1. Purpose and application range
This manual is devoted to the alignment procedure of connections in industrial systems. It is intended for maintenance technicians who perform alignment of connections using dial indicator and laser methods. The procedure is carried out before installation or reconstruction of connections, as well as during regular maintenance to ensure reliable operation of equipment.
2. Safety and Protection
Use of necessary personal protective equipment (PPE): During the alignment process, it is necessary to wear work gloves, goggles and work clothing to prevent injuries from vibrations or accidental contact with electrical components.
Mandatory execution of the lockout and tagging procedure: Before starting any work on alignment of connections, perform locking and securing of electrical or mechanical elements to avoid unexpected incidents.
3. Required Tools and Materials
| Tool Name | Specification | Quantity |
|---|---|---|
| Dialineary indicator | Range 0–10 mm, temperature range -10°C to +50°C | 1 |
| Laser device for leveling | Accuracy ±0.01 mm, distance up to 20 m | 1 |
| Torque ring | Range 0–100 Nm | 1 |
| Microscope or micrometer | Range 0–25 mm | 1 |
| Temperature sensor | Range -50°C to +150°C | 1 |
| Accessories for laser equipment | Clamp, impressions | 1 |
4. Check-list before servicing
| Item | Check | Acceptance/Rejection Criteria | Notes |
|---|---|---|---|
| 1 | Electric system is disconnected | Absence of voltage in the network | Perform locking and securing |
| 2 | Mechanical system is locked out | Absence of movement | Use locking nuts |
| 3 | Cleaned connection | Absence of dust and other grinding fluids | Use alcohol solution |
| 4 | Tools ready | All devices in working condition | Check compliance with standards EN 60950 |
5. Step by step procedure
Setting the Base Point
Mount the dial indicator on a stationary surface to ensure stable measurement. Use a micrometer to determine the distance to 0.01 mm.
Error: Use of incorrect indicator setup may lead to incorrect measurement.
Deviation Measurement
Measure the connection deviations using a dial indicator. The permissible deviations are set to 0.05 mm for critical systems. In case of using a laser device, set the reference point and measure the deviations.
Error: Use of incorrect device parameters may lead to inaccurate results.
Setting the appropriate clearances
Set the shaft clearance within the range of 0.05–0.15 mm. Use a micrometer or vernier caliper to determine the exact values. If the deviation exceeds 0.2 mm, perform the correction.
Error: Use of unstable clearances may lead to incorrect function of the connection.
Alignment Execution
Use the laser alignment instrument to align the shafts. Set the reference point, measure the deviation, and correct under the indicator's guidance. Perform measurements from different angles to ensure full accuracy.
Error: incorrect installation of the laser device may lead to deviation of results.
Check Results
After completing the alignment, perform the checking measurements. Use a dial indicator to determine the deviations. Set the value in the range of 0.05–0.15 mm. If the deviation exceeds these values, repeat the process.
Error: Use of unstable values during measurement may lead to realignment.
6. After Maintenance Checklist
| Test | Expected result | Actual Result | Pass/Fail |
|---|---|---|---|
| 1 | Deviation does not exceed 0.05 mm | Measure and record the value | |
| 2 | Clearance between shafts within the range of 0.05–0.15 mm | Measure and record the value | |
| 3 | No slip during operation | Start the system and check |
7. Search Diagnostic Table
| Symptom | Possible cause | Correction |
|---|---|---|
| Increase of deviations | Incorrect alignment | Realign the alignment |
| Reduction of efficiency | Insufficient clearance | Set the gap within 0.05–0.15 mm |
| Vibrations during operation | Incorrect alignment | Align using a laser device |
8. Recommended Maintenance Schedule
| Task | Frequency | Estimated duration | Skill Level |
|---|---|---|---|
| Alignment of connections | Annually | 2–3 years | Average |
| Deviation Check | Monthly | 15–30 minutes | Low |
| Cleaning the connection | Quarterly | 10–20 minutes | Low |
9. References to Spare Parts
| Part Description | Typical Specification | Category UNITEC-D |
|---|---|---|
| Linear indicator | 0–10 mm | TOOL-015 |
| Laser device for leveling | Accuracy ±0.01 mm | TOOL-016 |
| Micrometer | 0–25 mm | TOOL-017 |
| Torque ring | Range 0–100 Nm | TOOL-018 |
| Temperature sensor | Range -50°C to +150°C | TOOL-019 |
To obtain all the necessary spare parts, visit our catalog: https://www.unitecd.com/e-catalog/
10. References List
This manual complies with the standards:
- ISO 10426-1:2011 - Methods of Measurement of Gaps
- EN 13419:2007 - Alignment of Connections
- DSTU 2315:2005 - Industrial Equipment Maintenance
- CE, UkrSEPRO certification
Additional documents from the manufacturer and technical recommendations from UNITEC-D GmbH.
