Mechanical Drives 1 Lap 3

MECHANICAL
LEARNING
DRIVES 1 ACTIVITY
PACKET
Power transmission
systems
TM
B502-XC
LEARNING ACTIVITY PACKET 3
POWER TRANSMISSION SYSTEMS
INTRODUCTION
In the previous LAPs you learned how to attach the motor shaft to a hub using a key
fastener. In this LAP you will build on this skill by coupling the motor shaft to an
independently mounted driven shaft which requires precise alignment with the motor
shaft. Alignment is one the factors that most affects the life of rotating machinery. If it is
not done correctly, the components can wear out quickly.
Also, as part of this LAP you will learn about two important power transmission
components: bearings and couplings. Every transmission machine you will work with has
bearings and couplings of some kind. This LAP will serve as an introduction to both. In
later LAPs you will learn more about each of them.
ITEMS NEEDED
Needed Amatrol supplied
Items
950-ME1 Mechanical Drives 1 Learning System
Amatrol or School supplied

Assorted Hand Tools
FIRST EDITION, LAP 3, REV. B

Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered
trademarks of Amatrol, Inc. All other brand and product names are trademarks or registered trademarks of their
respective companies.
Copyright © 2006, 2005 by AMATROL, INC.
All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any
means, electronic, optical, mechanical, or magnetic, including but not limited to photographing, photocopying,
recording or any information storage and retrieval system, without written permission of the copyright owner.
Amatrol,Inc., P.O. Box 2697, Jeffersonville, IN 47131 USA, Ph 812-288-8285, FAX 812-283-1584 www.amatrol.com
B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

Copyright  2006 Amatrol, Inc. 2
TABLE OF CONTENTS
SEGMENT 1 INTRODUCTION TO SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OBJECTIVE 1 Describe the function of a shaft and give an application
OBJECTIVE 2 List four types of shaft materials and give an application of each
OBJECTIVE 3 Describe how shafts are specified
SKILL 1 Identify shaft size given a sample
SEGMENT 2 INTRODUCTION TO BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

OBJECTIVE 4 Describe the function of a bearing and give an application
OBJECTIVE 5 Define three types of bearing loads and give an example of each
OBJECTIVE 6 Describe how bearings are positioned to support a load
OBJECTIVE 7 Describe the operation of a two categories of bearings and give an application of each
OBJECTIVE 8 Describe two methods of mounting a shaft bearing and give an application of each
SKILL 2 Install and adjust a pillow block antifriction bearing and shaft
SEGMENT 3 INTRODUCTION TO COUPLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

OBJECTIVE 9 Describe the function of a coupling and give an application
OBJECTIVE 10 Describe the function and application of four categories of mechanical couplings
OBJECTIVE 11 Describe the operation of a flexible jaw coupling
SKILL 3 Install a flexible jaw coupling
SEGMENT 4 SHAFT ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

OBJECTIVE 12 Describe the purpose of shaft alignment and give two types of misalignment
OBJECTIVE 13 Describe a general procedure for shaft alignment and give four measurement methods
OBJECTIVE 14 Describe the operation of the straight edge and feeler gage alignment method
SKILL 4 Align two shafts using a straight edge and feeler gage

SEGMENT 1
INTRODUCTION TO SHAFTS
OBJECTIVE 1 DESCRIBE THE FUNCTION OF A SHAFT

AND GIVE AN APPLICATION
his
dT A shaft is a cylindrical piece of material, usually steel, which
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transmits mechanical power in the form of torque and rotating motion

from one location to another. It is a basic component but a very
important one.
Shafts are often used as part of a machine, such as an electrical
motor or gas turbine, to transmit the power to a location outside the
machine.
Figure 1. Shaft Used in an Electric Motor

Shafts are also used as extensions to other shafts. An example of this
is a drive shaft on a car, which transmits the power from the transmission
in the front of the car to the differential gearbox in the rear.
DIFFERENTIAL
GEARBOX DRIVE SHAFT
(ENGINE)
Figure 2. Shaft Used as an Extension
Still, a third and very common application of a shaft is to provide a

means of operating the working components of the machine. For
machines which use some type of rotating member to perform the work,
a rotating shaft is attached to the member to power it. For example, a
drill spindle consists basically of a shaft with a cutter tool attached to it,
as shown in figure 3. Another application is in a roller press as used in a
printing press or a paper making machine. In these cases, the roller is a
part of the shaft.
SPINDLE
SHAFT
Figure 3. Spindle Shaft of a Drill Press

OBJECTIVE 2 LIST FOUR TYPES OF SHAFT MATERIALS
AND GIVE AN APPLICATION OF EACH
his
dT Most machine shafts are made of some type of steel. The particular
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type depends on the amount of load the shaft has to carry and the
conditions of the environment in which the shaft has to work. If you are
replacing a shaft in a machine, make sure that you are using the same
material. Do not assume that two materials that look the same are the
same.
Some examples of common shaft materials are as follows:
• Cold Rolled Steel (CRS)
• Hardened Steel
• Chrome Plated Steel
• Stainless Steel (SS)
Cold Rolled Steel

Cold rolled steel is the most common of all shaft materials because it
is cheap and easy to machine. It is available in different strengths
according to its carbon content. Cold rolled steel is used in most
applications.
Hardened Steel
This is cold rolled steel which has been heat treated to increase its
strength in some manner. Hardened steel is used in heavy duty
applications such as high speed drive shafts.
Chrome Plated Steel

This can either be cold rolled steel or hardened steel which has been
given a coating or plated with chrome. Chrome is a metal which is
resistant to rusting and other corrosive applications. It is often used on
rollers in presses.
Stainless Steel
Stainless steel resists rusting and is very strong. It combines the
features of hardened steel and chrome plating. In fact, stainless steel has
some chrome in it. A stainless steel shaft would be used where you need
resistance to a corrosive environment and either a better surface finish or
stronger surface than chrome plating can provide. Applications include
machines such as those used in the food processing industry where the
equipment must be often washed down with cleaning fluids. These fluids
can cause chrome to flake off.
In addition to these examples, a shaft can be made from many other
types of steel as well as other materials. If you are designing a machine
that uses shafts, you must consider the cost of the material, ease of
machining, and size as well as the type of duty.

OBJECTIVE 3 DESCRIBE HOW SHAFTS ARE SPECIFIED
his
dT Shafts are specified by the type of material, nominal diameter,
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diameter tolerance, straightness and length. Since a shaft is made from
round stock material, nominal (approximate) shaft diameters are usually
the same as the common sizes of standard round stock.
It is also important to determine the diameter tolerances and
straightness needed as well. Standard round stock is often not precise
enough, so designers select “accuracy” stock for most shaft applications.
Accuracy stock is precision ground to more exact tolerances than
standard round stock, as shown in figure 4.
DIAMETER TOLERANCE (in) STRAIGHTNESS (in)

NOMINAL STANDARD ACCURACY STANDARD ACCURACY
DIAMETER
1/4 0.2600-0.2400 0.2495-0.2490 Unspecified 0.001-0.002
3/8 0.3765-0.3735 0.3745-0.3740 Unspecified 0.001-0.002
1/2 0.5020-0.4980 0.4995-0.4990 Unspecified 0.001-0.002
3/4 0.7520-0.7480 0.7495-0.7490 Unspecified 0.001-0.002
1 1.0025-0.9975 0.9995-0.9990 Unspecified 0.001-0.002
1-1/4 1.2525-1.475 1.2495-1.2490 Unspecified 0.001-0.002
1-1/2 1.6030-1.4970 1.4994-1.4989 Unspecified 0.001-0.002
2 2.0030-1.9970 1.9994-1.9987 Unspecified 0.001-0.002
Figure 4. Standard Stock Sizes
NOTE
e This
tic
Notice that the accuracy stock’s diameter is always less than
No
the nominal diameter. This makes sure that components having

a bore the same size will fit on the shaft without interference.
Accuracy-type round stock is sold in standard lengths. Since shafts

are usually shorter than the standard lengths, they are cut to length. This
means the shaft length in a particular machine can be any length.

