Maintenance managementMaintenance consultancy

Maintenance of concepts

In order to maintain theoptimisation of costs and benefitsachieved in the long term, regularassessments are carried out afterthe implementation phase. These measures are carried outby the customer himself, while the F’IS consultants are at the customer's disposal as a neutralpartner. Maintenance controllingcan be carried out through extension of the reporting systemby means of systems of main-tenance-relevant key performanceindicators and benchmarking projects. It is important that maintenancecontrolling is continually being checked in terms of its significanceand effect on the process.

83

IPS systems

In the field of Computerized Maintenance Management Systems(CMMS), F’IS apply their profoundtechnical knowledge to offer analysis of customer-specificrequirements independent of themanufacturer. On this basis, the F’IS team achieves a CMMSoptimised and tailor-made for thecustomer.

The F’IS service covers both complete solutions in the form ofCMMS implementation as wellas individual modules for the following areas:

Systems integration

Through the implementation ofinterfaces, for example to ERP(Enterprise Resource Planning) systems, the CMMS is integratedinto the IT environment of the

Company. This allows holisticassessment and data analyses in a complete system. Redundant data maintenance andmultiple inputting of data can beavoided. Process operations arestandardised and optimised, andthe exchange of information acrossdepartments is improved.

Services · Maintenance managementComputerized Maintenance Management Systems (CMMS)

Mobile solutions

With the use of electronic check-lists and a handheld PC, data canbe collected during an inspectionsuch that damage processing andfeedback takes place with ongoingacquisition. The data determinedand checked for consistency aretransferred via a workplace PC intothe CMMS database.

The mobile system ensuresthorough IT support to the main-tenance process and thus avoidsthe extensive use of paper andtime in manual order processing.Data quality and analysis potentialare increased through the use ofstandardised coding.

Establishment/expansion of thereporting system

The integration of reports into the CMMS provides an authoritativereporting system that offersversatile possibilities for data analysis and representation. Typical applications in this fieldinclude evaluation and failure analyses with multi-stage reports,stock and master data lists as wellas internal and external businesspapers. Reports can be generatedquickly and easily, the quality ofinformation is improved byelectronic completion of forms andthe use of standardised reportsconforms to the requirements ofcertification.

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Other services on CMMS• Release and database platform

changeover• CMMS modifications and

expanded functions• Data analysis and corrective data

maintenance• Implementation of automated

processes• Training of your personnel to user

and administrator level


Services · Maintenance managementComputerized Maintenance Management Systems (CMMS)

Training

85

Overview 86

Training descriptions 87

Mounting/Repair 87Lubrication 88Alignment 88Condition Monitoring 89Maintenance management 92

Training aids 93

F’IS offers, in relation to the product and service range, bothstandard training and customer-specific training. The individualtraining units are based on a modular concept with the resultthat customers can compile their

own customised training course onthe basis of these training components. The training coursesare offered both at FAG Group locations and also on site at ourcustomers. The current training programme including dates for the

Training · Overview

86

standard training courses can befound at www.fis-services.de in thesection Training.

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

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

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

AlignmentProduct training: FAG Top-Laser TRUMMY, SMARTY and INLINE •

Condition MonitoringVibration Analysis 0 •Vibration Analysis I • •Product training: FAG Easy Check •Product training: FAG Detector II • •Product training: FAG Bearing Analyser III • •Product training: FAG DTECT X1 • •Product training: FAG WiPro •Product training: FAG Screen Saver •Product training: FAG VibroCheck •

Maintenance managementUser training for implemented CMMS •System administrator training •

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

Overview of the most important F’IS training courses

Mounting / Repair

Basic training: Rolling bearing technology

This training communicates basicknowledge on rolling bearings andtheir use. Our rolling bearing expertswill explain types, characteristics anddesignations of rolling bearings. In thepractically-based part of the training,correct mounting and dismounting willbe communicated. Rolling bearing failures will be discussed, togetherwith their symptoms and causes.

