Free motor vibration analysis checklist

• The MapTrack motor vibration analysis checklist contains 24 checks across 5 sections. Sections covered: Pre-Test Setup, Baseline Readings, Axial Measurements, Radial Measurements, Analysis & Trending.
• Motor identification: asset ID, motor make, model, serial number, rated power (kW), rated speed (RPM), bearing types (drive end and non-drive end), frame size, driven equipment, coupling type, current date and analyst name.
• Measurement setup: sensor type (accelerometer, velocity transducer), mounting method (magnetic, stud, adhesive), measurement axis (horizontal, vertical, axial), measurement point locations (drive end horizontal/vertical/axial, non-drive end horizontal/vertical/axial, driven equipment bearings).
• Operating conditions: record motor operating speed (RPM), load percentage, supply voltage, current draw (amps), temperature and process conditions at the time of measurement, as vibration levels vary with load and speed.

Learn more about maintenance and work orders in MapTrack.

• Early fault detection: vibration analysis identifies developing mechanical faults including imbalance, misalignment, bearing degradation, looseness and electrical defects weeks or months before failure, enabling planned corrective action.
• Reduced unplanned downtime: detecting faults before failure allows repairs to be scheduled during planned shutdowns, avoiding the production losses, safety risks and premium repair costs associated with unexpected motor failures.
• Extended bearing and motor life: identifying and correcting root causes of excessive vibration (imbalance, misalignment, soft foot, resonance) reduces the mechanical stresses that accelerate bearing wear, shaft fatigue and seal failure.
• Optimised maintenance spending: condition-based vibration monitoring replaces conservative time-based maintenance intervals, avoiding unnecessary bearing replacements on healthy motors while catching faults that time-based schedules miss.
• ISO 10816 and AS 2625 compliance: standardised vibration measurement and evaluation against internationally recognised severity criteria provides objective, defensible condition assessments for critical and essential motors.
• Auditable condition history: a complete vibration trend history linked to each motor asset in MapTrack supports reliability analysis, failure investigation, warranty claims and capital replacement planning with objective condition data.

• Motor identification: asset ID, motor make, model, serial number, rated power (kW), rated speed (RPM), bearing types (drive end and non-drive end), frame size, driven equipment, coupling type, current date and analyst name.
• Measurement setup: sensor type (accelerometer, velocity transducer), mounting method (magnetic, stud, adhesive), measurement axis (horizontal, vertical, axial), measurement point locations (drive end horizontal/vertical/axial, non-drive end horizontal/vertical/axial, driven equipment bearings).
• Operating conditions: record motor operating speed (RPM), load percentage, supply voltage, current draw (amps), temperature and process conditions at the time of measurement, as vibration levels vary with load and speed.
• Overall vibration readings: record overall velocity (mm/s RMS) at each measurement point in each axis, and evaluate against ISO 10816 or AS 2625 zone boundaries (Zone A: newly commissioned, Zone B: acceptable for long-term operation, Zone C: limited acceptable, Zone D: damage occurring).
• Spectral analysis: capture and record the frequency spectrum at each measurement point, identifying fault signature frequencies including 1x RPM (imbalance), 2x RPM (misalignment, looseness), bearing fault frequencies (BPFO, BPFI, BSF, FTF), line frequency (electrical faults) and harmonics.
• Bearing condition: record high-frequency bearing condition indicators including envelope (demodulated) spectrum, bearing damage index, crest factor and kurtosis, comparing to baseline and alarm thresholds for each bearing type.
• Trending and alarms: compare current readings to previous measurements and baseline values, recording the trend direction (stable, increasing, decreasing) and any alarm or alert threshold exceedances.
• Phase analysis: where imbalance or misalignment is suspected, record phase angle readings at each measurement point to distinguish between fault types and identify correction planes for balancing.
• Corrective action recommendations: document recommended actions based on the analysis findings, including balancing, alignment, bearing replacement, lubrication, structural stiffening, resonance detuning or further investigation.

1. Review the motor vibration history, previous analysis reports, maintenance records and alarm thresholds before taking measurements.

   Obtain the motor asset record from MapTrack and review previous vibration measurements, trend data, spectral records and any corrective actions taken since the last analysis. Check the motor nameplate data, bearing types and calculated bearing fault frequencies. Confirm the measurement point locations, sensor mounting method and instrument calibration are consistent with previous measurements. Review the ISO 10816 or AS 2625 evaluation zone boundaries and any site-specific alarm thresholds for the motor class and mounting type.

