Heavy Equipment Technician

Bearings & Seals

Suspension, Wheels and Systems

First Period
Module 190102c
Objectives

1. State bearing functions and applications..

2. State seal functions and applications..

3. Diagnose common bearing and seal faults..

4. Performed bearing and seal service.

Objective One

State bearing functions and applications.

Functions of Bearings
Provides support and alignment to moving
parts by supporting or offsetting bearing
loads..

Reduces wear by reducing friction through

sliding contact (friction bearing) or rolling
contact (anti-friction bearing) assisted by
lubrication..
Provide a replaceable wear surface.
Applications of Bearings
Bearings are used whenever there is a
difference in speed between parts, or one part
exerts force or weight on another, and can be
found in:

Wheels, engines, transmissions..

Rear axles and drive lines..

Steering components..

Doors, locks, windows, seats, etc.

Loading Bearings
Bearings are designed for load, weight, and
speed applications..

Friction Bearing High-speed applications such

– as crankshaft and camshaft..

Ball Bearing – Light load, low or high-speed

applications..

Roller Bearing –Heavy load, high-speed

applications such as tapered
wheel bearings.
Bearing Loads
Radial Thrust Load:Occurs from forces acting
at 90° to shaft rotation..

Radial Load

Most bearing designs offset this loads.

Bearing Loads
Axial Thrust Load: Occurs from forces acting
end wise on the shaft.

Axial Load

May be offset by:

Thrust washers, thrust needle bearing, axial
thrust ball bearings, tapered roller bearings
and helical splines within a gear.
Bearing Loads
Combination Thrust Load:Radial and axial
forces combined.

Combination
Load

Tapered Roller Bearings are commonly

used to counteract combination thrust loads.
Classes of Bearings
Friction Bearings Anti-friction
Bearings Plain
Bushing Ball
Roller

Split Tapered
Needle
Bearing Roller

There are several types of bearings in

each of these classes.
Friction Bearings:
Bushing
Sometimes referred
to as:

Plain Bearings
Split
Bushings Bearing

Simple construction, quiet, cheap, rigid, and

require a small amount of installation space.

Higher friction operation (Lower speed and load)

and require frequent lubrication.
Design of Friction Bearings:
Split Bearings:
Split bearing halves (shell) are easier to install
and removed, and are widely used in engines
and automatic transmissions.

Usually made with a steel backing and lined

with babbit (composition of lead, tin, antimony)
Optional alloys are brass, alloy, aluminum,
copper, ceramic, vesconite, plastics, etc.
Design of Friction Bearings
Split Bearings:
Must have proper Crush and Fit..

Crush: Shell

The protrusion of the

insert’s split line above Crush
the bore, provides a tight
bearing shell to bore
radial fit, for retention
and heat dissipation.
Design of Friction Bearings:
Split Bearings:
Fit:
Is the closeness of the machined contact
mating surfaces of the bearing ends.

Excess Bearing may spin with the

tolerance: shaft..

Insufficient Distortion looseness

tolerance: and over-heating may
occur.
Design of Friction Bearings:
Split Bearings: Dowel Hole

Dowels Holes or Locking

Tabs are used to position Dowel
and prevent the bearings,
from turning in the bore.
Locking Tab
Backing and mating surface
must be clean and dry to
ensure proper heat Notch
dissipation.
Design of Friction Bearings:
Circumferential
Split Bearings & Bushings: Groove
Oil grooves may be used to
ensure:
Cooling.

Lubricating oil distribution.

Film of oil for shaft support.

Oil retention.
Elliptical Groove
Anti-friction Bearings:
Two basic types:
Outer Ring
Roller Element
Inner Ring
Separator or Cage

Roller Bearing Ball Bearing

Low friction ratio between elements allows
higher load and sustained speed operation.
May run in an oil bath, or require cleaning and
packing, or lubricated for life of the bearing.
Roller Bearings:

Common Designs of Roller Bearings

Tapered roller.

Plain roller.

Spherical roller.