SKILL 1 IDENTIFY SHAFT SIZE GIVEN A SAMPLE
Procedure Overview
In this procedure, you will be given a shaft and asked
to measure its diameter and length. The shaft size will
determine the bearings, coupling, and other component
sizes in a power transmission. Therefore, correctly
identifying the shaft size is very important.
This ❑ 1. Place Shaft Panel 1 and Shaft Panel 2 on the work station’s
Do
overhead rack.
❑ 2. Locate the following items from the Storage Unit.
• 1-inch Micrometer
• Tape Measure
❑ 3. Perform the following substeps to measure the diameter of the
shaft.
A. Open the micrometer so that it is more than halfway open.
B. Place the shaft into the micrometer so that it is positioned for
diameter measurement, as shown in figure 5.
SHAFT
Figure 5. Positioning of Shaft for Measurement

C. Close the micrometer until the spindle and anvil are very near
to the part.
D. Rock the micrometer from side to side as shown in figure 6,
while turning the thimble clockwise. Continue to do this until
you feel that the shaft is perpendicular to the line of
measurement.
ROCK
DIAMETER
IS SHORTEST
LINE
0
1
2
3
4
5
10
Figure 6. Rocking to Get Shaft Perpendicular

E. Now, sweep the micrometer as shown in figure 7 to find the
high point. This will be the position where the diameter is
being measured.
SWEEP
LONGEST
LINE
Figure 7. Sweeping to Get Correct Line of Measurement
F. Repeat substeps D and E rocking and then sweeping, until you

feel confident that the shaft is aligned and you are reading the
true diameter.
G. Read the micrometer measurement.
Shaft Diameter: _______________________________(in/mm)
The diameter of this shaft should be 0.625 inches. This is a
common shaft size and is generally referred to by its fractional
equivalent of 5/8 inches.
❑ 4. Repeat Step 3 to measure the diameters of the other shafts on Shaft
Panel 1 and Shaft Panel 2.
SHAFT DIAMETER
NO. (in/mm)
1
2
3
4
5

❑ 5. Perform the following substeps to measure the length of the shafts.
The length is not a critical dimension. However, shafts are cut to
the length needed for an application. Therefore, this dimension
should be checked.
A. Pick up the tape measure and a shaft.
B. Hook the tape measure to one end of a shaft and stretch the tape
measure to the end of the shaft as shown in figure 8.
TAPE
X MEASURE
1 2 3 4 5 6
SHAFT
Figure 8. Measuring Shaft with a Tape Measure
C. Pull on the tape so that you stretch it tight.

D. Position yourself so that you can accurately read the scale, as
shown in figure 9.
After positioning the hook, you should move to a location that
is directly over the measuring point to read the scale. This helps
avoid a reading error.
SHAFT
Figure 9. Operator’s Eye Located Directly Over Measuring Point

E. Now, roll the tape over so that the scale contacts the shaft, as
shown in figure 10. This avoids a problem called parallax error.
GRADUATED SURFACE
SURFACE TO
BE MEASURED
Figure 10. Eliminating Parallax Error While Reading a Tape Measure
F. Read the length to the nearest 1/8 inch. Be careful to look

straight down at the measuring point.
Shaft Length: _________________________________(in/mm)
❑ 6. Repeat Step 4 to measure the lengths of the remaining shafts on
Shaft Panel 1 and Shaft Panel 2.
SHAFT LENGTH
NO. (in/mm)
1
2
3
4
5

SEGMENT 1
SELF REVIEW
r This
we
Ans
1. A ______ is a cylindrical piece of material used to transmit
mechanical power in the form of torque.
2. _________ is the most common of all shaft materials

because it is cheap and easy to machine.
3. ________ is used to make shafts because it has been heat

treated to increase its strength.
4. Shafts are specified by their type of material, diameter,

tolerance and ______.
5. The diameter of a shaft _____ (is/is not) usually the same as

the common sizes of standard round stock.

SEGMENT 2
INTRODUCTION TO BEARINGS
OBJECTIVE 4 DESCRIBE THE FUNCTION OF A BEARING

his
dT The function of a bearing is to support and guide a moving machine
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member with a minimum amount of friction. To understand why

bearings are needed, it is important to understand that a machine member
often has loads acting on it in several directions. Without bearings to
hold the member in place, the loads would cause the member would
move out of place and cause the machine to fail.
PILLOW
BLOCK
COUPLING BEARINGS
Figure 11. Motor and Shaft System Supported by Bearings

OBJECTIVE 5 DEFINE THREE TYPES OF BEARING LOADS
AND GIVE AN EXAMPLE OF EACH
his
dT Bearings are designed to counteract three types of loads which are
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placed on it by the power transmission equipment: a radial load, a thrust
load, and a combination of the two.
Radial Loads
A radial or side load acts in a direction that is perpendicular to the
axis of the shaft. For example, in figure 12 the force on the bearings
creates a radial load. Bearings which carry a radial load are called radial
bearings.
RADIAL
LOAD
SHAFT
AXIS
SHAFT
BEARING
Figure 12. Radial Bearing Load

One source of radial load is the force from the weight of the power
transmission component itself. An example is the shaft shown in figure
13. The weight of the shaft creates a force that pulls downward on the
radial bearings.
SHAFT WEIGHT
FORCE
RADIAL RADIAL
LOAD LOAD
Figure 13. Radial Load Created by Weight of Shaft
Another type of radial load is caused by the tension or compression

of the device the shaft is turning. Examples include the tension caused by
a belt drive and the compression caused by a roller press. These forces
also create a radial load on the shaft, as shown in figure 14.
RADIAL RADIAL
LOAD LOAD
ROLLER
ROLLER
BEARING BEARING
Figure 14. Examples of Radial Shaft Loads

Thrust Loads
A thrust load acts in a direction parallel to the shaft axis and opposite
to the direction of force transmission, as shown in figure 15. These
bearings are called thrust bearings.
THRUST LOAD
THRUST
BEARING
SHAFT
AXIS
SHAFT
STEP
Figure 15. Thrust Bearing Load

A thrust load can also be caused by the weight of the drive
component. One example is machine element, such as a robot body or an
index table, which must rotate parallel to the ground.
INDEX TABLE
THRUST
LOAD
Figure 16. Thrust Load Created by the Weight of the Drive Component

Another example of thrust load is the load created by a screw drive.
As the screw drives the load, a thrust load is created on the shaft in the
opposite direction, as shown in figure 17.
THRUST
LOAD
Figure 17. Thrust Load Created by Screw Drive
Combination Loads
As you can imagine, many applications have a combination load
with both a radial load and a thrust load. One example is the robot body
shown in figure 18. When the body rotates, a radial load is created along
with the thrust load from the weight of the machine. In fact, most loads
that have a thrust load also have a radial load.
WAIST
AXIS RADIAL LOAD
BEARING FROM ROTATION
OF WAIST
THRUST LOAD
FROM WEIGHT
OF ARM
Figure 18. Robot Body Having Both a Radial and a Thrust Load

OBJECTIVE 6 DESCRIBE HOW BEARINGS ARE POSITIONED
TO SUPPORT A LOAD
his
dT No matter what the application, there are some basic concepts that
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can be applied to understand where bearings are placed in order to
support a load. For radial loads, at least two bearings should be used to
secure the position of the shaft. The load can either be placed between
the two bearings or it can be overhung, as shown in figure 19. An
overhung load is often called a cantilever load.
LOAD BETWEEN BEARINGS CANTILEVER LOAD

LOAD LOAD
BEARING BEARING BEARING BEARING
Figure 19. Placement of Bearings for Support of Radial Loads
In some cases, the bearings are built into the machine rather than
mounted externally. An example is an electric motor. All electric motors
have two bearings, one on each side of the housing, as shown in figure
20. These bearings are needed to support the motor’s rotor and shaft.
They are also designed so that they can support an external radial load.
This permits a mechanical member to be attached to the shaft without
being supported by external bearings.
REAR BEARING
ROTOR
FRONT
BEARING
SHAFT
Figure 20. Electric Motor Having Two Bearings

In contrast, thrust loads only need one bearing. This bearing can be
placed anywhere on the shaft, but it must be oriented so that it can
counteract the direction of the thrust load, as shown in figure 21.
THRUST LOAD
THRUST
BEARING
SHAFT
AXIS
SHAFT
STEP
Figure 21. Placement of Bearing of Thrust Load

OBJECTIVE 7 DESCRIBE THE OPERATION OF TWO CATEGORIES
OF BEARINGS AND GIVE AN APPLICATION OF EACH
his
dT There are two major categories of bearings used in industry:
Rea
• Plain Bearings
• Anti-friction Bearings
Plain Bearings
A plain bearing is a type of bearing in which the surface of the
moving machine component slides over the bearing surface, separated
only by a lubrication film, as shown in figure 22.
SOLID
BEARING
SHAFT
LUBRICATION
FILM BETWEEN
BEARING AND
HOUSING SHAFT
Figure 22. Plain Bearing Operation

Plain bearings are designed to support either radial loads or axial
(thrust) loads . Radial load plain bearings for shafts are commonly called
journal bearings. One application is on the crankshaft of a car engine.

