The Steps to Proactive Shaft Alignment

Introduction

This chapter provides the knowledge and skills needed to perform precision alignments on machines utilizing
a laser alignment tool. It also provides useful information on alternative alignment methods. It is impossible
to cover all conceivable alignment situations in a training course. However, with the firm understanding
gained in this class on the alignment of horizontal machines connected with flexible couplings, the majority of
more complex alignments can be tackled with sufficient on-the-job experience.

Chapter Objectives
The objectives of this chapter are to understand the steps and procedures required to obtain a precision
alignment, the use of precision alignment tools, and documentation and reporting procedures. Upon
completion, the student will understand and/or be able to perform the following:
 Understand the types of misalignment in machines.
 Understand the steps required to prepare the machine for alignment and the impact of improper
preparation on the alignment quality.
 Understand the impact of soft foot on machinery and the methods to identify and correct soft foot.

Machinery Alignment and Misalignment

Figure 1. Co-linear Shafts Indicating Proper Shaft-to-Shaft Alignment.

To achieve maximum bearing, seal, and shaft life, the shafts of all machines in a machine train must be
properly aligned. Proper alignment is achieved when the centerlines of each shaft are co-linear when the
machine is under load and at normal operating temperatures. This is often referred to as shaft-to-shaft
alignment. In essence, the objective is to have a straight line through the centers of all of the shafts of the
machines in the train. Notice that the term “coupling alignment” does not enter into the definition. For
reasons that will become clear in this section, the coupling may not be representative of the shaft centerline.
Alignment of couplings rather than shafts may introduce errors in the alignment process. The shafts of the
two machines in Figure 1 are co-linear and by definition, aligned.
If the shafts of a machine train are not co-linear when the machine is in operation, they are by definition
misaligned. While the actual shaft positions can be illustrated in three-dimensional space and the centerlines
can be defined mathematically, it is easier to relate the relationship between shafts at the coupling as an offset,
an angle, or any combination of the two. Misalignment is not restricted to any one axis or plane, and can
easily occur in both the horizontal and/or vertical directions.
Figure 2. Parallel / Offset Misalignment.

The shaft centerlines shown in Figure 2 are parallel to one another, but are offset. This pure misalignment
condition is referred to as offset or parallel misalignment; the terms can be used interchangeably.
An angular misalignment condition is shown in Figure 3. Notice that in a pure angular misalignment, the
intersection of the two shaft centerlines occurs at a point exactly between the coupling faces.

Figure 3. Angular Misalignment.

In most cases, the actual shaft misalignment in an operating machine consists of both parallel and angular
misalignment in the horizontal and vertical planes. In other words, the misalignment is neither purely
parallel, nor angular. This has little significance in the real world. If the machines are misaligned, one or both
of the machines must be moved to make the shafts collinear. However, when it comes to alignment diagnosis
and correction, some people attempt to define the misalignment strictly in parallel or angular terms, and,
therefore, make corrections that do not cure the entire misalignment condition. The realization that
misalignment corrections consist of both horizontal and vertical movements, and most likely unequal changes
at the inboard and outboard feet, allows the technician to make the correct moves more quickly and with
greater assurance that the moves are appropriate.

Alignment Tolerances

There are many misconceptions as to what tolerances should be used for machinery alignment. Coupling
manufacturers produce charts indicating maximum permissible misalignment, often based on shaft size,
machine speed, and the span between the machines. Groups such as NEMA and API produce guidelines.
Equipment manufacturers may include recommended alignment specifications in their literature. Usually,
they are all different, which leads to confusion as to which values are correct. Even when acceptable
alignment tolerances are available, few machines are ever aligned to these values. There are many reasons (or
excuses) for poor alignments, but the most common are lack of tools, training, and time.
Precision alignment requires precision tools. However, precision tools do not ensure that the final alignment
will be within precision tolerances. This is because there is more to an alignment than simply ensuring that
zeros appear on the screen of a laser alignment tool after all moves have been made. If the machine still has
soft foot, pipe strain, or has not been offset properly for thermal growth, it is still misaligned. It is important
to provide access to precision alignment tools to all personnel who will be aligning equipment. Commonly,
an expensive laser system will be locked up overnight in someone’s toolbox. Therefore, any alignments
performed during the night will be done by eyesight or at best with feeler gauges and straight edges.
Inexpensive precision tools available to all personnel, such as low cost laser systems, or reverse dial indicator
mechanical systems ensure that each job is performed with the proper tool.
Even the best tool is useless unless the person using it has been properly trained on its use, and on precision
alignment techniques. Training on the tool alone is not sufficient. The tool does not inspect the base, shims,
bolts, washers, etc. These are steps performed by a well-trained technician. There may be situations where
the alignment tool cannot handle thermal growth or base-bound or bolt-bound situations. Training on
alternative methods and graphing techniques enable the technician to handle nearly any alignment situation.
The rotation of the machine shaft and the computation of the required vertical and horizontal moves comprise
only a small percentage of the time necessary to perform a precision alignment. A machine with base
problems, corrosion, pipe strain, or tricky soft foot problems may require several hours if not days to align if
it has never been aligned properly or to precision standards. The tendency at many plants is to become
impatient and give up when it is “close enough.” This is typically a management problem and it must be
addressed if the company desires to positively impact the machinery. The benefit of investing the effort in
doing the alignment correctly is that realignment, when necessary, can be accomplished quickly, since all of
the time consuming preparation is already done.
Due to the time involved, attempting to bring all machinery to within precision tolerances during a single
shutdown is impractical, unless the plant will be shut down for an extended period, or if it only operates on a
seasonal basis. An effective way to approach alignment is to target the machines most in need of alignment
first. For example, machines exhibiting the highest vibration symptoms or higher than normal wear or failure
rates should be the first to be aligned. The rest of the machines can then be targeted during future shutdowns
as schedules permit. Machines that are being repaired or replaced, and newly installed equipment should be
aligned to precision standards at the time the job is executed.
The tolerances listed in the following sections should be applied to every piece of equipment, regardless of its
criticality or function. The only exceptions are where a machine manufacturer has specified even tighter
tolerances. Be very careful of tolerances listed in coupling manufacturers’ literature. The information is
accurate but is easily misinterpreted. The values from manufacturers typically indicate the maximum
permissible misalignment to avoid coupling damage. These are not alignment tolerances. They are merely an
indication of the maximum amount of temporary misalignment the coupling will tolerate at startup until the
machine reaches operating temperature. An uninformed decision maker may mistakenly begin purchasing
couplings that allow a great deal of misalignment thinking that it will not be necessary to properly align the
machines.