Needle.
Tapered Roller Bearings:
Come in two separate parts:
Cup (outer race)

Cone (inner race)

Can support both axial and

radial thrust loads..

Axial loads from both directions are counter-

acted, by two tapered roller bearings facing
each other.
Plain Roller Bearings: Separable
Outer Ring
Design supports radial thrust loads
only.
Usually inner race supports a shaft,
and outer race is stationary in the
housing..
Found in transmissions, rear axle
assemblies, and on axle shafts.
Spherical Roller Bearings:
Rollers are barreled shaped and are doubled
up, and will absorb radial loads and some axial
loads.
Rollers will move from side to
side within the outer race,
allowing self alignment of the
shaft.
Radial Needle Bearing
Called a needle bearing, because
the length of the roller element is
six times the diameter of the roller.
Absorbs radial thrust loads only.

Axial Needle Bearing

Needle bearing designed to
absorb axial thrust loads.
Needle bearings cannot absorb
combination thrust loads.
Ball Bearings
Categorized by the type of Raceway.

Single Row Ball Bearings:

Used for light load, low to

Raceway
medium speed applications,
packed with grease or run in
oil.

Withstands radial thrust loads

and minimal axial thrust loads.
Double Row Ball Bearings:
Used for heavier load, low to
medium speed applications,
packed with grease or run in oil.
Withstands radial thrust loads
and minimum axial thrust loads.

Deep Groove Ball Bearings:

Designed for radial thrust loads.
Will accept small axial thrust loads,
due to the deeper grooved raceway.
Angular Contact Ball Bearings:
Added support is given to any
end with an axial thrust load
placed upon it.

Axial Thrust Load Ball Bearings:

Usually designed with a single

row of balls and will accept full
axial thrust loads, and some
radial thrust loads.
Objective Two

State seal functions and applications.

Functions of Seals
Various types of Static or Dynamic seals
perform a variety of functions such as:

Retains fluids, may prevent leakage from

one housing to another, or to the exterior..

Keep out contaminants, thus extending

bearing life and component function..

Holds pressure or vacuum, and withstands

large amounts of heat.
Applications of Seals
Static Seals: Static seals function where
there are no moving parts..

Common static seal types:

Packings – Compression, molded, lip-type,

V-ring, V-cup, U-ring, U-cup,
squeeze-type and flange..

– Uses include cylinders, piston

and crankshafts.
Applications of Seals
Static Seals:

Common static seal types:

O-rings – A squeeze-type of packing, which

handles a wide range of fluids,
pressures and temperatures..

Gaskets – Used between non-moving

parts..

Sealant – May be used instead of a gasket

in some applications..
Applications of Seals
Dynamic Seals:
Designed to prevent leakage past a moving
shaft or housing.
May allow minimal leakage for
lubrication and cooling purposes.
Applications of Seals
Dynamic Seals:
Common dynamic seal types:

Radial Lip Seals – Prevents leakage past

a rotating shaft.

Exclusion Seals –Keeps contaminants out.

Dust Shields –Commonly found on rear

axle assemblies.
Applications of Seals
Dynamic Seals:

Common dynamic seal types are:

Clearance Seals – Two types are Rings and

Labyrinth.
– Tolerates a small amount
of leakage.
– Piston oil rings.
– Labyrinth seals are used
in heavy industrial areas.
Applications of Seals
Dynamic Seals:

Common dynamic seal types are:

Face Seals – Leak-proof retention of

lubricants..
– Low peripheral speeds..

– Severe service conditions.

(dirt, water)
External and Integral Seals

External Seal Integral

Seal

Axial Space Axial Space

Integral seal is more compact, less expensive.

Classes of Seals
Static Seals:

O-rings – Generally used where there are

no moving parts, and can be
pre-formed or made to size..

Gaskets – Can be both metallic and

non-metallic ..

Sealant – Silicone or RTVC (room

temperature vulcanizing cement),
hardening and non-hardening
types, and tapes.
Static Seals
O-Rings:

Are a squeeze-type of
packing capable of
withstanding a wide range
of fluids, pressures and
temperatures..

