Free bearing inspection checklist

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Free bearing inspection checklist (PDF-ready). Covers temperature, vibration, lubrication, clearance, noise and wear assessment. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

How to use: download the PDF, print or complete digitally on any device.

• ✓PDF format, ready to print or fill on screen
• ✓Use as-is or customise to suit your operation
• ✓Go digital in MapTrack for photos, alerts and audit trails

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Benefits of using this bearing inspection checklist

• Early failure detection: systematic monitoring of bearing temperature, vibration, noise and lubrication condition identifies early-stage deterioration weeks or months before catastrophic failure, enabling planned replacement.
• Reduced unplanned downtime: detecting bearing deterioration before failure allows replacement to be scheduled during planned shutdowns, avoiding the production losses and safety risks of unexpected equipment breakdowns.
• Root cause elimination: systematic damage classification per ISO 15243 during dismounted bearing inspections identifies the failure mode and root cause (misalignment, contamination, overloading, electrical damage, improper lubrication), enabling corrective actions that prevent recurrence.
• Optimised lubrication: regular inspection of lubricant condition, quantity and contamination ensures bearings receive the correct lubrication at the correct interval, the single most important factor in bearing service life.
• Extended equipment life: correct bearing selection, installation (per AS 1654 tolerances), lubrication and condition monitoring maximises bearing service life and prevents secondary damage to shafts, housings, seals and adjacent components.
• Spare parts optimisation: bearing condition data and failure trends inform spare parts stocking decisions, ensuring critical bearing sizes are available when needed while avoiding excess inventory of slow-moving sizes.

How to use this bearing inspection checklist

1. Review the equipment maintenance history, previous bearing inspection records, vibration trend data and lubrication schedule before starting the inspection.: Obtain the equipment asset record from MapTrack and review the bearing history including previous inspection results, vibration trends, bearing replacement dates, failure records and lubrication schedule compliance. Check the bearing designation, type, clearance class and specified fit (shaft and housing tolerances per AS 1654). Note any previous failure modes or recurring issues. Confirm the bearing manufacturer recommended inspection criteria and service life estimates for the application.
2. With the machine running, measure bearing temperature, vibration and noise at each bearing position. Compare to baseline and alarm thresholds.: Measure bearing housing temperature using an infrared thermometer or contact probe at each bearing position. A temperature rise of more than 20 to 30 degrees Celsius above ambient or above the bearing rated temperature limit indicates a potential problem. Measure overall vibration velocity (mm/s RMS) and high-frequency bearing condition indicators (envelope acceleration, HFD or equivalent) at each bearing position in horizontal, vertical and axial directions. Use an ultrasonic listening device to assess bearing noise for irregularities. Compare all readings to baseline values and ISO 10816 or AS 2625 evaluation criteria.
3. Inspect the bearing housing externally for seal condition, contamination, lubricant leakage, mounting integrity and alignment indicators.: Inspect the bearing housing for cracks, corrosion, mounting bolt torque (check for looseness), dowel pin condition and foot flatness. Inspect bearing seals and shields for damage, wear, lip contact and contamination ingress. Check for lubricant leakage around seals, drain plugs and lubrication fittings. Inspect the shaft for seal wear marks, corrosion and scoring. Assess alignment indicators including coupling condition, soft foot checks and any visible offset or angular misalignment.
4. Assess lubrication condition by sampling grease or oil, checking quantity, contamination and relubrication compliance.: For grease-lubricated bearings, sample grease from the drain port or during relubrication and assess colour, consistency, contamination (water droplets, metallic particles, discolouration) and oxidation. For oil-lubricated bearings, check the oil level, colour, clarity and take a sample for laboratory analysis if the bearing is critical. Verify that the lubrication schedule has been followed and the correct lubricant type and quantity have been applied. Incorrect lubrication (wrong type, over-greasing, under-greasing, contamination) is the leading cause of premature bearing failure.
5. For bearings removed during overhauls, conduct a dismounted inspection including visual assessment, dimensional checks and damage classification per ISO 15243.: Clean the bearing thoroughly using an approved solvent and inspect all components under good lighting (magnification if available). Inspect rolling elements for spalling, pitting, flaking, bruising, electrical erosion marks, discolouration and surface roughness. Inspect inner and outer raceways for the same damage modes, paying attention to the load zone. Inspect the cage for wear, cracking, deformation and missing material. Measure bearing internal clearance (radial play) and compare to the original clearance class. Measure shaft diameter and housing bore with a micrometer and compare to AS 1654 tolerance limits. Classify any damage according to ISO 15243 and identify the probable root cause. Photograph all damage for the record.
6. Record all findings on the checklist, update the vibration trend, raise corrective work orders, set the next inspection date and sign off.: Complete each checklist item with the recorded measurement, observation or Pass/Fail result. Update the bearing vibration and temperature trend in MapTrack. Attach photographs of any damage, lubricant samples and dimensional measurements to the equipment asset record. Raise work orders for recommended corrective actions including bearing replacement, lubrication changes, alignment correction, seal replacement or further investigation. Set the next scheduled inspection date based on the bearing condition and equipment criticality. Sign and date the completed checklist.

