Training Programme

BEARING FAILURE ANALYSIS

Centre for Management & Technology Development

New No.25 (Malligai T50), Oragadam Road, Ambattur, Chennai 600 053.
Phone: 044 - 26 5757 02,98,99. Fax: 044 26 5757 99.
E-mail train@cmtd.org

DETAILS REQUIRED FOR BEARING FAILURE ANALYSIS

Date

Information collected by :

Company

Designation

Place

Department

E-Mail ID

Cell phone no:

1. Bearing code number with all suffixes

2. Machine name and department.
3. How many such Similar machines?
4. RPM of bearing
5. Year of installation of the machine
6. Are there bearing failures from installation? Otherwise, since when
there are more frequent failures?
7. How often do bearing get damaged?
8. Is log-book for these machines available?
9. How many of these bearings in one machine?
10. Do bearings fail at the same frequency in all the similar machines?
11. Do other bearings in that machine also get damaged frequently? If
yes,
please give details.
12. Sketch of the machine and location of all bearings in the machine?
13. Assembly drawing and parts drawing relevant to bearing assembly
available. Yes/No
14. Machine manual available: Yes/No
15. Load type: smooth load / shock load

16. Load direction: radial / axial

17. Single shift / two shift / three shift.
18. Continuous operation / stoppage in between operation.
19. Having stand by machine: Yes / No
20. Dusty environment / water entry / chemicals entry.
21. Temperature : Normal / High / Low
22. Approximate temperature of bearing:
23. Lubrication-what oil / grease
24. Lubrication applying method and interval
25. Bearing mounting method and tools used
26. Bearing removing method and tools used
27. Observations made after removing bearings (log-book details)
1. Grease dried / melted / no grease / dusty oil or grease / oil
dark in colour / water in oil / metal particles in oil.
2. Bearing cage broken / inner race cracked / outer race
cracked / inner race slipped / outer race slipped / blue colour
of bearing components.
3. Shaft broken / shaft diameter worn-out / housing bore
damaged / punch marks in housing bore / punch marks on
shaft diameter.
4. Other observations:
28. Preventive maintenance works done on the machine.
29. Date of preventive maintenance before last bearing failure.
30. Condition monitoring data of the machine enclosed: Yes / No
31. No. of damaged bearings collected for analysis: (As many damaged
bearings as possible are to be collected for more accurate failure
analysis)

COMPANY :

DATE :

PLACE :
DEPARTMENT:

BEARING CONSUMPTION FOR LAST 3 YEARS

2006 - 07
BEARING CODE WITH
SUFFIXES

QTY

VALUE

2007 - 08
QTY

VALUE

2008 - 09
QTY

VALUE

2009 TILL DATE

QTY

VALUE

REASONS FOR BEARING FAILURES

A.

LUBRICATION :

1.
2.

Oil Leakage through damaged seals.

Oil level low.

3.

Oil ring not rotating.

4.

Oil pump not working properly.

5.

Oil pipe choked or leaking or removed.

6.

Thick oil used in oil mist lubrication system.

7.

Oil level high, producing heat and oxidising oil faster

8.

Wrong oil or grease

9.

Oil or grease not replaced in time

10. Oil or grease getting oxidised due to external heat.

11. Grease is not reaching inside the bearing.
12. Grease melting due to external heat
13. Excess grease producing heat.
14. Mixing of different types of greases or oils.

B.

CONTAMINATION:

15. Dust inside the bearing.

16. Water or chemical inside the bearing.

C. LESS CLEARANCE:
17. Oversize shaft diameter.
18. High spots on shaft diameter
19. Dust on shaft diameter
20. Undersize housing bore
21. High spots in housing bore
22. Dust in housing bore
23. Top half of housing pressing O.D. of the bearing
24. Taper sleeve tightened excessively
25. Lock nut of taper roller bearing or angular contact ball bearing tightened
excessively.

10

26.

Wrong width of shims or gaskets.

27.

Bearing with less than required clearance.

28.

Temperature of the bearing more than expected.

29.

Duplicate bearing with less clearance

30.

Two locating bearings on one shaft.

D.

INNER RACE SLIPPING :

31.
32.

Undersize shaft diameter

High spots on shaft diameter

33.

Dust on shaft diameter

34.

Cylindrical shaft having taper

35.

Taper sleeve not tightened properly

36.

Loosening of lock nut.

37.

Dust on taper sleeve

38.

High spots on taper sleeve

39.

Taper angle is not correct (poor quality sleeve)

E.

OUTER RACE SLIPPING:

40. Oversize housing bore and vibration.

41. Dust in housing bore.
42. High spots in housing bore.
43. Bearing is jammed.

F.

MISALIGNMENT OF BEARINGS:

44. Misalignment of shafts at coupling

45. Bearing seating diameters are not in line
46. Housing bore diameters are not in line
47. Bent shaft

G.

VIBRATION:

48. Unbalance.
49. Loose bolts
50. Foundation problem.
51. Misalignment of bearings

11

52. Excess clearance in the bearing.

53. Stationery machine is vibrating (stand-by machine or while transporting)

H. OVERLOADING :
54. More load than expected.
55. Wrong bearing with less load carrying capacity.
56. Misalignment of bearings.
57. Heavy vibration.
58. Tight belts.
59. Insufficient backlash of gear teeth.

