Four-Row Tpered Roller Berings Mounting Instructions
Contents Mounting instructions for four-row tpered roller berings 1. Preprtions for mounting... 4 2. Checking the roll neck nd chock... 5-6 3. Arrnging the bering set... 7-8 4. Mounting... 9 4.1 Mounting the bering prts... 9-12 4.2 Turning in the berings... 13-14 4.3 Finl mounting... 15-16 5. Lubriction... 17 6. Mesures to be tken with seled berings... 18 7. Mintennce... 19 8. Checking the xil clernce... 20-24 8.1 Berings with outside dimeters of up to 450 mm... 20-21 8.2 Berings with outside dimeters lrger thn 450 mm... 22-24 9. Sttisticl records... 25 10. Storge... 26 3
Mounting instructions for four-row tpered roller berings Plese red these instructions crefully before strting the mounting procedure. Mke sure tht the ssembly nd mounting drwings re t hnd. 1. Preprtions for mounting The mounting site must be clen nd dry. FAG tpered roller berings re precision products whose service life is considerbly reduced by contmintion. For this reson, plese remove the originl pcking only fter you hve completed the following preprtions. Clen the bering sets in the chock nd on the roll neck thoroughly. If ny dmge such s scrtches or turning mrks is found, the bering sets must be reworked. Clen ll lubricting nd ventilting holes with compressed ir nd remove ny chips using mgnetic rod. Check ll mting prts for dimensionl nd form ccurcy. Any burrs must be removed, nd ll shrp edges must be broken off. Check the dimensionl nd form tolernces of the bering sets on the roll neck nd in the chock. 4
2. Checking the roll neck nd chock To obtin ccurte dimensionl nd form mesurement results, the following mesurements must be conducted: The roll necks must be mesured in three cross sections (long the bering set) nd the chock bores must be mesured in four cross sections. All mesurements must be crried out on four dimeters ech (offset by 45 ). The recommended tolernces for new rolls nd chocks re indicted in tbles 1 nd 1b (for inch-size berings) nd in 1c nd 1d (for metric berings). After n extended operting period, the rough operting conditions chnge the form of the chocks. The operting conditions, nd reltive movement between cone nd roll neck cuse wer of the roll neck. In tbles 1 to 1d, the permissible dimensionl nd form devitions re listed s well. If devitions exceed these limits, we recommend overhuling/reworking of the bering sets. Bering bore [mm] Tolernce New roll neck [mm] Mx. permissible dimensionl devition [mm] Up to 127,0-0,100-0,125-0,430 127,0 152,4-0,130-0,155-0,510 152,4 203,2-0,150-0,175-0,580 203,2 304,8-0,180-0,205-0,670 304,8 609,6-0,200-0,249-0,850 609,6 914,4-0,250-0,334-1,150 over 914,4-0,300-0,400-1,400 Tble 1: Permissible dimensionl devitions of the roll neck for inch-size tpered roller berings. Bering outside dimeter [mm] Tolernce New chock bore [mm] Mx. permissible dimensionl devition [mm] Devition from cylindricity [mm] Up to 304,8 +0,055 +0,080 +0,200 0,130 304,8 609,6 +0,101 +0,150 +0,380 0,260 609,6 914,4 +0,156 +0,230 +0,580 0,400 914,4 1219,2 +0,202 +0,300 +0,760 0,510 1219,2 1524,0 +0,257 +0,380 +1,000 0,670 Tble 1b: Permissible dimensionl nd form devitions of the chock for inch-size tpered roller berings. 5
Bering bore [mm] Tolernce New roll neck [mm] Mx. permissible dimensionl devition [mm] Up to 180-0,125-0,175-0,400 180 315-0,180-0,230-0,650 315 630-0,240-0,300-0,900 630 800-0,325-0,410-1,100 800 1000-0,350-0,450-1,250 over 1000-0,400-0,500-1,450 Tble 1c: Permissible dimensionl devitions of the roll neck for metric tpered roller berings. Bering outside dimeter [mm] Tolernce New chock bore [mm] Mx. permissible dimensionl devition [mm] Devition from cylindricity [mm] Up to 315 +0,000/+0,032 (H6) +0,170 0,130 315 400 +0,000/+0,036 (H6) +0,200 0,150 400 500 +0,000/+0,040 (H6) +0,240 0,170 500 630 +0,000/+0,044 (H6) +0,290 0,200 630 800 +0,000/+0,050 (H6) +0,360 0,240 800 1000 +0,000/+0,090 (H7) +0,450 0,300 1000 1250 +0,000/+0,105 (H7) +0,560 0,390 1250 1600 +0,000/+0,125 (H7) +0,690 0,520 Tble 1d: Permissible dimensionl nd form devitions of the chock for metric tpered roller berings. 6