The Base and Foundation

A machine base must be capable of withstanding the forces produced by the machine with minimal distortion.
It must also not distort under static loading as the feet are tightened or the base is anchored to its foundation.
Many machine skids do not meet these criteria and deficiencies may have to be accommodated in the
alignment. In some situations, replacement or modification of the skid is warranted.
A well-prepared skid should have coplanar mounting pads for each machine, and the driver and driven
machine pads must be parallel, even if they are not at the same elevation. The recommended tolerance is 0,02
mm (0.001”) for all mounting pads, and the feet of the machines should be coplanar to within 0,02 mm
(0.001”). This is an excellent specification for new equipment purchases, but may be impractical for installed
machinery. If a distorted base is to be repaired, these values should be used. Proper shimming at each foot, to
account for angular and parallel irregularities, may overcome a marginal base.
Figure 4. Base and Foundation Flatness.

Piping and Conduit

Piping and electrical conduit can place tremendous strain on a machine and will impact shaft alignment. A
motor can be aligned to a pump subjected to significant pipe strain. Although the alignment tool may indicate
that the alignment is within tolerance, the change in the shaft position internally in the pump and the stresses
in the casing will still produce alignment related damage. In extreme conditions, it may even affect pump
performance if the impeller is displaced within its housing. Many seal manufacturers recommend no more
than 0,05 mm (0.002”) of shaft deflection at the seal or packing box when all piping connections have been
made. The recommend precision tolerance is to limit shaft deflection to 0,05 mm (0.002”) at the centerline of
the coupling in any direction, making this measurement at the coupling more stringent than most seal
manufacturers recommend; it is good practice, nonetheless.

Soft Foot
The gap under all feet should not exceed 0,02 mm (0.001”). This reading must be made with feeler gauges
around each foot, at four corners if possible. Values obtained by a laser or dial indicator setup should be used
only as an indicator of the presence of soft foot. Actual corrections must be measured and corrected at the
feet.

Figure 5. Maximum Allowable Soft Foot Must Not Exceed 0.001” (1 mil).

Alignment Angularity and Offset Tolerance Guidelines

Alignment values at the coupling are not necessarily the best indication of alignment quality. For example, a
machine with a long shaft and a long span between bearings may be aligned according to a specification chart
in terms of offset and angularity. However, the outboard feet of the machine can still have a significant error.
Therefore, a specification that combines critical factors at the coupling and the planes of the machine’s feet
will provide a precision tolerance for any machine configuration. Several alignment guidelines suggest
tolerances based on speed and/or shaft diameter. Aside from adding confusion, some of the tolerances for
low-speed machines with large shafts are excessively large. To ensure precision values are used on all
equipment, it is best to have a single alignment value regardless of speed or shaft diameter. The only
exception to the following recommended tolerances is if the machine manufacturer demands values that are
even more stringent.
 Maximum offset at the coupling – 0,02 mm (0.001”)
 Maximum offset at the non-drive end feet (either machine) – 0,05 mm (0.002”)
This combination will yield angular and offset misalignment values well within most published specifications.

Alignment Methods

Straight Edge and Feeler Gauge

A rough alignment can be accomplished using straight edges, feeler gauges, and taper gauges to determine the
relationship of the two coupling halves.
This method aligns the coupling halves and is not necessarily aligning shaft centerlines. Axial and radial
runout of the coupling or shaft will limit accuracy. Feeler gauges or taper gauges are used to measure the gap
between coupling gaps at the 12, 3, 6, and 9 o’clock positions. The feet of the machine are then moved until
the horizontal and vertical gaps are equal. These moves correct the angular component of the misalignment.
Offset misalignment is identified with a straight edge placed across the rims of the coupling halves at the top
and one of the sides. Using dial indicators at the inboard and outboard feet, the machine can be moved
equally in the horizontal plane to reduce any horizontal offset. Equal shim changes at the four feet will reduce
the vertical offset and minimize any angular movement.

Figure 6. Feeler Gauge Method.

The advantage of this method is that it is fast. It provides a good initial alignment and ensures that readings
acquired with precision instrumentation are within their measurement range.
The use of straight edges and feeler gauges do not provide a precision alignment. Boring or machining errors
in the coupling may produce significant misalignment of the shaft centerlines, even though the couplings
appear to be aligned with respect to one another. Radial play in the shaft due to excessive bearing clearances
may change the stationary position of the shaft relative to its running centerline. A bent shaft or other
eccentricity, or any corrosion or surface defects will affect the measurements. Axial end float, particularly in
machines with plain bearings, may change the coupling gap during the alignment, especially if the shafts are
rotated.
This method requires human intervention, which will also contribute to a poor alignment. The “feel” of a
feeler gauge along with eyesight and viewing limitations cause variances between mechanics.

Rim and Face Alignment

The rim and face method is very similar to the feeler gauge method outlined above. In the case of rim and
face, however, more precise readings can be obtained, as there are no “feel” or sighting problems. To
measure parallel misalignment, a dial indicator base is affixed to one shaft, and the tip of the indicator is
placed perpendicular to the rim of the coupling on the opposite shaft. Angular alignment readings are
obtained from a dial indicator placed on the face of the coupling near the rim. Alignment moves can be
determined through trial and error or graphical means. Graphing, when properly performed, minimizes the
number of moves.

Figure 7. Rim and Face Alignment Setup.

The rim and face method still has a place in machinery alignment. In some situations, the shaft of one of the
machines cannot be rotated. Therefore, reverse dial or laser methods may not be practical or possible. If
given enough time, a rim and face precision alignment is possible, and is significantly better than the straight
edge and feeler gauge method.
However, rim and face alignment is prone to many of the same limitations as the feeler gauge method. Since
readings are taken from coupling surfaces, this method is essentially aligning the couplings, not the shafts.
Any irregularities in the coupling produce errors, and this method is sensitive to shaft and bearing clearance
problems and axial end float.
The use of dial indicators and fixtures introduces additional error sources. All fixtures sag due to gravity.
Therefore, sag of the measurement setup should be measured on a test fixture prior to taking readings. Fixture
sag does not affect the accuracy of this method when steps are made to properly compensate for it. Parallax
errors are possible when viewing dial indicators at an angle. If the machine is significantly misaligned
initially, it may be possible for the indicator to make several rotations or change direction. A rough alignment
using the feeler gauge method limits the dial excursions. Good measurement technique overcomes any of
these instrument problems.

Reverse Dial Indicator Method

The reverse dial indicator method acquires two simultaneous parallel readings of the stationary machine with
respect to the moveable machine, and the moveable machine with respect to the stationary machine.
Alignment moves are determined using graphing techniques or calculations.
Figure 8. Reverse Dial Indicator Method.

Reverse dial alignment has many advantages over the rim and face method. Since the indicators and indicator
targets rotate on the shaft axes, or centerlines, a true centerline alignment is possible. However, this method is
still sensitive to excessive bearing play and coupling backlash and other errors associated with dial indicators
such as bar sag, parallax errors, etc.

Laser Alignment Methods

Laser alignment systems represent the latest advancements in alignment technology. There are numerous
configurations utilizing single and dual lasers, inclinometers, etc., and each has advantages and disadvantages.
Lasers provide accurate measurements, but final alignment results are dependent on the qualifications of the
technician using the tool. For example, failure to correct for soft foot, base distortion, and pipe strain produce
alignment errors even when the most sophisticated tool is used. A typical laser alignment system is shown in
Figure 9.