I. OTHER REASONS:
60. External heat (metallurgical & dimensional deformation)
61. Insufficient cooling.
62. Brass cage in ammonia environment.
63. Electric current passing through bearing while welding.
64. Leakage electric current passing through bearing in H.T.Motors.
65. Rusting of new bearing due to lack of protection.
66. Bearing was dropped by mistake.
67. Duplicate or reconditioned bearing.
68. Mistakes in fitting the bearing.
69. Normal fatigue failure.

C O N T E N T S
Coverage

page No.

1. Types of bearings

14

2. Bearing Codes

21

3. Bearing fitting methods

29
12

4. Bearing removing methods

36

5. Lubrication of bearings

44

6. Identification of duplicate bearing

47

Acknowledgement for Sketches: SKF Catalogue No.200E

1.

Types of Bearings

There are different types of bearings. Each type has some advantages and
some limitations.
1.

Single row deep groove ball bearing

There is one row of balls. Grooves in the raceway are very deep. That is why
these bearings are called Single row deep groove ball bearings. Outer race is
fixed in the housing of the machine. Inner race is fitted on the shaft. Cage
separates balls and keeps them equally spaced. These bearings can carry

13

radial load and axial load (thrust) in both directions. These are the cheapest of
all types of bearings. A ball bearing with 40 mm bore diameter costs about
Rs.200/- and same size cylindrical roller bearing costs about Rs.1000/-.
These bearings are manufactured with metallic shield or rubber seal. Metallic
shield is fixed to the outer race and there will be a small gap between the
shield and the inner race. Otherwise, the stationary metallic shield will get
damaged by rotating shaft. Because of this gap, sealing effect is not 100%. In
rubber sealed bearings, rubber seal touches the inner race without gap. So,
sealing effect is almost 100%. Shields and seals are used for two purposes 1.
To avoid contamination going into the bearing and 2. To avoid grease in the
bearing going inside the machine.
Shield and seal are fitted on one side of the bearing or on both sides. If the
sealing is on both sides, bearing should be used at low rpm and normal
temperature so that grease inside the bearing remains effective for long time.
There is no need to regrease these bearings. If the sealing is on one side,
fitter should be careful in fitting the bearing. He should know whether the seal
or shield is towards inside or outside. If the shield or seal is to prevent
contamination entering into the bearing, they should be towards outside. If
they are to avoid grease going into the machine, they should be towards
inside. Wrong fitting will damage the bearing or inner parts of the machine.
The ball bearings can have a groove on the outer diameter to fix a snap ring.
This snap ring fixes the bearing in the housing without axial movement. It is
called axial location.
2.

Double row deep groove ball bearing

There are 2 rows of balls in these bearings. These bearings can carry radial
load and axial load in both directions. Misalignment between shaft axis and
housing bore damages the deep groove ball bearings. If the shaft is
misaligned, bearing clearance becomes zero. In this condition if the bearing

14

rotates continuously, it will get jammed because of thermal expansion and

bearing life gets reduced. So, deep groove ball bearings cannot withstand
misalignment.
3.

Self aligning ball bearings

These bearings align automatically if there is misalignment. Outer race has

spherical raceway. Inner race has two grooves for two rows of balls. This
bearing can carry radial load. But, it can withstand only very little axial load.
These bearings are used if there is possibility of misalignment between two
bearings, for example, in plummer blocks.
These bearings are manufactured with rubber seal also on both sides, for
shaft diameter from 10 mm to 70 mm. Self aligning ball bearings are produced
with taper bore also. These bearings are fitted on straight shaft with a taper
sleeve in between. Bearing is pushed on the taper sleeve by a lock nut and
lock nut is locked by a star washer.
Adaptor sleeve or withdrawal sleeve can be used. In adaptor sleeve, taper
angle increases after the thread. These threads are used for fitting the
bearing. In withdrawal sleeve, taper angle decreases after the thread. These
threads are used for withdrawal nut, which is required for removing the
bearing. Bearing is fitted by pushing the withdrawal sleeve into the bearing
bore with the help of a nut on the shaft threads.
4.

Single row angular contact ball bearing

In these bearings, ball contacts the raceways at an angle. That is why these
bearings are called angular contact ball bearings. Normally, the angle of
contact is 40. These bearings are used where axial loads are heavier. These
bearings can carry radial load and axial load in one direction. They get
damaged due to misalignment.

15

This bearing is not identical on both sides. The side in which inner race is
thicker,' is called face side. The other side in which inner race is thinner, is
called back side.
As this bearing is not identical on both sides, it can withstand axial load in only
one direction. If the bearing is fitted in the wrong direction, there will be more
vibration or the bearing will get jammed. Before- fixing this bearing in the
machine, it has large clearance. Proper clearance is maintained when this
bearing is fixed in the machine.
Two bearings are fitted on the shaft so that their angles are opposite, to carry
axial load in both directions. In face-to-face arrangement, both face sides of
the bearings will be towards each other. This arrangement is called Xarrangement also. This arrangement is used in less precision machines with
less rigidity of the shaft. Two bearings can be fitted with back sides towards
each other. This back-to-back arrangement is known as O-arrangement. This
arrangement is used for higher speed and high rigidity of the shaft.
If two bearings are fitted at two ends of a long shaft and if the shaft is likely to
expand because of temperature variation, clearance will reduce or increase
and it will create problem in the machine. In such condition, both bearings are
fitted at the same end of the shaft. This is called paired mounting. For this
paired mounting, special bearings with the code CB with their number are
used. If the axial load is heavier in one direction, two angular contact ball
bearings are fitted with angle in the same direction. This is called tandem
arrangement.
5.