2. Record operating conditions, mount the vibration sensor at each measurement point and capture overall vibration and spectral data in all three axes.

   Record the motor operating speed, load condition, supply voltage, current draw and bearing temperatures at the time of measurement. Mount the accelerometer or velocity sensor at the drive end bearing in the horizontal direction using the established mounting method (magnetic mount for routine monitoring, stud mount for permanent installations). Capture the overall vibration velocity (mm/s RMS), the frequency spectrum (typically 0 to 1000 Hz for standard motor speeds) and the time waveform. Repeat for vertical and axial directions at the drive end, then repeat all three axes at the non-drive end bearing. Capture driven equipment bearing measurements where accessible.

3. Analyse the spectral data to identify fault signatures and evaluate overall vibration levels against ISO 10816 or AS 2625 zone criteria.

   Evaluate the overall vibration velocity at each measurement point against the ISO 10816 zone boundaries for the motor class (Group 1: small machines up to 15 kW, Group 2: medium machines 15 to 75 kW, Group 3: large rigid-mounted machines above 75 kW, Group 4: large flexible-mounted machines). Analyse the frequency spectrum for characteristic fault patterns: dominant 1x RPM indicates imbalance, dominant 2x RPM with axial component indicates misalignment, bearing fault frequencies indicate bearing damage, 2x line frequency indicates electrical faults, and sub-synchronous frequencies may indicate looseness or oil whirl.

4. Assess bearing condition using high-frequency demodulation, envelope analysis and bearing condition indicators. Compare to bearing-specific alarm thresholds.

   Process the high-frequency acceleration data (typically 1 kHz to 10 kHz) using envelope (demodulated) spectrum analysis to identify early-stage bearing damage that may not be visible in the velocity spectrum. Compare bearing fault frequency amplitudes (BPFO: ball pass frequency outer race, BPFI: ball pass frequency inner race, BSF: ball spin frequency, FTF: fundamental train frequency) to baseline levels and alarm thresholds. Record bearing condition indicators including the overall high-frequency acceleration level (gE, HFD or equivalent), crest factor and kurtosis. Note any bearing lubrication issues indicated by high broadband high-frequency energy.

5. Update the vibration trend, compare to baseline, identify any alarm exceedances and document corrective action recommendations.

   Enter the current measurements into the motor vibration trend in MapTrack. Compare current levels to the baseline (established when the motor was in known good condition) and to the previous measurement, noting the trend direction and rate of change. Flag any readings that exceed alert or alarm thresholds. Document corrective action recommendations with priority and timing: immediate (Zone D or rapid deterioration), planned (Zone C or steady increase), or monitor (Zone B with upward trend). Recommended actions may include precision balancing, laser alignment, bearing replacement, lubrication, soft foot correction, structural modification or increased monitoring frequency.

6. Record all findings on the checklist, raise corrective work orders in MapTrack, set the next analysis date and sign off.

   Complete each checklist item with the recorded measurement, evaluation zone classification and trend assessment. Attach the spectral plots, trend charts and bearing analysis data to the motor asset record. Raise work orders for any recommended corrective actions with priority ratings, target completion dates and the specific fault identified. Set the next scheduled vibration analysis date based on the motor criticality and current condition (monthly for Zone C, quarterly for Zone B, six-monthly for Zone A). Sign and date the completed checklist.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• ISO 10816-3:2009 - Mechanical Vibration, Evaluation of Machine Vibration by Measurements on Non-Rotating Parts, Part 3: Industrial Machines with Nominal Power Above 15 kW (vibration evaluation criteria and zone boundaries)
• AS 2625:2005 - Rotating and Reciprocating Machinery, Mechanical Vibration (Australian adoption of ISO vibration evaluation standards for rotating machinery)
• ISO 13373-1:2002 - Condition Monitoring and Diagnostics of Machines, Vibration Condition Monitoring, Part 1: General Procedures (data acquisition, processing and presentation for vibration monitoring programmes)
• ISO 15243:2017 - Rolling Bearings, Damage and Failures, Terms, Characteristics and Causes (bearing failure classification and terminology for root cause analysis)
• WHS Regulations 2011, Chapter 5 - Plant and Structures

• Model WHS Regulations (Safe Work Australia)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

• Electric motor quarterly service
• Electric motor annual service
• Bearing inspection checklist
• Pump maintenance checklist
• Preventive maintenance checklist
• Maintenance management
• Compliance management
• What is preventive maintenance?
• Condition monitoring log