(a XSL Technical information 202 Mounting and maintenance in! Slewing bearingsMounting and maintenance instructions Note 1. Those general instructions for mounting ‘and maintenance apply to RKS bearings used in normal applications. For specia ‘applications, please consult RKS/SKF ‘Sewing Bearings. 2.The validity of the terms of warranty as Stated in our general conditions is depen- dent upon strict observance ofthese instruc- tions for mounting and maintenance. 3. Storage ‘Sewing bearings should be stored horizon- tally (flat on their side) and should not be subjected to shocks or damage. The bearings Should Be apt an 0 fiet mcfice int ay environnement. They should not be stored for a period exceeding one year except where special provision is made at the time of onlaag (ag erm pachaging et) CONTENTS MOUNTING. 1 Flatness of seating surfaces after machining 2 Markings 3 Mounting sequence 4 Securing 5 Tightening procedure 6 Gear backlash MAINTENANCE 7 Lubrication 8 Regreasing 9 Periodic inspection of fastenings 10 Periodic inspection of seals Flatness of seating surfaces after machining Mounting should be underta- ken with great care. Incorrect mounting of a bearing can lead to stress concentrations on the rolling elements, which will foreshorten bearing life. FLATNESS AFTER MACHINING ADMISSIBLE ERROR FRAME, ‘The bearings have limited rigidity, due to their relatively small cross section with respect to the diameter. The supporting framework should therefore be designed for maximum axial and radial rigidity. The seating surfaces must be flat, therefore machining is ‘mandatory. They should be free from rust, paint or burrs and have a good finish (between 3,2 and 6,3 im CLA).Degreasing is required before mounting. In cases where the admissible tolerances are exceeded, either hine the seating(s) or contact RKS / SKF Slewing bearings res ‘THREE ESSENTIAL STs 1 OVERHALL FLATNESS (Fi. Ia) ‘The flatness planicity tolerance for the supporting surfaces is defined as follow : Dm +1000 10000 (earings with halls o crossed rollers) a= Dm+2000 20000 (ciple row bearings) 2 LOCAL FLATNESS (Fis. Ib) s-t = variation in inclination between two consecutive ‘measurements taken at a distance I st $0,0002 +1 where I = distance between two attachment holes. tu = variation in inclination between two consecutive ‘measurements where there isa change of inclination tus 0,0002 +1 3 Comicrry (Fig. 1c) ‘The variation in the radial direction (conicity c) must not exceed 1/1000 of the width b of the seating surface for the ring. b Sig. te regarding mounting using resin to seat the bearing,WwW Bearing markings ¢ Red marking and letter “ ‘on ring : indicate the zone here the raceway is not har- dened (soft zone). For rings with a plugged hole this zone coincides with the position of the plug. Blue marking and letter “B” on geared ring : point of maximum runout of the gear, for backlash adjustement. ‘© Black marking on the rings of certain bearings having a nar- row section with respect to their diameter. The position of these markings corresponds to the minimum out-of-roundness of the assembled bearing VW Mounting sequence MOUNTING THE FIRST RING 1 Place one of the rings (the first ring) to its support (sea- ting surface), 2 Position the bearing so that the red marking of the first ring is at 90° angle to the axis of the loaded zone, when such an axis can be determi- ned or estimated. ‘3 -Adjust the position of the bea- ring so that the holes of the first ring coincide with those of the support. Check the bea- ring is leveled on its seating. Insert the bolts and washers and manually tighten the bolts, then tight to 40 t0 50% of the prescribed value, fol lowing the sequence show in section 5, For bearings with black mar- king, check the out-of-round- ness of the bearing before final tightening. If necessary follow the procedure as des- cribed in the paragraph “trueing up”, 5 Finally, tighten the bolts of the first ring to