Chamfered O-ring grooves

prevent damaged, if installed correctly.
Static Seals
Gaskets:

Used between non-moving

parts.

Materials can be cork, rubber,

plastic, or a combination of
various materials.

Various forms of Metallic Gaskets usually

withstand higher pressures and temperatures.
Static Seals
Sealants:
Use only the retaining glue or material
recommended by manufacturer.
Dynamic Seals

Designed to prevent leakage past a moving

shaft or housing, and may allow on some
applications minimal leakage for lubrication
and cooling purposes.

Some types of dynamic seals are:

Radial Lip Seal.
Exclusion Seal.
Mechanical Seal.
Packings.
Radial Lip Seals
Stops fluid from leaking past rotating shafts,
and their sealing element are rubber or a
synthetic material..

Four basic designs:

Single Lip.
Single Lip Spring
Loaded.
Double Lip.
Dual Lip.
Radial Lip Seals
Single Lip Seal

Are not spring loaded,

and have only one fluid
lip and no dust
exclusion lip..

Not designed for high

speeds or dirty
conditions.
Radial Lip Seals
Single Lip Spring Loaded:

Spring

Spring under lip is to assist the retention of

fluids, at higher pressures and speeds,
with no dust exclusion lip.
Radial Lip Seals
Double Lip:
Seal Housing
Spring
Fluid Lip
Shaft Dust Lip

High Pressure

Fluid Lip seals fluids in at higher pressures and

speed, and Dust Lip keeps contaminants out.
Radial Lip Seals
Dual Lip Seal:

Both Lips are

spring-loaded

Lips face opposite each other..

Prevents fluid transfer, between housings.
Mechanical Seals:
Common mechanical seals found in heavy-duty
equipment are:

Exclusion Seals.

Clearance Seals.

Wind back.

Face seals.

Dust shields.
Mechanical Seals:

Exclusion Seals:
Seal lip faces outward, keep contaminants
out, may have a conical scraper or ring
scraper to remove foreign material.

Clearance Seals:
Two types are Ring and labyrinth, and they
control fluid leakage by limiting clearances,
between moving sections.
Mechanical
Seals:
Wind Back Seals:
Limited clearance between moving parts..

Inner Wind Back

Shaft Wind Back
Circular groove causes fluid to return
to housing or chamber.
Mechanical Seals:
Face Seals:
Sealing Surface
O-rings

Axial Mechanical Seals (Duo-cone seal®)

are able to contain high pressures with low
leakage rates, with minimum wear on the shaft,
as moving parts work against each other.
Mechanical Seals:
Face Seals:
Static Seal Spring Loading Device
(Opposed Washers)
Stationary
Housing Static Seal

Rotating
Shaft

Stationary Seal Ring Rotating Seal Ring

Precision finished surfaces rub against each

other under pressure, maintaining a tight seal.
Mechanical Seals:
Dust Shields:

Prevents ingressive contamination, if a unit is

operated in extreme conditions.

Dust shields are commonly found on rear axle

assemblies, where the seal faces forward.
Mechanical Seals:
Packings:
Compression Packing

Pressure

Compression, molded, lip-type, V-ring, V-cup,

U-ring, U-cup, squeeze-type and flange..
Materials can be metallic, fabric, leather,
rubber, felt, plastic.
Mechanical Seals:
Packings:

Requires lubrication to
prevent overheating.

May be found in cylinders,

pistons and crankshaft.
Objective Three
Diagnose common bearing and seal faults.
Bearing Failures
Troubleshooting:
Bearing failure can be caused by:
Dirt and water. Incorrect lubricant.
Vibration. Incorrect adjustment.
Extreme heat. Excessive looseness.

At higher road speeds, noise has a tendency

to transmit to other areas.
Eliminate any possible areas while the
vehicle is stationary.
Bearing Failures

Failure Analysis:

Look: Give proper visual inspection to the

bearing, shaft and bore.

