training courses rolling bearings and condition monitoring

Training CoursesRolling Bearings and Condition Monitoring

For Beginners and Advanced Students

FAG Industrial Services

FAG Industrial Services GmbH (F’IS),with headquarters in Herzogenrathnear Aachen, is an independentcompany that is responsible for theworldwide service business ofSchaeffler Group Industrial coveringthe brands INA and FAG.Helping customers reduce main-tenance costs, optimise plant avail-ability and prevent unforeseenmachine downtimes is one of F’IStopmost goals.The services are provided regardlessof the brand of the machinecomponents used.F’IS is therefore the specialistcontact for the maintenance ofrotating components.

The F’IS range

F’IS offers products, services andtraining in the following five areas:• Mounting/Repair• Lubrication• Alignment• Condition monitoring• Maintenance management

F’IS training programme

F’IS offers, in relation to its portfolioof products and services, bothstandard training and customer-specific training. The individualtraining units are based on a modular concept with the result thatcustomers can compile their owncustomised training course on thebasis of these elements. Thetraining courses are offered both at Schaeffler Group locations andalso on site at the customers.

In all standard training coursessound theoretical knowledge iscombined with practical exercises.Experienced trainers communicatetheir tried and tested knowledge ina competent and up-to-date format.In the training courses, demonstra-tion materials simulating practicaloperation are used. The participantscan work hands-on, which serves toimmediately apply and deepen thetheoretical knowledge just gained.

FAG Industrial Services · F’IS training programme

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Customer-specific training coursesare always an appropriate optionwhen a large group of participantsis to be trained or it seems advisableto carry out the practical partsof the training directly on thecustomer’s plant and machinery. In this case, a trainer will bring thenecessary training material to thecustomer’s location. In this way,the customer receives training thatis specifically matched to him andhis facility.

The current training programme,including dates for the standardtraining courses, can be found atwww.fis-services.com in the sectionTraining.If you have any further questionsabout our seminar programme, theorganisation of seminars or toregister, please send an e-mail [email protected].

Contents

Training overview 4

Training descriptions 5

Mounting 5Lubrication 7Alignment 7Condition monitoring 8Maintenance management 11

Training aids for apprenticeship 12

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Training overview

Training module Training formatStandard Customer-specific

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

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

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

F’IS training courses

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

Training module Training formatStandard Customer-specific

Condition monitoringProduct training: FAG Detector III Basic •Product training: FAG Detector III Balancing •Product training: FAG Detector III Advanced •Product training: F’IS Administrator 4 •Product training: FAG DTECT X1 (with F’IS Administrator 4) •Product training: FAG ProCheck (with F’IS Administrator 4) •Product training: FAG VibroCheck: Installation (hardware) •Product training: FAG VibroCheck: Application (software) •Product training: FAG DTECT X1 (with F’IS Administrator 3.8) •Product training: FAG Detector II •

Maintenance managementUser training for implemented CMMS •CMMS administrator training •

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Mounting

Basic training: Rolling bearing technology

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

Target group: The course is aimedat head foremen, foremen andmounting personnel frommaintenance shops as well asinterested employees. No specialknowledge is required.

Training objective: The participantswill learn the correct and professionalhandling of rolling bearings and gainbasic knowledge of mounting anddismounting.

Duration: 1–2 days

Product training: Mounting tools

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


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

Duration: By agreement

Training descriptionsMounting

Basic training: Spindle bearing technology

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


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

Duration: 1 day

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Rolling bearing maintenance forrail vehicle maintenance personnel(general)

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

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

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

Duration: 1–2,5 days

Rolling bearing maintenance forTAROL bearings

Training content: The subject of thistraining is the maintenance of TAROLwheelset bearings. These doublerow tapered roller bearing units areadjusted, greased and sealed onboth sides. Rolling bearing expertsfrom Application Engineering –Railway will communicate currentknowledge on the bearings andtheir applications. Experiencedsetting supervisors will pass ontheir knowledge concerning manualwork for the maintenance of TAROL

Training descriptionsMounting

bearings and show the particularaspects of this maintenance usingselected demonstration items.

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

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

Duration: 1 day (by agreementonly)

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Lubrication

Product training:FAG lubrication systemsMotion Guard

Training content: This trainingcovers the FAG lubrication systems“Motion Guard” in relation tofunctionality, possible applications,usage and handling.The focus is on the safe handlingand boundary operating conditionsof FAG lubrication systems.


Training objective: Following thecourse, the participants will beable to correctly select and use thevarious products in the lubricationsystem “Motion Guard”. Thisensures that unplanned machinedowntime due to defective lubrica-tion is avoided.


Product training:FAG Arcanol lubricants

Training content: In this training,the participants will acquire furtherknowledge of the FAG lubricantfamily “Arcanol” in relation topossible applications, usage andhandling. It will be shown how thechoice of the correct lubricant canincrease the performance capacityand life of rolling bearings.