Antifriction Bearings
Antifriction bearings, unlike plain bearings, rotate with the moving
machine component. This is accomplished by using rollers or balls that
rotate within the bearing, as shown in figure 23. These rollers replace the
function of the lubrication film of the plain bearing. However,
antifriction bearings must use lubrication between the rollers.
ANTI-FRICTION
BEARING
SHAFT
HOUSING
Figure 23. Antifriction Bearing Operation

OBJECTIVE 8 DESCRIBE TWO METHODS OF MOUNTING A SHAFT BEARING
AND GIVE AN APPLICATION OF EACH
dT
his All bearings require a housing or mounting of some type in order to
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hold the bearing in place in the machine. Both plain and anti-friction
shaft bearings can be mounted in one of two ways:
• Pillow Block Bearing Mount
• Flange Bearing Mount
Pillow Block Bearing Mount

A pillow block consists of a housing with two mounting feet which
are oriented so that the shaft can be mounted to a horizontal or angled
surface. A pillow block can be designed as either a single assembly or a
split assembly, as shown in figure 24.
SINGLE SPLIT
ASSEMBLY ASSEMBLY
Figure 24. Two Types of Pillow Block Designs
Flange Bearing Mount

A flange type bearing mount consists of a housing with mounting
feet which are oriented so that the shaft can be mounted to a surface
which is perpendicular to the shaft. Flanges are designed with either two
or four mounting holes, as shown in figure 25.
Some flanges are built into the housing of the machine itself, as is
the case for an electric motor or pump.
FOUR-BOLT
SQUARE FLANGE
TWO-BOLT
FLANGE
Figure 25. Flange Designs

Both the pillow block and flange bearing mounts are very popular.
You will commonly find them both in industry.

SKILL 2 INSTALL AND ADJUST A PILLOW BLOCK ANTIFRICTION
BEARING AND SHAFT
Procedure Overview
In this procedure, you will install two pillow block
anti-friction bearings and mount a shaft between the two
bearings. You will also adjust the pillow blocks to make
sure the shaft is correctly aligned.
This ❑ 1. Perform the following safety checkout. Make sure that you are
Do
able to answer yes to each item before proceeding.
YES/NO SAFETY CHECKOUT

Wearing safety glasses
Wearing tight fitting clothes
Ties, watches, rings, and other jewelry are removed
Long hair is tied up or put it in a cap or under shirt
Wearing heavy duty shoes
Wearing short sleeves or long sleeves are rolled up
Floor is not wet
❑ 2. Perform a lockout/tagout on the Motor Control Unit’s safety

switch.
❑ 3. Place Shaft Panel 1 on the work station’s overhead rack.

❑ 4. Perform the following substeps to mount the pillow block
bearings.
A. Remove four bearing standoffs from Shaft Panel 1.
These will be used to raise the bearings to the correct height.
B. Place the four bearing standoffs on the 950-ME work surface,
as shown in figure 26.
The shaft and bearings that will be attached to the standoffs are
also shown.
12" SHAFT
Figure 26. Mounting the Four Aluminum Standoffs

C. Remove two pillow block bearings from Shaft Panel 1.
Figure 27. Pillow Block Bearing with Lock Collar
D. Place one of the pillow block bearings across two of the

standoffs, as shown in figure 28.
Orient the bearing so that the side with the set screws is pointed
toward the other set of standoffs.
SET SCREWS
Figure 28. Pillow Block Bearing Placed on the Standoff
E. Locate four bolts with the specification 3/8-16UNC-2A x 4-1/2

hex head, along with compatible flat washers, lock washers,
and nuts.

F. Loosely fasten the pillow block bearing to the table by placing
two of the 3/8-16 bolts through the bearing, standoff and
mounting surface. Use both flat and lock washers, as shown in
figure 29.
Do not tighten these fasteners yet.
tic
e This NOTE
No
Remember that the lock washer should contact the nut and
the flat washer should contact the mounting surface.
PILLOW
BLOCK
BEARING
STANDOFFS HEX
BOLT
FLAT
WASHER
950-ME
WORK SURFACE
PLATE
FLAT
LOCK WASHER
WASHER
HEX
NUT
Figure 29. Fastener Configuration
G. Place a second pillow block bearing on top of the other two

standoffs. Orient the bearing so that its set screws point toward
the other bearing.
H. Fasten this second pillow block bearing loosely to the work
surface.

❑ 5. Perform the following substeps to mount the shaft within the two
bearings.
A. Remove a 12-inch long shaft from Shaft Panel 1.
B. Slide the shaft through both pillow block bearings, as shown in
figure 30.
C. Position the shaft so that it extends approximately 3 inches
from the bearing nearest the edge of the work surface, as is also
shown in figure 30.
e This NOTE
tic
These bearings are self-aligning, which means the bearing
No
can move in the housing. If necessary, use the shaft to

straighten the bearing in the housing.
APPROXIMATELY
3 INCHES
Figure 30. Shaft/Bearing Assembly

D. Tighten the set screws on each bearing to lock the bearing to
the shaft and prevent it from slipping.
LOCK COLLAR
SET SCREW
Figure 31. Attachment of Bearing Lock Collars
E. Tighten the pillow block bearing mounting bolts.

Remember to hold the head of the fastener and turn the nut.
F. Turn the shaft by hand to make sure it turns freely.
If not, loosen the bolts and adjust the positions of the bearings.

❑ 6. Perform the following substeps to level the shaft.
A. Place the level on the shaft, as shown in figure 32, and observe
the position of the bubble.
Make sure the level sits on a smooth surface of the shaft.
LEVEL
SHAFT
Figure 32. Level Positioned on Shaft
B. If the shaft is not perfectly level, insert various feeler gage leaf
sizes under one end of the level until the bubble is centered.
Record the thickness.
If the bubble is shifted to the right, shim the left end of the
level.
Feeler Gage Thickness __________________________(in/mm)

C. Measure the distance between the edge of the level and the
edge of the feeler gage (LE), as shown in figure 33.
Effective Level Length _________________________(in/mm)

D. Measure the distance between the bearing mounting bolts (LB),
Mounting Bolt Distance_________________________(in/mm)
FEELER GAGE
LE
LB
Figure 33. Ratio Measurement Distances
E. Calculate the shim ratio.

LB
R =
LE
Length Ratio ________________________________________

F. Calculate shim thickness needed.
Shim thickness = feeler gage leaf thickness x shim ratio
Shim Thickness =______________________________(in/mm)

G. Loosen and shim either the front bearing or the back bearing
which will cause the shaft to be level.
Use the pre-cut shims from the shim package. These shims are
slotted in a horse shoe shape to fit around the bolts. Place the
shims between the standoff and the mounting surface. This will
help prevent the shims from being damaged. Whichever
bearing you shim, shim each side equally.
Use the shim thickness calculated in substep F.
e This NOTE
tic
No
Use as few shims as possible. As an example, two 0.005 inch

shims should be replaced one 0.010 inch shim.
H. Tighten the bolts again. Use a criss-cross pattern.