Training content: Basic knowledge ofstandard rolling bearings and theirmounting / dismounting

Target group: Head foremen, foremenand mounting personnel from mainte-nance shops and interested employees

Duration: 1 – 2 days

Basic training: Spindle bearing technology

In this training, the participants willacquire basic knowledge of spindlebearings and their use. Our spindlebearing experts will explain types, char-acteristics and designations of spindlebearings. In the practically-based partof the training, correct mounting anddismounting of spindle bearings willbe communicated. Specific spindlebearing failures will be discussed.

Training content: Basic knowledge ofspindle bearings and their mounting,dismounting and maintenance.

Target group: Head foremen, foremen and mounting personnelfrom maintenance shops and interested employees

Duration: 1 day

Rolling bearing maintenance for railvehicle maintenance personnel(general)

This training covers the maintenanceof wheelset bearings based on cylindrical and tapered rollerbearings. Rolling bearing expertsfrom Application Engineering – Railway will communicate currentknowledge on the bearings and theirapplication. Experienced settingsupervisors will pass on theirknowledge of manual work for rollingbearing maintenance and show correct handling using selecteddemonstration items.

Training content: Maintenance ofwheelset bearings based on simplecylindrical and tapered rollerbearings

Target group: Head foremen, foremen and mounting personnelfrom rail vehicle maintenance workshops

Duration: 1 – 2,5 days

Rolling bearing maintenance forTAROL bearings

The subject of this training is themaintenance of TAROL wheelsetbearings. These double row taperedroller bearing units are adjusted,greased and sealed on both sides.Rolling bearing experts from Appli-cation Engineering - Railway willcommunicate current knowledge onthe bearings and their application.Experienced setting supervisors willpass on their knowledge of manualwork for the maintenance of TAROLbearings and show the particularaspects of this maintenance usingselected demonstration items.

Training · Training descriptionsMounting / Repair

87

Training content: Maintenance ofTAROL wheelset bearings

Target group: Head foremen, foremen and mounting personnelfrom rail vehicle maintenance workshops

Duration: 1 day

Product training: Mounting tools

This training focuses on varioustools for the correct mounting anddismounting of rolling bearings. Particular emphasis is placed on thecorrect use of tools on a day-to-daybasis. The content of customer-specific training is always agreedwith the customer.

Training content: Technically correctuse of mounting and dismountingtools

Target group: Head foremen,foremen and mounting personnelfrom maintenance shops andinterested employees

Duration: By agreement

Lubrication

Product trainingFAG lubrication systemsMotion Guard

This training covers the FAG lubrication systems “MotionGuard“ in relation to functionality,possible applications, usage andhandling. This course will enablethe participants to correctly selectand use the various products in thelubrication system “Motion Guard“.Thus unplanned machine downtimedue to defective lubrication isavoided.

Training content: Safe handlingand framework usage conditions ofFAG lubrication systems “MotionGuard“



Product training: FAG lubricants Arcanol

In this training, the participantswill acquire further knowledge ofthe FAG lubricant family “Arcanol”in relation to possible applications,usage and handling. Following thecourse, the participants will beable to select the correct grease fortheir particular application.

Training content: Selection and framework usage conditions of theFAG lubricant family “Arcanol”



Alignment

Product trainingFAG Top-Laser SMARTYFAG Top-Laser TRUMMYFAG Top-Laser INLINE

This course conveys well-foundedknowledge on the alignment of beltdrives and shafts and the measurement of belt tension. Thefunctionality, possible applicationsand handling of the measuring systems Top-Laser TRUMMY, SMARTY and INLINE are explained.Following the course, the participants will be able to carryout the required alignment workusing the measuring systems.

Training content: Safe handlingand framework usage conditions ofthe measuring systems

Training · Training descriptionsLubrication · Alignment

88

“FAG Top-Laser SMARTY”,“FAG Top-Laser TRUMMY”,“FAG Top-Laser INLINE”.



Vibration Analysis 0

This training gives an overview ofconventional vibration diagnosismethods, their essentialadvantages and boundaryconditions for the use of vibration diagnosis as part ofcondition-based maintenance.

Training content: Basic overview ofvibration diagnosis methods

Target group: Techniciansand engineers from maintenancedepartment and interestedemployees

Duration: 1 day

Vibration Analysis I

Building on the training unit“Vibration Analysis 0“, this coursecovers in greater depth the principles of vibration diagnosiswith emphasis on frequencyanalysis. Based on practicalexamples, the participants willlearn to differentiate machinedefects and damage such asbearing failure, imbalance, gearteeth defects, alignment and coupling defects using measure-ment signals.