Listen: For bearing noise, when rotating by

hand.

Feel: For rough spots or grinding, when

rotating bearing by hand.
Types of Bearing Failures
Peeling:

Caused by insufficient lubricating film,

and has a frosted appearance.
Types of Bearing Failures
Spalling:

Caused by heavy
preload, and poor
lubricating film..

But can be just

normal wear, check
life of bearing.
Types of Bearing Failures
Brinelling:
Impact denting,
caused by stationary
inner race on a non-
moving shaft..

Can be prevented by
Bearing Creep..

Can be caused by dropping the bearing on a

hard surface, hammer blows during installation,
or shock loading.
Types of Bearing Failures
Arcing:

Caused by welding (poor ground), or

static electrical charges due to high speed.
Types of Bearing Failures
Fatigue:
Caused by:
Load and speed
beyond rating. Load

Shock loads.

Vibration.
Flaking
Micro Crack
Misalignment.

High temperatures above 150° C (300° F).

Seal Failures
Types of Seal Failures.
Contamination:

The most common cause

of bearing failure.

Can be caused by:

Lubricant breakdown.

Built in during assembly.

Types of Seal Failures.
Ingested Contamination:

Can be caused by:

Contaminants entering through the breather.

Seal failure, missing seal or slinger not

positioned properly.
Seal Failures
Pitting and Bruising:

Caused by hard particles

rolling through the bearing,
due to contamination
getting past a damaged
seal.
Seal Failures
Etching:

Most often caused by water contamination, or

condensation due to temperature change.
Objective Four
Perform bearing and seal service
Bearing Service
Always wear proper P.P.E. when working
with bearings..
Anti-friction bearing material is brittle,
while friction bearing material is soft.

Non-Destructive Removal Methods:

Clean shaft of any burrs or deposits, for
ease of bearing removal and installation,
and preventing shaft and bearing damage.
Non-Destructive Removal Methods
Cooling:

Cooling causes the part to contract and become

brittle, do not apply force to cooled part..
Use gloves … can cause severe frostbite.
Non-Destructive Removal Methods

Heating Ring:
Inner
Using open flame to heat Ring
bearings causes uneven
heating, distortion, and
oxidation of rollers and
raceways, affecting
bearing service life. Heating
Ring
Heating Ring is limited to cylindrical roller
bearings, with separable roller and cage
assemblies.
Non-Destructive Removal Methods
Using a Hydraulic Cylinder and Puller:

Danger
Large forces are being applied while pulling a
bearing, which could lead to:
Bearing exploding under pressure, or the tie
rods connected to the strong back could
spread, and the ram could fly out.

Stand at the end of the shaft opposite to the

end that the puller is on.
Non-Destructive Removal Methods
Using a Hydraulic Cylinder and Puller:

Use the proper size and

attachments for the task at
hand..

Ensure splitter is contacting

the inner ring of the bearing
only, to prevent damaging
the shaft.
Splitter
Non-Destructive Removal Methods
Using a Hydraulic Cylinder and Puller:
If the shaft is threaded, use
a piece of soft metal to
protect the end of the shaft.

Always pull on the tight

bearing race.

Usually the most efficient

way of bearing removal.
Non-Destructive Removal Methods
Using a Hydraulic Press:
High stress on parts are
potentially dangerous.
Spacer
Ensure alignment of all Safety Bearing
parts, they could slip or Cage
explode causing injury Support Plate
or death.
Use the provided safety
Beam
devices. Support Pins
Non-Destructive Removal Methods

External Puller:

Puller jaws should contact

inner ring if possible..
Smaller bearings can be
pulled by their outer ring..
Rotate outer ring with screw
stationary to distribute the
pullers loading forces.
Non-Destructive Removal Methods
Hydraulic Cylinder and Puller:

Larger bearing should be

removed with a splitter,
whenever room permits, to Bearing
minimize bearing damage. Splitter

Support Surfaces to
Contact Inner Ring
Non-Destructive Removal Methods
Internal Puller:
Jaws Attach to the Inside
Rotate outer ring with of the Outer Ring.
screw stationary, to
distribute the pullers
loading forces.
Non-Destructive Removal Methods
Driver Set

Is a tool used to prevent damage to

bearings and seals during installation.
Slide Hammer:
Expanded Collet

Pinch Point
Caution
Beware of Pinch Points..
Destructive Removable Methods
This may be the only method available..