the prescribed preload, following the sequence indicated in section 5. Red mark and letter “F” (on outer ring 6 Check for correct mounting by turning the second ring. The torque (which is high due to preload, grease and friction of the seals) should not show any excessive variation or “tight spots” uring rotation, If the torque varies excessively © check the flatness of the sup- port © check the out-of-roundness of the bearing, and correct if necessary (as described under “trueing up’. MOUNTING THE SECOND RING 1 Position the support or the second ring so that the red mark is at 180° to the red mark on the first ring, or in the zone of minimum load during operation. 2 Adjust the position of sup- port so that the holes coinci- de with those of the second ring. 3 Insert and tight the bolts (same procedure as for first ring). Check correctness of moun- ting by rotating the support. letter “F* Sig.2 TRUEING UP Only applicable to bearings with black marking. 1 Align black marking by rota- ting second ring. 2 Measure bearing out-of- round : check the diameter of each ring at 6 points (30° intervals) on one the centring diameters dl, D1, D2.Permissible out-of-roundness tolerances for bearings with black marking (see figure 3) 2000 mm <9 3000 mm =0,5 mm 3000 mm <9 < 4500 mm =0.8 mm 4500 mm <9 s 7000 mm = 1,0 mm. 3 Tiueing up the bearing : if necessary, this is achieved through elastic deformation of the bearing, The out-of- round should not exceed the indicated permissible limits ‘Small deformations required to bring the out of round within these tolerances can be achieved by means of small screw jacks or star-sha- ped tool NOTE : to facilitate the trueing up, a simple tool can bbe used. This consists of a bar provided with adjustable serew at the ends, to com- press the inner ring. CAUTION : only minimal pressure should be used. A reference point at the cen- ter of the bar facilitates the operation. If a multiple arm (star) tool is available, the ‘mounting operation is further simplified. 4 Finally, tighten the bolts of the first ring to the prescribed preload, following the ins- tructions given in section 5. 5 Remove adjustment tools, 6 Turn the second ring to check for correct mounting, The torque required (high due to the preloading, grease and seals friction) should not show any excessive variation during rotation, W Securing Secure attachment of the bearing to the supports. will ensure maximum rigidity of the assembly and so avoid the risk of fatigue failure Always use good quality bolts of high tensile strenght, with a lenght of at least 5 times Used flat, hardened washers. Spring washers should never be used. ‘Threads should be lightly lubricated. Sig. 4 Tightening methods The bolt torque should be ‘ghtened with a torque wrench or a hydraulic tensioner in at least two stages. For alternative methods, plea~ se consult RKS/SKF Slewing Bearings. The bolts must be tightened in the order shown in the dia- gram below. The follo ing table shows © tightening torque in Nm (Gightening by torque wrench) ‘© the comesponding preload values Fm © the preload values obtained when using a hydraulic ten- sioner (e.g SKF Hydrocam), Nota : the tightening torque values correspond toa coefficient of friction (nuv/bolt) of 0.14 with Jubricated thread, ‘The preload Fm corresponds to 70% of the elastic limit (wrench) and 90% (hydraulic tensioner).Tightening method Wrench Hydraulic tensioner type of bolts ae 109 129 ss] 109 | to ISO 898 d pitch [torque ] FM [torque | FM | torque | FM | FM | FM (mm) | mm | wm | a | em | oo | om | om | we | ove M6 1 to | 9000 | ia | 13200 [16 | 15.400 ms | 12s | 23 | 16so0 | 34 | 24200 | 40 _| 28500 Mio | 15 45__| 26000 | 67 | 38500 | 77 | 45 000 Miz | is [80 | asso [ns | sooo | 135 | 66000 Mia | 2 125_| 53000 | 185 | 77000 | 215 | 90000 Mio | 2 195_| 72000 [285 | 106000 | 335 | 124 000 mis | 25 | 280 | 1000 | 395 | 129000 | 465 | 151.000 | m20 | 25 | 395] 117000] 560 | 166000 | 655 _| 194000 m22 | 25 | s40_[ 146000| 770 | 208000 | 900 | 243000 M24 | 3 680_| 168.000 | 970 _| 239000 | 1130 | 280000 | 199.000 | 283 000 | M27 3 1000 | 221000 | 1420 | 315000 | 1670 | 370.000 | 261.000 | 372.000 m30 | 35 | 1360 | 270000 | 1930 | 385000 | 2260 | 450000 | 319000 | 454.000 m33_| 35 | 1850 | 335.000 | 2630 | 480000 | 3.080 | 560000 | 396000 | 564 000 M36_| 4 | 2380 | 395000 | 3380 | 560000 | 3.960 | 660.000 | 466.000 | 664 000 M39 | 4 559.000 | 797 000 Ma | 45 b 642.000 | 916 000 mas | 45 750 000 | 1.070 o00] Mas | 5 846 000 | 1 206 ovo] Ms | 5 1.013 000) 1 443 o00] Ms6 | 55 1.170.000] 1666 000] Mo | 6 1 543.000) 2 198 000 M2 6 2 002 000] 2 852 000] * Tolérances according to DIN 2510, sheet 2 Gear backlash The gear backlash should be checked when the pinion is atthe point of maximum radial runout (marked in blue and stamped with a leter “B”) (fg. 6).The following table shows the recommended minimum backlash values t ensure satis- factory meshing under heavy load. The maximum values are dependent upon the backlash and the cumulative radial error. Module backlash over incl. from © : (um) (um) 3,15 63 250 375 63 10 300 450 | 10 12,5 450 675, 12,5 16 600 900 16 20 800 1200 20 25 1000 1500 ENCE WEAR © The gear teeth of a slewing bearing accomodate heavy loads ~ mesh with pinions having a relatively small number of teeth (normally less than 10. In spite of the precautions taken during design (profile correction) wear (undercut) © This type of wear which manifests itself as increased noise is not generally dange- rous. The degree of wear will become progressively smal- ler and the noise level will decrease. © Modification of the tip of the tooth profile in accordance with the table below will may occur at the base of the minimize this kind of dama- teeth (see fig. 7) for unharde- ge ned gear teeth driven by har- dened pinions a=001m| Db r fig. 7 minimum | 04m | 0,1 m maximum | 0,6 m | 0,15 m m= module Lubrication For the correct functioning of a bearing and achievement of a long operational life, regular lubrication and maintenance are essential. The primary function of a lubricant is to prevent metal-to-metal contact between the components. The lubricant should maintain a film between the rolling elements and race- ways. Slewing bearings are gene- rally lubricated with grease which also contributes to the sealing (providing added protec- tion against the ingress of water or contaminants and less risk of loss of lubricant), As slewing bearings normal- ly rotate at slow speed, the free space between the rings can be entirely filled with grease. Raceways ‘The grease used should be resistant to ageing, and have good mechanical stability. A lithium base EP grease with a consistency of 2 on the NLGI scale is generally used. The grease should be water resistant, with a temperature range of 30°C to +110°C. In some cases the operating or environmental conditions call for a special grease (e.g with a consistency of 1 or 0 for low temperature ope- ration), Unless otherwise specified, the bearing are greased by RKS before delivery, using SKF LGEP? grease, or similar.GEAR In most cases the gear is lubricated with a “compound” type lubricant, should have good adhesive properties and a good resistance to being washed out by worker. The lubricant should be capable of withstanding opera- ting temperatures of 100°C as a minimum and the base oil should have a kinematic viscosi- ty of at feast 500 mm2/s at 40°C. N.B. : at the time of delive- ry the gear is not greased. ‘The table below lists some suitable greases for the lubrica- tion of slewing bearing race- ways and gears This list is by no means exhaustive and many more sui- table exist around the world, s 10 1s 25 0 7 140 ‘Operation weeks) Diagram 1 Fabricant | Graissage roulement | Lubrification denture ARAL | Aralub HLP2 ‘Aralub LFZI BP LS6EP2 Energol WRL. ELF ELF EPEX 2 ELF NERA BSSO__| BEACON EP2 Surett Fluid KLUBER | Centoplex GLP 