Course 204-500 Rolling Element Bearing Maintenance

11/01/06 Exercise Guide

Exercise E204-S05-EXR-DFT.wpd

Bearing Maintenance Pre-Checks

Objectives

’ Given the DAC Bearing Maintenance Trainer, its Use Guide,

the bearings supplied with the Trainer, and hand tools,
demonstrate the ability to recall at least eight common bearing
pre-checks without reference material.
’ Demonstrate the ability to recall three bearing care and
handling precautions without reference material.

Performance Standard

’ Demonstrate the ability to recall a minimum of eight bearing

pre-checks outlined in this exercise.
’ Demonstrate the ability to recall three major bearing care and
handling precautions outlined in this exercise.

Foundation Competencies

’ Use of hand tools

’ Use of feeler gauge
’ Use of digital caliper
’ Basic understanding of rolling element bearing terminology
(Exercise E204-S01)
’ Basic knowledge of bearing types (Exercise E204-S02)
’ Basic knowledge of bearing identification systems (Exercise
E204-S03)

Required Background Reading

’ IPT’s Industrial Trades Training Manual (DAC, #510-000),

pages 199-202 and 215-220
’ SKF Bearing Maintenance Handbook (DAC, #512-002), pages
90-91 and 134-137

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Tools Required

’ Combination wrench set

’ Hex wrench set
’ Digital caliper
’ Soft, lint-free cloth
’ Feeler gauge

Components Required

’ DAC Bearing Maintenance Trainer, #204, including basic

components
’ Bearing Maintenance Trainer Use Guide, #204-500
’ Bearing Installation and Maintenance Instructions

Introductory Discussion

Bearing installation requires a knowledge of the correct bearing for a

particular application, including bearing clearances and fits, and the ability to
perform accurate measurements of clearances and fits.
Certain preliminary checks and activities must be performed before a bearing
can be installed in the field. The performance of these pre-checks helps ensure
that any fundamental equipment and component problems, environmental
conditions, and tool inaccuracies are resolved prior to installation. Successful
completion of these preparatory activities helps to ensure maximum bearing
efficiency, longer bearing life, less equipment maintenance time, and lower bearing
installation and maintenance costs. Insufficient preparation can make bearing
maintenance and installation more difficult, and can result in damage to the bearing
and, ultimately, the equipment in which it is installed.
Bearing maintenance experts have developed pre-check lists of “must do”
activities for maintenance and installation; the lists vary according to the sources.
The list offered in this exercise is a compilation of the suggestions of the experts.
It is intended to be used as a checklist whenever performing bearing installation
and/or maintenance. Practical considerations, including time constraints and the
relative importance of the bearing job at hand, may impact what checks, if any,
might prudently be omitted for the particular application. W hile ideal conditions may
dictate that all pre-checks be performed, the reality of working situations differs from
site to site. The checks that must be performed are noted within the exercise.

The following pre-checks and preliminary activities will be discussed:

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T Bearing Check
T Procedure Review
T Shaft, Foundation, and Machine Component Checks
T Lubrication Openings Checks
T Housing Vent Hole Checks
T Shaft-to-Bore Misalignment
T Shaft Run-out
T Seal Selection
T Environment and Component Cleanliness Checks
T Component (Including Bearings) Handling
T Lubricant Selection

W hile all of these checks should ideally be performed with each bearing
maintenance or installation activity, the following must be performed in preparation
for bearing maintenance jobs:

g Bearing Check
g Procedure Review
g Shaft, Foundation, and Machine Component Checks
g Environment Cleanliness Checks
g Lubrication Openings Checks
g Shaft-to-Bore Misalignment

Performance Steps

Step 1. Prepare the DAC Bearing Maintenance Trainer. This is the

same setup that was performed in exercise E204-S01. If no
alterations have been made to the trainer then proceed to step
2.

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’ Bolt a mounting bracket onto each end of the baseplate, so that

the shaft openings in the brackets are facing outward.

’ Bolt the third mounting bracket onto the bracket located on the
right side of the baseplate. Mount this bracket so that the shaft
opening is facing toward you.

’ Install stub shaft #4 into the mounting bracket located on the

left side of the baseplate so that the shaft is extending away
from the baseplate.

’ Install stub shaft #2 into the mounting bracket located on the

right side of the baseplate so that the shaft is extending away
from the baseplate and toward you.

Step 2. Perform a bearing check.

’ Open the deep groove ball bearing #6313ZZ package, supplied

with the DAC trainer, and carefully remove the bearing, using
a clean, soft, lint-free cloth.

g Note: Bearings should be left in their original packaging until

they are mounted so that they are not subjected to any
contaminants. New bearings are thoroughly coated
with a preservative compound to keep out air, moisture
and rust. Care should be taken not to drop bearings or
handle them roughly. They should not be exposed to
large temperature changes which might cause
condensation to form. Do not handle the bearing more
than necessary. Fingerprints can initiate corrosion.

’ Verify that the number on the bearing matches the designation

on the drawing or parts list.

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’ Verify that bearing races (rings) are free of burrs, nicks, and
sharp edges.

’ Check the bearing races for signs of brinelling or other marring

or distortion.

’ Measure the inner diameter of the bearing, using an digital

caliper. Take at least four measurements in different positions
to ensure that the bearing has not been damaged. All
measurements should be identical.

g Note: Never attempt to modify a bearing. Never spin the

outer race of a bearing with compressed air.

’ Carefully return the bearing to its original packaging.