Numbers should be taken off the bearing

before removal..

Safety and care not to damage other

components, should be observed..

Bearings are brittle, do not strike directly with

a hammer.
Destructive Removable Method
Grinder:

Use P.P.E. … Face Shield, proper gloves.

Destructive Removal Method
Cutting Torch:

Incline torch to
avoid cutting
the shaft.
Destructive Removable Method
Hammer and Drift:
Split
Always wear eye Sleeve
protection and use a
drift holder or gloves to Welded
hold the drift, and strike Lug
on the welded lugs.
Bearing

Shaft
Vise
Destructive Removal Method
Weld:
Heavy Bead of Weld
If bearing bore does
not go through the Outer
housing, welding a Ring
bead on the race
surface will shrink
bearing for easier
removal..
Destructive Removal Method
Weld:
Nuts welded to
bearing.
Puller
Rods
Cleaning Bearings
Use fresh clean solvent to do the final cleaning
of bearing and housing.

Hold bearing to a light source … slowly rotate

inner and outer race, and inspect for damage.
Inspect each roller if possible for damage.

Danger: Spinning bearing with compressed air

may cause overheating, seizing and
the bearing to flying apart.
Lubrication of Bearings
Most bearings use the oil of the unit they are in.
Use correct type, grade and level of lubricant
specified by the manufacturer.
Friction bearings require a continuous supply of
oil, therefore any oil holes in the bearing should
be lined up with oil galleries in the housing.

Over-packing of greased bearings (bearing

and housing) could cause the bearing to
overheat.
Lubrication of Bearings
Sealed Bearing:

Sealed bearings are generally wiped clean, and

inspected for
serviceability.
Packing Bearings

When properly packed,

grease appears on the
opposite end of all of the
bearing’s rolling elements.

A properly packed
bearing will dissipate
heat and bearing
longevity will increase.

Bearing Packer
Bearing Installation
Cold Mounting Methods:
Make sure the shaft and bore are clear of any
burrs or distortions, and oil the bearing seat..

When installing needle bearings, always press

on the number side..

Press or drive on the tight inner or outer ring,

and do not directly strike the bearing with a
hammer..

Do not use brass as a punch or sleeve. (Flaking)

Cold Mounting Methods

Sleeve Kit
Driver Set
Arbor
Press

Hydraulic Press
Cold Mounting Methods

Dead Blow Impact

Hammer Ring

Interference Fit
in the Housing

Interference Fit
Interference Fit on the Shaft and
on the Shaft in the Housing.
Cold Mounting Methods
Separable Cylindrical Bore Bearing:

Chamfer housing bore, clean and oil shaft, install

inner ring.

Install guide
sleeve before
installing outer
ring and rollers.

Remove
installation tools. Slide on bearing
and housing
Cold Mounting Methods
Needle Bearings: Guide Mandrel
Undercut
Easily damaged.
Ram
Clean and lubricate
shaft. Bearing
Cup
Lubricate bearing Needle
and install using Bearing
proper installation Guide Housing
tools. Mandrel Press
Bed
Cold Mounting Method
Installing Tapered Roller Bearing Cup:

Clean and lubricate bore.. Hydraulic Press

Drive or press in till seated.

Hot Mounting Methods
Preparation:

1. Organize area, clean and inspect machined

surface and bearing assembly.

