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Course 204-500 11/01/06

Bearing Maintenance Use Guide

E204-F05-USE-DFT.wpd

Use Guide
General Discussion
The DAC #204 Bearing Maintenance Trainer is designed to be a heavy-duty, desk-top or bench-top fixture for instruction and practice in the installation and maintenance of industrial-quality rolling element bearings. Inspired by common configurations found in industry, the device allows for exercises in identification, installation, maintenance, and removal procedures for a variety of rolling element bearing types. In addition to allowing the user to refine skills in a safe and distraction-free environment, the device allows for hands-on learning without risk to company machinery or production.

Components Supplied
Baseplate (4) Steel Shaft Mounting Brackets (4) High-Grade Alloy Steel CNC-Machined Stub Shafts (8) Bearing Types (1) Shaft Seal (4) 5/8-11X2-1/2" Hex Head Bolt (2) -13X1-1/4" Hex Head Bolt (18) 3/8-16X3/4" Hex Head Bolt (18) 3/8" Flat W ashers (8) 1/4-20X3/4" Hex Head Bolt (8) 1/4" Lockwashers (1) " Combination W rench (1) 9/16" Combination W rench (1) 3/4" Combination W rench (1) Hex (Allen) W rench Set (1) Mounting Sleeve Installation Tool Kit (4-piece) DAC Use/Exercise Guide IPTs Industrial Trades Training Manual SKF Bearing Maintenance Handbook

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Course 204-500 11/01/06

Bearing Maintenance Use Guide

Features and Their Uses


The DAC #204 Bearing Maintenance Trainer is designed to replicate common maintenance scenarios found in the field that relate to the installation, maintenance, and removal of rolling element bearings. Through a broad variety of components and installation options, many rolling element bearing problem scenarios can be created. 1. Versatile Shaft Configurations The CNC-machined stub shafts are mounted using the shaft mounting brackets and/or pillow blocks provided with the Extended Unit. Two student workstations can be created, one at each end of the device. Shafts can be mounted at various 90-degree angles with the steel baseplate. A variety of shaft types are provided with the trainer. This flexibility allows for creation of many installation/ removal and maintenance conditions. 2. Large Bearing Selection A selection of large-diameter spherical roller bearings, radial ball bearings, angular contact bearings, cylindrical roller bearings, a needle bearing, and shaft seals are provided with the trainer. Also, loose and interference fit bearing seating locations are provided on the shafts. These features allow for a wide range of training scenarios. 3. Extended Version The extended version of the Bearing Maintenance Trainer adds a 24" long, multi-land shaft with two pillow blocks. This shaft assembly allows an even greater variety of configurations and fits, in addition to allowing for exercises using an arbor press and for locating a shaft within pillow blocks. 4. Bench-Top Mounting Several clearance holes are provided that allow for permanent or temporary attachment of the device to a shop bench. Assuming a stable, flat, surface, attaching the training device to a shop bench will improve the stability of the device.

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Course 204-500 11/01/06

Bearing Maintenance Use Guide

5. DAC Electromechanical Integration Bench Considerations The primary components of the trainer can be incorporated into the DAC Electromechanical Integration Bench, #905 (purchased separately). The mounting bolt patterns of the mounting brackets all match the primary centerlines of the t-slot mounting surface on the bench. All exercises identified in the Exercise Guide can be performed on the bench.

Accessories/Options
204E Extended Unit, which includes all features of the basic unit, plus a CNC-machined, 24" long, multi-land shaft and pillow blocks (For a complete description see product #204 in the DAC catalog) Tool kit, including spanner wrenches, gear puller, bearing puller, feeler gauge, soft-face hammer, lint-free cloth, universal soft jaws, light oil, crocus cloth, and shaft protector Bearing heater (cone type) Bearing interchange/nomenclature wall charts Bearing sample board with ten bearing samples and magnetic bearing nameplates Bearing inner race puller tool Video on ball bearing maintenance and installation (Majec) Video on spherical roller bearing installation and maintenance (Majec) Video on unmounted rolling element bearings (IBT) Video on mounted rolling element bearings (IBT) Video on bearing fault analysis (ITI) CD-Rom on bearing fault identification (TW I Press) Industrial Trades Training Manual (additional) Industrial Trades Handbook SKF Bearing Maintenance Handbook (additional)

204-001

T T T T

204-002 204-003 204-004 204-005 030-024 030-025 099-005 099-006 020-130 096-001 510-000 510-001 512-002

T Marked Items are suggested to complete all standard exercises.

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Course 204-500 11/01/06

Bearing Maintenance Use Guide

Reference Drawings
Four drawings are included with the training aid to be used as course references and as references when ordering replacement parts. The drawings are located at the end of this section. 1. 2. 3. 4. DAC Bearing Trainer Shafts/Bearing Locations, Product #204, D204-A01 Bearing Location Table, D204-A02 DAC Basic Bearing Trainer Assembly Drawing, Product #204, D204-A03 DAC Extended Bearing Trainer Assembly Drawing, Product #204, D204-A04

Help and Comments


W e encourage your comments on the design and use of this training aid. Our current product line has evolved primarily through the creative input of our customers. W e are always interested in your feedback on both the hardware and courseware supplied. W e also are always interested in developing new exercises to be used with our devices. If you need a training exercise beyond the standard and optional exercises listed, please call to discuss your needs. Regarding the ordering of replacement parts: W e will do our utmost to provide replacement parts, if necessary, at nominal charge. W hen calling regarding replacement parts, you will need to have your arrangement/assembly drawing and the serial number embossed on your training aids nameplate. Phone numbers are provided below. Again, thank you for purchasing the DAC #204/204E Bearing Maintenance Trainer. For questions regarding use, replacement parts, or our product line in general, please feel free to contact us at: Design Assistance Corporation 5 Gilchris Drive PO BOX 215 Swedesboro, NJ 08085-0125 United States of America Tel: Fax: W eb: E-mail: 800-662-5877 856-241-9500 856-241-9545 www.dac-3d.com sales@dac-3d.com

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