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


Training descriptionsLubrication · Alignment

Alignment

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

Training content: This coursecommunicates sound knowledge onthe alignment of belt drives andshafts and the measurement of belttension. The functionality, possibleapplications and handling of themeasuring systems Top-LaserTRUMMY2, SMARTY2 and INLINE areexplained. The focus is on the safehandling and boundary operatingconditions of the measuringsystems.


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


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Product training: FAG Detector III Balancing

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

Target group: The course is aimedat participants who are alreadyfamiliar with the use of the FAG Detector III. Participantsmust have previously attended the product training course “FAG Detector III Basic”.

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

Duration: 1 day

Training descriptionsCondition monitoring

Condition monitoring

Product training: FAG Detector III Basic

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

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

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

Duration: 3 days

Product training: FAG Detector III Advanced

Training content: Building on thetraining “FAG Detector III Basic”,this course goes into greater detailon the theory of vibration analysisand monitoring covered in the abovementioned course. This coursecomprehensively covers specialsubjects such as the symptomaticform of individual machine defects.Aspects relating to the conditionmonitoring of individual machineparts will be discussed in detail inrelation to defects and problemsand reconstructed in some casesusing practical exercises.

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

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

Duration: 2 days

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Product training: F’IS Administrator 4

Training content: This training dealswith the installation and the indi-vidual modules of the software F’ISAdministrator 4. The focus is on thefunction of the individual modulesand the use of the Data Viewer – aspecial analysis tool. The principlesof communication technologies arealso presented.

Target group: The course is aimedin particular at participants whohave already attended the training units “FAG Detector IIIBasic/Advanced”. Alternatively, atleast one year’s practical experiencewith an offline or online conditionmonitoring system is required.

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

Duration: 2 days

Product training: FAG DTECT X1*(with F’IS Administrator 4)

Training content: On the basis ofthe training units “FAG Detector IIIBasic/Advanced” and “F’IS Administrator 4”, this coursegives sound knowledge on theonline condition monitoring system “FAG DTECT X1” in relation tofunctionality, possible applications,usage and handling. In particular,the versatile possible configurationsof the system are communicatedintensively in practical use.

Target group: The course is aimed in particular at technicians andengineers working in maintenanceas well as interested employees.Participants must have previouslyattended the product trainingcourse “F’IS Administrator 4”.

Training objective: With this onlinemonitoring system the participantwill be able to identify machinedefects and damages per telediag-nosis based on vibration analysis.

Duration: 2 days

* Also usable for FAG WiPro.

Product training: FAG ProCheck(with F’IS Administrator 4)

Training content: In this training,the participant will learn to applythe knowledge acquired in thetraining unit “F’IS Administrator 4”to the online measuring system FAG ProCheck. The focus is onconfiguration and independentpreparation, implementation andevaluation of a measurementprocess using examples.

Target group: The course is aimed in particular at technicians andengineers working in maintenanceas well as interested employees.Participants must have previouslyattended the product trainingcourse “F’IS Administrator 4”.

Training objective: After attendingthis course, the participant shouldbe in a position to configure themonitoring system FAG ProCheckand independently prepare, imple-ment and evaluate measurementprocesses.

Duration: 2 days

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Product training: FAG VibroCheck: Application (software)*

Training content: The knowledgeacquired in the course “Detector IIIAdvanced” on the vibration analy-sis will be expanded and deepenedon the measuring system “FAGVibroCheck (VC)". The focus will beon the monitoring configurationand evaluation of the recordedmeasurement data.

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

Training objective: The participantswill be able to work confidentlywith the online condition monitoringsystem "FAG VibroCheck". The focusof the training is on theconfiguration. The course participantcan subsequently visualise theplant machinery using the VC soft-ware and analyse trend data, timesignals and frequency spectra. Hecan assess and interpret parameterand expert alarms and handle thealarm logbook.

Duration: 2 days

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


Product training: FAG VibroCheck: Installation (hardware)*

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

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

Training objective: The participantswill be in a position to maintain themeasuring system in relation tohardware extension and trouble-shooting as well as independentlycarry out hard- and software instal-lations.

Duration: 2 days

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

Training content: On the basis ofthe training unit “FAG Detector IIIBasic”, this course gives soundknowledge both on vibrationdiagnosis as well as of the onlinecondition monitoring system “FAGDTECT X1” in relation to functionali-ty, possible applications, usageand handling. In particular, the ver-satile possible configurations ofthe system are communicatedintensively in practice. In addition,the principles of communicationtechnology for teleservice arepresented.

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

Training objective: With this onlinemonitoring system the participantwill be able to identify machinedefects and damages per telediag-nosis based on vibration analysis.