2. Use proper bearing heating equipment.

3. Use gloves when handling bearings.

4. Monitor bearing temperature with a

pyrometer or temp stick.
5. Have lifting gear ready, for heavy bearings.
Hot Mounting Methods
Heating Method: Induction Heating
Removable 120º C Maximum
Laminated
Rotate
Bar
Bearing

OFF
Temperature Probe to
ON Contact Inner Bearing Ring
Hot Mounting Methods
Heating Method: Heat Cabinet
Hot Mounting Methods
Heating Method: Heating in Oil
Bearings Thermometer
Suspended
Bearing Not
Suspended

Right Wrong
Hot Mounting Methods
Heating Method: Heat Ring

Lubricate

Inner Ring of Separable

Bearing
Hot Mounting Methods
Procedure for Heating:

1. Applying an open flame directly to bearing,

may distort bearing and leave oxidation
deposit on the raceway and rolling elements..

2. Higher temperatures than 120° C (250° F)

permanently alters shape of the bearing
rings..

3. Heating a sealed bearing above 80° C

(180° F) will damage the seal lip.
Hot Mounting Methods
Procedure for Heating:

4. Monitor bearing temperature with a

pyrometer or a wax Tempilstik of a pre-
determined temperature..

5. The oil in the Oil Bath must be new, high

temperature oil, and do not use oil that
has been used to cool hot metal.
Bearing Adjustments
Anti-friction bearings require adjustments,
following manufacture’s procedures and
specifications..

Considerations while performing adjustments:

Is the bearing subjected to large thrust

loads, heavy weight, high speeds, external
temperatures and other environmental
conditions.
Bearing Adjustments
A bearing operating under extreme loads or
high speeds are not normally preloaded as
much, as a bearing operating under low loads
and low speed, due to heat expansion.

A bearing that is too loose may fail prematurely

due to excessive movement, and may cause
parts failure in other areas.
Bearing Adjustments

When performing
adjustment, ensure all Nut
endplay is removed by
slightly preloading the
bearing, which also
helps to seat the cups..

Do not use an impact

wrench to adjust bearing.
Bearing Adjustments

Check for Zero Endplay.

Bearing Adjustments Shims

Some applications may

use Adjustment Shims
to provide bearing
preload or end play.

Cover
Bearing Adjustments
Three most common bearing adjustments are:

Endplay: Amount of clearance between the

cup, rolling element and cone, and
is dependent on speed and load.

Zero Clearance or Zero End Play:

Preload: Pressure is applied to the cup and

cone by a nut or shims, to prevent the
shaft from axial movement caused by
large amounts of thrust loads.
Bearing Adjustments
Locking Methods:
Methods used to lock the bearings into position
may include:

Self locking nuts.

Washers with tabs.
Washers with cotter pin holes.
Washers with dowel holes.
Double nuts.
Bearing Terms

Residual Clearance:
Is the internal clearance (radial or axial) in a
bearing after it has been mounted.

Running Clearance:
Is the internal clearance (radial or axial) in a
bearing when at its operating temperature.
Bearing Terms
Radial Internal Clearance:

Measurement between Dial Indicator

the rolling element and
the race will identify if
excessive wear is
present.. Radial
Movement
Bearing Terms
Axial Internal Clearance:

Axial Movement

Dial Indicator

Axial Internal Clearance

Seal Service Procedures
Static Seals
Replace any static seal that was disturbed.
Clean machine surfaces and check for
warpage before installation.
Matching new gaskets with old ensures
correct fluid transfer.
Do not use excessive sealant.
Use proper torque and sequence.
Seal Service Procedures
Dynamic Seals:
Check shaft and bore for nicks, gouges etc.

Tape up splines when installing seal over them.

Follow manufacturers recommendations for

type and direction of seal to be used, along
with the proper installation tools.

Lubricate lips of seals unless otherwise stated

by the manufacturer.
Seal Service Procedures
Dynamic Seals:

Some sealant may be applied to the casing

of the seal if not pre-coated.
Check for loose, broken or missing dust
shields or oil slingers.
Seal Service Procedures
When Installing Seals:

Ensure parts are clean and the proper seal is

being installed..

Ensure the lip or lips of the seal, face the

proper direction..

Drive the seal in firmly and evenly with no

cocking.
THE END