Training content: Detection ofmachine defects and damage usingvibration diagnosis based on frequency analysis.

Target group: Technicians and engineers from maintenancedepartment and interestedemployees

Duration: 2 days

Product trainingFAG Easy Check/ FAG Easy Check Online

This training covers the advantagesand boundary conditions for theuse of the vibration measuring system “FAG Easy Check”. Following the course, the partici-pants will be able to correctly applythe vibration diagnosis system inrelation to the application.

Training content: Correct usage/handling of the vibration measuringsystem “FAG Easy Check”



Training · Training descriptionsCondition Monitoring

89

Product training: FAG Detector II

Well-based knowledge on the measuring system “FAG Detector II“in relation to functionality, possible applications and usage/handling is communicated in thiscourse. The participants will thenbe able to identify machine defectsand damage based on trend analysis using the measuring system.

Training content: Advantagesand boundary conditions ofvibration diagnosis and the safehandling of the measuring system“FAG Detector II” for detection ofmachine defects and damage usingvibration diagnosis based on parameters


Duration: 2 days

Product training FAG Bearing Analyser III

This training builds on the trainingunit “Vibration Analysis I” andcommunicates in-depth knowledgeon the measuring system “FAG Bearing Analyser III” in relation to functionality, possibleapplications and usage/handling.Following the course, the partici-pants will be able to identifymachine defects and damage indetail based on trend analysisusing the measuring system.

Training content: Safe use of the“FAG Bearing Analyser III” to detectmachine machine defects anddamage using vibration diagnosisbased on frequency analysis.


Duration: 1 day

Product trainingFAG DTECT X1

On the basis of the training unit“Vibration Analysis I”, this coursegives well-founded knowledge bothon vibration diagnosis as well asthe online measuring system “FAG DTECT X1” in relation tofunctionality, possible applicationsand usage/handling. In particular,the versatile configurationpossibilities of the system are com-municated intensively in practicalusage. In addition, the principlesof communication technology forteleservice are presented. This course will enable the participants to identify machinedefects and damage in detail basedon trend analysis using themeasuring system by remotediagnosis and online.

Training content: Extensiveknowledge of online vibration diagnosis and safe use of the “FAG DTECT X1” for detection ofmachine defects and damage byremote access.


Duration: 4 days


90

Product training FAG WiPro

This course is based on the trainingmodule “Vibration Analysis I” andconveys knowledge both on vibration diagnosis and the onlinemeasuring system “FAG WiPro” inrelation to functionality and possible applications in the windpower sector as well as usage/handling. Particular attention ispaid to the system configurationsrequired in a wind turbine on thebasis of practical examples. In addition, the principles ofcommunication technology for teleservice are presented. Following the course, the partici-pants will be able to identify indetail machine defects and damageon wind turbines based on frequency analysis by remote diagnosis and online.

Training content: Profoundknowledge of online vibration diagnosis and safe use of the “FAG WiPro” for detection ofmachine defects and damage byremote access in the wind powersector.


Duration: 4 days

Product training FAG Screen Saver

On the basis of the training unit“Vibration Analysis I”, this traininggives well-founded knowledge bothon vibration diagnosis and theonline measuring system “FAG Screen Saver” in relation tofunctionality and possibleapplications in the vibratoryscreens sector as well asusage/handling. Particular attentionis paid to the system configurationsrequired in vibratory screens on thebasis of practical examples. In addition, the principles ofcommunication technology forteleservice are presented. Followingthe course, the participants will beable to identify in detail machinedefects and damage on vibratoryscreens by remote diagnosis andonline.

Training content: Competentknowledge of online vibration diagnosis and safe use of the “FAG Screen Saver” for detection of machine defects and damage by remote access in the vibratoryscreens sector.


Duration: 4 days

Product training FAG VibroCheck

On the basis of the training module“Vibration Analysis I”, in thiscourse participants will gain in-depth knowledge both on onlinevibration diagnosis and themeasuring system “FAG VibroCheck”in relation to functionality, possibleapplications and usage/handling.In addition, the principles ofcommunication technology for network-based measuring systemsare presented. Following the course, the participants will beable to configure the online monitoring system in relation toautomated detection of machinedefects and damage and analysethe measurement data.