I. Check the level of the shaft.
This
NOTE
e
tic
Do not use wrinkled or bent shims. Also do not push the
No
shims into contact with the bolt. When the bolt is tightened, it will
damage the shims.
If the shaft is level, go to the next substep. If not, repeat step 6

until it is level.
J. Turn the shaft by hand. The shaft should turn easily.
❑ 7. Check the driven shaft for run-out.
In a later procedure, you will attach this shaft to the electric motor
using a coupling so it is important the shaft does not have
excessive run-out.
Run-out:________________________________________(in/mm)
The shaft should have no more than 0.002 inch run-out. If so, it is
bent and should be replaced.
❑ 8. Leave your setup in place and continue to the Self Review.

SEGMENT 2
SELF REVIEW
r This
we
Ans
1. The function of a bearing is to ________ and ______ a
moving machine member with a minimum amount of
friction.
2. A _______ load acts in a direction that is perpendicular to

the direction of force transmission.
3. For radial loads, at least _______ bearing(s) should be used

to secure the position of the shaft.
4. A _______ bearing is a type of bearing in which the surface

of the moving machine component slides over the bearing
surface separated by a film of lubrication.
5. A _______ bearing mount consists of a housing with two

mounting feet which are oriented so that the shaft can be
mounted to a horizontal or angled surface.

SEGMENT 3
INTRODUCTION TO COUPLINGS
OBJECTIVE 9 DESCRIBE THE FUNCTION OF A COUPLING

his
dT Couplings are used to connect one shaft to another. They are
Rea
commonly used to connect electric motors and other prime movers to

driven devices such as pumps and gear reducers, as shown in figure 34.
They can also be used to connect two shafts to create one long shaft.
AXIAL SHAFT TRANSMISSION

PUMP
ELECTRIC
MOTOR
Figure 34. Electric Motor Coupled to a Hydraulic Pump

The coupling provides a secure method of transmitting the torque
and speed from one shaft to another. Although they appear to perform a
rather simple task, there are many types of couplings, and their correct
installation will greatly affect the mechanical efficiency and life of the
system.

OBJECTIVE 10 DESCRIBE THE FUNCTION AND APPLICATION OF FOUR
CATEGORIES OF MECHANICAL COUPLINGS
dT
his The many types of mechanical couplings fall under four general
Rea
categories:
• Rigid Couplings
• Flexible Couplings
• Universal Joints
• Clutches
Rigid Couplings
Rigid couplings are designed to couple two shafts together rigidly,
so that the shafts act as a single continuous assembly. One type of rigid
coupling is a flange coupling, as shown in figure 35.
Figure 35. Flange Couplings

Rigid couplings allow for no misalignment. They are used mainly to
extend the length of a shaft in applications which need very long shaft
lengths, as shown in figure 36. Sometimes they are used to connect
motors to pumps, but this is not usually recommended because any
misalignment will cause the bearings to wear out more quickly.
EXTENDED SHAFT SYSTEM
BEARING COUPLING BEARING COUPLING
Figure 36. Rigid Coupling Application

Flexible Couplings
Flexible couplings are designed to connect two shafts together and
allow for some misalignment. Although there are many designs of
flexible couplings, in general, they consist of two hubs and some type of
flexible component which connects the two hubs together.
Figure 37. Two Shafts Coupled by a Flexible Coupling

Flexible couplings are used in applications which require two
independently supported coaxial shafts to be coupled together. When
two shafts are independently supported it is very difficult to align them
perfectly. The flexible coupling allows enough misalignment to make the
alignment process a practical task. Applications that use flexible
couplings include any electric motor or engine which must be coupled to
a pump or gear reducer.

Universal Joint Coupling
The universal joint is designed to allow two shafts which are not
coaxially aligned to be connected to each other, as shown in figure 38.
The universal joint consists of one or two swivel connections that allow
it to direct the shaft power to a shaft that is oriented at an angle to the
driving shaft. Universal joints are used in drive shafts for automobiles.
One example of an industrial application is a paper making machine,
which requires a motor to drive a roller that is offset from the motor
shaft.
Figure 38. Universal Joint Application
Clutch Type Couplings

The fourth category of couplings are clutches. These couplings are
designed to not only connect two shafts together but to also connect and
disconnect them while the shafts are turning. Clutches are used to start
machines in an unloaded condition, prevent reverse rotation, and act as a
safety device if the shaft torque overloads.
Figure 39. Clutch Application

OBJECTIVE 11 DESCRIBE THE OPERATION OF A FLEXIBLE JAW COUPLING
dT
his The flexible jaw coupling is a type of flexible coupling which uses a
Rea
rubber-like insert called a spider to connect the two hubs. As shown in
figure 40, each hub has jaws that mesh with the spider.
When the driver coupling half rotates, its jaws press on the spider,
which in turn press on the jaws of the driver coupling half, causing it to
turn.
This type of coupling belongs to a family of couplings called
elastomeric couplings, which refers to couplings that use a rubber-like
elements to separate the two coupling halves. Specifically, it is a type of
coupling called an Elastomer-in-compression.
Figure 40. Flexible Jaw Coupling

The hubs of a jaw coupling are constructed of either aluminum, cast
iron, or steel, depending on the power rating. They can be mounted with
either a key fastener or bushing.
The spider can be made of either Buna N (Nitrile) rubber, urethane,
Hytril, or even metals such as bronze. They are usually designed as a
one-piece construction, but can be supplied as pieces, as shown in figure
41.
Figure 41. Spider Designs
The advantage of this type of coupling is that it allows more

misalignment than most flexible couplings because of the elastic
properties of the elastomer spider.
However, it is usually used for low to medium power/speed
applications. This type of coupling is also known as a jaw and spider
coupler, elastomeric jaw coupling, and simply a jaw coupling.

SKILL 3 INSTALL A FLEXIBLE JAW COUPLING
Procedure Overview
In this procedure, you will install a flexible jaw coupling
to connect a motor to the shaft you mounted in the
previous segment.
This ❑ 1. Perform the following safety checkout to prepare for working with
Do
power transmission equipment. Make sure that you are able to

answer yes to each item before proceeding.

Floor is not wet

switch.
❑ 3. Make sure the shaft and bearing assembly is still set up from the
previous segment. If not, repeat Skill 2 to do so.

❑ 4. Perform the following substeps to mount and level the Constant
Speed Motor.
A. Locate the Constant Speed Motor and place it on the work
surface.
B. Locate the four Constant Speed Motor Risers from Shaft Panel
1.
C. Make sure that the motor base, risers, and mounting area of the
work surface shown in figure 42 are free of dirt, rust, and burrs.
D. Position the Constant Speed Motor over the set of holes on the
950-ME work surface, as shown in figure 42.
The outlines of the other components to be mounted are also
shown.
FLEXIBLE
COUPLING
MOTOR
Figure 42. Location of Components on 950-ME Work Surface

E. Place one Constant Speed Motor Riser under each of the motor
feet.
F. Locate four bolts with the specifications 5/16-18UNC-2A x 1-1/2
Hex Head, along with compatible flat washers, lock washers, and
nuts.
G. Fasten the motor and risers to the work surface by assembling
bolts, washers, and nuts.
Use a criss-cross pattern to tighten the bolts.
H. Check the shaft for run-out. Record below the amount of
run-out.
Run-out: _____________________________________(in/mm)
The run-out should be less than 0.002 inches.
I. Check for motor shaft end float.
End Float ____________________________________(in/mm)
It should be less than 0.002 inches.
J. Check the level of the motor shaft. Shim the motor feet as
needed.
Feeler Gage Leaf Thickness______________________(in/mm)
Effective Level Length _________________________(in/mm)
Mounting Bolt Distance_________________________(in/mm)
Shim Ratio _________________________________________
Shim Thickness _______________________________(in/mm)