Double row angular contact ball bearing

There are two rows of balls with opposite angles of contact. This bearing can
carry radial load and axial load in both directions. These are very rigid
bearings which cannot withstand misalignment.
6.

Four point contact ball bearing

16

These are special bearings. Each ball has 4 points of contact with the
raceways, whereas each ball in deep groove ball bearing has only 2 points of
contact. So, four point contact ball bearings can carry more radial load and
axial load in both directions. Inner race is made of two parts so that more balls
can be inserted into the bearings. This is a costly bearing costing 8 times the
cost of the same size ball bearing.
7.

Thrust ball bearing

This bearing is for carrying only thrust load. This bearing will slip out under
radial load. There are three parts in this bearing - shaft ring, housing ring and
cage with balls. One should be careful while fitting this bearing, because shaft
ring and housing ring have different bore diameters. Shaft ring has sliding fit
on the shaft because it rotates alongwith the shaft. Housing ring bore diameter
is slightly more than the shaft diameter because it does not rotate alongwith
the shaft.
If the shaft and housing bore are not aligned, this bearing will get loaded on
one side. In such situation, self aligning thrust ball bearings are used. Housing
ring is in 2 parts. There is spherical seating surface, between these two parts.
This spherical surface gives self aligning capacity.
Single row thrust ball bearing is for carrying thrust load in one direction.
Double row thrust ball bearing is for carrying thrust load in both directions.
This bearing has 2 sets of balls. Self aligning thrust ball bearings are also
available with single row or double row.
8. Cylindrical roller bearings
Roller bearings have line contact whereas ball bearings have point contact. So
roller bearings can carry more load. In cylindrical roller bearings, rollers are
cylindrical in shape. There are different designs of these bearings -N, NU and
NJ type. In N type bearing, rollers and cage are with the inner race. Outer race
17

is a plain sleeve. So, this bearing cannot carry any axial load. In NU type
bearing, rollers and cage are with the outer race. Inner race is a plain sleeve.
This bearing also cannot carry axial load. In NJ type bearing, outer race is
similar to NU type. But, inner race has a collar on one side so that this bearing
can take axial load in one direction. Cylindrical roller bearings will get
damaged by misalignment, because edge of the rollers will get loaded.
9.

Needle bearings

This bearing is similar to cylindrical roller bearing. Rollers are very thin and so
these bearings are called needle bearings. These bearings are available with
inner race or without inner race. Without inner race, needle bearing is fitted on
a hardened
shaft directly. These bearings are used when there is space limitation in the
machine. Needle bearings can carry radial load only. These bearings get
damaged if there is misalignment.

10. Taper roller bearings

These bearings have taper rollers fixed to the inner race with cage. Inner race
is called cone and outer race is called cup. This bearing can carry heavy radial
load and axial load in one direction. Similar to angular contact ball bearings,
two taper roller bearings are fitted at opposite angles to take up axial load in
both directions. There can be X-arrangement or O-arrangement. As the inner
race and outer race can be separated, proper clearance is maintained while
fitting the bearing in the machine. These bearings cannot take misalignment.
11. Spherical roller bearings

18

These bearings have two rows of spherical rollers. Inner race has 2 raceways
and outer race has one spherical raceway. So this bearing has self aligning
capability and so it can withstand misalignment. These bearings can carry
heavy radial load and axial load in both directions. They are manufactured
with cylindrical bore or taper bore.
12. Cylindrical roller thrust bearings
These bearings are similar to thrust ball bearings. Instead of balls, cylindrical
rollers are used. They can carry only thrust load. Misalignment of shaft axis
with housing bore axis creates one side loading.
13. Spherical roller thrust bearings
These bearings have one row of spherical rollers in spherical raceways. So,
these bearings have self aligning capability. As the rollers are at angle with
respect to the axis, these bearings can carry radial load also alongwith thrust
load.

19

20

2. Bearing Codes
Bearing codes are used for ordering and for reference. We can understand
few details about the bearings from their code numbers. Sometimes, the code
number of an available bearing may not match exactly with the code number
of recommended bearing. In such situation, user should be able to decide
whether the available bearing is suitable for use. For this, all the users should
be aware of bearing codes.
As per ISO recommendation, a bearing code should normally have 5 digits.
But, bearing manufacturer, shorten the bearing codes to 4 digits or 3 digits.
1

5
Bearing type
Bearing width series
Bearing O.D. series
Bearing I.D.

1. Types of bearings
Normally first digit indicates bearing type. Sometimes, there are special rules
also.
Type of bearing

First digit

Self aligning ball bearing

Spherical roller bearing

2 (only 4 numbers)
2 (5 numbers)

Taper roller bearing

3 (5 numbers)

Double row angular contact ball bearing

(actual code is 0. But this 0 is omitted)
Double row deep groove ball bearing
Type of bearing

3 (4 numbers)
4
First digit

21

Thrust ball bearing

- Single row

51

- Double row

52

- Single row, self aligning type

53

- Double row, self aligning type

54

Single row deep groove ball bearing

Single row angular contact ball bearing

Cylindrical roller thrust bearing

81

Spherical roller thrust bearing

29

4-point contact ball bearing

QJ

Cylindrical roller bearing

N, NU, NJ

Needle bearing

NK, NA, RNA, BK, HK

2.