Figure 9. Typical Laser Alignment Setup.

If proper procedures are recognized and followed, a laser alignment system has many advantages over other
alignment methods. Laser systems are sensitive to lens cleanliness and any interference that prevents proper
transmission and reception of the beam. These include dirt or debris on the lenses, interference from other
light sources, and heat waves. The mounting of the laser is important. Steps should be followed to ensure
that the laser heads do not slip or rock on the shafts. If very tall posts must be used to clear the coupling, be
careful of torsion or sag in the fixture arms, especially with single post designs. If the laser is out of
calibration, the readings will be in error. Laser systems should be calibrated periodically, and heads
(measurement units) that are dropped or damaged should be verified before being put back into service.
Generally, the more sophisticated laser systems handle a variety of alignment situations such as base-bound
and bolt-bound conditions, and will accept thermal growth offsets for both machines. Graphing may be
necessary with basic laser systems to determine optimum moves and cold alignment positions.

Figure 10. Laser Alignment System.

The Proactive Alignment Process

A precision alignment involves much more than having the laser alignment computer display zeros for offset
and angle. Precision alignment is a process with important steps that must be followed each time a machine is
aligned. Unfortunately, in the heat of the battle, or through lack of training, these steps are often skipped,
resulting in a machine that performs poorly. An experienced airline pilot completes a checklist before any
flight, regardless of the number of years that he or she has been flying; shaft alignment should be no different.
The following steps are suggested for any facility; however, plant safety practices, operating, and workforce
procedures must take precedence. Therefore, it is suggested that a procedure based on the following steps be
created and modified to fit the particular plant environment.
An alignment procedure can be attached to or included within any work order that requires a shaft alignment.
This ensures that recommended work practices are followed and it provides a documentation trail for future
work on the machine. For example, a problem with a machine base can be documented so repair can be
scheduled for the next outage or repair.

Proactive Steps
1. Verify or measure the difference between the operating and non-operating shaft positions of the two
machines to be aligned, to allow for thermal growth and dynamic misalignment offsets when aligning the
cold machine (i.e., non-operating).

Review machine maintenance and/or alignment records prior to an alignment job to determine if thermal
growth and dynamic misalignment figures are available. If the plant has not traditionally accommodated
thermal growth, these records may not be available. If the driver or driven machine has been changed to
a new design, it is recommended that new thermal growth figures be determined. Differences in cooling
and efficiency may make one or both of the machine components run cooler or hotter.

The machine manufacturer may have provided thermal growth data that can be reviewed to provide a
reference point. Experience has shown, however, that manufacturer supplied values rarely reflect the as-
installed position of the machine.

If operating position data do not exist for a machine, every effort should be made to acquire running
temperatures or positions prior to shutdown. There are a number of methods to determine thermal growth
and position changes, (discussed in Chapter 5).

Under no circumstances should a “hot alignment” be conducted. This method attempts to align the
machine while it is still hot. However, the rapid temperature changes in a machine after shutdown create
a moving target regardless of how quickly alignment instruments can be attached and a first reading
taken.

If measurements cannot be taken before shutdown and no previous data are available, measurements can
be acquired before startup and after the machine has reached full operating temperature. These values
can then be applied the next time the machine is available for alignment. If the change in position does
not move the alignment outside of a precision specification, then realignment will not be necessary.
2. Check and correct any soft foot at all feet on the driver and driven machines prior to shutdown (if plant
operating procedures permit). Preferably, a vibration sensitivity test should also be conducted to
determine if the feet affect machine vibration amplitudes.
Many machines are sensitive to soft foot conditions. A simple test can be conducted with a basic
vibration instrument to identify soft foot. An increase or decrease in vibration amplitude when a foot is
loosened may identify a possible soft foot or resonant condition. While all feet should be inspected with
feeler gauges, special attention should be placed on feet producing noticeable changes in vibration
amplitude. If a soft foot inspection cannot be conducted prior to shutdown, each foot should still be
checked before an alignment is attempted. This creates a level playing field and minimizes the number of
moves required to obtain a precision alignment. When a machine has one or more soft feet, every time
the machine is loosened and retightened, it will move unpredictably. This problem is exacerbated when
adding shims for vertical corrections or when moving the machine horizontally. When the machine does
not move as expected during an alignment job, it is a good idea to re-check for soft foot.
3. Before performing work, ensure that the machine has been locked out and isolated per plant procedures.
All valves and dampers should be checked to verify that they are in the proper positions for work to be
conducted.
 All plant safety rules must be followed to ensure safety of the personnel performing the alignment.
4. Verify that the alignment tools are in proper working order before installing on the machine.

If using a laser alignment system, ensure that the batteries are fully charged, the alignment fixtures are
sound, and that the lenses are cleaned according to manufacturer’s recommendations. If using dials,
check the operation of each dial indicator over its full measurement span to ensure that it is not sticking
or rough.
5. Verify that all bearings are lubricated before rotating the shafts on newly installed or overhauled
equipment.

Plain and rolling element bearings must be lubricated before they are turned, or damage may result.
Verify that the lubricants are at proper levels and that the correct lubricant has been used. If the machine
has a circulating oil system, it should be started to ensure a proper oil film thickness is obtained.
6. If possible, slowly rotate the shafts. Check and correct any condition causing binding or rubs.

Damage in bearings or couplings may be revealed by slowly rotating the shaft. The best time to find this
damage is before the alignment.

Inspect the shafts on the driver and driven machine for excessive axial or radial movement or runout due
to a bent shaft, coupling bore machining errors or excessive bearing clearance.

It may be appropriate to perform shaft and bearing checks before the base inspection; as once a shaft or
bearing problem is identified the alignment process stops until the condition can be corrected. Use runout
and radial and axial play values provided by the machine manufacturer. The following figures show
typical dial indicator readings for common shaft and coupling runout problems.

Figure 11. Coupling Eccentricity.

Figure 12. Coupling Cocked on Shaft.

Figure 13. Bent Shaft.

7. Before moving the machine, acquire a full set of readings to determine the as-found position of the
machines.

Verification of the as-found alignment condition assists the vibration team when analyzing the machine
in the future. If the alignment is found to be within specification, it may indicate there is some other fault
with the machine, and that further analysis is required. Record the values with the machine records for
future reference. Differences between the final values from the previous alignment and the as-found
condition may reveal changes in the base or piping that have caused the machine to move or creep. The
soft foot correction performed as described above may have altered the as-found values slightly, and
some may prefer to re-measure the as-found alignment values before any changes are made.
8. Perform a visual inspection of the base and foundation to identify cracks, broken welds, failed grout,
corrosion, etc. Make repairs before performing the final alignment.