❑ 5. Perform the following substeps to check the height of the two
machines.
NOTE
e This It is important that the driven shaft be a little higher than the
tic
motor shaft, typically 0.010-0.015 inches. This will allow you to
No
correct misalignment by shimming the motor. You will learn more
about this in the next segment. It is being done now because it is
easiest to do when the couplings are not mounted and a straight
edge can be placed across the two shafts.
A. Place the 4-inch straight edge across the shaft which appears to
be higher, as shown in figure 43.
B. Select a combination of feeler gage leaves which will cause a slight
drag on the leaves when they are passed under the straight edge.
This is the height difference between the two shafts.
Shaft Height Difference _________________________(in/mm)
If the independent shaft is between 0.010-0.015 inches higher
than the motor shaft, proceed to the next step.
If it is less, shim the bearing standoffs equally so that it is.
Figure 43. Measurement of Shaft Height Difference

❑ 6. Perform the following substeps to mount one of the jaws of the
coupling to the motor shaft.
A. Loosen the motor mounting bolts and slide the motor back far
enough so that the coupling hub to be installed will fit between
the shafts.
B. Pick up one of the coupling hubs.
C. Clean the shaft keyseat and the hub keyseat to make sure that
no dirt or burrs are in the keyseats.
D. Test the key fit by sliding one of the keys into the keyseat of
the hub.
The key should fit into the keyseat without forcing it. If it is too
tight or too loose, replace it with another key.
E. Remove the key from the hub keyseat and insert it into the
keyseat of the shaft.
It also should slide in without forcing it and have no play.
F. Line up the key flush with the end of the shaft, as shown in
figure 44.
KEY FLUSH
WITH END
OF SHAFT
Figure 44. Key Positioned on Shaft

G. Pick up the coupling hub in your hand and line it up in front of
the shaft so that the hub’s keyseat is in line with the key on the
shaft.
H. Slide the hub onto the shaft and pull it back from the end of the
shaft, as shown in figure 45. This position will allow room for
the other coupling hub to be put on.
The hub should slide on without using tools. If it does not, use
precision measuring equipment to measure the dimensions of
the shaft and the hub bore.
Do not tighten the set screws yet.
Figure 45. Hub Slid Onto Shaft

❑ 7. Repeat step 6 to place the other coupling hub on the shaft which is
supported by the bearings.
❑ 8. Move the two coupling hubs so that each hub is flush with its
shaft, as shown in figure 46.
Figure 46. Jaws Engaged

❑ 9. Tighten the set screws onto the keys of both hubs.
❑ 10. Move the motor to a position where the gap between the coupling
teeth is large enough to allow insertion of the spider.
❑ 11. Then place the spider on the driven shaft coupling hub.
Figure 47. Spider Mounted on Coupling Hub

❑ 12. Slide the motor forward so that the two hubs’ jaws engage.
❑ 13. Adjust the gap to 0.5 inches, as shown in figure 48, and tighten
down the motor mounting hardware.
Now the coupling assembly is complete. The next step is to align
it. You will do this in the next skill.
Figure 48. Coupling Gap

SEGMENT 3
SELF REVIEW
r This
we
Ans
1. __________ are used to connect one shaft to another.
2. ________ couplings allow for no misalignment.
3. ________ couplings are designed to allow for some

misalignment.
4. ________ couplings are designed to connect two shafts that

are not coaxially aligned.
5. The ______ ______ coupling is a flexible coupling that uses

a rubber-like insert to connect two hubs.

SEGMENT 4
SHAFT ALIGNMENT
OBJECTIVE 12 DESCRIBE THE PURPOSE OF SHAFT ALIGNMENT

AND GIVE TWO TYPES OF MISALIGNMENT
his
dT The centerlines of two shafts which are connected by a flexible
Rea
coupling should be brought into line with each other before operating the
shafts. This process is called shaft alignment.
The goal of shaft alignment is not perfect alignment but just good
alignment. This helps reduce vibration and extend the life of the
coupling, bearings, and seals. It is well known to be a main cause of
early failure of equipment.
DRIVER SHAFT DRIVEN SHAFT

CENTERLINE CENTERLINE
Figure 49. Alignment of Center Lines of Coaxial Shafts
The two types of misalignment that are corrected by shaft alignment

are angular and parallel misalignment, as shown in figure 49. This can
appear anywhere in a 360 degree circle but they are usually measured on
the horizontal and vertical planes.
ANGULAR PARALLEL
MISALIGNMENT MISALIGNMENT (OFFSET)
Figure 50. Parallel and Angular Misalignment

OBJECTIVE 13 DESCRIBE A GENERAL PROCEDURE FOR SHAFT ALIGNMENT
AND GIVE FOUR MEASUREMENT METHODS
his
dT The general procedure for aligning two shafts is to check and correct
Rea
for angular and parallel misalignment in two planes, vertical and
horizontal, as shown in figure 51. Also, the coupling gap is set, which is
done when horizontal angular misalignment is corrected. This means that
there are five checks and corrections that have to be made:
• Vertical Angular
• Vertical Parallel
• Horizontal Angular and Coupling Gap
• Horizontal Parallel
Notice that the two vertical alignment checks are done first. This is
because they require shims to be added to the motor’s feet. Doing this
last would upset the horizontal alignments.
VERTICAL HORIZONTAL
ALIGNMENT ALIGNMENT
Figure 51. Vertical and Horizontal Alignment

To make these five checks of misalignment between the two shafts,
measurements are normally taken on the orientation of the two coupling
hubs with each other. For this reason, shaft alignment is also called
coupling alignment. However, it is important to remember that the real
goal is the alignment of the shafts.

The details of each step are described as follows:
Step 1. Vertical Angular Alignment

To correct the vertical angular alignment, shims are added to the
front or back of the motor, depending on the location of the
misalignment. If the gap between the couplings is greater at the top of
the coupling, the back of the motor must be raised with shims. If the gap
between the coupling hubs is greater at the bottom, the front of the motor
must be raised with shims, as shown in figure 52.
TOP
GAP
BOTTOM
GAP
SHIMS
VERTICAL ANGULAR
MISALIGNMENT
Figure 52. Adjustments for Vertical Angular Misalignment
Step 2. Vertical Parallel Alignment

Vertical parallel alignment means to make the height of the two
shafts the same. To correct for vertical parallel misalignment, the entire
motor must be raised or lowered. This is done by adding or removing
shims equally on all four motor feet, as shown in figure 53.
VERTICAL PARALLEL
MISALIGNMENT
EQUAL
SHIMS
Figure 53. Adjustments for Vertical Parallel Alignment

Step 3. Horizontal Angular Alignment and Coupling Gap
The horizontal angular alignment is the same as the vertical angular
alignment except that the gap measurements are taken from the sides of
the coupling halves. Shims are not used to correct this misalignment. The
motor foot mount must be loosened and the motor slightly turned to
correct the horizontal angular alignment, as shown in figure 54.
OVERHEAD VIEW
HORIZONTAL
ANGULAR
ADJUSTMENT
MISALIGNMENT
Figure 54. Adjustments for Horizontal Angular Alignment

The coupling gap is the distance between the two coupling hubs.
This should be set to the coupling manufacturer’s specification. This
specification is designed to permit the coupling to assemble correctly.
Since the measurements for horizontal angular alignment are
measuring the coupling gap, it is natural to adjust the gap at the same
time. It simply requires that the motor be moved forward or back as well
as angled.

Step 4. Horizontal Parallel Alignment
The horizontal parallel alignment is the parallel alignment of the
coupling hubs when viewed from overhead. To correct for the horizontal
parallel alignment, the motor foot mounts must be loosened and all four
feet moved an equal amount, as shown in figure 55.
This will often upset the horizontal angular alignment so you should
perform step 3 again to check it. In fact, you should repeat steps 3 and 4
until the measurements are within the tolerances before tightening the
bolts.
OVERHEAD VIEW
TOP OF TOP OF
MOTOR MOTOR
HORIZONTAL
PARALLEL
MISALIGNMENT MOVE
FEET
EQUALLY
Figure 55. Adjustments for Horizontal Parallel Alignment
The actual measurement of the amount of misalignment can be

measured by using one of four methods. These are as follows in order of
their accuracy from least accurate to most accurate:
• Straight Edge and Feeler Gage Method
• Face and Rim Method using one dial indicator or two dial
indicators
• Reverse Indicator Method using two dial indicators
• Laser Alignment
The straight edge and feeler gage method is the least accurate
method, but it is very quick. It is the method most people use to align a
flexible jaw coupling because this type of coupling can accept more
misalignment than most other couplings. Other types of couplings
require better methods. The straight edge and feeler gage method is also
useful to make a rough alignment before using one of the other methods.
You will learn about each of these methods in later LAPs.