Width & Outer diameter

For the following bearings, second digit indicates relative width and third digit
indicates relative outer diameter.
Spherical roller bearing (Codes no.2; have 5 digits)
Taper roller bearing (Codes no.3; have 5 digits)
Cylindrical roller bearings having 4 digits after N, NU or NJ
For other bearings, either width code or O.D. code is omitted and the second
digit indicates relative width and outer diameter together.

Width series can have following numbers:

0, 1, 2, 3 and 4 (in the order of increasing width)
O.D. series can have following numbers:
8, 9, 0, 1, 2, 3 and 4 (in the order of increasing OD)

22

3.

Bore diameter (ID)

Normally, last 2 digits indicate bearing bore diameter (ID). When the last 2
digits are from 04 to 98, if they are multiplied by 5, bore diameter is obtained.
04 x 5 = 20 mm
98 x 5 = 490 mm
Below 20 mm and above 490 mm, the rule is different. For bearings with bore
diameter more than 490 mm, actual bore diameter is given in millimeter after
the symbol "/". For example, 60/500 indicates single row deep groove ball
bearing with 500 mm bore diameter.
For 10 mm bore diameter, last 2 digits are 00.
For 12 mm bore diameter, last 2 digits are 01.
For 15 mm bore diameter, last 2 digits are 02.
For 17 mm bore diameter, last 2 digits are 03.
When bore diameter is less than 10 mm, it is shown directly in millimetre as a
single digit. These codes have only 3 digits. For example, 629 is for single row
deep groove ball bearing with 9 mm bore diameter.
Examples:
a)

21312 and 22312

First digit is 2 and there are 5 digits in the code. So, these are spherical roller
bearings. Last 2 digits are 12 in both codes. 12 x 5 = 60 mm is the bore
diameter. Second digit indicates relative size of width and third digit indicates
relative size of O.D.

Bearing number

Width

OD

ID

21312

31 mm

130 mm

60 mm

22312

46 mm

130 mm

60 mm
23

We should refer to the bearing catalogue to know the width and O.D. of a
bearing.
b) 1208 and 2208
Actual code numbers of these two bearings are 10208 and 12208. These are
self aligning ball bearings. From the first code, 0 has been removed and from
the second code, 1 has been removed and so the codes have become 1208
and 2208.
Bearing number

Width

OD

ID

1208 (10208)

18 mm

80 mm

40 mm

2208 (12208)

23 mm

80 mm

40 mm

So, when a bearing code starts with 1 or when it starts with 2 and has only 4
digits, it is self aligning ball bearing.
c) 6208 and 6308
First digit 6 indicates single row deep groove ball bearing. Second digit and 2
and 3 indicate size of OD and width. Last 2 digits 08 indicate bore diameter 40
mm (08 x 5 = 40)
Bearing number

Width

OD

ID

6208

18 mm

80 mm

40 mm

6308

23 mm

90 mm

40 mm

4. Secondary codes (Suffix)

24

So far, we have discussed primary codes of bearings. More information about

bearings are given by secondary codes or suffixes which follow the primary
code. For example, 6208-C3. In this code C3 indicates that this bearing has
more than normal clearance and so this bearing is used where temperature is
higher.
All bearings have internal clearance. This clearance is required for following
reasons.
a) To take up expansion of inner race while fitting it on the shaft with tight fit.
b) To take up thermal expansion of inner race when the machine is running
continuously.
c) For a thin film of lubricant
For general applications, bearings with normal clearance are used. There is
no special code for normal clearance. If there is possibility of higher internal
temperature in the machine, bearing with higher clearance is used. Code for
this bearing will contain the suffix C3. When the internal temperature is still
higher, C4 clearance which is more than C3 is used. In very special
application, C5 clearance is also used, which is more than C4 clearance.
C2 is less than normal clearance. This clearance is used where the shaft
should rotate without much radial play and vibration. For example, in machine
tools. CI is less than C2 clearance which is used in very accurate machine
tools.
So, the order of increasing clearance is CI, C2, (normal), C3, C4 and C5.
Clearance value depends upon the type of bearings, size and clearance
classification. Let us compare clearance values of few bearings.

Clearance in microns
Bearing type

Shaft

Clearance in microns

25

C2

normal

Single row deep groove 40 mm

1 to 11

6 to 20

15 to 33

ball bearing

100 mm

1 to 18

12 to 36

30 to 58

Cylindrical roller

40 mm

5 to 30

25 to 50

45 to 70

bearing

100 mm

15 to 50

50 to 85

75 to 110

diameter

C3

Spherical roller bearing 40 mm

15 to 30 30 to 45

45

(with cylindrical bore)

35 to 60

100 to 135

100 mm

60 to 100

to

60

Clearance values of various types of bearings are available in the bearing

catalogue. Followings are the secondary codes which are used very
frequently. Note that same code can have different meanings in different
bearings.
Suffix
A

Meaning

- Modified internal design. For example, 4208 A is double row

deep groove ball bearing without filling slot for inserting balls.

AS

- Needle roller bearings with lubrication holes in the outer ring.

Additional figures indicates number of holes.

- Modified internal design. For example, 7212B is single row angular

contact ball bearing with 40 contact angle.

- Modified internal design. For example, 22315C is spherical roller

bearing with flangeless inner ring, symmetrical rollers, loose guide
ring and pressed cage.

CA

- Single row angular contact ball bearing for paired mounting to

have little axial clearance.