402 | Grasfloscon AG | Ultra Grasfloscon CA 901 Ultra Spray MOBIL | Mobilux EP2 Mobiltac 81 SHELL | Alvania EP(LF)2 | Cardium compound, Malleus SKF SKF LGEP2 : TEXACO | Multifak EP2 Crater 2 X Fluid TOTAL | Multis EP2 ENS / EP700 ‘TRIBOL | TRIBOL* 3020 Molub-Alloy* 936 SFH Retin interval woes) on Sto ge grams) a ow } ao VW Lubrication intervals and quantities ‘The first regreasing and first lubrication of the gear should be carried out immediately after mounting the bearing, until the grease exudes from the seals around the whole circumference The grease (or oil) will dete~ riorate with time due to the mechanical stresses to wich it is “subjected. It will therefore be necessary to relubricate the bea- ring at regular intervals follo- wing the operating conditions and frequency of operation. Diagram | gives the recom- mended values, based on expe- rience, for relubrication. Curve 1 is for bearing raceways and curve 2 for the gear. This values are applicable where operating temperatures do not exceed 70°C. At higher temperatures, the relubrication intervals must be reduced. The quantity of fresh grease will depend on the size of the bearing. Diagram 2 gives the recommanded quantities to be applied to the raceways at each relubrication. Curve 1 is for single row slewing bearings incorporating balls or rollers and curve 2 is for bearings with 2 or 3 rows of rollers. ‘To use an automatic or semi- automatic centralised lubrica- tion system, the bearing should be rotated during relubrication to ensure proper distribution of the grease. The new grease must be identical to or miscible with grease already contained in the bearing. A mixture of two immiscible greases will impair the efficiency of lubrication.In order to assure good pro- tection and lubrication, the space between the rings should be completely filled. ‘The gear may be lubricated cither by brushing, spraying or any other suitable method (the quantity depending on the method chosen), Before regreasing, the teeth should be cleaned from any impurities. vW Periodic inspection of bolts Between 2 weeks to 3 months after commissioning : re-tight all bolts, During each mounting, or ‘once a year, or after 2000 urs of operation : re-tighten all the bolts. If one or more bolts have lost 20% or more of the © Copyright SKF 1998 Te contents of this publication are the copyright ofthe publisher and may not be reproduced (even extracts) unless permission is granted Publication T1202 Reg. 471 8 1 000 + 2002-08, prescribed preload, then the actual bolt(s) as well as the two adjacent ones, should be repla- ced. If 20% or more of the total number bolts of a single ring are found to have less than 80% of the prescribed preload, all the bolts should be replaced. When replacing the bea- ring, always replace the bolts. When inspecting the moun- ting, ensure that : = the moving part is balanced (tilting moment close to zero) = there are no radial forces upon it Provided that the bearing is supporting a centrally-acting axial load, re-tighten the bolts individually in accordance with the prescribed procedure. Never loosen or exchange more than one bolt at a time. Use the same tightening method, the same tools and the same type of bolts employed for the origi- nal mounting, Check the bolts for damage or corrosion and replace if necessary. vW Periodic inspection of seals ‘The seals or sealing system should be inspected at least every six months, for instance, during routine maintenance of the installation. Check the condition of the seals and clean if necessary, if there are signs of damage, chan- ge the seal in order to prevent any possible contamination of the bearing. Furthermore, check the even- ness of the ring of grease around the bearing, There should always be a sufficient amount of grease at the lip of the seal. Head Office and Factory RKS S.A. Route de Vassy BP 137 89204 AVALLON Cedex France ‘Tel : + 33-(0)3 8631 41 00 Telefax : + 33-(0)3 86 34 10 70