Pre Alignment Steps
Before beginning the 4-step alignment process, there are several
points that must be considered. One point is which device is going to be
moved and which will remain in place. These are called the Machine to
be Moved (M.T.B.M.) and the Stationary Machine.
Normally, the driver component is the M.T.B.M. and the driven
component is the stationary machine. This is because the driver
component is usually easier to move. For example, a pump may not be
easy to move if it has rigid plumbing attached to it.
The next point is to make sure that the height of the M.T.B.M. is
slightly lower than the stationary machine. This is because the movable
component will rise as it is shimmed during alignment.
To accomplish this, the stationary component can be shimmed when
it is mounted, as shown in figure 56. A beginning height difference
between the two shafts of 0.010 to 0.015 inches is good.
INITIAL HEIGHT
DIFFERENCE
SHIMS
Figure 56. Initial Height Different of Components
Also, the couplings should be placed on the shafts and the M.T.B.M.
then moved into a position where the gap between coupling hubs is
approximately the amount recommended by the manufacturer. This is
normally done with the coupling hubs mounted flush with the ends of the
shafts.
One or both coupling hubs will then be secured in place on the
shafts, depending on the coupling design and method of alignment used.
In some cases, only one hub is secured, usually the stationary machine,
and the other is pulled back on the shaft to give room to get at the
coupling face for measurement.

OBJECTIVE 14 DESCRIBE THE OPERATION OF THE STRAIGHT EDGE AND
FEELER GAGE ALIGNMENT METHOD
his
dT The general 4-step procedure just described is used by the straight
Rea
edge and feeler gage method to align two shafts. The specific steps to
follow including prealignment are as follows:
Step 1. Perform Pre-alignment Steps

Before starting the alignment process, you should do the following:
• Perform a lockout/tagout
• Clean and make free of burrs the motor and driven machines’
baseplate, shims, and mounting surface
• Check both machines for an initial soft foot
• Mount the motor and driven machine and tighten bolts
• Check both machines for a final soft foot
• Check both shafts for run-out and end float
• Level both shafts
• Make sure the height of the stationary machine is higher than the
machine to be moved (MTBM)
• Clean the coupling of dirt or grease and mount the coupling hubs
on the shafts
• Adjust the positions of the two machines so that the gap between
the couplings halves is approximately the amount recommended
by the manufacturer
• Tighten the mounting bolts of the two machines

Step 2. Perform Vertical Angular Alignment
First, mark the two coupling halves with a chalk or ink mark on a
place on the hubs which is free of nicks or burrs This is where all your
measurements will be taken from during the alignment process. Next,
rotate the coupling hubs so that the two chalk marks are both at the 0
degree position, as shown in figure 57.
OVERHEAD VIEW
TOP OF
MOTOR
CHALK MARKS
AT 0º
Figure 57. Check Marks at 0 Degrees

Use a feeler gage to measure the gap between the two coupling hubs
at 0 degrees, as shown in figure 58. Select the feeler gage leaf or leaves
that give a slight drag when passed through the gap. Make sure you do
not insert the feeler gage leaves too far, less than 1/2-inch. With angular
alignment, your measurement will vary depending on how far you stick
in the leaves.
FEELER
GAGE
0º
180º
10
Figure 58. Measurement of Gap at 0 and 180 Degrees
Next, rotate the coupling hubs so that the chalk marks are at the 180
degree position and measure the gap here, as is also shown in figure 58.
The difference between the two measurements is the amount of vertical
angular misalignment. For example, if the top gap is 0.010 inches and
the bottom gap is 0.017 inches, the misalignment is 0.007 inches.
To correct this misalignment, either the front two feet or the back
two feet must be shimmed. The amount of shims needed can be
determined by multiplying the misalignment by the shim ratio. The shim
ratio is the ratio of the mounting bolt distance to the hub diameter. In
figure 58, for example, the shim ratio is 2 (2=10/5). The amount to shim
then 0.014 (2 x 0.007).
If the gap is larger at the top, shim the back two feet. If is larger at
the bottom, shim the front two feet. Tighten the motor feet and recheck
the gaps. If it is not equal at the top and bottom, or at least within the
tolerance, change your shims.
NOTE
The reason you are rotating the coupling hubs before making
e This
each measurement is so that you can take measurements off of
tic
the same places on the hubs each time. This avoids errors in
No
measurement caused by imperfections on the outside diameters

(rims) of the coupling hubs.
In some cases, one or both of the shafts will not rotate by
hand. You can still use this procedure but you will not be as
accurate.

Step 3. Perform Vertical Parallel Alignment
Before checking the vertical alignment, or offset, first, measure the
hub diameters to determine if the hubs are the same size. When hubs
have different diameters, the alignment steps are different. If they are the
same size, rotate the two marks to the 0 degree position and measure the
offset. This is done by placing a straight edge on the hub that is higher
and measuring the gap with a feeler gage, as shown in figure 59.
Next, rotate the coupling hubs so that the chalk marks are at the 180
degree position and measure the gap here. If the two measurements are
the same, this is the amount of vertical parallel misalignment, or offset. If
they are different, calculate the average of the two and use this as the
vertical offset.
Shim all four motor feet equally with shims having the same
thickness as the offset you measured.
FEELER
GAGE STRAIGHT EDGE
3 2 1
0º
180º
Figure 59. Measurement of Vertical Parallel Misalignment

If the diameters of the two hubs are different, shim the MTBM so
that the hub gap is the same on both sides, as shown in figure 60.
0.050
0.050
Figure 60. Compensation for Different Hub Diameters

Now that the vertical alignments have been done, you can go on to
the horizontal alignments. These alignments do not require shimming.
Step 5. Perform Horizontal Angular Alignment and Set

Coupling Gap
First, center the end-play of the driver shaft and the driven shaft if
they have any. Then rotate the chalk marks to the 90 degree position (as
you look down onto the driver shaft) and use either a steel rule or feeler
gage to measure the gap, as shown in figure 61. Loosen the mounting
bolts and move the MTBM either in or out to adjust the gap to the
manufacturer’s specifications. This amount will vary, depending on the
type of coupling.
TOP OF
MOTOR
90º
GAP
RULE
Figure 61. Measurement of Horizontal Angular Misalignment at 90°

Now rotate the marks to the 270 degree position and measure the
gap again, as shown in figure 62. Adjust the position of the motor so that
the gap is the same (or the difference is within the manufacturer’s
tolerance) on both sides at both 90 and 270 degrees it is within the
manufacturer’s gap specification. This sets the horizontal angular
alignment.
Leave the bolts untightened and go to the final step.
RULE
GAP
270º
TOP OF
MOTOR
Figure 62. Measurement of Horizontal Angular Misalignment at 270°
Step 6. Perform Horizontal Parallel Alignment

Use a straight edge and feeler gage to measure the misalignment
when the chalk marks are at the 90 and 270 degree positions, as shown in
figure 63.
270º
3 2 1
3 2 1
90º
FEELER
STRAIGHT
GAGE
EDGE
Figure 63. Measurement of Horizontal Parallel Misalignment

Carefully bump or move the side of the motor without losing angular
alignment until the offset measurements at 90 and 270 degrees are the
same or zero.
Larger motors have jack bolts which allow you to precisely move the
front and the back of the motor equally.
TOP OF
MOTOR
JACK BOLTS
Figure 64. Correction of Parallel Misalignment with Jack Bolts
Regardless of the method you use to move the motor, you should
repeat steps 5 and 6 to recheck the gap and horizontal alignments until
the settings are within the manufacturer’s specifications. Once done,
tighten down the motor’s mounting bolts. Then recheck all
measurements. If any one of the five measurements, are outside its
allowable tolerance, repeat the alignment procedure.