Any condition that would cause the base to move or deflect unexpectedly during the alignment must be
corrected. Surface discontinuities at the feet, such as corrosion, make it difficult to obtain repeatable
 readings and reliable moves. These should be repaired properly if time permits. Temporary corrections
using epoxies or compressible plastic shims should only be used until proper repairs can be made.
9. Check the condition of the shims under the feet of all machines in the train. Any defective or
inappropriate shims should be removed and replaced with pre-cut stainless steel shims. Verify the shims
are the correct size for the foot “pad” and the base bolt.

Improper or damaged shims make it difficult to eliminate soft foot and contribute to unexpected moves
during the alignment. Shims that are smaller than the machine feet do not provide proper support and
may lead to resonance related problems or unanticipated machine deflection under load. Shims that are
too large make it difficult to remove soft foot and may rest on un-machined surfaces.
Where practical, place a thick shim under each foot to allow for both positive and negative vertical
moves. A thickness of 2 to 3 mm (0.1” to 0.125”) is recommended.

The use of thick shims minimizes the possibility of encountering a base-bound condition. Take care to
ensure that pipes or ducts are not strained when adding shims. This step may be impractical on existing
equipment but is highly recommended when installing new machinery.

10. Ensure that all horizontal and vertical jacking bolts are loose and are not contacting the base or the
machine feet.

Any binding pressure should be removed from jacking screws when an alignment has been completed,
and when checking the results of each move. Tight jacking screws may restrict normal expansion
movement and can cause the machine or machine frame to distort. Lock nuts can be used to prevent the
screws from working loose during machine operation.
11. Inspect all base bolts, nuts, and washers. Replace any bent or field-machined bolts with new bolts of the
proper length and grade.
Cupped washers must be replaced with hardened washers of the correct size. If holes in machine feet
have been drilled or flame cut to provide additional horizontal movement, a thick washer must be used to
provide adequate clamping force when bolts are torqued.
12. Check the feet on the moveable machine for any dowels or tapered pins. These pins must be removed for
the alignment. If safety requirements demand the use of pins, new holes must be drilled or the existing
holes must be reamed to secure the machine in its new position.

Properly torqued base bolts on most machines provide adequate clamping forces to withstand startup and
other transient forces produced by a machine. Therefore, few machines require dowel or tapered pins,
but approval should be obtained before they are eliminated. Pinning a foot may restrict movement and
create binding and unusual thermal effects.
13. Lubricate and torque all base bolts in the recommended sequence. If a bolt tightening sequence has not
been provided, number the bolt locations so they can be loosened and tightened in the same order.

When the machine base bolts are loosened and re-tightened to the correct torque value, the machine will
return to the exact same position. Failure to follow the same sequence, or failure to use a torque wrench,
will cause the machine to move unpredictably through successive alignment moves. Lack of repeatability
is one of the major reasons a technician gives up before a precision alignment is obtained.
14. Verify and correct pipe, duct, and conduit strain on the driven and driver machines.

It is impossible to align a motor to a pump that has a serious pipe strain problem. The alignment may be
acceptable according to the numbers, but the machines are still technically misaligned. The stresses of
pipe strain may produce movement of the shaft / rotor with respect to the housing and seals and place
 strain on the bearings. Additionally, pipe strain may induce deflections in the base or foundation.
Wherever practical, pipe strain must be eliminated as the damage potential is far reaching.

Preferably, all piping should be disconnected during the alignment. Once the machines are properly
positioned, the piping should be modified so that minimal shaft deflections are detected when each joint
is tightened. The reality of existing machines in the field is that it may not be practical to pump the
system down to remove the fluids, allowing safe disconnection of the joints. An alternative with some
base mounted machinery is to loosen the bolts connecting the base to the foundation and allow the
machine to align itself to the piping. Once the majority of strain has been eliminated, the base is attached
at its new position. This procedure does not account for strain induced between two pipes and is not
practical for bases that have been grouted to their foundations. It is far better to correct the piping than to
attempt to accommodate the piping. Some machines may encounter pipe strain due to thermal expansion
in the piping. A properly designed piping system provides for thermal expansion before the piping
reaches the machine. However, few field-installed piping systems fall into this category. No changes
should be made to any piping supports away from the machine without consulting with plant engineering
to ensure that other unwanted stresses are not created.
15. Inspect the coupling to identify unusual wear, looseness, lubrication, and correct assembly.

Coupling health has an important impact on machine performance. Looseness of power transmission
components such as grids, gear teeth, and elastomers can produce unusual vibration, potential unbalance,
and accelerated wear of mating components. If the coupling requires lubrication, it is recommended that
the coupling be hand-packed to ensure proper grease distribution. Over lubrication can lead to possible
unbalance and in extreme cases can hydraulically lock the coupling in the axial direction. Hydraulic
lock-up can damage thrust bearings, produce unusual loads on gears, and can force sleeve bearing motors
to run off of magnetic center.

Inspect the bore of the coupling and the shaft OD for any signs of improper coupling-to-shaft fit. Check
the keyways for unusual key wear and improper key fit. Ensure that any setscrews are the proper length
and that they have been properly tightened. Even an excessively long or short setscrew can affect the
balance quality of the machine. If the coupling has covers that are bolted together, check the length of
each bolt, the sizes and numbers of washers and the type of nuts used. When some couplings are
balanced, the bolts may be match-marked to a particular location. In other cases, the bolts, nuts, and
washers may have been individually weighed and then ground, if necessary, to ensure that the bolts are of
uniform weight and can be used at any location around the coupling.

Couplings that have been balanced as an assembly often have match marks to indicate the correct
positioning of the coupling halves when installed on the machine. Some facilities practice installing the
couplings so the keyways on the two shafts are 180 degrees opposite. It is felt that any machining error,
such as eccentric boring, can be corrected by rotating the coupling halves. The potential static unbalance
may have been minimized but an equally damaging couple unbalance may have been introduced. The
practice at some plants is to balance every coupling after boring, rather than attempting to compensate for
errors.

Finally, check the length of the keys on the two shafts. Incorrect key length can significantly impact the
overall balance condition of the machine and is one of the most frequently identified assembly errors
during machinery assessments. When a motor is balanced, it is typically fitted with a half-key filling the
entire usable portion of the keyway (not into the radius of the end mill or radial cutting tool). The half-
key is held in place with tape during balancing. When a coupling half or other rotor component is
balanced, it is fitted with a half-key in its full useable length. The half-keys are shown in Figure 14.
Modern balancing machines have software capabilities to simulate the half-key so even if a half-key was
not physically used on the balancing machine, it must be considered during assembly.
Figure 14. Rotors Typically Balanced with a Half-Key.

The potential balancing problem comes when the machine is assembled. If the keyways on the shaft and on
the rotor are the same length, a full-length key can be used and the balance is preserved. However, in many
cases, the rotor length is shorter than the keyway on the shaft, as shown in Figure 15. If a full-length key is
used, a portion of the key is not accounted for in the balance of the shaft or the rotor. It is a mass at a radius,
and, therefore, an unbalance. In most cases, the unbalance created by the use of the incorrect key length will
take the rotor from precision to mediocre. In some cases, however, it may render the machine inoperable.
This would typically only happen on machines with relatively high key cross-section to shaft diameter ratios
running at medium to high speeds.