CB

- Single row angular contact ball bearing for paired mounting to

have normal axial clearance.

Suffix

Meaning

26

CC

- Single row angular contact ball bearing for paired mounting to

have greater axial clearance.
- Spherical roller bearing of C design, but with improved roller
guidance and so less friction.

CI, C2, C3,

C4, C5 - Clearance Classification
D

- Modified internal design. For example, 3312D is double row angular

contact ball bearing with two part inner ring and 45 contact angle.

- Modified internal design. For example, NU215E is cylindrical roller

bearing with more number of larger rollers than the original design to
carry more load.
- Single row angular contact ball bearing with plastic cage and
reinforced ball set.
- Spherical roller bearing, better than CC design, having guide ring
positioned towards outer race. This better design facilitates inclusion
of more number of larger balls and reduction of friction.

EC

- Cylindrical roller bearing with more number of larger rollers and higher
axial load carrying capacity when used with HJ angle rings.

- Machined steel cage.

- Single row angular contact ball bearing for paired mounting with
preload (negative clearance)

- Pressed steel cage

- Taper bore with 1 : 12 taper

K30 - Taper bore with 1 : 30 taper

M

- Machined brass cage

27

Suffix

Meaning

- Snap ring groove on outer ring

NR

- Snap ring groove on outer ring and appropriate snap ring

- Plastic cage

RS

- One side rubber seal

RSI

- One side rubber seal of better quality

2RS1 - Both side rubber seal of better quality

TN9 - Injection moulded plastic cage
V

- Bearing without cage

W33 - Lubrication groove and 3 holes on outer race

X

- One or more external dimensions modified to suit ISO standard.

- Metallic shield on one side.

2Z

- Metallic shields on both sides.

3. Bearing Fitting Methods

28

New bearings are fitted when a new machine is assembled. Later, bearings
are removed and fitted for various reasons. However, bearings should never
be removed unnecessarily. Because it damages the shaft and other pails.
Following precautions should be used while fitting a bearing:
a.

Bearing should be removed from its packet just before fitting to avoid
dust
going into it.

b.

There is no need to clean the new bearing in diesel, petrol or Kerosene, if

you are sure that the bearing is clean. If some dust has gone inside,
bearing should be cleaned in clean diesel or kerosene. Bearing should be
dipped in clean oil to avoid rusting and it should be packed in a clean
cover to reserve for longer period.

c.

Shaft diameter and housing bore diameter where the bearing fits, should
be
cleaned thoroughly. Any rust should be removed by rust removing
solutions.

d.

High spots on the shaft and housing should be removed by emery paper
and file. Otherwise the bearing will not have proper grip on the shaft or
housing.

e.

If a bearing fails frequently, shaft diameter and housing bore diameter

should be measured and confirmed.

f.

Putting few drops of oil on the shaft diameter will help in fitting bearing
with
tight fit on the shaft.

g.

Proper tools and methods explained below should be followed for easy
fitting of the bearing.

29

Fig.1, 2 and 3: (For the sketches, please refer to the pages at the end of this
chapter). Inner race is fitted on the shaft with tight fit if the shaft is the rotating
one. A pipe should be used on the inner race and force should be given by a
mallet or hammer. Bearing mounting tool kit can be used from 10 to 50 mm
shaft diameter. For bigger size bearings, proper pipes should be kept ready.
Hitting the bearing directly will result in shaft damage as bearing will not enter
straight. Wooden pieces should never- be used as the wood particles will go
into the bearing. When the tight fit is on the shaft, force should not be given on
the outer race.
Fig.4: If there is internal or external threads on the shaft, it can be used to
push the bearing with even force.
Fig.5: Mechanical or hydraulic press can be used to fit medium size bearings.
Fig.6, 7: Larger bearings have very tight fit on the shaft. They should be
heated upto 120C by suitable methods. Inner race will expand sufficiently and
it can be pushed easily on the shaft. Bearing will get cooled and shrink on the
shaft creating tight fit.
Fig.8: Oil bath heating is a simple method. But, few precautions should be
followed, so that bearing life is long.
a)

Clean oil should be used, Otherwise dust in the oil will get in between

cage and rolling elements. It will damage the cage. Used hydraulic oil or
transformer oil can be used. This oil should not be dusty.
b)

Second precaution is to heat the oil bath upto 120C. A simple

thermometer costing just Rs.300/- will help to measure the temperature.

c)

Third precaution is that the bearing should never be kept directly on the

bottom surface. This surface will be very hot, more than 300C. If the bearing

30

contacts this surface directly, it will also become very hot and its life will get
reduced. Simple insulating material like broken switches or fuse carriers can
be kept on the bottom surface. On the top of this insulation, bearing should be
placed. Wood or asbestos should never be used as they form fibre and it can
get into the bearing.
Fig.9: Electric induction heater is a convenient tool to heat the bearing. Within
few-minutes even larger bearings get heated upto 120C. Hot bearings can be
handled easily as they do not become oily. Good induction heaters have inbuilt temperature probe. Once the bearing attains the temperature set by the
operator, power supply-cuts of automatically. If this control is not available,
power should be cut off manually by measuring the temperature. Bearing
becomes magnetic while heating in induction heater. This bearing should be
demagnetised properly. Otherwise, the magnetised bearing will not have
proper life. Good induction heaters have in-built demagnetisation cycle.
Otherwise, the bearing should be kept in reverse position and power supply
should be given for about 10 seconds.