SKILL 4 ALIGN TWO SHAFTS USING A STRAIGHT EDGE
AND FEELER GAGE
Procedure Overview
In this procedure, you will continue from the previous
skill where you partially completed the installation of the
jaw and spider coupling. In this skill, you will align the
coupling and complete its installation.
This ❑ 1. Perform the following safety checkout to prepare for working with
Do
power transmission equipment. Make sure that you are able to

answer yes to each item before proceeding.

Floor is not wet

switch.
❑ 3. Continuing from the previous skill, the flexible jaw coupling hubs
should be on the motor shaft and the shaft supported by the pillow
block bearings.
If you review the steps you followed in the last skill, you will find
that you have performed all of the coupling prealignment steps, so
your next step is to perform the vertical angular alignment.

❑ 4. Obtain a feeler gage, a 4-inch straight edge, and a dial caliper.
❑ 5. Perform the following substeps to adjust the vertical angular
alignment of the two shafts.
A. Place a chalk mark on the hub, as shown in figure 65.
Choose an area which is free of burrs.
B. Rotate the chalk marks to the 0 degree position, as shown in
figure 65.
ALIGNMENT
MARKS
AT 0°
Figure 65. Chalk Marks at 0 Degrees

C. Use the dial caliper to measure the X dimension at 0 degrees,
top of the coupling, at the chalk marks, as shown in figure 66.
XO = _______________________________________(in/mm)
NOTE
e This
Notic Normally you would measure the coupling gap, but is not easy
to do on a flexible jaw coupling because the spider has been
inserted. The X dimension is an indirect measurement of the
gap.
0º
180º
Figure 66. Measuring the Distance at the Top of the Coupling
D. Rotate the coupling so that the chalk marks are at the bottom at
180 degrees.
E. Use the dial caliper to measure the X dimension at the chalk
mark which is now at 180 degrees, the bottom of the coupling.
X180 = ______________________________________(in/mm)
F. Subtract two to get the vertical angular misalignment.
Vertical Angular Misalignment = X0 - X180
Vertical Misalignment = ________________________(in/mm)
The manufacturer recommends that the angular misalignment

be less than 0.035 inches. Even if your measurement is less,
continue to the next substep to make your alignment even
better. The value of 0.035 inches is a worst case. This coupling
should be aligned to within 0.015 inches or better.

G. Use the dial caliper to measure the diameter of the coupling, as
shown in figure 67.
Coupling Diameter: ____________________________(in/mm)
H. Use a rule to measure the length of the motor mount distance,
Motor Mount Distance: _________________________(in/mm)
COUPLING
DIAMETER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
MOTOR
MOUNT
DISTANCE
Figure 67. Measuring the Length of the Motor’s Foot Mount
I. Calculate the shim ratio.

Motor Mount Distance
Shim Ratio =
Coupling Diameter
Ratio =_____________________________________________
J. Calculate the shim thickness needed.
Shim Thickness = Vertical Misalignment x Shim Ratio
Shim Thickness =______________________________(inches)

K. Determine which end of the motor should be shimmed.
If the X dimension at 0 degrees is smaller than the X dimension
at 180 degrees, the top gap is smaller than the bottom gap.
Shim the front of the motor. If the top gap is larger, shim the
back of the motor.
End of Motor to Shim: ______________________(Front/Back)
SHIM FRONT SHIM BACK

OF MOTOR OF MOTOR
TOP GAP TOP GAP

SMALLER LARGER
MOTOR MOTOR
Figure 68. Determining which End of the Motor to Shim
L. Loosen the motor’s mounting bolts.

M. Apply the correct amount of shims to two of the motor’s feet.
Be sure to shim both sides of the motor equally.
N. Retighten the motor’s mounting bolts using a criss-cross
pattern.
O. Measure the coupling distances, X0 and X180, again to verify
that the vertical angular misalignment has been corrected to
within 0.015 inches. If not, repeat this step.

❑ 6. Perform the following substeps to adjust the vertical parallel
alignment of the coupling.
A. Measure the hubs to make sure they have the same diameter.
tic
e This NOTE
No
The hubs used with the flexible jaw coupling in the 950-ME
Mechanical Drives System have matching diameters. However,
this substep should always be preformed.
Hub 1 Diameter _______________________________(in/mm)

Proceed to substep B, assuming that the hubs are of the same
diameter.
B. Rotate the hubs so that the chalk marks are on top again at 0
degrees.
C. Place the straight edge across the top of the coupling on top of
the chalk marks, as shown in figure 69. Hold it firmly on the
higher coupling hub.
JAW
COUPLING PILLOW BLOCK
BEARING
*ELASTOMER SPIDER
NOT SHOWN FOR CLARITY
Figure 69. Straight Edge Placed Across the Top of the Coupling

D. Slide a leaf of the feeler gage between the straight edge and the
lower coupling hub.
Increase the amount of leaf thickness until you feel a slight
drag. Record the total leaf thickness. This is the parallel
misalignment.
Vertical Parallel Misalignment (0): ________________(in/mm)
FEELER
GAGE
*ELASTOMER SPIDER
Figure 70. Determining the Vertical Parallel Misalignment at 0°
E. Rotate the chalk marks to the bottom and check the

misalignment again, as shown in figure 71.
Place the straight edge against the opposite hub.
Vertical Parallel Misalignment (180): ______________(in/mm)

If the measurement at the bottom is the same as at the top, this
is the amount of shims you need. If the measurements are
slightly different, take an average of the two to determine shim
thickness.
FEELER
*ELASTOMER SPIDER
GAGE
Figure 71. Verifying Measurement at 180°

The manufacturer recommends that the parallel misalignment
continue to the next substeps to see if you can improve it.
Again, the value of 0.015 inches is a worst case.
F. Add a set of shims to each of the four motor mounting feet
which is equal in thickness to the vertical parallel misalignment
just measured.
G. Tighten the motor mounting bolts.
H. Recheck both the vertical parallel and angular alignment again
to make sure that they are within the tolerances.
❑ 7. Perform the following substeps to adjust the horizontal angular
alignment and the gap.
tic
e This NOTE
No
These alignment corrections will not require the use of

additional shims. Do not add or remove shims during this step.
A. Rotate the hubs so that the chalk marks are at the side at 90
degrees.
B. Use a rule to measure from the bottom of one hub’s jaw to the
bottom of the other hub’s jaw, as shown in figure 72.
Gap: ________________________________________(in/mm)
COUPLING
*ELASTOMER SPIDER GAP
Figure 72. Measurement of Coupling Gap

C. Use the dial caliper to measure the X dimension at 90 degrees,
X90: ________________________________________(in/mm)
DIAL
CALIPER
270º
90°
*ELASTOMER SPIDER
Figure 73. Checking the Horizontal Angular Alignment Using a Dial

Caliper
D. Then rotate the coupling hubs so that the chalk marks are at
270 degrees.
E. Measure the X dimension at 270 degrees.
X270:________________________________________(in/mm)
F. Calculate the horizontal angular misalignment.
Horizontal Angular Misalignment = X90 - X270
Angular Misalignment __________________________(in/mm)

The coupling gap should be 0.5 inches and the angular
misalignment should be less than 0.035 inches. Regardless of
your measurement, proceed to substep G to improve the
alignment.
G. Loosen the motor mounting bolts and adjust the position of the
motor so that the difference between X90 and X270 is less than
0.015 inches and the coupling gap is 0.5 inches.
e This
NOTE
tic
On larger motors, a hammer can be used to bump the top of
No
the feet to adjust its position. Do not hit the motor housing
with a hammer.
H. Tighten the motor mounting bolts.

❑ 8. Perform the following substeps to adjust the horizontal parallel
alignment of the coupling.
A. Measure the hubs to make sure they have the same diameter.
tic
e This NOTE
No
The hubs used with the flexible jaw coupling in the 950-ME
Mechanical Drives System have matching diameters. However,
this substep should always be performed.