Figure 15. Note the Unbalance Created with a Full-Size Key.

There are two simple solutions to prevent the unbalance from incorrect key length. Prior to assembly, a full-
length key can be machined to remove the excess material that does not fill the keyways of the shaft or rotor.
This is called a step-key (Figure 16).
Figure 16. Use of a Step-Key.

An easy alternative is to create a full-size key with a mass equal to the half-keys in the shaft and rotor. For
square or rectangular keys where there is not a change in cross-section, the length of the correct key is equal
to the length of the keyway (A) on the shaft plus the length of the keyway in the rotor (B) divided by two. An
example key and the equation are shown in Figure 17.

Figure 17. Cutting Key to Correct Length.

Properly set the axial gap between coupling faces. For motors with sleeve bearings, ensure the motor shaft is
set at its magnetic center before performing this step.
Axial forces generated by a sleeve bearing motor running off its magnetic center can be very large when
operating at full load. Extreme offsets, due to improper axial coupling gap settings, can lead to premature
wear of thrust bearings and damage to coupling components. A history of repeated thrust bearing failures in
the driven machine are often a sign of this problem. Motor manufacturers or rebuilders typically place a mark
on the shaft, or provide some other indication of the true magnetic center. If the motor has not been altered,
this is the best guide to use. When a motor is run uncoupled, the axial centering forces are small and the rotor
can easily be displaced by pushing on the shaft (not a recommended practice), gravity, and cooling fan
windage. If the motor must be tested to check for magnetic center, ensure that it is level to within one degree.
Use duct tape to close off any air passages to minimize windage. Start the motor and allow it to fully stabilize
before marking the position. Compare the mark to the mechanical limits of axial shaft movement. The
magnetic center should be close to the mechanical center. If there is a difference greater than ¼ inch, for
example, there may be a problem with the motor. Consult the motor manufacturer’s documentation to
determine the acceptable limits.
1. Perform a rough alignment of the machine if the shaft positions are beyond the limits of the measuring
device, or if it is a new / re-installation.
2. Use straight edges and feeler gauges to move the machine so that it is within the measurement range of
the device being used for the alignment.
3. Check the feet on both machines for soft foot, and correct as necessary.
If a running soft foot check and correction was performed prior to shutdown, verify each foot to determine if
any machine flexibility or thermal growth may affect the feet. If the current as-found misalignment exceeds
0,25 mm (0.010”) offset in the vertical or horizontal planes, perform precision soft foot corrections after the
first correction moves.

Machine Soft Foot

In an ideal installation, all four feet of a machine, such as a motor, would rest fully on its frame or foundation
when installed and aligned. Instead, the situation encountered in many machines is like a dining chair on a
hard floor surface. Inevitably, the chair will rock due to unequal leg lengths or an uneven floor. The solution
in the kitchen is a three-legged stool, but since a machine-to-base interface is usually a surface rather than a
point, it is possible to encounter soft foot even when all four feet touch. Any gap, whether parallel or angular
will at a minimum, make a machine difficult to align. Every time the machine feet are loosened and re-
tightened, it will move to a slightly different position.
Soft foot may also distort the machine or frame. Figure 18 shows an obvious soft foot at one location. Notice
the potential for distortion when the bolt is tightened down without correcting the soft foot.

Figure 18. No Frame Distortion.

Figure 19. Frame Distortion.

Potential problems that can result from machine or frame distortion include:
Internal shaft / bearing misalignment – When all of the feet of a machine with a soft foot problem have been
tightened, it is possible that the centerline positions of the two bearings have changed. Some bearings are
tolerant of slight internal misalignment, but deep groove ball bearings, for example, allow for very little
misalignment.
Bearing housing distortion – This condition is more likely in steel fabricated machine frames. Distortion of
the machine may create an egg-shaped bearing housing that could pinch the outer ring of a bearing or inhibit
normal thermal expansion. It is also possible that the outer ring could become slightly cocked.
Change in induction motor air gap – A soft foot condition can cause the centerline positions of the end-bells
of a motor to change. This may create an air gap problem in the motor since the rotor would be slightly offset
in the stator bore. Any more than five percent deviation in air gap can produce extremely high radial loads in
a motor. Even levels less than five percent can lead to higher than normal levels of electrical hum. Light
frame motors of fabricated steel construction are prone to stator distortion in the presence of soft foot, which
produces similar air gap symptoms.
Change in pump impeller (or other rotor) position – Soft foot in a pump can produce a change in the position
of the impeller with respect to the pump housing or wear rings. This may alter pump characteristics and in
extreme cases could cause a rub.
Change in machine / base resonant frequency – When an uncorrected soft foot is tightened, the distortion can
change the resonant frequencies of the machine / base. The effect is similar to tightening a guitar string. In
most situations, this effect is harmless, but, in some cases, one of the new resonant frequencies may line up
with a machine forcing function. A resonant condition has the potential to produce very high vibration
amplitudes. This situation should be suspected if loosening a particular foot while the machine is running
produces a significant reduction (or increase) in vibration. This subject is covered in more detail in the
section dealing with operating soft foot checks.

Soft Foot Sources

Soft foot in a non-operating machine has three sources – machining errors or damage that has caused the feet
to no longer be co-planar; wear, corrosion, settling, improper installation of machine bases or frames; and
influences from attachments or other machines. The offsets required for thermal growth may be sufficient to
create an angle between the feet and the base. In reality, soft foot will involve at least two of the three
sources, and often all three affect the machine. Soft foot can also exist at more than one foot. For example,
the machine may rock across two diagonal feet, or may fully rest on only two feet, on the left or right-hand
sides or the front and rear foot pairs. In one case, modifications and distortion, due to welding on an angle
iron motor base, on an ammonia compressor tank produced soft foot at all four feet. Figures 20 and 21
illustrate parallel and angular soft foot problems commonly associated with machine feet. Both cases may
produce equally harmful effects if the feet are tightened without correction. However, the movement of the
shaft at the coupling produced by the two cases may be different. This illustrates the importance of a
thorough check at all feet, rather than relying on the quick checks that many laser alignment systems provide.

Figure 20. Parallel Gap at Foot.

Figure 21. Angular Gap at Foot.

