FAG PUMP1000-4L-CONTROL User manual

Hand pump
PUMP1000-4L-CONTROL
User manual

2 BA 20 Schaeffler Group Industrial
Safety guidelines and symbols
High product safety Our products correspond to the current level of research and
technology. If the bearing arrangement is designed correctly,
the products are handled and fitted correctly and as agreed and
if they are maintained as instructed, they do not give rise to any
direct hazards.
Follow instructions This publication describes standard products.
Since these are used in numerous applications, we cannot make
a judgement as to whether any malfunctions will cause harm to
persons or property.
It is always and fundamentally the responsibility of the designer
and user to ensure that all specifications are observed and that all
necessary safety information is communicated to the end user.
This applies in particular to applications in which product failure and
malfunction may constitute a hazard to human beings.
Definition of guidelines
and symbols
The warning and hazard symbols are defined along the lines of
ANSI Z535.6–2006.
The meaning of the guidelines and symbols is as follows:
Warning
If these safety guidelines are not observed, death or serious injury
may occur.
If these safety guidelines are not observed, damage or
malfunctions in the product or the adjacent construction will occur.
Note There follows additional or more detailed information that must be
observed.
 Numbers within a circle are item numbers.

Schaeffler Group Industrial BA 20 3
Page
Features Scope of delivery ....................................................................... 5
Design and
safety guidelines
Intended purpose ...................................................................... 6
Qualified personnel................................................................... 6
Protective equipment ................................................................ 6
Hydraulic oil .............................................................................. 7
Maximum pressure.................................................................... 7
Ambient conditions ................................................................... 7
Initial operation Checking the hand pump........................................................... 8
Setting the stroke volume.......................................................... 9
Spacer ring .......................................................................... 9
Mounting the spacer ring ..................................................... 9
Dismounting the spacer ring ................................................ 9
Operation Mounting the rolling bearing...................................................... 10
Mounting the hydraulic nut........................................................ 10
Connecting the hand pump ....................................................... 11
Venting the hand pump ....................................................... 11
Connection .......................................................................... 11
Venting the hydraulic nut........................................................... 11
Setting the start position ........................................................... 12
Determining the start pressure............................................. 12
Building up the start pressure.............................................. 12
Setting the end position ............................................................ 13
Determining the number of strokes ...................................... 13
Moving the rolling bearing to the end position ..................... 14
Dismounting the hand pump ..................................................... 14
Releasing the pressure ........................................................ 14
Removing the hand pump .................................................... 14
Maintenance ............................................................................. 15
Changing the oil................................................................... 15
Cleaning the tank................................................................. 15
Hand pump

4BA 20 Schaeffler Group Industrial
Page
Technical data Ordering designation................................................................. 16
EU Declaration of Conformity..................................................... 17
Digital manometer Features .................................................................................... 18
Operation.................................................................................. 18
Control keys ........................................................................ 18
Control diagram................................................................... 19
Maintenance ............................................................................. 20
Changing the battery ........................................................... 20
Dismantling......................................................................... 20
Mounting............................................................................. 20
Technical data........................................................................... 21
Ordering designations............................................................... 21
Troubleshooting ................................................................................................. 22
Value table Displacement distance, number of strokes................................ 24
Hand pump

Schaeffler Group Industrial BA 20 5
Features The hand pump and accessories are supplied in a sturdy metal case
made from sheet steel. The metal case and parts should be checked
immediately for any damage during transit. The carrier should be
informed of any damage without delay.
Scope of delivery The items included in delivery are shown in Figure 1.
Warning
If the hand pump or accessories are damaged, they must not be
used. Do not attempt to carry out repairs. Any repair work required
should be carried out by Schaeffler KG, Schweinfurt.
Metal case
Hand pump
Spacer ring (half ring),
HYDNUT50 to 150
Digital manometer
High pressure hose
with coupling sleeve
Coupling nipple
User manual
Figure 1
Scope of delivery
1
2
3
5
4
7
6
00015F98
Hand pump

6BA 20 Schaeffler Group Industrial
Hand pump
Design and
safety guidelines
Intended purpose The hand pump PUMP1000-4L-CONTROL is used to operate
FAG hydraulic nuts. These are used to mount rolling bearings on
a tapered seat, Figure 2.
Note The hand pump can also be used for dismounting,
see BA 007, FAG Hand Pump Sets.
Qualified personnel The hand pump must only be used by qualified personnel.
A person defined as qualified personnel:
■is authorised to use the hand pump
■has all the necessary knowledge
■is familiar with the safety guidelines
■has read and understood this manual.
Protective equipment Protective equipment is intended to protect personnel against
health hazards.
When working with the hand pump, the following protective
equipment must be used at all times:
■protective goggles
■gloves or oil-based cream.
Tapered seat
Rolling bearing
Hydraulic nut
Hand pump
Figure 2
Mounting
3
2
1
4
00015F99

