What standards apply to motor vibration analysis?

ISO 10816 (Mechanical Vibration, Evaluation of Machine Vibration by Measurements on Non-Rotating Parts) is the internationally recognised standard for evaluating motor vibration severity, classifying readings into Zones A through D based on machine class, power and mounting type. AS 2625 is the Australian adoption of ISO vibration evaluation standards. ISO 13373 covers vibration condition monitoring procedures including data acquisition, processing and presentation. ISO 15243 covers rolling bearing damage classification and failure analysis terminology. These standards provide the measurement methods, evaluation criteria and reporting frameworks used by vibration analysts in Australian industry.

What are the ISO 10816 vibration evaluation zones?

ISO 10816 classifies machine vibration into four zones. Zone A represents vibration levels typical of newly commissioned machines in good condition. Zone B represents vibration levels acceptable for long-term, unrestricted operation. Zone C represents vibration levels that are only acceptable for limited periods and warrant corrective action at the next planned opportunity. Zone D represents vibration levels severe enough to cause damage and requiring immediate action. The zone boundaries (in mm/s RMS velocity) vary by machine group, power rating and mounting type, with larger or flexibly mounted machines permitted higher vibration levels than smaller rigid-mounted machines.

What common faults can vibration analysis detect on electric motors?

Vibration analysis can detect mechanical imbalance (dominant 1x RPM vibration), shaft misalignment (elevated 2x RPM with axial component), bearing damage (bearing fault frequencies in the envelope spectrum), mechanical looseness (multiple harmonics of running speed and sub-harmonics), soft foot (vibration changes when mounting bolts are loosened), electrical faults such as rotor bar defects and stator eccentricity (sidebands around line frequency and running speed harmonics), resonance (high vibration at a specific frequency with low excitation force), and coupling defects. Each fault produces a characteristic frequency signature that an experienced analyst can identify from the vibration spectrum.

How do I maintain a digital vibration analysis programme?

Asset tracking platforms such as MapTrack allow you to store vibration measurement records, spectral data, trend charts, bearing analysis results and corrective action histories against each motor asset. Route-based measurement schedules with automated reminders ensure motors are analysed at the correct intervals based on their criticality. Trend alerts flag motors with increasing vibration levels for early attention. The complete vibration history supports reliability analysis, maintenance planning and asset replacement decisions with objective condition data.

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Free motor vibration analysis checklist (PDF-ready). Covers baseline readings, bearing frequencies, alignment, imbalance and trending. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a motor vibration analysis checklist?

A motor vibration analysis checklist is a structured document used by maintenance engineers, reliability technicians, condition monitoring specialists and plant maintenance teams to systematically measure, record and analyse vibration levels on electric motors and their driven equipment at scheduled intervals. It covers measurement setup (sensor type, mounting method, axis orientation, measurement points and instrument calibration), baseline and reference data (motor nameplate data, operating speed, load condition, bearing types and fault frequencies), overall vibration measurements (velocity, displacement and acceleration readings in the horizontal, vertical and axial directions at each measurement point), spectral analysis (frequency domain data identifying specific fault signatures such as imbalance, misalignment, bearing defects, looseness, electrical faults and resonance), bearing condition indicators (envelope analysis, high-frequency demodulation, bearing fault frequencies and lubrication condition), trending and alarm levels (comparison to baseline, ISO 10816 evaluation zones and site-specific alarm thresholds), and corrective action recommendations (balancing, alignment, bearing replacement, lubrication, structural modification).

Vibration analysis is the most widely used condition monitoring technique for rotating machinery and is a cornerstone of predictive maintenance programmes. ISO 10816 (Mechanical Vibration, Evaluation of Machine Vibration by Measurements on Non-Rotating Parts) and the Australian adoption AS 2625 provide standardised evaluation criteria for classifying machine vibration severity. Excessive vibration accelerates bearing wear, shaft fatigue, seal failure, coupling damage and structural cracking, leading to unplanned breakdowns, production losses and safety hazards. A documented vibration analysis programme identifies developing faults weeks or months before failure, enabling planned corrective action during scheduled shutdowns. When managed through MapTrack, vibration measurement records and trend data are stored against each motor asset, providing a complete condition monitoring history for reliability analysis, maintenance planning and asset lifecycle decisions.