An uneven base can also create soft foot. The net result of a foot or a base problem is the same, since the gap
or space between the two mating surfaces is the concern. Forces acting on the machine from attachments or
appendages can also create or induce a soft foot condition. For example, a pump may rest flat upon its base,
with no soft foot, before piping is connected. An angle or offset at a pipe flange could create a soft foot
condition at one or more of the pump’s feet. This condition is the same as pipe strain.
The solution depends on whether it is easier to shim the pump to remove soft foot or correct the piping. The
shims required to fill any gaps may move the pump shaft centerline to a position where it is not possible to
align the motor without base modifications. Additionally, correction of any soft foot induced by piping does
not address internal stresses that may develop if both pipes are fighting each other. Other sources of soft foot
to consider are electrical conduit and fan ductwork.
It is possible to produce a soft foot condition that is present only when the machine is in operation. This is
often difficult to identify. Vibration symptoms when the machine is operating may indicate misalignment.
However, when the machine is shut down so the alignment can be checked, it will appear to be correct. There
are subtle differences between an operating soft foot condition and what is referred to as dynamic
misalignment. Dynamic misalignment changes the relative position of the two shaft centerlines due to
thermal growth and/or frame distortion, but does not affect the foot / base relationship. An operating soft foot
condition does affect the foot / base relationship at, perhaps, one or two feet. For example, unequal thermal
growth will change the relative positions of the feet when the machine reaches operating temperature. Some
light-frame motors will actually twist at full load and essentially try to lift one of the feet. Thermal expansion
of piping is another possible source.
The solution to an operating soft foot condition often involves compromise. Relieving the condition when the
machine is operating may change the centerline position of the shafts. However, if the correction produces a
measurable reduction in vibration, the change in shaft position can be considered inconsequential as compared
to the reduction in shaft and bearing forces. Proper documentation of the as-found condition when the
machine is shut down for future repairs will provide the correct static “misalignment” required, ensuring
smooth operation at load and temperature.
Soft Foot Correction Procedure
Initial Correction

If an existing machine is to be realigned, a running soft foot test is recommended prior to taking the machine
out of service. If the machine has already been taken off-line, the procedures outlined in the following steps
should be followed, as it is likely that only small corrections will be required to remove any residual soft foot.
For new installations or for machine components being reinstalled after overhaul or repair, a rough alignment
should be performed to get the machine close to its final position. This will identify any parallel and/or
angular gaps that may not appear if the machine is simply sitting on the base. Loosen all base bolts and
ensure that all horizontal and vertical positioning screws are loose. On smaller equipment, attempt to rock the
machine to identify any obvious soft foot. On some larger machines, it may be possible to use a pry-bar to
detect movement. Correct the feet identified in this rocking test first. The selection of which foot to correct if
there is diagonal rocking, for example, is not arbitrary. If the machine appears to rest on one particular foot,
the foot with the gap should be corrected first. If the machine easily rocks or will rest on either foot, equal
shims under the diagonal feet would be advised. These are not hard, fast rules. Each situation will be
different, especially if the machine is asymmetric. For critical machines, it may be more important to correct
the feet so the machine is level.
Since this is only an initial correction, use full shims under the feet with gaps. This can be done by trial and
error with the actual shims, or a feeler gauge can be used to more precisely measure the gap. At this point, the
parallel portion of any soft foot should be minimal.
Precision Soft Foot Correction

If the rough alignment is close, it is a good idea to complete the soft foot correction before any further
machine moves are made. This will minimize the number of moves required to bring the machine within
proper alignment tolerance. Once the soft foot is removed, re-check the alignment and make final position
corrections.
If the rough alignment is significantly out of tolerance, it may be easier to correct the soft foot as the first
moves are made since it is likely that more than one move will be required. Depending on the condition of
the base or the feet, the required soft foot correction may change after the machine has been moved.
Therefore, make the required horizontal moves and install the shims for the vertical correction before
addressing precision soft foot adjustments.
Several methods can be used to identify the presence of soft foot. One method, the measurement of shaft
deflection, can be used with laser or dial indicator alignment systems. This method is used primarily to find
the foot, or feet, that have an influence on the position of the shaft centerline.
Every alignment system uses slightly different methods to detect shaft deflection, and several laser systems
have dedicated soft foot detection modes. Generally, when a soft foot is loosened, it produces a combined
horizontal and vertical movement of the shaft centerline at the coupling. A reverse dial system can be
positioned at an angle of 45 degrees from vertical, and the dials will read the combined movement of the
shaft. Lasers that are capable of measuring two axes can be left in the vertical position; however, it is best to
refer to the instruction manual for specific procedures.
Consider a machine with a parallel gap at one foot, as shown in Figure 20. If that foot is tightened (assuming
the machine is symmetric), the shaft will move one half of the vertical gap at the centerline and in the plane of
the foot. The effect will be amplified when measured out at the coupling. If the plane of the machine feet is
at the same height of the shaft centerline, the horizontal movement of the shaft is nearly zero. When the feet
are below the centerline, there will be some horizontal component when the shaft moves. It is not important
to know the horizontal versus vertical movement relationship, only to recognize that a measurement of shaft
deflection at the coupling in only a single direction will either under-report the soft foot effect, or, in extreme
cases, not measure it at all.
Figure 22. Shaft Deflection Due to Soft Foot.

The effect of an angular foot offset will produce different readings than a parallel offset. This technique
cannot differentiate between the two conditions. The suggested corrections provided in some laser systems
assume a parallel offset; at best, these are an indication of the effect of soft foot rather than the true foot gap.
More precise measurements taken at the feet should be used to correct the soft foot identified through shaft
deflection measurements.
Precision Foot Detection Measurements

Once rough soft foot corrections have been performed, procedures that are more exacting must be followed to
reduce any gap under the foot to 0,02 mm (0.001”) or less. There is no perfect method available to do this,
but as long as the limitations are known, attention to detail will ensure that the best correction is obtained.
A pure parallel gap under a foot is rare. If the gap all the way around a foot is uniform and does not vary
more than 0,02 mm (0.001”), as shown in Figure 22, a feeler gauge or a dial indicator will produce the same
gap measurement, and a single shim of the correct thickness can be inserted.

Figure 23. Parallel Gap as Measured with a Dial Indicator.

Problems arise when the gap is not uniform. For example, the apparent gap under the foot shown in Figure 24
depends upon where the dial indicator reading is taken. A single shim will not correct this angled-foot
condition.

Figure 24. Angular Gap Under- or Over-Estimated with a Dial Indicator.

In fact, it is possible that there will be different gaps under each corner of a foot. If a dial indicator is used,
either four separate readings at the four corners of the foot will be required, or four separate feeler gauges
must be used. Either method presents difficulties. The indicator and base cannot move as the bolt is
loosened, and the use of a wrench or socket is awkward when surrounded by indicators. In addition, some
feet are not readily accessible with dial indicators. The advantages of the indicator method are that it shows
the actual foot deflection and is less prone to the errors inherent with the use of feeler gauges.
The easiest method uses a feeler gauge to measure the gap under a foot’s four corners. This method is
accurate as long as the shims, foot, and base are clean and free of burrs, and the technician is able to
determine the proper “feel” for the gauge.

Figure 25. A Foot’s Four Corners.