In MapTrack, you can schedule and track maintenance digitally. Each submission is stored as a timestamped PDF against the asset record.

Frequently asked questions

What standards apply to bearing inspection and failure analysis?

ISO 15243 (Rolling Bearings, Damage and Failures) is the primary international standard for classifying bearing damage into six major modes: fatigue, wear, corrosion, electrical erosion, plastic deformation and fracture. AS 1654 (Limits and Fits for Engineering) specifies shaft and housing tolerances critical to correct bearing installation. ISO 10816 and AS 2625 provide vibration evaluation criteria used for bearing condition assessment during operation. ISO 281 covers bearing life calculations. Bearing manufacturers also publish detailed inspection guides and damage atlases specific to their bearing types and applications.

How often should bearings be inspected?

Operational monitoring (temperature, vibration, noise) should be performed monthly on critical equipment and quarterly on standard equipment. External housing, seal and lubrication inspections should be performed quarterly. Detailed vibration analysis with spectral and envelope processing should be performed monthly on critical bearings and quarterly on others. Dismounted inspections are performed whenever bearings are removed during overhauls or failures. Bearings approaching their calculated L10 service life should be monitored more frequently. Continuous online monitoring is recommended for the most critical or high-value applications.

What is the leading cause of premature bearing failure?

Improper lubrication is the leading cause of premature bearing failure, responsible for an estimated 40 to 50 per cent of all bearing failures. This includes using the wrong lubricant type, over-greasing (which causes overheating), under-greasing (which causes metal-to-metal contact), contaminated lubricant (water, particles, incompatible grease), and missed relubrication intervals. The second most common cause is contamination ingress (dust, water, process material) through damaged or worn seals. Together, lubrication and contamination account for approximately 70 per cent of all premature bearing failures, making lubrication management and seal integrity the highest-priority items on any bearing inspection checklist.

What are the six ISO 15243 bearing damage classifications?

ISO 15243 classifies rolling bearing damage into six major modes. Fatigue (subsurface-initiated or surface-initiated spalling) results from cyclic stress exceeding the material endurance limit. Wear (abrasive, adhesive or erosive) results from relative motion between surfaces. Corrosion (moisture, frictional and false brinelling) results from chemical or electrochemical attack. Electrical erosion (excessive current or current leakage) results from current passing through the bearing. Plastic deformation (overload or indentations from debris) results from stress exceeding the material yield strength. Fracture (forced, fatigue or thermal cracking) results from stress exceeding the material ultimate strength. Identifying the correct damage mode guides root cause analysis and corrective action.

How do I track bearing condition and failure history digitally?

Asset tracking platforms such as MapTrack allow you to store bearing inspection records, vibration trends, temperature histories, lubrication records, dismounted inspection reports with photographs, damage classifications and failure root cause analyses against each equipment asset. This creates a searchable bearing condition and failure database that supports reliability improvement, lubricant optimisation, spare parts planning and maintenance interval adjustment based on actual bearing performance rather than generic manufacturer estimates.