CAUSES OF BEARING FAILURE Improper Lubrication - 43% – – How Much, How Often, What Type, What Thickness, What Properties are Important Improper Mounting - 27% – Alignment, Work Area, General Practices, Inventory Control and Storage of Bearings Other Lubrication Causes - 21% – – – – Separation in Storage Temperature Limit Exceeded Moisture Contamination Other Contamination Fatigue - 9% Ultimate L10 Life Expectancy 64% of Bearing Failures are Lubrication Related IS Not The Whole Story In the Industry We Serve, Most Bearings Fail Due To Some Form of CORROSION CHESTERTON INDUSTRIES SERVED CHESTERTON INDUSTRIES SERVED CHESTERTON . % Percent Mineral Oil -Dried 0.00 32-43 80 29-73 45 4-Ball 4-Ball #204 Bearings Angular Contact Bearings Author Reference Scott. Moist environment 0.002 48 0.000 Not Stated.050 1.014 54 4-Ball 3. 1969 Felsen. 1969 Ciruna & Szieleit. Test Equipment Wet Oil.EFFECT OF MOISTURE ON BEARING LIFE MOBIL OIL REPRINT Fatigue Life Water Content of Base Oil Description Reduction.1972 CHESTERTON .00 83 Squalene Oil Mineral Oil-Dried Esters Mineral Oil-Based Hydraulic Oil 1. 1972 Fein.00 78 6. 1960 Schatzberg & Felsen. WATER WASHOUT RESISTANCE ASTM D1264 (DIN 51807) Grease Packed Bearings Water. 80oC (175oF) % Weight Loss of Grease Measured Typical Grease (Lithium) .5% Water Resistant Grease <2% Exceptional < 0.5% CHESTERTON . 0 48 78 83 6.002 3.0 % WATER IN OIL Mobil Oil evaluation on bearing fatigue life – 0.WATER CONTAMINATION REDUCES BEARING LIFE SIGNIFICANTLY % REDUCTION IN FATIGUE LIFE 90 80 70 60 50 40 30 20 10 0.0% water reduces fatigue life 83% – 0.002% water is 1 drop of water in a quart of oil .002% water reduces fatigue life 48% – 6. A newly installed Lip Seal riding in same location on shaft will leak.FRETTED SHAFTS & SLEEVES When shaft scoring occurs. Water penetrates the bearing immediately…in all cases corrosion is RAPID and Bearing Life is reduced CHESTERTON ^30K^ Contacts Here . Fretted Shafts & Sleeves When shaft scoring occurs. the seal eventually fails. A newly installed Lip Seal riding in same location on shaft will leak. While an improvement. A SpediSleve Seal is often used. water penetrates the bearing immediately…in all cases corrosion is RAPID and Bearing Life is reduced CHESTERTON ^30K^ Contacts Here . Numerous SelfFretting Bearing Seals Available Some are just metallic shields as OEM ^30K^ Contacts Here CHESTERTON . 7 16.43 74. Hours to Leakage 10 0 Hours to Failure( 182 188 275 300 556 648 772 902 1264 % Failure) Hours to Failure 6.19 54.68 144 576 1343 1736 1763 1973 1979 2946 2982 CR % FAILURE 80 60 40 20 NATIONAL 1366 (57 Days) 93.32 25. CIC 7810-192 Exhibit IV Percent Failure vs.57 45.06 83.81 64.Conventional Bearing Lip Seals Testing Data CIC 7810-192 Exhibit III NATIONAL MEDIAN RANK CR WAVESEAL ®.30 3003 (125 Days) 1000 2000 3000 4000 TIME HOURS TO FAILURE NATIONAL (Mean Life 645 hours) CR (Mean Life 1844 hours) REPRINT FROM A CR INDUSTRIES REPORT CHESTERTON .94 35. CORROSION PROTECTION Salt Fog Performance .ASTM B117 Lithium Complex Film Thickness 12 microns 37 microns Aluminum Complex # 615 HTG 0 200 400 600 800 Hours to Failure 1000 1200 CHESTERTON . @ 38oC (100oF) 150 to 185 250 to 350 400 to 1.500 to 2.000 to 750 to 500 to 10.000rpm 3.500rpm 1.000rpm 5.1cm 1” to 2” 5. 