The number of shims under the foot must be kept to a minimum. When there are too many shims, the shim
pack will tend to expand when the foot is loosened and any remaining gap will not be representative of the
true gap under the foot. This “squishy” foot symptom is actually another form of soft foot. If suspected, the
existing shim pack should be removed and replaced with three fresh shims. The remaining parallel gap
should be removed by exchanging shims to increase or decrease the shim pack thickness.
There may be situations where little or no soft foot is measured with a dial indicator or feeler gauge, but a
large shaft deflection is observed when one or more feet are loosened. This condition is more likely to be
encountered with machines mounted on lightweight fabricated bases. As a base bolt is loosened, the frame
and foot may essentially move together as the clamping pressure is removed. The entire machine has moved
but the relative gap under the foot may not change. It is likely that there is an angle offset between the foot
and frame, and correcting it with the procedures outlined below may be sufficient to eliminate the machine /
base distortion. However, high frame flexibility may indicate that it is insufficient for the job, making base
modifications necessary.
To cover all possible conditions, it is best to use all three methods – shaft deflection measured with the
alignment tool, dial indicators, and feeler gauges – when dealing with soft foot correction. A frequent mistake
is to assume that the stationary machine, the one not moved during the alignment, does not require checking
for soft foot. Unless the history of the machine is well documented, it should always be assumed that soft
foot exists and should be checked and corrected for both the stationary and moveable machines.
As long as the alignment does not require large horizontal or vertical adjustments, it is not necessary to
perform checks between moves. However, once the machine is properly aligned, it is good practice to check
each foot one more time.
Final Soft Foot Correction

The initial soft foot correction will eliminate the majority of parallel offset at each foot and any residual soft
foot gap will be an angle. While it may be tempting to machine the surfaces of the feet or base to be coplanar,
the more practical solution is to fill the angle gap with either step shims, or other products designed to
accommodate angular or irregular contact surfaces. The easiest, cheapest, and least time consuming approach
is step shims. Some mechanics claim that step shims do not work and have a tendency to “walk out” from
under the foot after a while. Any difficulties usually arise from not using enough steps, or thick enough steps.
From the feeler gauge or dial indicator readings, determine the high spot and low spot under the foot, which
may be side-to-side, front-to-back, or diagonal. Subtract the smallest gap from the biggest gap and divide that
value by four. Round down to the next whole number, which gives the thickness of the four step shims that
will be used for the correction. Insert the first shim from the high spot towards the low spot. Ensure that the
shim does not interfere with the base bolt and there is nothing preventing the shim from sliding in smoothly.
Insert the second through fourth shims in a step fashion to fill the gap being careful not to push them in too far
to avoid lifting the foot, as shown in Figure 26.

Figure 26. Step Shims

Mark the shims so they can be removed and reinserted at the same position. When making alignment moves
that require the shim pack thickness to be changed, remove the step shims, then make corrections to the full-
sized shims and then reinsert the step shims and tighten the base bolt. Once the alignment is within tolerance,
the step shims can be trimmed to eliminate the hazard of sharp shims sticking out from under the foot.
If the machine must be realigned in the future and is not being removed from the base, the existing step shims
can be reused as long as a final soft foot check is performed. If a new machine component is installed, or the
machine is removed and replaced, new step shims should be made.
One alternative solution to step shims is the use of specially designed plastic shims that are designed to
accommodate irregular surfaces when clamped. One of these shims is placed directly under the foot and the
other on the base. Shims for vertical adjustment are inserted between the two plastic shims. The shims
remain resilient during the alignment but after approximately two weeks, they harden and retain their shape.
Because of this characteristic, they must be discarded and replaced if the machine is serviced or realigned.
These shims are meant to be a temporary solution and are especially useful when dealing with severe base or
foot corrosion. As with many temporary fixes, it is not unusual to see these used for extended periods. The
plastic material in these shims is sensitive to some chemicals and lubricants. It is best to contact the
manufacturer if there is any question regarding suitability for a given application.
Another technique that can be used to correct angular problems or corrosion is self-leveling epoxies. The
machine foot is treated with a release compound so that the epoxy will not stick to the foot. A dam is built up
around the foot on the base, and the epoxy is poured in. After curing, the base has a smooth and flat surface,
and normal shims are used for the alignment. The epoxy technique addresses base problems, and is not a cure
for a foot that is bent or uneven if shims are to be used. For stationary machines (machines not meant to be
moved during alignment), the entire gap is filled with epoxy, and foot and base problems are both corrected.
Precision Alignment Moves

There are many ways to move a machine during the misalignment correction process, and no single method is
always correct. In fact, a method that may work well on one machine configuration may be difficult to use on
another. The best approach is to first evaluate the machine, and recognize any limitations; then work in a
manner that produces the best result in the smallest amount of time.
There is debate whether to first align the machine horizontally or vertically. Logical reasons support either
position. The methods presented in this section assume the machine is to be first aligned vertically, then
horizontally. The argument against this method is that the action of moving a machine horizontally will
change the vertical alignment. The primary reasons for change in vertical alignment are insufficient soft foot
correction and improper bolt torque methods. However, it is likely that these two problems will affect the
quality of the vertical alignment, regardless of the machine’s horizontal position. However, when soft foot is
removed and proper torque methods are employed, the machine can be moved horizontally with great success.
If the machine is first aligned horizontally, the action of loosening the feet to add or remove shims for the
vertical alignment will likely cause a shift in the horizontal position and may encourage bad practices, such
as:
 Prying feet up to make shimming changes, which may bend the other feet or the frame.
 Using excessive clamping forces on horizontal jacking screws to keep the machine from shifting.
When fighting an alignment problem, the mechanic performing the work makes the final choice; however, try
the suggested methods outlined below as they may help identify the problem spot and improve the final
alignment results.
Step 1 – Verify the machine has vertical / horizontal jacking screws in place. On smaller machines, vertical
jacking screws may not be necessary. While the machine may move easily in the horizontal plane with hand
pressure, it is difficult to make controlled precision moves and to maintain horizontal position while
tightening the hold-down bolts without them. Leaving the bolts somewhat snug and then hitting the machine
to shift it is not recommended, as the hold-down bolts can bend or shift, and the feet will squirm as they are
tightened to full torque.
Temporary horizontal jacking screws that bolt on the sides of the machine frame are easy to fabricate. They
will not interfere with other maintenance activities since they are easy to remove. If properly designed, they
can be used on a number of machines.
Step 2 – Check the as-found alignment readings for the machine. If this is a new installation or a machine
component has been replaced, acquire a set of horizontal and vertical readings. If the horizontal misalignment
exceeds more than 2.5 mm (0.1”), it is likely that the large horizontal correction will impact the vertical
alignment. The machine may also become bolt-bound if such a large move is required. Move the machine to
obtain a rough horizontal alignment and verify there is sufficient bolt clearance in both horizontal directions,
and reacquire a set of readings.
Step 3 – Measure the distance between the inboard and outboard hold-down bolts on the moveable machine,
and the distance between the bolts across the machine. This will help to determine if the machine can be
jacked side-to-side or front-to-back for vertical corrections, and minimize potential bolt or foot damage from
bending. Exact measurements are not required; a visual comparison of the measurements is all that is
normally required. If the machine is longer than it is wide, as shown in Figure 27, corrections can be made at
the outboard or inboard ends by lifting or lowering one end at a time. If the machine is wider than it is long,
as shown in Figure 28, corrections should be made on one side at a time. If the machine has plates instead of
distinct feet, it will probably be wise to fully loosen all base bolts to avoid bending.
Figure 27. Long Machines Can Be Aligned Vertically by Raising One End at a Time.