Fig.10 : If the housing rotates and shaft is stationary, outer race will have
interference fit in the housing bore. Here, a pipe should be used on the outer
race to hit with hammer.
Fig.11 : Cylindrical roller bearing should be assembled carefully. In this
bearing, inner race and outer race can be separated. Inner race is fitted on the
shaft. Outer race is fitted in the housing. Then housing is lifted and assembled
on the shaft or shaft is lifted and assembled in the housing.
While doing so, roller assembly should be straight with respect to the raceway.
If assembly is tried by keeping the bearing at an angle, rollers or cage may got
damaged. Few rollers in the top will come down due to clearance in the cage.
These rollers should be pushed up with fingers while assembling.

31

Fig. 12 : In this assembly, housing rotates. So, outer race of taper roller
bearing has tight fit. Pipe is kept on the outer race for hitting. Hitting is done till
the outer race touches the circlip used for positioning the bearing. Then, wheel
is kept upside down and the second outer race is fitted.
Fig.13 : On the shaft, one inner race is fitted and greased. Then the wheel is
assembled. Next, other inner race is filled with grease and fitted on the shaft.
Fig.14 : Finally, lock nut is tightened on the shaft thread. Tightening of lock nut
should be done carefully. Too much tightening will not allow free rotation.
Insufficient tightening will make the assembly loose and the wheel will wobble.
It will damage the bearing and the wheel. Correct procedure is to tighten the
nut fully and then loosen slightly so that wheel rotates freely.
Fig. 15 : Then the play in the bearing is checked by shaking the wheel back
and forth. This is skilled work. If the assembly is critical, then the play is
measured by dial gauge.
Fig. 16 : Dial gauge is fitted on the stationary part and the plunger is kept on
the moving part. Moving the shaft or wheel back and forth will show exact play
in the dial gauge. According to the required play, nut can be further tightened
or loosened. Then the nut is locked by a split pin, wire or check nut.
Fig.17 : Bearings with taper bore are fitted on taper sleeves. These sleeves
have slot for spring action. Bearing is tightened on the adaptor sleeve with
lock nut. A star washer is used to avoid loosening of locknut.

Fig.18 : Adaptor sleeve is kept on the shaft at correct location. This correct
location can be marked with a sharp edged tool while disassembling the
bearing.
Fig. 19 : Lock nut can be tightened easily with a C-spanner. Overtightening
will result in insufficient clearance. Otherwise, if the nut is not tightened
32

sufficiently, bearing and sleeve will not have proper grip and they may slip
while rotating, leading to damage. Measuring internal clearance will confirm
whether the lock nut has been tightened sufficiently.
For this, measure the clearance of the bearing using feeler gauges before
fitting. For example, in the spherical roller bearing 22314 K, whose bore
diameter is 70 mm, clearance is 0.08 mm. As per SKF catalogue, this
clearance should get reduced by 0.04 to 0.05 mm for proper tightness. That
means, after tightening, clearance should be between 0.03 and 0.04 mm.
(0.08 - 0.04 = 0.04 and 0.08 - 0.05 = 0.03 mm). Following chart is the
simplified form of the chart recommended by SKF.
Spherical roller bearings on taper sleeve :
Bearing bore diameter (mm)

Reduction in Clearance (mm)

25 and 30

0.015 to 0.02

35 and 40

0.02 to 0.025

45 and 50

0.025 to 0.03

55 to 65

0.03 to 0.04

70 to 80

0.04 to 0.05

85 to 100

0.045 to 0.06

110 and 120

0.05 to 0.07

130 and 140

0.065 to 0.09

150 and 160

0.075 to 0.1

170 and 180

0.08 to 0.11

190 and 200

0.09 to 0.13

220

0.1 to 0.14

240

0.11 to 0.15

33

Fig.22: After fully tightening the lock nut, lock nut is removed and locking
washer is kept in position. Lock nut is tightened again fully. One of the tabs of
the lock washer is bent in the slot of the lock nut so that it does not get
loosened.
Fig.23: Withdrawal sleeve has decreasing taper after the thread. Here, the nut
on the sleeve is used for removing the bearings. Bearing and sleeve are fitted
by means of nut on the shaft thread or by means of a clamping plate which is
bolted to the shaft. By pushing the withdrawal sleeve into the bearing taper,
bearing in fitted. Here also, proper tightness is confirmed by measuring
bearing clearance.
Fig.24: In some machines, bearing housing can be separated into top half and
bottom half. In this kind of housings, if the bore is oversize, outer race of the
bearing may slip and it will damage the bearing and the housing. On the other
hand, if the housing bore is undersize, it may squeeze the bearing and the
bearing will not have long life due to reduced clearance. Both these problems
can be solved by keeping proper size shims on the O.D. of the bearing or
between the two halves of the housing. To know the correct size of shim,
following procedure is used. 3 small pieces of lead wire used for soldering are
kept as shown in fig. 24. (One wire on the top of the bearing and two wires on
the parting line of the housing.) Housing is tightened fully and loosened again.
Lead wires would have been pressed. Thickness of these wires are
measured.
Fig.25: This is one possibility; Lead Wires on the parting line measure 0.2 mm
and the lead wire on the O.D. of the bearing measures 0.5 mm. If we remove
0.2 mm wires and tighten the bolts again, 0.5 mm thick wire on the bearing
O.D. will get pressed to 0.5-0. 2=0.3 mm.