Training content: Extensiveknowledge of online vibration diagnosis and safe use of the “FAG VibroCheck” includingconfiguration of the automaticevaluation algorithms for timelydetection of machine defects anddamage.




91

User training for implemented CMMS

This course focuses on the setupand use of CMMS implemented atthe customer. The content isdefined upon customer’s request.

Training content: Setting up andusing a CMMS

Target group: At customer’soption


CMMS administrator training

This training covers the supportand maintenance of the CMMSimplemented at the customer. Thecontent is defined upon customer’srequest and taken from the areasof database management, Internettechnology, server support and authorisation concepts.

Training content: Supporting andmaintaining a CMMS

Target group: System administrators and key users


Training · Training descriptionsMaintenance management

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INA/FAG Technical Training Centre, Hirschaid

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

Plenty of literature is available onthe correct mounting of rollingbearings but there is usually a lackof components for trainees topractice on realistically. For thisreason the FAG training shopinstructors have prepared a basiccourse. The objective of this basiccourse is to convey the knowledgerequired for suitable bearingselection, appropriate mountingand dismounting, and bearingmaintenance. The course is splitinto two parts: a theoretical sectiondeals with the fundamentalknowledge of rolling bearings and a practical section imparts the fundamental skills needed formounting and dismounting.In the theoretical section greatsignificance was set on mergingtechnical drawing, computating andmechanical engineering into onetraining unit. The practical sectionconsists of practising the mountingand dismounting of common

bearing types with mechanical andhydraulic equipment on model-likesimplified mating parts of rollingbearings (shafts, housings).The teaching material is based onsmaller instruction steps and doesnot exceed the standard required invocational training today.Other units such as gearboxes,pumps, spindles, car wheels etc.can be prepared for practicaltraining on the basis of this basiccourse.

Handbook 1 (Theoretical part)

• Mechanical engineering• Technical computating• Technical drawing

Handbook 2 (Practical part)

• Mounting of bearingswith a cylindrical bore

• Mounting of bearingswith a tapered bore

• Hydraulic method• Practical training with

shafts and housings

Training · Training aids

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Technical data

Mounting cabinet: Dimensions 1135~710~380 mmMass (including contents) 94 kgSuitable for 10 mounting exercises:5 with shafts2 with housings3 with shafts and housingsSmallest shaft diameter: 15 mmLargest shaft diameter: 55 mm

Ordering designation (mounting cabinet with contentsand angle plate): MOUNTING.CABINET

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

Mounting sets 1 und 2The trainer can use the FAG mounting sets 1 and 2 – individualexercises from the FAG mountingcabinet – to demonstrate the

mounting and dismounting ofrolling bearings during teaching orhave the apprentices carry theseout. The shaft and housing partscan be clamped in a vice for moun-ting.

Training · Training aids

94

Mounting set 3Mounting set 3 is an additionalexercise to the FAG mounting cabinet and facilitates the mounting of a self-aligning ballbearing in a housing.

Mounting set 3: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: MOUNTING.CABINET.SET3

Mounting set 1: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• Fitting of a rotary shaft seal• Assembly (locating bearing)• Dismounting using extractor

Ordering designation: MOUNTING.CABINET.SET1

Mounting set 2: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: MOUNTING.CABINET.SET2

Training videos:

1 ~ 1 of rolling bearingsThe film is particularly suitable forcommunicating initial basic knowledgeon rolling bearings. It presentsall types of bearings and highlightstheir characteristic features.Ordering designation: VIDEOFILM201D

Mounting and dismounting of rolling bearingsThe film explains the mostimportant rules of mounting in

simple pictures and text. Cardinalmistakes are named in simpleunambiguous terms. It is clearlyshown, step by step, how variousbearings are to be correctlymounted.Ordering designation: VIDEOFILM202D