Schaeffler Group Industrial BA 20 7
Hydraulic oil The only hydraulic oils that can be used are:
■any hydraulic oils with a viscosity of 32 mm2/s at +40 °C.
Only clean hydraulic oil should be used.
If the oil is not clean, this may lead to blockage of the filter fitted.
Warning
Hydraulic oil can cause irritation to skin and respiratory passages.
Skin contact should therefore be avoided, vapours and fumes
should not be inhaled. Eyes must be protected against hydraulic oil.
Maximum pressure The hand pump delivers a pressure of up to 1000 bar. The maximum
pressure that can be used with a hydraulic nut is 800 bar.
Warning
800 bar must never be exceeded.
The manometer must be monitored continuously during operation.
Ambient conditions The hand pump should be used under the following ambient
conditions:
■The surface underneath must be even and capable
of supporting loads
■Temperature: 0 °C to +60 °C
■Humidity: max. 90%, no condensation.
Ensure that the ambient conditions are maintained throughout
the operating period.

8BA 20 Schaeffler Group Industrial
Hand pump
Initial operation This manual describes the initial operation of the hand pump,
for information on the initial operation of hydraulic nuts
see BA 004, FAG Hydraulic Nuts.
Checking the hand pump Before any use, check the hand pump and the accessories to be
used, Figure 3.
The hand pump can only be put into operation if all the following
questions can be answered with “yes”:
■Is the hand pump  free from corrosion, cracks and damage?
■Is the tank  completely filled with a suitable hydraulic oil,
see page 7?
■Is the escape valve easy to move and free from damage?
■Is the battery in digital manometer  in acceptable condition
(if not, see the section Changing the battery, page 20)?
■Is the high pressure hose  free from damage and kinks?
■Is the high pressure hose suitable for at least 1000 bar?
■Is the required stroke volume set
(see the section Setting the stroke volume, page 9)?
Warning
If the hand pump or accessories are damaged, they must not be
used. Do not attempt to carry out repairs. Any repair work required
should be carried out by Schaeffler KG, Schweinfurt.
Hand pump
Tank
Tank lid
Escape valve
Spacer ring (half ring),
HYDNUT50 to 150
Digital manometer
High pressure hose
Figure 3
Checking for initial operation
2
1
3
4
5
7
6
00015F97

Schaeffler Group Industrial BA 20 9
Setting the stroke volume The stroke volume of the hand pump can be adjusted as a function
of the hydraulic nut used.
Spacer ring The spacer ring (half ring) restricts the stroke and thus reduces
the stroke volume. The volume without a spacer ring (half ring)
is 0,9 cm3 per stroke, when the spacer ring (half ring) is mounted,
0,2 cm3of hydraulic oil is pressed into the hydraulic nut on
a complete stroke.
The spacer ring (half ring) should be mounted when using:
■HYDNUT50 to HYDNUT150.
Mounting the spacer ring A small flat blade screwdriver is recommended as a mounting tool,
Figure 4:
■Insert the spacer ring (half ring) (position A, )
■Press the arm of the hand pump down almost to the stop
■Rotate the spacer ring (half ring) by 180° into position B, .
Dismounting the spacer ring ■Press the arm down almost to the stop
■Rotate the spacer ring (half ring) by 180° into position A, 
■Move the arm upwards
■Remove the spacer ring (half ring).
Do not replace the spacer ring (half ring) during operation of
the pump. Any inaccuracies in the displacement distance can
damage the bearing.
Spacer ring (half ring),
position A
Spacer ring (half ring),
position B
Screwdriver
Figure 4
Spacer ring (half ring)
P
0 0 0 0
1
2 3
00015F9A

10 BA 20 Schaeffler Group Industrial
Hand pump
Operation The mounting operation begins with mounting of the rolling bearing
on the tapered seat, Figure 5. Slide the rolling bearing gently onto
the shaft or slide the mounting sleeve into the original position.
A suitable hydraulic nut is then screwed onto the shaft and the hand
pump is connected. The hand pump is then operated until
the pressure to reach the start position is achieved. The hand pump
is now operated (number of strokes in accordance with the table)
until the rolling bearing has been driven up the required
displacement distance and the end position is achieved.
The pressure is then released and the hydraulic oil flows back into
the pump, after which the pump can be removed.
Note In order to avoid delays during mounting, we recommend that
the initial pressure and the number of strokes is determined before
the start of mounting.
Mounting the rolling bearing Slide the rolling bearing gently onto the shaft. In this way,
it is possible to avoid sliding the rolling bearing on further than
the start position.
If the rolling bearing is slid on further than the start position,
the radial clearance is too small.
Mounting the hydraulic nut Locate the hydraulic nut on the tapered shaft or withdrawal sleeve.
Screw a coupling nipple into the hydraulic nut.
Hand pump
Hydraulic nut
Rolling bearing
Tapered seat
Original position
Start position
Displacement distance
End position
Figure 5
Mounting
5
8
6
5
8
7
7
6
4
3
2
1
00015F9B