0 to 1 1 2 2 to 3 0 to 1 1 2 2 Up to Up to 1.500 150 to 185 250 to 350 400 to 600 700 to 1.BALL AND ROLLER BEARING LUBRICATION (OIL AND GREASES) Shaft Diameter <2.000 to 3.1 cm10.500 to 1.000rpm 500 to 300 to 200 to 1.2cm Over 4” Up to 100rpm Below 0oC (32oF) 0oC (32oF) to 38oC (100oF) 38oC (100oF) to 93oC (200oF) Over 93oC (200oF) Below 0oC (32oF) 0oC (32oF) to 38oC (100oF) 38oC (100oF) to 93oC (200oF) Over 93oC (200oF) Below 0oC (32oF) 0oC (32oF) to 38oC (100oF) 38oC (100oF) to 93oC (200oF) Over 93oC (200oF) Below 0oC (32oF) 0oC (32oF) to 38oC (100oF) 38oC (100oF) to 93oC (200oF) Over 93oC (200oF) Operating Temperatures Lubricant Recommended Oil Viscosity Sec.5cm <1” 2.2cm 3” to 4” Up to 200rpm 10.000rpm 2.000 Greases NLGI No.5cm5.000 1.1cm7.000rpm 3.000rpm CHESTERTON .000 33 to 85 50 to 110 75 to 250 350 to 550 0 to 1 0 to 1 1 2 0 to 1 0 to 1 1 2 Over Over Over Over Over 10.000 to 1.000rpm 500rpm 1.000rpm 1.000rpm 90 to 120 150 to 185 250 to 350 500 to 1.000rpm 2.000rpm 1.000rpm 5.000rpm 750rpm 100 to 500rpm 3.1cm 2” to 3” Up to 300rpm 7. 000rpm 500 to 300 to 200 to 1.5cm 2.500 150 to 185 250 to 350 400 to 600 700 to 1.500 to 1.000 to 750 to 500 to 10.000 33 to 85 50 to 110 75 to 250 350 to 550 0 to 1 0 to 1 1 2 0 to 1 0 to 1 1 2 Over Over Over Over Over 10.000rpm 750rpm 100 to 500rpm 3.500 to 2.2cm 10.000rpm 5.1 cm10.000 1.BALL AND ROLLER BEARING LUBRICATION (OIL AND GREASES) Shaft Diameter <2.000rpm 2.000rpm 90 to 120 150 to 185 250 to 350 500 to 1.1cm 5.000rpm 500rpm Up to 300rpm Up to 200rpm Up to 100rpm Below 0oC 0oC to 38oC 38oC to 93oC Over 93oC Below 0oC 0oC to 38oC 38oC to 93oC Over 93oC Below 0oC 0oC to 38oC 38oC to 93oC Over 93oC Below 0oC 0oC to 38oC 38oC to 93oC Over 93oC 150 to 185 250 to 350 400 to 1. @ 38oC Greases NLGI No.000rpm 5.000rpm 3.000rpm CHESTERTON .000rpm 1.1cm 7.000 to 1.1cm7.000rpm 1. Up to Up to 1.000 0 to 1 1 2 2 to 3 0 to 1 1 2 2 1.000 to 3.2cm Operating Temperatures Lubricant Recommended Oil Viscosity Sec.000rpm 3.000rpm 2.5cm5.500rpm 1. Load 29 kg (65 lbs.615 HIGH TEMPERATURE GREASE Very High Dropping Point.) Timken) Excellent Corrosion Resistance o o o o o o Highest Rating Possible for Automotive Bearing and Chassis Lubrication.40 F to 400 F) Excellent Shear Resistance Excellent Shock Load and Wear Properties Very High Timken O. NLGI GC-LB CHESTERTON .40 C to 204 C (.6% Loss Extreme Water Tolerance (Add 30% Water and Still Get 20 kg (45 lbs. 300 C ( 570 F) Temperature Range . Below 1.) Good Compatibility with Popular Greases Very High Water Washout Resistance.K. 615 HTG #1 “Best in Class” Extreme Pressure Properties and Antiwear Characteristics Exceptional Corrosion Protection Excellent Oxidation Resistance.40 F to 400 F) CHESTERTON o o o o . Good in Central Lubrication Systems Shear Stability and Grease Performance Maintained Over Wide Temperature Range Measurably Longer Bearing Life Temperature Range .40 C to 204 C (. Long Grease Life Excellent Resistance to Water Washout and Contamination Easily Pumpable. 