3. Arrnging the bering set Remove the pcking from the bering set. Do not wsh out the nti-corrosion oil. It does not rect with ny of the commonly used rolling bering lubricnts. The bering set consists of: 2 single-row cups, 1 double-row cup, 2 outer spcers, 2 cones with roller-cge ssemblies, 1 inner spcer nd with seled berings, 2 sel crriers with sels (Fig. 1). sel crrier A with sel cup A-B outer spcer B cone A-C inner spcer C double-row cup D-B inner spcer E-Ce outer spcer D cup E-D sel crrier E with sel 1: Stndrd design of seled four-row tpered roller bering with mrking system 7
Mke sure tht the bering set is complete. Check the mrkings on the ring fces. The bering designtion, the yer nd the consecutive number must be identicl on ll prts. To ensure tht the bering works properly, ll prts of the bering set must be ssembled nd mounted in the order of the letters A to E on the fces of the rings nd on the outside dimeters of the spcers (Fig. 1). The bering prts must not be interchnged! 4 lod zones re mrked on the fces of the cups with the Romn numerls I to IV, offset by 90 ech. In ddition, the position of lod zone I is mrked by n xil etched line on the outside dimeter of the cups. When ssembling the bering set, mke sure tht the lod zone mrkings re ligned in row (Fig. 2). 2: Mrkings on the bering rings 8
4. Mounting To protect the bering sets on the roll neck nd in the chock from fretting corrosion, they must be coted thinly with mounting pste (e. g. FAG ARCA.MOUNTINGPASTE). Plese observe the mounting instructions in the mounting nd ssembly drwings. Bolt the cover on the roll body side securely to the chock (Fig. 3). Plce the chock on level support with the open side up (verticl xis). The mounting procedure described in the following depends on the bering design (berings with pressed cge, berings with pin-type cge or seled berings). 4.1 Mounting the bering prts Lift the prts of the bering set nd lower them into the chock in the specified order, strting with cup D-E. The lod zone I mrkings on the cups must be ligned. We recommend to position lod zone I in lod direction. Mke sure tht djcent prts but ech other completely nd the set in the chock does not get dmged by jmming. Lift the single-row cup mrked D-E with side E down nd the outer spcer D into the chock (Fig. 4). Note: In the following mounting instructions, the prt currently being mounted is shown red. 3: Fstening the cover on the roll body side 4: Mounting the cup D-E nd spcer D 9
Berings with pressed cge Plce cone E-Ce flt on supports (side E down). Then plce the other prts on top in the correct order (Fig. 4). Use the lifting device to lift the complete bering set into the chock (Fig. 4b). Mke sure tht lod zone I is ligned correctly. 4: Completing the bering set (berings with pressed cge) 4b: Mounting the pressembled bering set 10
Berings with pin-type cge Lift cone E-Ce with side E down, the inner spcer C with the retining lip down, the double-row cup B-D nd the outer spcer B into the chock (Fig. 5). Lift cone A-C nd the single-row cup A-B into the chock (Fig. 6). Mke sure tht lod zone I is ligned correctly. Berings with pin-type cge cn be mounted, like berings with pressed cge, with the help of lifting device (Fig. 4b). 5: Mounting cone E-Ce, spcer C, cup B-D nd spcer B (berings with pin-type cge) 6: Mounting cone A-C nd cup A-B 11
Seled berings Seled tpered roller berings re mounted with the help of specil lifting device. The bering is ssembled completely on the lifting device in the specified order (Fig. 1). Strt with sel crrier ring E. When ssembling grese-lubricted berings, the roller-cge ssemblies must be gresed mnully. The required grese quntity will be indicted by FAG on request. Then lift the completely ssembled bering into the chock (Fig. 6). Mke sure tht lod zone I is ligned correctly. 6: Mounting seled bering 12
4.2 Turning in the berings Slightly bolt the second chock cover to the chock using four dimetriclly opposed bolts (Fig. 7). Tilt the chock by 90 into horizontl position (level xis). Brce the clmping fixture on the cone fces with the tie rods, slightly t first. The clmping fixture must touch only the cone fces. The cge must not get jmmed (Fig. 8). With seled berings, the lifting device lso serves s clmping fixture. To turn in the bering, push in the holding ledges until they touch only the cone fce. 7: Mounting the chock cover without seling ring 8: Turning in with the clmping fixture 13
