Hi-Roller Bearings
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Hi-Roller Bearings
What is a Hi-Roller bearing?
A Hi-Roller is a heavy-duty idler roller. It is a thick, hardened outer roller with a complete bearing built inside, designed to roll along a track, rail, or beam while carrying both radial and thrust loads. Unlike a standard cam follower, which uses needle rollers, a Hi-Roller uses either deep groove ball bearings or tapered roller bearings inside, which lets it run at higher speeds and take heavy thrust loads.
A standard Hi-Roller has four main parts:
- A thick outer roller, which rolls on the track and may be plain, crowned, flanged, or V-grooved
- Internal bearings, either deep groove ball bearings or tapered roller bearings
- A threaded stud with a hexagon socket in the end, or a bore for yoke mounting on a pin
- Seals, including radial contact lip seals and an expansion plug on one end.
The type of internal bearing depends on the size and duty.
- Ball bearing versions suit higher speeds and lighter loads.
- Tapered roller bearing versions carry much higher radial and thrust loads, and are used in the larger, heavy-duty sizes.
Hi-Rollers are supplied sealed and ready to fit, and are made to inch dimensions, with UNF threads on stud types. The tight sealing makes them well suited to dusty, wet, and heavy-use environments.
Why are Hi-Roller bearings essential?
They are built for jobs where a standard cam follower would wear out quickly, especially where there is a constant side load as well as a radial load. Because they use ball or tapered roller bearings inside instead of needle rollers, they handle thrust loads well and can run at much higher speeds than traditional cam followers.
Their heavy outer roller, robust sealing, and choice of plain, crowned, flanged, and V-groove profiles make them a versatile choice for conveyors, beam rollers, and guide wheels in harsh conditions. Stud and yoke mounting options, along with eccentric versions for adjustment, let them suit a wide range of machine designs.
Typical applications include:
- Industrial conveying systems
- Lumber and wood processing machinery
- Mining and bulk handling equipment
- Automated storage and retrieval systems (AS/RS)
- Overhead crane conveyors
- Beam and track roller applications
- Load transfer systems
- Printing equipment
- General industrial machinery
The main types of Hi-Roller bearings
- Plain Hi-Rollers (PHR) - These have a flat, cylindrical outer roller and a threaded stud. They are the standard design for running on flat tracks and beams.
- Crowned plain Hi-Rollers (CPHR) - These have a slightly curved outer roller, which keeps the load near the centre of the roller if it is not perfectly aligned with the track. This reduces edge loading and track wear.
- Flanged Hi-Rollers (FHR) - These have an integral flange on the outer roller, which guides the roller along the edge of a track or beam and takes side loads.
- V-groove Hi-Rollers (VHR) - These have a V-shaped groove in the outer roller, for guiding along V-track rails or angle iron.
- Eccentric Hi-Rollers - Plain, crowned, flanged, and V-groove types are also available with an eccentric stud, so the roller position can be adjusted after fitting to remove play or share the load.
- Yoke type Hi-Rollers - Plain, flanged, and V-groove types are also available for yoke mounting, where the roller fits on a pin supported on both sides for higher loads.
How to choose the right Hi-Roller bearing?
- Roller profile - Choose plain for flat tracks, crowned where alignment cannot be guaranteed, flanged where the roller must be guided along an edge or take side loads, and V-groove for V-track or angle rails.
- Size - Choose the outer diameter to suit the track, load, and space available. Check the roller width, and for stud types, the stud diameter, length, and thread.
- Load - Work out the radial load and any thrust or side load. Compare them with the basic dynamic rating, dynamic thrust load, and maximum static capacity published for each part.
- Ball or tapered roller - Ball bearing versions suit higher speeds and moderate loads. Tapered roller versions suit heavy radial and thrust loads.
- Stud or yoke mounting - Choose a stud type for quick fitting into a single hole. Choose a yoke type where the roller can be supported on both sides for higher loads.
- Adjustment - Choose an eccentric type if the roller position needs to be adjusted after fitting.
- Track - The track or rail must be hard enough and smooth enough for the load, or it will wear quickly.
Essential references and specialised ranges
How the numbering works:
Hi-Roller part numbers are made up of a prefix, a size number, and a suffix, for example PHR-250-A.
The letters at the start identify the roller type:
PHR = plain Hi-Roller
CPHR = crowned plain Hi-Roller
FHR = flanged Hi-Roller
VHR = V-groove Hi-Roller
An E at the end of the prefix shows an eccentric version, for example PHRE, CPHRE, FHRE, and VHRE.
A Y at the end of the prefix shows a yoke type, for example PHRY, FHRY, and VHRY.
The middle number is the roller outer diameter in hundredths of an inch:
100 = 1.00 inch, 175 = 1.75 inch, 250 = 2.50 inch, 450 = 4.50 inch
Suffixes:
A = the standard suffix used on current Hi-Roller part numbers
Always check the full part number, outer diameter, width, and stud or bore size before ordering a replacement, and contact Carter or your supplier for the exact meaning of any other codes.
FAQ - All you need to know about Hi-Roller bearings
What is the difference between a Hi-Roller and a cam follower?
A standard cam follower usually uses needle rollers inside, which carry high radial loads but little thrust load and run at moderate speeds. A Hi-Roller uses deep groove ball bearings or tapered roller bearings inside, so it carries radial and thrust loads together and can run at much higher speeds.
Which Hi-Rollers use ball bearings and which use tapered roller bearings?
It depends on the size and model. Smaller sizes generally use deep groove ball bearings, while larger, heavy-duty sizes use tapered roller bearings. The bearing type is listed in the specification for each part number.
Can Hi-Rollers take side loads?
Yes. Because of their internal ball or tapered roller bearings, Hi-Rollers are designed to carry thrust loads as well as radial loads. Flanged and V-groove types are particularly suited to guiding and side loading.
Do Hi-Roller bearings need lubrication?
Hi-Rollers are supplied sealed and lubricated, with contact lip seals and an expansion plug to keep grease in and dirt and moisture out. Check Carter’s installation and maintenance guidance for whether your model can be relubricated.
Click here to learn how to maintain a bearing.
Can I replace a Hi-Roller myself?
In most cases, yes. For stud types, hold the stud with an Allen key in the hexagon socket while undoing the nut, then fit the new roller and tighten the nut to the torque given in the specification for that part. For yoke types, remove the pin, fit the new roller, and make sure it is located correctly. Never hammer on the outer roller.
How do I identify a Hi-Roller I need to replace?
The part number is usually marked on the roller or stud. If it is not readable, measure the outer diameter, roller width, and the stud diameter, length, and thread, or the bore for yoke types. Also note the roller profile, whether it is plain, crowned, flanged, or V-groove, and whether the stud is eccentric.
Click here to learn how to measure a bearing.
How can I tell if a Hi-Roller is worn or failing?
Warning signs include:
- Flat spots, pitting, or flaking on the outer roller
- The roller sliding instead of rolling along the track
- Rough or uneven rotation when turned by hand
- Play between the roller and the stud
- Noise or vibration as the roller passes along the track
- Damaged seals or grease leaking from the roller
- Wear marks or grooves forming on the track
