Shovel Hoist Drum Gear Alignment Procedure

Shovel Models: 2300XPA/XPB, 2800XPA/XPB, 4100/4100A, 4100TS/BOSS, 4100XPB

Purpose:

Improper alignment of the hoist drum gear will cause end loading of the gear teeth and pitti

the mating pinions. Pitting typically results on one end of the gear teeth on one of the pinio

and on the other end on the opposite pinion. The hoist drum gear must be aligned any time

hoist drum assembly is installed in a machine, whether during a machine erection or mainte

procedure.

Alignment of the hoist drum gear is accomplished by shimming under and in front of the

sidestand bearing block. The goal of this procedure is to achieve equal backlash across the

face, check for good contact patterns in the front and rear gear mesh, and eliminate any evid

of misalignment.

Materials Required:
 Solder ( ~ .125” diameter solid – for best results, do not use hollow core solder)
 Dykem Hi-Spot Blue 107, Prussian Blue or PT-650 Tooth Marking Grease
 Scotch #845 Book Tape (2 ½ - 3” wide)
 Duct tape

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Machine Conditions:

The ideal circumstance to perform the alignment is on a fully assembled machine, but thi

always the most practical.

Note machine conditions below by circling “Yes” or “No” and making any additional com

 Is the machine complete? Yes or No

 Is the boom pinned and raised? Yes or No

 Is all of the counterweight installed? Yes or No

 Is all cribbing removed from under counterweight? Yes or No

Additional comments:

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Checking Backlash:

Prior to taking any measurements, if the gearcase cover is not installed or torqued down,

sure all bearings are properly seated in the gearcase bores. This can be visually checked

feeler gages.

Total backlash is to be measured in the front and rear pinion/gear mesh. There will be tw

samples taken for the front mesh and two for the rear (see Figures 1, 3 & 5). Samples 1 a

will be front inboard and outboard, respectively. Samples 3 and 4 will be rear inboard an

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A total of eight measurements will be taken (see Table 1). Measurements are to be taken

approximately 1.00 inch from each end of the gear (see Figure 1). Depending on pinion

width, the distance to place the solder on the pinion will be 1.25 or 1.50 inches from each

See Table 1 and Figures 1, 3 and 5 for locations and distances.

Procedure for Checking Backlash:

1) Attach solder to one pinion to make contact 1.00 inch from each end of the drum gea

to Table 1 for correct distance. Position the solder in the pinion tooth as shown in Fig

and 5 with ends attached to adjacent teeth with duct tape.

2) When checking the front mesh, rotate the rear pinion by turning the rear input couplin

vice versa. Rotate the input coupling clockwise (while facing gearcase) until the 2

reduction pinion rotates one complete turn.

3) Carefully remove and measure each solder sample from the pinion, making sure not t

up locations. Measure the thickness near the pitch line using a micrometer or vernier

as shown in Figures 4 and 6.

4) Record the thickness measurements for the load and non-load side for the inboard an

outboard locations in Table 1.

5) Repeat steps 1 through 4 for the opposite pinion/gear mesh.

6) Use the formulas in Table 1 to calculate the amount of shimming required. If you ha

spreadsheet program, simply enter the values in the boxes, and the program will

automatically perform the calculations. If not, hand calculations will be required usin

formulas and factors provided.

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Procedure for Checking Contact Pattern:

1) After final assembly of the gear set, rotate the pinions so that the drum gear makes at

one complete revolution.

2) Thoroughly clean the teeth of the pinions and drum gear with degreaser.

3) Apply a thin layer of bluing compound to the load side of one tooth on the front pinio

Figure 2). A thin film is defined as .0003” (.008 mm) to .0005” (.012mm) thick. A th

is best accomplished by wiping the compound on the tooth and then using a rag or fin

remove any excess (see figure 7). Excessive film thickness will result in false contac

readings. The pinion teeth are crowned; therefore full contact across the gear face wi

should not be seen.

4) Roll the gear mesh by turning the input coupling clockwise (while facing gearcase) u

blue pinion tooth comes in contact with a gear tooth to transfer the bluing compound

pinion tooth onto the gear tooth.

5) Apply 3M book tape of proper width (2 ½ - 3”) to cover the face of the gear tooth. T

purpose of this is to transfer the bluing impression on the gear tooth to the book tape.

6) The sheet provided for contact patterns (sht 13) will have to be scaled up to fit 11 x 1

paper to provide enough space for the book tape. Use a photocopy machine to do thi

the book tape with the bluing impression on the sheet. Record the gear and pinion pa

numbers on the sheet.