Duration: 4 days (by agreementonly)

** Also usable for FAG WiPro.

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Maintenance management

User training for an establishedCMMS

Training content: This course focuseson the installation and use of theComputerized Maintenance Manage-ment System (CMMS) established atthe customers. Upon customerrequest the contents will be definedaccording to the participants.

Target group: The course is for per-sonnel who are to operate the CMMSin their company. No special know-ledge is required.

Training objective: The participantswill learn how to safely use the CMMS and will acquire sound know-ledge relating to the relevant keypoints of the training.


Training descriptionsCondition monitoring · Maintenance management

CMMS administrator training

Training content: This training coversthe support and maintenance of theCMMS established at the customers.The contents will be definedaccording to customer request fromthe areas of database management,internet technology, server supportand authorisation concepts.

Target group: The course is aimedat system administrators and keyusers.

Training objective: The participantswill be capable of independentsupport and maintenance of aCMMS.


Schaeffler Technical Training Centre, Hirschaid

Product training: FAG Detector II

Training content: In this course,sound knowledge will becommunicated on the measuringsystem “FAG Detector II” in relationto functionality, possibleapplications, usage and handling.

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

Training objective: Based on trendanalysis the participant will be ableto identify machine defects anddamage using the measuring system.


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Rolling bearing mounting cabinetand mounting sets: Basic coursefor vocational training

There is plenty of literature availableon the the correct mounting ofbearings. However, there is ageneral lack of parts on whichapprentices can train under realisticconditions. The trainers from theSchaeffler training workshopstherefore have compiled a basiccourse. The aim of this two-part rollingbearing course is to communicateknowledge on the selection of thecorrect bearing, proper mountingand dismounting and themaintenance of bearing positions.A theoretical part covers the basicknowledge of rolling bearingtechnology, while the practical partcovers the basic skills involved inmounting and dismounting.In the theoretical part, knowledgeon technical drawing, calculationand theory is communicated. Thepractical part uses exemplary sim-plified mating parts (shafts, hous-

ings) on which the mounting anddismounting of common types ofbearings can be practised with theaid of mechanical or hydraulicdevices.The teaching material is dividedinto smaller modules and is alignedto the degree of difficulty of thevocational training. Building on this basic course, otherassemblies such as gearboxes,pumps, spindles, road vehiclewheels etc. can be prepared fortraining.

Handbook 1 (Theoretical part)

• Technical theory• Technical calculation• Technical drawing

Handbook 2 (Practical part)

• Mounting of bearings withcylindrical bore

• Mounting of bearings withtapered bore

• Hydraulic methods• Exercises on shafts and housings

Training aids for apprenticeship

Technical data

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

(mounting cabinet with contentsand mounting bracket)Ordering designation insideEurope: TRAINING-CABINET-MOD-1A-DOrdering designation outsideEurope: MOUNTING.CABINET

Further demonstration models fortraining are always available onrequest. Please contact:[email protected]

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Mounting sets 2 und 3

The trainer can use the FAGmounting sets 2 and 3 – individualexercises from the FAG mountingcabinet – to demonstrate themounting and dismounting ofrolling bearings during teaching orhave the apprentices carry theseout. The shaft and housing partscan be clamped in a vice formounting.

Mounting set 1

Mounting set 1 is an additionalexercise to the FAG mountingcabinet and facilitates the mountingof a self-aligning ball bearing in ahousing.

Training · Training aids for apprenticeship

Mounting set 2:Shaft with housing

Suitable for the following exercises:• Selection of fits• Checking the bearing positions• Mounting the bearing on the

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

Ordering designation inside Europe: TRAINING-CABINET-MOD-2Ordering designation outside Europe:MOUNTING.CABINET.SET2

Mounting set 3:Hydraulic mounting

Suitable 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• Dismantling using an oil injector

Ordering designation inside Europe:TRAINING-CABINET-MOD-3Ordering designation outside Europe:MOUNTING.CABINET.SET3

Mounting set 1:Plummer block housing

Suitable 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 sleeve

Ordering designation inside Europe:TRAINING-CABINET-MOD-1BOrdering designation outside Europe:MOUNTING.CABINET.SET1

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Every care has been taken to ensure the

correctness of the information contained

in this publication but no liability can be

accepted for any errors or omissions.

We reserve the right to make technical

changes.

© Schaeffler KG · 2007, August

This publication or parts thereof may not

be reproduced without our permission.

TPI WL 80-71 EA

Schaeffler KG

Postfach 1260

97419 Schweinfurt (Germany)

Georg-Schäfer-Strasse 30

97421 Schweinfurt (Germany)

Service Hotline:

Phone +49 2407 9149-99

Fax +49 2407 9149-59

E-mail [email protected]

Internet www.fis-services.com

training courses rolling bearings and condition monitoring

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