615 HTG #1 General Rule of Thumb on Where to Use 615 # 1 Vs. the Standard 615: Where Operating Speeds are Higher Where Average Operating Temperatures are Lower When Customer Wants to Use in Automatic Lubrication System See Pocket Guide for Reference on Specific Operating Conditions CHESTERTON . A Smaller Number Can Handle 150 C (300 F).Rolling Element Bearings.6 Months . 8 hours per Day 82 C (180 F) o o 104 C (220 F) o o 149 C (300 F) o o 193 C (380 F) o o 238 C (460 F) o o .” o o Relubrication Intervals .1 Week . Lubricating Grease Guide CHESTERTON .3 Months .TEMPERATURE EFFECT ON GREASE LIFETIME “ Most Mineral-Oil-Based Greases (of Adequate Dropping Point) o o Will Operate Successfully to About 121 C (250 F).1 Day Source: NLGI.1 Month . A Few Mineralo o Oil-Based Greases Can Operate to About 177 C (350 F). LUBRICUP® Demand Feed System Patented Metering System. Slowly Feeds Grease Only as Needed Prevents Over or Under Filling of Bearings – Eliminates Cause of Over 40% of Bearing Failures Low Feed Pressure Prevents Bearing Seal Failure Time Interval for Relubrication Increased by 6x Reduces Labor Cost to Regrease by Over 80% Can Be Mounted at Any Angle Transparent Grease Reservoir Easy to See Grease Level Easy to Refill in Place CHESTERTON . REFILLING THE LUBRICUP® Refilling Lubri-Cup® with 615 CHESTERTON . BEARING LIFE EXTENSION with LUBRICUP and 615 GREASE CHESTERTON . Khz 615 HTG APPLIED [email protected] 5.615 HTG – Vibration Analysis Dryer Fan. Paper Mill 10. Horizontal Bearing. Wilcoxon Model 782A Sensor CHESTERTON .500 Vibration.5000 20/10/99 14/11/99 09/12/99 03/01/00 28/01/00 MPM Multiparamater Receiver.0Khz [email protected] 2.000 7. 615 Additive Plating Technology 615 smoothes out surface roughness. Extends bearing life. CHESTERTON . reduces wear and vibration. 615 Additive Plating Technology CHESTERTON . Proprietary polar and non-polar additives and thickener chemically fuse to the metal surfaces filling in asperities to form a "wear shield" on the metal surfaces. Chesterton 615 is immune to hydrolysis or water breakdown. Unlike conventional Aluminum. & Lithium soap and complexed thickeners. Lubricity. The resulting grease is "Best in Class" with respect to EP. protects the bearings from WEAR. PRESSURE and WATER CORROSION. The grease remains functional even in heavy water contaminated bearings and equipment. Corrosion & Water Resistance. EP and Anti-Wear additives. blended into a highly refined G III base oil. with QBT (Quiet Bearing Technology) uses state of the art tribological technology to reduce vibration and ultra-sonic bearing noise. CHESTERTON . Calcium. and thickened with a metallic organosulfonate complex. This fusion of lubricating additives and thickeners to the molecular surface of the metal.615 HTG – Technology Overview Chesterton's 615 is formulated using a surplus of Lubricity. Chesterton's 615.