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Benefits of using this motor vibration analysis checklist

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.

Benefits of digitising forms in MapTrack

When you digitise electric motor checklists in MapTrack, you get:

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Build conditional logic (show or hide questions based on answers).
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Trigger work orders automatically when a fault is logged during an inspection.
Track service intervals by hours, kilometres or calendar date in one place.
Attach supplier invoices and parts receipts to each maintenance record.

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What to include in a motor vibration analysis checklist

This motor vibration analysis checklist covers 9 key areas:

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.

How to use this motor vibration analysis checklist

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.
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.
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.
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.
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.
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.

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How often should you complete this checklist?

Motor vibration analysis frequency depends on the motor criticality, operating conditions and current vibration trend. As a general guide, critical motors (those whose failure would cause significant production loss, safety risk or environmental impact) should be analysed monthly. Essential motors should be analysed quarterly. Standard motors in Zone A or B can be analysed every six months. Motors showing an increasing vibration trend or in Zone C should be monitored monthly or more frequently until corrective action is completed.

Continuous online vibration monitoring systems are cost-effective for critical, high-value or difficult-to-access motors, providing real-time trending and automatic alarm notification. Route-based portable vibration analysis is suitable for the majority of motors in a typical plant. The analysis interval should be shorter than the expected fault development period to ensure faults are detected before failure.

Frequently asked questions

What standards apply to motor vibration analysis?: ISO 10816 (Mechanical Vibration, Evaluation of Machine Vibration by Measurements on Non-Rotating Parts) is the internationally recognised standard for evaluating motor vibration severity, classifying readings into Zones A through D based on machine class, power and mounting type. AS 2625 is the Australian adoption of ISO vibration evaluation standards. ISO 13373 covers vibration condition monitoring procedures including data acquisition, processing and presentation. ISO 15243 covers rolling bearing damage classification and failure analysis terminology. These standards provide the measurement methods, evaluation criteria and reporting frameworks used by vibration analysts in Australian industry.
How often should motor vibration be measured?: Measurement frequency depends on motor criticality and current condition. Critical motors should be analysed monthly, essential motors quarterly, and standard motors every six months. Motors with increasing vibration trends or readings in ISO 10816 Zone C should be monitored monthly or more frequently until corrective action is completed. The analysis interval should be shorter than the expected fault development period for the bearing type and operating conditions. Continuous online monitoring is recommended for the most critical or high-value motors.
What are the ISO 10816 vibration evaluation zones?: ISO 10816 classifies machine vibration into four zones. Zone A represents vibration levels typical of newly commissioned machines in good condition. Zone B represents vibration levels acceptable for long-term, unrestricted operation. Zone C represents vibration levels that are only acceptable for limited periods and warrant corrective action at the next planned opportunity. Zone D represents vibration levels severe enough to cause damage and requiring immediate action. The zone boundaries (in mm/s RMS velocity) vary by machine group, power rating and mounting type, with larger or flexibly mounted machines permitted higher vibration levels than smaller rigid-mounted machines.
What common faults can vibration analysis detect on electric motors?: Vibration analysis can detect mechanical imbalance (dominant 1x RPM vibration), shaft misalignment (elevated 2x RPM with axial component), bearing damage (bearing fault frequencies in the envelope spectrum), mechanical looseness (multiple harmonics of running speed and sub-harmonics), soft foot (vibration changes when mounting bolts are loosened), electrical faults such as rotor bar defects and stator eccentricity (sidebands around line frequency and running speed harmonics), resonance (high vibration at a specific frequency with low excitation force), and coupling defects. Each fault produces a characteristic frequency signature that an experienced analyst can identify from the vibration spectrum.
How do I maintain a digital vibration analysis programme?: Asset tracking platforms such as MapTrack allow you to store vibration measurement records, spectral data, trend charts, bearing analysis results and corrective action histories against each motor asset. Route-based measurement schedules with automated reminders ensure motors are analysed at the correct intervals based on their criticality. Trend alerts flag motors with increasing vibration levels for early attention. The complete vibration history supports reliability analysis, maintenance planning and asset replacement decisions with objective condition data.

Applicable regulatory standards

This template aligns with the following regulations and standards:

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

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