Figure 28. Short Machines Can Be Aligned Vertically by Raising One Side at a Time.

Step 4 – Move the horizontal jacking screws so they are about 0,25 mm (0.001”) from the sides of the feet.
Avoid any binding pressure, as this will restrict vertical movement of the machine and may bend the screws.
For example, if the alignment correction calls for the inboard feet to be raised 0,25 mm (0.010”) and the
outboard feet to be lowered 0,12 mm (0.005”), loosen all four hold-down bolts to the point where there is no
clamping pressure. In this example, the motor is the moveable machine, and is longer than it is wide.
Continue to loosen both outboard bolts until there is sufficient clearance to raise the motor up to remove the
shims. This will help determine the changes necessary to lower the feet the required amount. Inspect the
shims carefully and attempt to obtain the proper shim thickness with only three shims. If step shims have
been made for the feet to correct an angle or bent foot problem, replace the step shims when the new shim
pack is inserted.
Lower the machine onto the outboard shims and tighten the hold down bolts so they just contact the surface of
the washers. Loosen the inboard feet and make the appropriate shimming changes. With all four feet still
slightly loose, check for any obvious soft foot by rocking the machine, and correct if necessary. Torque the
hold down bolts to the proper setting in the sequence recommended by the manufacturer, or simply number
the bolts and tighten in the same sequence each time. If the machine is easily rotated, acquire a full set of
readings to confirm the vertical alignment, and get fresh horizontal readings.
If the vertical readings are not within specifications, evaluate the situation before attempting to make another
correction. Consider the following:
 Excessive shaft clearances
 Soft foot
 Improper initial torque or re-torque
 Shaft bending due to stiff coupling
 Coupling backlash
 Locked coupling
 Bad readings or improper alignment tool mounting
 Large initial move
 Binding from vertical or horizontal jacking screws
 Misinterpretation of the moves (plus or minus / raise or lower)
 Incorrect shim thickness
 Dirt or debris under the feet or between shims
The condition of the shims is very important and will have a dramatic effect on the vertical alignment.
Wherever practical, replace any homemade, brass, bent, or wrinkled shims with shims that match the footprint
of the machine and with a slot that matches the diameter of the hold-down bolts / studs. Inspect the bottom of
each foot for dirt or debris and any burrs that could affect how the foot rests on the shims. Remove all paint
from the machine and base surfaces. Use a micrometer to measure the shims to ensure they are properly
labeled. Thick shims are often labeled with a nominal thickness rather than the actual value. For example, a
1,25 mm (0.050”) shim may actually be 1,2 or 1,3 mm (0.047” or 0.053”). Sandwich thin shims between
thicker shims so that they do not catch when the shim stack is reinserted under the foot.
Eliminate potential problems and make another move. If the readings get worse, it is likely a problem with
the alignment tool or misinterpreted readings. When satisfactory vertical readings are obtained, the horizontal
alignment can be performed.
Step 5 - Horizontal alignment is easily accomplished when proper techniques are used. Many laser alignment
systems provide a live measurement mode in either the horizontal or vertical planes, and, in some cases, both
planes. Viewing the change in horizontal misalignment as the feet are moved can prove to be very effective
as long as certain precautions are followed. First, ensure the shafts do not rotate as corrective moves are
performed. Second, avoid hitting or jarring the machine while taking live readings. The laser system may be
damaged if the machine is being beat into position with sledgehammers, and the fixtures may slide or slip on
the shafts. If the machine moves too easily in the horizontal plane, the sudden change in position from an
uncontrolled move may move the laser beam out of range. These same precautions apply to dial indicator
alignment methods.
For training purposes, or when moving large machines, the use of two or four-dial indicators is recommended
so the moves at the feet can be monitored rather than relying on the alignment system. A four-dial
arrangement is shown in Figure 29.
Figure 29. Four-dial arrangement

Hand-tighten the horizontal jacking screws so they barely contact all four feet. Loosen the base bolts so there
is slight clamping pressure. This enables controlled moves to be made without the machine suddenly shifting.
Do not attempt to align the machine horizontally by keeping one side of the machine tight while pushing on
the feet of the other side. This will distort or damage the feet and stress the machine housing. When the bolts
are re-tightened, the machine will often move back to its original position. When moving a machine that is
offset diagonally, where the inboard end is offset to the left and the outboard end is offset to the right, it is
acceptable to rotate the machine against the diagonally opposite jacking screw as long as all the base bolts
have been loosened, as shown in Figure 30.

Figure 30. Correct Method for Rotation of a Machine Using Two Jacking Screws.

Determine the required horizontal moves. Verify the sign conventions for left or right movements, as viewed
from the end of the moveable machine. If only two dial indicators are used to monitor the movements, install
them on the feet that are in the direction of machine travel. This allows free access to the jacking screws
without the interference of the dial indicator setup, as shown in Figure 31.
Figure 31. Horizontal Move Using Two Dial Indicators.

An advantage of using four indicators is that it is easier to see bolt-bound conditions or hold-down bolts that
are too tight. If the outboard foot on the right-hand side shows 0,25 mm (0.010”) of movement, the foot on
the left-hand side should move the same distance. The use of only the laser to monitor the move will not
show this potential problem.
Once the dials are in place, loosen the appropriate jacking screws and back them off so there is a gap that is
slightly greater than the required move. Slowly tighten the opposite jacking screw and monitor progress until
the machine has been moved the correct distance. Remove the pressure on the jacking screw and observe
whether the machine springs back. This may indicate that the hold-down bolts were too tight or that a bolt-
bound condition is present. Do not simply push the machine back into position and torque the bolts, as this
will develop machine stresses and the potential for the machine to shift once it has reached operating
temperatures and loads.
After the machine is properly positioned horizontally, lightly snug all four jacking screws so they have slight
binding pressure. Monitor the dial indicators as the base bolts are torqued. Movement of more than a few
mils may indicate soft foot, bent hold-down bolts, or cupped washers. Correct the condition and then re-
torque.
Step 6 – Perform one final soft foot inspection and correction. It is tempting to skip this last step, but soft foot
may potentially change or develop when the machine is shifted horizontally. It requires only a few minutes,
and is best to correct any identified condition while the machine is still out of service.
While the above procedures seem somewhat tedious, the outcome is typically an alignment that can be
accomplished with only a single vertical and horizontal move, which saves time in the long run.