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Fig;26: That means there is 0.3 mm gap in the bore. So, 0.3 mm thick shim
should be kept on the bearing OD before fixing the top half of the housing.
This is how the problem of oversize housing bore can be solved.
Fig.27: There is another possibility. Lead wire on the top of the bearing may
be 0.2 mm and the wires at the parting line may be 0.4 mm. If we remove 0.2
mm wire from the top of the bearing and tighten the bolt again, wires at the
parting line will be pressed to 0.2 mm.
Fig.28: That means there is 0.2 mm gap at the parting line when the top half
of the housing touches the bearing OD. Here, 0.2 mm thick shims should be
kept between the top and bottom halves of the housing. This way the problem
of undersize . housing bore can be solved.

Fig.29: Very big bearings are fitted by hydraulic method. Big roller bearings
have very tight fit on the shaft. Even if the bearing is heated upto 120C, it
may not expand sufficiently. These bearings are expanded. by hydraulic
pressure, by injecting oil between shaft and the bearing. There is a circular
groove around the shaft where the bearing is fitted. There is radial hole and an
axial hole connecting the circular groove to a threaded hole. A hand pump is
connected to this threaded hole with a hydraulic hose. Oil is injected at high
pressure.
Fig.30: This is the hand pump. Many fitters use hydraulic oil because this
method is called hydraulic method. But, it is not correct. Hydraulic oil is very
thin. It will leak out easily and so pressure will not develop. A thick oil having
more than 30cSt viscosity should be used. It will expand the inner race
sufficiently without leaking out.

35

36

37

38

4. Bearing Removing Method

A bearing should be removed only if it is very much necessary. There is

possibility of damage to shaft and other components if the bearing is removed
unnecessarily. Following points will help for easy and quick removal of
bearings.
1.

If a machine has not been opened so far, it is better to read the manual

and study the drawings. It will help to understand the correct method for
opening the machine and the precautions to be taken so that there is no
damage to the machine parts.
2.

Proper tools are to be kept ready so that bearing can be removed easily

and quickly.
3. Machine surfaces should be cleaned as much as possible so that it is
convenient to open it.
4. Immediately after opening, all the parts should be inspected and their
condition should be noted down in the log book. This information will be useful
later while analysing causes of bearing failure.
Fig.1 : (Figures are given in the end of this chapter). Puller is the convenient
and simple tool to remove a bearing having tight fit on the shaft. Little force is
sufficient to remove the bearing. There is no need to give any support to the
shaft. It is best to fix the puller legs on the inner race. But, in many situations,
it is not possible. So, puller legs will be fixed on outer race. If the bearing is to
be re-used, puller legs should be carefully fixed so that cage or shield is not
damaged. For smaller size bearings, mechanical puller is used and for bigger
size bearings, hydraulic puller is used. If these pullers can not be fixed, plate
type pullers made locally can be used.

39

Fig.2 : If it is not possible to use any type of puller, a blunt edged chisel can
be used to hammer the bearing out of the shaft.
Fig.3 : In this arrangement, outer race has interference fit in the housing. So,
pipe should be kept on the outer race and force should be given. Pipes in the
bearing fitting tool kit can be used.
Fig.4 : This is similar to Fig.3. But, the housing bore is not uniform throughout
the length. In between two bearings, there is a step. So, pipe cannot be used
to push the bearings out from one side. Instead a chisel should be used.
Fig.5 : In this arrangement outer race has tight fit. Inner race of the self
aligning ball bearing can be swivelled and puller can be used. See, how the
screw of the puller is supported on a cross bar.
Fig.6,7 : If a bearing is fitted on the taper sleeve, if is easy to remove the
bearing. First, the bent tab of the lock washer is disengaged from the lock nut
slot. Then lock nut is unscrewed by few turns.
Fig.8 : In this arrangement, there is a spacer behind the bearing. There is a
gap in the spacer near the taper sleeve. Adaptor sleeve alongwith the
loosened nut can be pushed inside the bearing by keeping a pipe on the nut.
When the taper sleeve is pushed inside, bearing becomes free.
Fig.9 : This bearing has been fitted on withdrawal sleeve. Here, threads on
the sleeve are used for tightening withdrawal nut. When the withdrawal nut is
tightened, it pulls out the sleeve from the bearing bore. Bearing becomes free.
Fig.10 : Very big bearings are removed by hydraulic methods. For this, the
shaft should have appropriate groove and holes. This method has been
explained in bearing fitting methods (Fig.29 and 30). Thick oil with viscosity
more than 300 cSt should be used.
Fig.11 : If the machine is not going to be assembled immediately, it should be
covered properly so that dust or water does not go into critical areas.

If a bearing seizes on the shaft, any of the above methods may not work. In
that condition, bearing should be cut and removed.