Step 3. Perform a procedure review to ensure that you understand the

drawing and design details of the application and assembly
sequence that will be performed following pre-checks.

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 Course 204-500 Rolling Element Bearing Maintenance
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Step 4. Perform shaft, foundation, and machine component checks.

g Note: Not all of these pre-checks can be performed on the

DAC Bearing Maintenance Trainer. Some must be
visualized.

’ Check the shaft, foundation, and machine components.

T Look for damaged, worn, or badly corroded shafts, shaft

seals, bearings, machine casings, motor feet, and coupling
components.
T Aggressively move shaft components to detect axial or
radial movement resulting from worn or damaged
components.
T Check shaft-to-bore alignment. Make sure the bore of the
housing is parallel to the shaft.

T Check for shaft run-out. Using the dial indicator, rotate the
shaft 360E and note any changes on the dial indicator. If
shaft Run-out beyond 0.005" is present, the shaft must be
replaced.

Using the DAC Bearing Maintenance Trainer:

T Use the digital caliper to measure the shaft diameter for

uniformity. Measure from top to bottom and from side to
side. Take measurements in at least four different
positions.

g Note: As an alternate method, a shaft can be

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positioned between the centers on a lathe, and

a magnetic dial indicator attached to the bearing
seat area can be used to detect out of round
conditions when the shaft is rotated.

g Note: Even slight shaft high spots or out of round

conditions can cause damage to bearing
raceways.

T Check shaft and housing tolerances.

T Rotate the shaft to check for binding.
T Replace worn or broken components, if necessary.
T Check the shaft, foundation, and machine components for
dirt and other contaminants, and clean them, if needed.

Step 5. Perform Environment/Cleanliness Checks. (Visualize.)

T Look for cracks in supporting concrete and grout.

T Look for loose foundation bolts.
T Look for voids in the grout under the shaft baseplate due to
improper installation. This can sometimes be detected by
gently hitting the baseplate with a mallet and listening for
changes in tone.
T Look for cracks in the machine baseplate.
T If an existing seal is to be used, inspect it for wear.

g Note: Always replace a rubber seal.

T Check the environment for cleanliness. Clean the areas

that will impact bearing installation or maintenance to
prevent contaminants from damaging the bearing.
T Check all lubrication openings to make sure they are not
clogged.
T Verify that vent holes in the housing are free of obstructions.
T Make sure the proper tools are available, clean, and ready
to use.

Step 6. Perform Lubricant Selection.

g Note: Lubricant selection depends on variables such as

operating speed and temperature, load and load type,
the bearing environment, and maintenance schedules.

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Lubricant types are specified for particular bearings by

the manufacturer.

’ Select grease for the lubricant for a bearing that operates under
normal speed and temperature conditions. Grease is simpler
to use and less expensive than oil, adheres more easily, and
protects against moisture and contaminants from the operating
environment.

’ Select oil for the lubricant for higher operating speeds and
wider temperature ranges, when heat must be transferred from
the bearing, and when oil is required for other components,
such as seals and gears.

Summary

You have now learned how to prepare for bearing installation and
maintenance by performing (or visualizing) the pre-checks necessary to ensure that
bearing installation and maintenance are performed appropriately. These
procedures include ensuring that the environmental conditions are suitable; that the
bearings, shafts, and other components are clean and not damaged; and that the
appropriate tools and materials are available. These pre-checks must be performed
consistently, every time, when installing, monitoring, and maintaining rolling
element bearings. By following good pre-check practices, you will avoid the
common problems associated with bearing installation and maintenance.

Optional Tasks

’ Check other shafts and/or bearings at your site for signs of

wear and damage.

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Resources

Basaraba, Bruce M., IPT’s Industrial Trades Training Manual. Edmonton, Alberta,
Canada: IPT Publishing and Training, Ltd., 1989.
Power Transmission Distributors Association, Power Transmission Handbook. 1st
ed. Cleveland, Ohio: Penton Custom Publishing Group,1993.
Reliability Magazine, June 1996, “A Quick Method of Determining Root Causes and
Corrective Actions of Failed Ball Bearings.”
SKF Group, SKF Bearing Maintenance Handbook. Denmark: SKF, 1996.

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Review Questions

Answer the following questions from the Industrial Trades Training Manual, (DAC,
#510-000) at the end of Section 4. Circle the correct answer.

Name: Date:

#27 Cleaning and spinning roller bearings with compressed air is recommended.

(a) true
(b) false

#28 Measuring the shaft and housing diameter, at one spot, from top to bottom
and from side to side indicates signs of:

(a) taper
(b) out of roundness

#33 W hich tool or device should NOT be used for roller bearing work?

(a) lead hammer

(b) brass hammer
(c) hardened steel drifts
(d) all of the above

#40 The shoulder on a shaft:

(a) must contact only the bearing corner

(b) must be tapered
(c) must extend beyond the radius and against the flat surface of the race

#41 W hy does a bearing’s inner race sometimes not correctly seat against the
shaft shoulder?

(a) interference from the shaft threads

(b) shoulder burrs
(c) faulty bearing
(d) undercut shaft

#42 W hen bearings are misaligned in their bearing housing, the rollers:

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(a) will re-align themselves uniformly along their full length and will carry
the load on their entire surface
(b) will not seat uniformly along their full length and will carry the load
only on a small portion of their surface
(c) will seat uniformly along their full length, but will carry the load only on
a small portion of their surface

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