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Purpose:
Improper alignment of the hoist drum gear will cause end loading of the gear teeth and pitti
the mating pinions. Pitting typically results on one end of the gear teeth on one of the pinio
and on the other end on the opposite pinion. The hoist drum gear must be aligned any time
hoist drum assembly is installed in a machine, whether during a machine erection or mainte
procedure.
Alignment of the hoist drum gear is accomplished by shimming under and in front of the
sidestand bearing block. The goal of this procedure is to achieve equal backlash across the
face, check for good contact patterns in the front and rear gear mesh, and eliminate any evid
of misalignment.
Materials Required:
Solder ( ~ .125” diameter solid – for best results, do not use hollow core solder)
Dykem Hi-Spot Blue 107, Prussian Blue or PT-650 Tooth Marking Grease
Scotch #845 Book Tape (2 ½ - 3” wide)
Duct tape
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Machine Conditions:
The ideal circumstance to perform the alignment is on a fully assembled machine, but thi
Note machine conditions below by circling “Yes” or “No” and making any additional com
Additional comments:
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Checking Backlash:
Prior to taking any measurements, if the gearcase cover is not installed or torqued down,
sure all bearings are properly seated in the gearcase bores. This can be visually checked
feeler gages.
Total backlash is to be measured in the front and rear pinion/gear mesh. There will be tw
samples taken for the front mesh and two for the rear (see Figures 1, 3 & 5). Samples 1 a
will be front inboard and outboard, respectively. Samples 3 and 4 will be rear inboard an
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A total of eight measurements will be taken (see Table 1). Measurements are to be taken
approximately 1.00 inch from each end of the gear (see Figure 1). Depending on pinion
width, the distance to place the solder on the pinion will be 1.25 or 1.50 inches from each
to Table 1 for correct distance. Position the solder in the pinion tooth as shown in Fig
2) When checking the front mesh, rotate the rear pinion by turning the rear input couplin
vice versa. Rotate the input coupling clockwise (while facing gearcase) until the 2
3) Carefully remove and measure each solder sample from the pinion, making sure not t
up locations. Measure the thickness near the pitch line using a micrometer or vernier
4) Record the thickness measurements for the load and non-load side for the inboard an
6) Use the formulas in Table 1 to calculate the amount of shimming required. If you ha
spreadsheet program, simply enter the values in the boxes, and the program will
automatically perform the calculations. If not, hand calculations will be required usin
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Procedure for Checking Contact Pattern:
1) After final assembly of the gear set, rotate the pinions so that the drum gear makes at
2) Thoroughly clean the teeth of the pinions and drum gear with degreaser.
3) Apply a thin layer of bluing compound to the load side of one tooth on the front pinio
Figure 2). A thin film is defined as .0003” (.008 mm) to .0005” (.012mm) thick. A th
is best accomplished by wiping the compound on the tooth and then using a rag or fin
remove any excess (see figure 7). Excessive film thickness will result in false contac
readings. The pinion teeth are crowned; therefore full contact across the gear face wi
4) Roll the gear mesh by turning the input coupling clockwise (while facing gearcase) u
blue pinion tooth comes in contact with a gear tooth to transfer the bluing compound
5) Apply 3M book tape of proper width (2 ½ - 3”) to cover the face of the gear tooth. T
purpose of this is to transfer the bluing impression on the gear tooth to the book tape.
6) The sheet provided for contact patterns (sht 13) will have to be scaled up to fit 11 x 1
paper to provide enough space for the book tape. Use a photocopy machine to do thi
the book tape with the bluing impression on the sheet. Record the gear and pinion pa
7) Check for acceptable contact pattern per MOP 9.3, figure 1 provided. MOP 9.3, Figu
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Deviation:
If contact patterns other than those shown in MOP 9.3, Fig. 1 are observed, or contact patterns
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Table 1
1st Calculation
1st Backlash Measurements
Front Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Horizontally By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Towards Front, Less Than Zero = Towards Rear)
A B C D
Rear Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Vertically By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Up, Less Than Zero = Down)
2nd Calculation
2nd Backlash Measurements (after adjustment of sidestand)
Front Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Horizontally By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Towards Front, Less Than Zero = Towards Rear)
A B C D
Rear Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Vertically By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Up, Less Than Zero = Down)
Formulas for hand calculations: Final Check of Lead Error Across Gear Face (Load Side):
Maximum Permissible
Shim Sidestand Horizontally By: (- A + B - C + D + E - F + G - H) x Horizontal Factor Model Lead Error **
(Greater Than Zero = Towards Front) 2300XPA .003" Actual Lead Actual Lead
(Less Than Zero = Towards Rear) 2300XPB .003" Error (front) Error (rear)
2800XPA/XPB .004" *[ A - B ] *[ E - F ]
4100/4100A .004"
Shim Sidestand Vertically By: (A - B - C + D - E + F + G - H) x Vertical Factor 4100TS/BOSS .004"
(Greater Than Zero = Up) 4100XPB .004"
(Less Than Zero = Down) * Note: Use 2nd BL measurements
** If unobtainable contact Engineering
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Example - 4100XPB Down .010" & Back .010" Table 1
1st Calculation
1st Backlash Measurements
Front Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Horizontally By: .0152 .0152 .0143 .0133 .0095 .0100
Outboard Inboard Outboard Inboard (Greater Than Zero = Towards Front, Less Than Zero = Towards Rear)
2nd Calculation
2nd Backlash Measurements (after adjustment of sidestand)
Front Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Horizontally By: .0080 .0080 .0075 .0070 .0050 .0053
Outboard Inboard Outboard Inboard (Greater Than Zero = Towards Front, Less Than Zero = Towards Rear)
Formulas for hand calculations: Final Check of Lead Error Across Gear Face (Load Side):
Maximum Permissible
Shim Sidestand Horizontally By: (- A + B - C + D + E - F + G - H) x Horizontal Factor Model Lead Error **
(Greater Than Zero = Towards Front) (- .0159 +.0154 - .0181 + .0195 + .017 - .0174 + .0147 - .0133) x 5.25 = .010 2300XPA .003" Actual Lead Actual Lead
(Less Than Zero = Towards Rear) 2300XPB .003" Error (front) Error (rear)
2800XPA/XPB .004" *[ A - B ] *[ E - F ]
4100/4100A .004" .001 .001
Shim Sidestand Vertically By: (A - B - C + D - E + F + G - H) x Vertical Factor 4100TS/BOSS .004"
(Greater Than Zero = Up) (.0159 - .0154 - .0181 + .0195 - .017 + .0174 + .0147 - .0133) x 2.72 = .0101 4100XPB .004"
(Less Than Zero = Down) *Note: Use 2nd BL measurements
** If unobtainable contact Engineering
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Figure 3 - Applying Solder to Front Pinion
Note: Points A & B are on the Load Side. Points C & D are on the NON-Load Side
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Figure 5 - Applying Solder to Rear Pinion
Note: Points E & F are on the Load Side. Points G & H are on the NON-Load Side
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Note: Use copy machine to increase scale of this sheet to fit 11 x 17 paper
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