40

41

42

5. Lubrication of Bearings
Oil and grease are two types of lubricants used for bearings. These lubricants
form a thin oil film between rubbing surfaces and reduce friction. By reducing
friction, wear and tear is reduced and bearing life is increased. Lubrication is
the simplest part of bearing maintenance - removing old grease and oil and
putting new grease and oil. But, this simple work is very critical. If it is not
done properly, it will be the reason for bearing damage and subsequent break
down.
If few precautions are followed, most of the bearing failures due to lack of
lubrication can be avoided.
a) Right type
b) Right interval
c) Right quantity
d) Right method
e) Without contamination
a) Right type:
Right type of oil or grease recommended by the machine manufacturer should
be used. Equivalent oil or grease can be used only if it is certain that they are
correct equivalents. Servo system 68 and Turbinol 68 are equivalent oils.
These are ordinary thin oils having a viscosity of 68 centistokes (cSt). These
oils are used in lightly loaded and high speed bearings. In many cases, the
number alongwith the oil name indicates the viscosity in centistokes.
Servomesh 320 is a thick oil having a viscosity of 320 centistokes. This oil is
used for heavier load. Servomesh SP320 is also a thick oil with 320 cSt
viscosity. But, this is not an ordinary oil. This is a special oil used for extreme

43

pressure applications. So, 'this oil is called EP oil. Usually Sulphur and
Phosphorous are the chemicals added in these oil so that they can withstand
extreme pressures. Because of Sulphur and Phosphorous chemicals, these
oils are called SP oil also. These oils are used in slow

speed and heavily

loaded machines.
Parthan EP 320 and Servomesh SP 320 are equivalent extreme pressure oils.
If an oil without EP or SP is used, wear out of bearings or gear will be quicker
in extreme pressure applications.
For higher temperatures, special oils with better oxidation stability should be
used. Servocyl C460 is a high temperature oil.
Servogem 2 and Lithon 2 are equivalent ordinary greases. These greases
remain good upto 120C. But, these greases are not useful for extreme
pressure applications. For, extreme pressure applications, Servogem EP2 or
Lithon EP2 grease should be used. For temperatures above 120C, high
temperature greases should be used. Servogem HTXX and Lithoplex are high
temperature greases.
Hence, depending upon the machine, correct types of oil or grease should be
used. Different oils and greases should never be mixed up. It is better to use
colour coding on the machine and drums of oil and grease so that the right
lubricant is used in the right place.
b. Right interval :
Second precaution to be followed is right interval. Oils and greases lose their
properties on continuous use. Before they become ineffective, they should be
replaced. If machine manufacturer's recommendation is available, it is better
to follow it. If manufacturer's recommendation is not available, oil can be

44

changed based on the past experience or by checking the condition of the oil.
Grease can be replaced based on the regreasing chart prepared by SKF.
c. Right quantity
Third precaution is right quantity of oil or grease as per recommendation. If oil
or grease becomes excess, bearing temperature will increase. Oil and grease
will lose their properties before the actual relubrication schedule and bearing
may get damaged because of lack of lubrication. If oil or grease is less in
quantity, they may not reach the inside of the bearing. Or, they will lose their
properties very soon. Once again, bearing will get damaged due to lack of
lubrication.
d. Right method
Wherever possible, it is better to use grease gun on grease nipple. It takes
very little time and effort if grease gun is used. If it is not possible to fix grease
nipple, then bearing housing should be opened for greasing. Old grease is
removed from the housing. Fresh grease is pressed from one side of the
bearing. Old grease coming out of the bearing from the other side is removed.
Grease is pressed till fresh grease starts coming out from the other side. Shaft
should be rotated now and then so that fresh grease goes into the bearing all
around.
e) Without contamination
Fifth precaution is to avoid contamination. Contamination can get into the
bearing because of several reasons: i) If the oil or grease drum is kept open,
ii) If the bearing housing is opened in dusty environment or iii) If the container
in which grease or oil is taken to the machine is dirty. Dust getting between
cage and rolling elements does not come out so easily. It remains there and
wears out the cage and the cage breaks. Bearing can totally get damaged if
cage breaks. So, all possible efforts should be taken to avoid contamination.

45

6. Identification of duplicate bearings

Bearings of reputed manufacturers are in high demand. Some third quality
manufacturers put these reputed brand names on their bearings and sell
these duplicate bearings as original ones. These bearings are made of low
quality steel and the accuracy and heat treatment may not be good. Their life
will be very less.
There are few simple methods by which these duplicate bearings can be
identified. First the printing quality on the cover can be checked. If the quality
of printing on the cover is good, then the cover can be opened and the
surfaces of bearing can be checked. Lot of scratches on the surface indicates
duplicate bearing. Next, the style of writing the bearing number, brand name
etc on the bearing itself can be compared with that of original bearing.
Thickness of the bearing can be checked at various places, especially at the
place where brand name is printed. Any variation in thickness will be the proof
for duplicate bearing.
Internal

clearance

is

very

accurate

in

original

bearings.

Duplicate

manufacturers cannot get this accuracy in clearance. By measuring internal

clearance of the bearings, it can be technically confirmed whether a bearing is
original or not.
In cylindrical roller, spherical roller and self aligning ball bearings, clearance
can be checked with feeler gauge. This measured clearance is compared with
the values given in bearing catalogue. In deep groove and double row angular
contact ball bearings, clearance can be checked with dial gauge. For angular
contact ball bearings, taper roller bearing and thrust bearings, clearance need

46

not be checked as the actual clearance is maintained only while fitting the
bearing in the machine.
Usually, bearings discarded by the users are sold as scrap. Some people buy
these used bearings and recondition them. These reconditioned bearings
have lost some of their life. Probably, cage is also damaged while removing
the bearing or while handling it So, these reconditioned bearings will have less
life. To avoid these problems, it is better to cut these bearings before selling as
scrap. Both inner race and outer race should be cut. Small bearings can be
put in salt water so that they get rusted. This way reconditioned bearings can
be avoided to a large extent.

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50