Tighten the tie rod nuts nd the cover bolts grdully nd evenly, constntly turning the cones, until the cones but the inner spcer C over their entire circumference without clernce. Keep checking this with feeler guge. Mesure the width of gp S between cover nd chock with feeler guge (Fig. 9). Loosen the cover bolts nd remove the cover gin. Insert sel of the required thickness into the cover. Bolt the cover tightly to the chock, tightening the bolts crosswise. Remove the clmping fixture nd cot the cone bore with grese. Determine the thickness of the sel. ) Sel mde of inflexible mteril B = S (0,05 to 0,1) mm b) Elstic sel: B = S + 0,2 x S mm 9: Gp between cover nd chock 10: Monting the sel nd the cover 14
4.3 Finl mounting Push the lbyrinth ring you hve heted in n oil bth onto the roll neck together with the O-ring. While the lbyrinth ring cools down, it must be pressed tightly ginst the roll body fce (Fig. 11). Push the ssembled chock onto the roll neck (Fig. 12). 11. Mounting the lbyrinth ring 12: Pushing the ssembled chock onto the roll neck 15
If the bering mounting is secured xilly by mens of quick ctch, plese observe the relevnt guidelines. If the bering mounting is secured xilly by mens of split groove ring (position 1) nd locknut (position 2), push the spcer ring nd the locknut onto the roll neck one by one. Fix the split groove ring in the roll neck groove. Tighten the locknut only modertely t first while moving the chock constntly to the right nd to the left so tht the cones but the mting prts nd the bering is ligned. Tighten the locknut securely ginst the groove ring. Loosen the locknut until clernce of 0.2 to 0.6 mm is obtined. Secure the locknut to prevent it from ccidentlly being turned (Fig. 13). If the unit is to be lubricted with grese, mke sure tht the lbyrinth nd bering re pcked with grese before use (see pge 17, item 5). The unit hs now been mounted completely. Dismounting is effected in the reverse order of mounting. 2 1 13: Axilly securing the bering with locknut 16
5. Lubriction Grese lubriction Oil lubriction We recommend to lubricte the roll berings with lithium sop bse grese with EP (high-pressure) dditives nd high level of corrosion protection (see Arcnol rolling bering-tested grese, publiction WL 81116). Unseled berings should be gresed only fter mounting s otherwise the bering my get contminted. Press grese into the bering by mens of grese gun until excess grese escpes on both sides of the bering over the entire circumference. If no grese gun is vilble, the roller-cge ssemblies must be gresed mnully before being inserted into the chock. Seled berings see pge 12. The required grese quntity for your ppliction will be indicted on request. Depending on the operting nd environmentl conditions, four-row tpered roller berings cn be operted using the following oil lubriction methods: oil sump oil-ir (oil mist) oil circultion The required oil qulity is determined on cse-to-cse bsis. Lbyrinth lubriction When being mounted for the first time, the lbyrinths should be filled well with grese nd then relubricted t regulr intervls/on the occsion of roll chnges. The sme pplies to oil-lubricted berings. The relubriction intervl nd the replenishment quntity re determined for ech specific ppliction on the bsis of the previling operting conditions. 17
6. Mesures to be tken with seled berings With seled berings, the roll neck must be lubricted t lest every 8 hours if no utomtic roll neck relubriction is provided. Drin holes must be provided in the underside of the chocks (Fig. 14). Plese consult FAG bout the dimensions. The drin holes prevent excessive pressure in front of the bering sel permit wter to drin from the chock cvities must be kept free from grese nd contminnts 14: Drin holes in the chock 18