Hydraulic method for mounting and dismounting of large rollingbearingsUsing trick and real scenes, the filmshows all the common methodsand devices in hydraulic mounting:

pumps, hydraulic nuts, specialextraction devices, adapter andextraction sleeves. Furthermore, the film explains whathas to be borne in mind with tapered or cylindrical shaft seatsand how the radial clearance or theaxial drive-up distance is measuredcorrectly and expertly to ensure aperfect fit of parts on the shaft.Ordering designation: VIDEOFILM203D

Publications · Index of FAG products

95

Publications 96

Index of FAG products 97

Publications

Publication WL 80 100 Mounting and dismounting of rolling bearingsPublication WL 80 102 How to mount and dismount rolling bearings hydraulicallyPublication WL 80 123 All about rolling bearings – The FAG training offer on the theory and practice of

rolling bearingsPublication WL 80 134 FAG video on the mounting and dismounting of rolling bearingsPublication WL 80 135 FAG video on the hydraulic method for the mounting and dismounting of rolling bearingsPublication WL 80 151 Repair service for large rolling bearingsPublication WL 81 115 Rolling bearing lubricationPublication WL 81 116 Arcanol · Grease tested for use in rolling bearingsPublication WL 81 122 Motion Guard – Automatic LubricatorPublication WL 82 102 Rolling bearing damage

Technical Information

TI WL 00-11 FAG videos on rolling bearingsTI WL 80-14 Mounting and dismounting of spherical roller bearings with tapered boreTI WL 80-38 Mounting of self-aligning ball bearings using adapter sleevesTI WL 80-50 FAG pressure generatorsTI WL 80-53 Rolling bearing mounting cabinet and mounting sets –

Basic course for vocational training TI WL 80-54 FAG heating devicesTI WL 80-55 FAG alignment toolsTI WL 80-56 FAG tools for mechanical mounting and dismounting of rolling bearingsTI WL 80-57 FAG hydraulic nutsTI WL 80-58 FAG extraction devicesTI WL 80-62 FAG Detector II – the “mobile phone” among data collectorsTI WL 80-63 Rolling bearing diagnosis with the FAG Bearing Analyser IIITI WL 80-65 Modern, condition-oriented monitoring of plant and machinery

using FAG digital vibration monitorsTI WL 80-66 FAG WiPro – Wind Turbine ProtectionTI WL 80-67 FAG VibroCheck online monitoring system for heavy industryTI WL 80-68 FAG Easy Check · FAG Easy Check OnlineTI WL 80-69 FAG ScreensaverTI WL 80-70 Measurement and dimensioning of tapered studs using the FAG taper gauge MGK9205

CD-ROMs

CD Medias 4.0 Electronic INA/FAG rolling bearing catalogueCD – WLS Rolling bearing learning systemCD – MGSM 2.0 FAG Motion Guard Select ManagerCD – MM 1.0 FAG Mounting Manager

Publications

96

Index of FAG products

97

Ordering designation Product Page


ABZIEHER... Mechanical extractor for small bearings 12

AGGREGATE.E700 Electrically driven FAG hydraulic unit 27AGGREGATE.P1000/2500 Compressed air driven hydraulic unit 27

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

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

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

ARCA.LUB. .… Lubricator COMPACT with grease charge, without activation screw 49ARCA.LUB. …. .CLEAR Lubricator COMPACT CLEAR 50ARCA.LUB. …. .LC60 (~LC120, ~LC250) LC unit with 60 (120, 250) cm3 of grease for lubricator CHAMPION 51ARCA.LUB. …. .LC120.SET (~LC250.SET) Lubricator set CHAMPION with LC unit 120 (250) cm3 51

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

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

ARCA.MOUNTINGPASTE… Arcanol mounting paste 42

ARCA.PUMP25 (~180) Grease dosing device for 25 (180) kg grease container 53

AWG25 Induction heating device for workpieces up to 600 kg mass 33AWG40 Induction heating device for workpieces up to 1200 kg mass 33AWG100 Induction heating device for workpieces up to 3000 kg mass 33


98

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

COIL…./…LOW.. Electric induction heating device with low voltage 35COIL.TRANSFORMER... Single phase dry transformer for heating device with low voltage 35