Proceed to substep B, assuming that the hubs are of the same
diameter.
B. Rotate the hubs so that the chalk marks are on the side at 90
degrees.
C. Place the straight edge across the side of the coupling on top of
the chalk marks, as shown in figure 74.
JAW
COUPLING PILLOW BLOCK
BEARING
*ELASTOMER SPIDER
Figure 74. Straight Edge Placed Across the Side of the Coupling

D. Slide a leaf of the feeler gage between the straight edge and the
coupling hub.
Increase the amount of leaf thickness until you feel a slight
drag. Record the total leaf thickness. This is the parallel
misalignment.
Horizontal Parallel Misalignment (90): _____________(in/mm)
FEELER
GAGE
*ELASTOMER SPIDER
Figure 75. Determining the Horizontal Parallel Misalignment at 90°
E. Rotate the chalk marks to the other side (270°) and check the
misalignment again, as shown in figure 76.
Place the straight edge against the opposite hub.
Horizontal Parallel Misalignment (270): ____________(in/mm)

If the measurement at one side is the same as at the other, this
is the amount of shift you need. If the measurements are
slightly different, take an average of the two to determine
amount of shift.
FEELER
*ELASTOMER SPIDER
GAGE
Figure 76. Verifying Measurement at 270°

The manufacturer recommends that the parallel misalignment
continue to the next substeps to see if you can improve it.
Again, the value of 0.015 inches is a worst case.
F. Move the motor in the direction needed to correct the
misalignment. Both sides need to be moved evenly and by the
amount of shift you determined in substep E, as shown in figure 77.
G. Tighten the motor mounting bolts.
H. Recheck both the vertical parallel and angular alignment again
to make sure that they are within the tolerances.
*ELASTOMER SPIDER
Figure 77. Correction of Horizontal Parallel Misalignment
❑ 9. Perform the following substeps to verify the alignment by

repeating the alignment measurements made in steps 5-8.
A. Measure the vertical angular misalignment using a dial caliper.
X0: _________________________________________(in/mm)
X180:________________________________________(in/mm)
Vertical Angular Misalignment ___________________(in/mm)

B. Measure the vertical parallel misalignment using the straight
edge and feeler gage.
Parallel Misalignment (0): _______________________(in/mm)
Parallel Misalignment (180): _____________________(in/mm)

C. Measure the coupling gap using a rule.
Coupling Gap _________________________________(in/mm)
D. Measure the horizontal angular misalignment.
X90: ________________________________________(in/mm)
X270:________________________________________(in/mm)
Horizontal Angular Misalignment _________________(in/mm)

E. Measure the horizontal parallel misalignment using a straight
edge and feeler gage.
Parallel Misalignment (90): ______________________(in/mm)
Parallel Misalignment (270): _____________________(in/mm)

The allowable angular misalignment for this coupling is 0.035
inches.
The allowable parallel misalignment (either horizontal or
vertical) for the coupling, given by the coupling manufacturer,
is 0.015 inches.
Correct any misalignment that is greater than these tolerances
before proceeding.
❑ 10. Turn the shaft by hand to make sure the coupling is working
properly. If there is any binding, recheck the alignment.
ning WARNING
ar
W
Do not turn on the motor if the coupling is not working

properly.
❑ 11. Ask the instructor to verify your setup.

❑ 12. Install the guard.
WARNING
ning Do not operate the mechanical drives learning system without
ar
W
the guard in place. Also, do not attempt to open or bypass the

guard at any time during operation. Performing any of these
actions will create a hazardous situation.
❑ 13. Perform the following substeps to start the motor.

A. Make sure that the Motor Control Unit’s power cord is plugged
into a wall outlet.
B. Make sure the Motor Power switch is in the OFF or down
position and is still locked out.
C. Connect the Constant Speed Motor’s power cord to the Motor
Control Port.
D. Remove the lockout/tagout.
E. Turn on the safety switch.
The Main Power Indicator on the Motor Control Unit should
turn on.
F. Make sure that no one is near the motor.
G. Turn on the Constant Speed Motor by moving the Motor Power
switch to the ON up position.
The motor should accelerate to full speed quickly and run at a
constant speed.
❑ 14. Turn off the motor and allow it to coast to a stop.

❑ 15. Turn off the safety switch.
❑ 16. Perform a lockout/tagout.
❑ 17. Disassemble the setup and store components.
❑ 18. Remove the lockout/tagout.

SEGMENT 4
SELF REVIEW
r This
we
Ans
1. Two types of misalignment that are corrected by coupling
alignment are angular and ________ misalignment.
2. Coupling alignment will help reduce ______ and extend the

life of the coupling, bearings, and seals.
3. ______ _______ alignment is checked by measuring the gap

between the coupling halves at the top and bottom.
4. ______ ______ alignment sets the height of the two

coupling halves.
5. _____ ______ alignment is checked by measuring the gap

between the coupling halves at each side.
6. ______ ______ alignment is the parallel alignment of the

coupling halves when viewed from overhead.


Mechanical Drives 1 Lap 3

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Mechanical Drives 1 Lap 3

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MECHANICAL

POWER TRANSMISSION SYSTEMS

950-ME1 Mechanical Drives 1 Learning System

Amatrol or School supplied

FIRST EDITION, LAP 3, REV. B

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

SEGMENT 1 INTRODUCTION TO SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SEGMENT 2 INTRODUCTION TO BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SEGMENT 3 INTRODUCTION TO COUPLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SEGMENT 4 SHAFT ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

OBJECTIVE 1 DESCRIBE THE FUNCTION OF A SHAFT

transmits mechanical power in the form of torque and rotating motion

Figure 1. Shaft Used in an Electric Motor

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

Figure 2. Shaft Used as an Extension

Still, a third and very common application of a shaft is to provide a

Figure 3. Spindle Shaft of a Drill Press

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

Cold Rolled Steel

Chrome Plated Steel

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

DIAMETER TOLERANCE (in) STRAIGHTNESS (in)

3/8 0.3765-0.3735 0.3745-0.3740 Unspecified 0.001-0.002

1/2 0.5020-0.4980 0.4995-0.4990 Unspecified 0.001-0.002

3/4 0.7520-0.7480 0.7495-0.7490 Unspecified 0.001-0.002

1 1.0025-0.9975 0.9995-0.9990 Unspecified 0.001-0.002

1-1/4 1.2525-1.475 1.2495-1.2490 Unspecified 0.001-0.002

1-1/2 1.6030-1.4970 1.4994-1.4989 Unspecified 0.001-0.002

2 2.0030-1.9970 1.9994-1.9987 Unspecified 0.001-0.002

Figure 4. Standard Stock Sizes

the nominal diameter. This makes sure that components having

Accuracy-type round stock is sold in standard lengths. Since shafts

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

Figure 5. Positioning of Shaft for Measurement

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

Figure 6. Rocking to Get Shaft Perpendicular

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

Figure 7. Sweeping to Get Correct Line of Measurement

F. Repeat substeps D and E rocking and then sweeping, until you

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

Figure 8. Measuring Shaft with a Tape Measure

C. Pull on the tape so that you stretch it tight.

Figure 9. Operator’s Eye Located Directly Over Measuring Point

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

Figure 10. Eliminating Parallax Error While Reading a Tape Measure

F. Read the length to the nearest 1/8 inch. Be careful to look

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

2. _________ is the most common of all shaft materials

3. ________ is used to make shafts because it has been heat

4. Shafts are specified by their type of material, diameter,

5. The diameter of a shaft _____ (is/is not) usually the same as

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

OBJECTIVE 4 DESCRIBE THE FUNCTION OF A BEARING

member with a minimum amount of friction. To understand why

Figure 11. Motor and Shaft System Supported by Bearings

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

Figure 12. Radial Bearing Load

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

Figure 13. Radial Load Created by Weight of Shaft

Another type of radial load is caused by the tension or compression

Figure 14. Examples of Radial Shaft Loads

B502-XC LAP 3 POWER TRANSMISSION SYSTEMS

Figure 15. Thrust Bearing Load