7. Mintennce Check the effectiveness of the chock sels nd the temperture of the bering regulrly. If the bering works properly, its temperture increses slowly to operting temperture nd then remins constnt. If you detect even the slightest dmge, the sel must be replced. FAG recommends n inspection nd shift of lod zones fter every 1,000 to 1,200 operting hours. Dismount the berings in the reverse order of mounting. Clen the bering prts thoroughly with petroleum ether nd oil them immeditely fterwrds. Check ll rcewys nd rollers for visible dmge. If there is ny dmge in rcewys nd on rollers: Consult n FAG engineer. Check the xil clernce (see items 8.1 nd 8.2). Pck the bering with fresh grese. Mount the bering, in ccordnce with the mounting instructions, shifting to the next lod zone. The cups should be turned inside the chock by 180 when chnging lod zones the first time. If, for exmple, lod zone I ws ligned in lod direction before dismounting, lign the cups in such wy tht the lod zone III mrkings re now ligned in lod direction. The next times, turn to lod zone II nd then IV. Enter ll inspections nd mintennce work performed on the bering in the rolling bering inspection crd (exmple on pge 25). With seled tpered roller berings, we recommend to perform dditionl inspections fter 300, 600 nd 900 operting hours, proceeding s follows: Withdrw the chock nd remove the cover. Check the grese quntity nd the condition of the grese in the bering nd in the lbyrinths. If the grese is discoloured or contminted, we recommend to pck bering nd lbyrinths with fresh grese. The bering sel must be checked crefully nd replced if even the slightest dmge is found. Enter the checks nd mintennce work in the rolling bering inspection crd (exmple on pge 25). 19
8. Checking the xil clernce 8.1 Berings with outside dimeters of up to 450 mm Mesuring rrngement 1: blck Plce the single-row cup A-B on level supports. Plce the other bering prts, without spcers, on top of it in the specified order (the bering cge must not be supported). Lod the bering vi the upper cone with bout hlf the bering weight. Turn the cups until ll roller rows but the guiding lips. Mesure the distnce D-D nd the distnce B-B between the cups nd the distnce C-C of the cones t four points ech. Enter the results into the mesuring report (see pge 21). Mesuring rrngement 2: red To obtin more precise mesurement results, we recommend to rrnge the bering prts in reverse order nd conduct second mesurement. Strt with cup E-D. Crry out the steps described under mesuring rrngement 1. Enter the results into the mesuring report (see pge 21). Mesuring rrngement 1: blck Mesuring rrngement 2: red 20
Mesuring report Mesurement of gp B-B Mesurement of gp D-D Mesurement of gp C-C Mesurement 1 Mesurement 2 Mesurement 1 Mesurement 2 Mesurement 1 Mesurement 2 Mesurement vlue 1 Mesurement vlue 2 Mesurement vlue 3 Mesurement vlue 4 Men vlues Sm for (B-B), (D-D) nd (C-C) e.g.: Sm(B-B)=(W11+W12+ +W24)/8 Originl xil clernce A Trget xil clernce L = A * 1.3 Spcer width Sm(B-B)+L Spcer width Sm(D-D)+L Spcer width Sm(C-C)+L W1 W2 W3 W4 Sm A L B D C Mesured vlues Reding Clculted vlues The vlue of the originl clernce is mrked on the spcers. When the mount of xil clernce hs doubled in the course of opertion, the spcers must be reground. The spcer re reground to the clculted vlues. The trget xil clernce correspond to 1.3 times the originl xil clernce. 21
8.2 Berings with outside dimeters lrger thn 450 mm Step 1: Width of spcer C Mesuring rrngement 1: blck Plce cone A-C level on supports nd put cup B-D on top (the cge must not be supported). Turn the cup until ll rollers in the upper row but the guiding lip. Mesure s shown in the picture the distnce M t four points round the circumference using micrometer nd ril. Mesure the width of the double-row cup K. Enter the results into the mesuring report (see pge 24). Mesuring rrngement 2: red Plce cone E-Ce level onto supports nd put cup D-B on top (the cge must not be supported). Turn the outer ring until the rollers in the upper row but the guiding lip. Mesure the distnce N t four points round the circumference. Enter the results into the mesuring report(see pge 24). Mesuring rrngement 1: blck Mesuring rrngement 2: red 22