FEELER.GAUGE100 (~300) Feeler gauges, 100 (300) mm long, 13 (23) blade 36

FIS.BAIII.SET.001 Bearing Analyser III 65FIS.DETECTORII.SET.1MB Detector II 65FIS.EASYCHECK.V1 Easy Check 66FIS.EASYCHECK.ONLINE.SET Easy Check Online 66FIS.X1.K2.BASIC (~K4.BASIC, ~K8.BASIC) DTECT X1 2-channel (4-channel, 8-channel) 66

FITTING.TOOL.ALU.SET10-50 Mounting tool set (aluminium) for rolling bearings, bore size 10-50 mm 8FITTING.TOOL.STEEL.SET10-50 Mounting tool set (steel) for rolling bearings, bore size 10-50 mm 8

HANDSCHUH1 (~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 33

HEATER.PLATE Heating plate (1500 W) 31HEATING.RING.... Heating ring for inner ring of cylindrical roller bearing or needle roller bearing 34HEATING.RING.PASTE.20ML Heat conducting paste (20 ml expendable syringe) 34

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

KLR… Taper ring gauge 36

LASER.INLINE Shaft alignment device 58LASER.SMARTY Belt pulley alignment device 56LASER.SHIMS… Shims for Top-Laser alignment devices 60LASER.TRUMMY Belt tension measuring device 57

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 sets (for locknuts KM5-KM8 / KM9-KM13) 11




99

LOCKNUT.FACE.PIN… Jointed face wrench for precision locknut LNP… 10LOCKNUT.FLEXI.HOOK… Jointed hook wrench for locknut KM.. or precision locknut LNPG... 10LOCKNUT.FLEXI.PIN… Jointed pin wrench for precision locknut AM.. 10

LOCKNUT.HOOK.KM... Hook wrench for locknut KM.. or precision locknut LNPG... 9

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

MGA 31 Enveloping circle gauge for outer enveloping circle 39MGI 21 Enveloping circle gauge for inner enveloping circle 39

MGK 132 (~133) Taper gauge for 90...510 mm (27…205 mm) 38MGK9205.12.SET (~30.SET) Taper gauge set for large studs, taper 1:12 (1:30) 37

MOUNTING.CABINET.D (E, F, NL) Mounting cabinet with contents and mounting bracket for basic course in German (English, French, Dutch) 93

MOUNTING.CABINET.SET1 (~SET2, ~SET3) Training case with rolling bearing, mounting tool, … 94

OILINJECTOR1600 (~2500) Oil injector 1600 bar (2500 bar) 24OILINJECTOR….VALVE Valve nipple 24OILINJECTOR….SET Set comprising oil injector and valve nipple 24

PULLER.HYD… Hydraulic extractor 15PULLER.INTERNAL.SET10-100 Internal extractor set (for bearings with bore 10 to 100 mm) 14PULLER.TRISECTION… Three-section FAG extraction plate for hydraulic and mechanical extractors 17

PUMP1000… (~1600…, ~2500…) Hand pumps and accessories 25

PUMP2500.0,2L.SET High pressure pump set (2500 bar) 26

PUMP4000… High pressure pump (4000 bar) and accessories 26

PUMP.ADAPTER… Pressure device accessory, adapters 28

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

PUMP....MANO... Manometer 29

PUMP.NIPPLE… Pressure device accessory, reduction nipples 28

PUMP.PIPE… Pressure device accessory, high pressure hoses 30

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




100



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

SOUND.CHECK Polyscope sonar device 64

TACHOMETER Digital hand tachometer 63

TAROL.MOUNTING.AGGREGATE Mobile hydraulic unit for batch mounting of TAROL bearings 27

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

TEMP.MG Temperature measuring device, contact type 62

VIDEOFILM201D 1 ~ 1 of rolling bearings 94VIDEOFILM202D Mounting and dismounting of rolling bearings 94VIDEOFILM203D Hydraulic method for mounting and dismounting 94

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 modifications in

the interests of technical improvement.

© by FAG 2005.

Reproduction in whole or in part without

our authorisation is prohibited.

WL 80 250/2 EA

FAG Kugelfischer AG & Co. oHG

Postfach 1260

D-97419 Schweinfurt

Georg-Schäfer-Straße 30

D-97421 Schweinfurt

Service Hotline:

Phone +49 2407 9149-99

Fax +49 2407 9149-59

E-Mail [email protected]

www.fis-services.de

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