Step 2: Width of the outer spcers D nd B Mesuring rrngement 1: gp B-B red Plce cone E-Ce level onto supports nd put the other bering prts, with reworked or new inner spcer C, on top in the specified order (the bering cge must not be supported). Omit the outer spcers. Plce cup D-E onto cup A-B s mesuring lod. Turn the cups until the first (upper) nd the third roller row but the guiding lips. Mesure the gp B-B t four points round the circumference using prllel end block. Enter the results into the mesuring report (see pge 24). Mesuring rrngement 2: gp D-D blck Arrnge the bering prts in the reverse order, strting with cone A-C. Crry out the steps described under mesuring rrngement 1. Mesure s shown in the picture the gp D-D t four points round the circumference using prllel end blocks. Enter the results into the mesuring report (see pge 24). The outer spcers must be ground to the clculted vlues (corresponding to 1.3 times the mount of originl xil clernce). Mesuring rrngement 1: red Mesuring rrngement 2: blck 23
Mesuring report for spcer C Double-row cup width K Mesurement of distnce M Mesurement of distnce N Mesurement vlue 1 Mesurement vlue 2 Mesurement vlue 3 Mesurement vlue 4 Men vlue Sm from K, M nd N e.g. SmK=(W1+W2+W3+W4)/4 Originl xil clernce A Trget xil clernce L = A * 1.3 C=SmM+SmN-SmK+L W1 W2 W3 W4 Sm A L C Mesuring report for spcers B nd D Mesurement of gp B-B Mesurement of gp D-D Mesurement vlue 1 Mesurement vlue 2 Mesurement vlue 3 Mesurement vlue 4 Men vlues Sm for (B-B) nd (D-D) W1 W2 W3 W4 Sm Mesured vlues Reding Clculted vlues The vlue of the originl clernce is mrked on the spcers. When the mount of xil clernce hs doubled in the course of opertion, the spcers must be reground. Spcer C is either reground or new one must be provided. The trget xil clernce correspond to 1.3 times the originl xil clernce. 24
9. Sttisticl records On delivery of the berings, it is dvisble to crete record crd for ech bering in order to be ble to evlute the performnce of bering more ccurtely. An exmple of such record crd is shown below. Mill Bck-up roll O Rolling Bering Check Crd Trin Work roll O Bering type Bering No. Seril No. Bore di. Double row Rdil Clernce Lubricnt O. D. Width Four-row Axil Clernce Lubr. Intervls Instll No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Mounted Dism. Stnd No. Chock No. Top Roll Bot. Roll No. Loded zone Drive Side With. Side Inner Outer Inner Outer Running (hours) Totl run (hrs.) Production (tons) Totl production (tons) Dte of order Dte of delivery 1 st instlltion Hrs. totl Totl (tons) Remrks Instll No. 21 Mounted Dism. Stnd No. Chock No. 22 23 24 25 26 27 28 29 30 31 32 33 34 35 For Inspection of Four Row Tpered Roller Berings Top Roll Bot. Roll No. Loded zone Drive Side With. Side Inner Outer Inner Outer Running (hours) Totl run (hrs.) Production (tons) Totl production (tons) Remrks Dte Gp Spcer width Clernce Ground to New clernce Dte Gp Spcer width Clernce Ground to New clernce Dte Gp Spcer width Clernce Ground to New clernce B C D B C D B C D B C D B C D B C D 25
10. Storge Spre berings should be stored in their originl pcking, lying in dry wrehouse, supported over their entire circumference. Used berings must be clened crefully with petroleum ether, oiled immeditely fterwrds, wrpped in oiled pper nd plced in suitble wooden crte (idelly their originl pcking) before being wrehoused. Prior to extended storge periods, grese-lubricted berings must be regresed. If the chocks re withdrwn from the roll neck, they must be covered to protect the berings inside from moisture nd dirt. 26
00/01/07 Printed in Germny by Druckhus WEPPERT GmbH Scheffler KG Hevy Industries Steel Georg-Schäfer-Strße 30 97421 Schweinfurt (Germny) Internet www.fg.com E-Mil steel@scheffler.com Phone +49 9721 91-0 Fx +49 9721 91-3435 Every cre hs been tken to ensure the correctness of the informtion contined in this publiction but no libility cn be ccepted for ny errors or omissions. We reserve the right to mke technicl chnges. Scheffler KG 2007, Jnury This publiction or prts thereof my not be reproduced without our permission. WL 80 154 EA