7) Check for acceptable contact pattern per MOP 9.3, figure 1 provided. MOP 9.3, Figu

shows unacceptable contact patterns.

8) Repeat steps 1 through 7 for the rear pinion/gear mesh.

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Deviation:

If contact patterns other than those shown in MOP 9.3, Fig. 1 are observed, or contact patterns

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 Table 1
1st Calculation
1st Backlash Measurements
Front Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Horizontally By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Towards Front, Less Than Zero = Towards Rear)

A B C D
Rear Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Vertically By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Up, Less Than Zero = Down)

E F G H Note: Shim sidestand bearing block to the nearest .005"

2nd Calculation
2nd Backlash Measurements (after adjustment of sidestand)
Front Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Horizontally By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Towards Front, Less Than Zero = Towards Rear)

A B C D
Rear Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Vertically By:
Outboard Inboard Outboard Inboard (Greater Than Zero = Up, Less Than Zero = Down)

E F G H Note: Shim sidestand bearing block to the nearest .005"

Distance Which Solder Nominal Actual Avg.

Factors is to Be Placed From Backlash in Backlash in
Model Horizontal Vertical Edge Of Pinion Face Pinion Gear in Gear Mesh Front Mesh
2300XPA 8.00 2.94 1.25" 1N1111 1N1165 .019" - .032" *(A + B + C + D) / 2
2300XPB 8.00 2.94 1.25" 1N1617 1N1616 .026" - .048"
2800XPA/XPB 7.50 2.75 1.25" 1N1035 1N1526 .048" - .064" Actual Avg.
4100/4100A 7.00 2.50 1.50" 1J329 1J199 .023" - .038" Backlash in
4100TS/BOSS 5.00 2.63 1.50" R37179 R32245 .026" - .048" Rear Mesh
4100XPB 5.25 2.72 1.50" R37179 R32245 .026" - .048" *(E + F + G + H) / 2

Formulas for hand calculations: Final Check of Lead Error Across Gear Face (Load Side):
Maximum Permissible
Shim Sidestand Horizontally By: (- A + B - C + D + E - F + G - H) x Horizontal Factor Model Lead Error **
(Greater Than Zero = Towards Front) 2300XPA .003" Actual Lead Actual Lead
(Less Than Zero = Towards Rear) 2300XPB .003" Error (front) Error (rear)
2800XPA/XPB .004" *[ A - B ] *[ E - F ]
4100/4100A .004"
Shim Sidestand Vertically By: (A - B - C + D - E + F + G - H) x Vertical Factor 4100TS/BOSS .004"
(Greater Than Zero = Up) 4100XPB .004"
(Less Than Zero = Down) * Note: Use 2nd BL measurements
** If unobtainable contact Engineering

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Example - 4100XPB Down .010" & Back .010" Table 1
1st Calculation
1st Backlash Measurements
Front Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Horizontally By: .0152 .0152 .0143 .0133 .0095 .0100
Outboard Inboard Outboard Inboard (Greater Than Zero = Towards Front, Less Than Zero = Towards Rear)

.0159 .0154 .0181 .0195

A B C D
Rear Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Vertically By: .0109 .0109 .0102 .0092 .0097 .0101
Outboard Inboard Outboard Inboard (Greater Than Zero = Up, Less Than Zero = Down)

.0170 .0174 .0147 .0133

E F G H Note: Shim sidestand bearing block to the nearest .005"

2nd Calculation
2nd Backlash Measurements (after adjustment of sidestand)
Front Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Horizontally By: .0080 .0080 .0075 .0070 .0050 .0053
Outboard Inboard Outboard Inboard (Greater Than Zero = Towards Front, Less Than Zero = Towards Rear)

.0160 .0170 .0160 .0170

A B C D
Rear Pinon 2300XPA 2300XPB 2800XPA/XPB 4100/4100A 4100TS/BOSS 4100XPB
Load Side NON-Load Side Shim Sidestand Vertically By: .0029 .0029 .0028 .0025 .0026 .0027
Outboard Inboard Outboard Inboard (Greater Than Zero = Up, Less Than Zero = Down)

.0160 .0170 .0160 .0160

E F G H Note: Shim sidestand bearing block to the nearest .005"

Distance Which Solder Nominal Actual Avg.

Factors is to Be Placed From Backlash in Backlash in
Model Horizontal Vertical Edge Of Pinion Face Pinion Gear in Gear Mesh Front Mesh
2300XPA 8.00 2.94 1.25" 1N1111 1N1165 .019" - .032" *(A + B + C + D) / 2
2300XPB 8.00 2.94 1.25" 1N1617 1N1616 .026" - .048" .033
2800XPA/XPB 7.50 2.75 1.25" 1N1035 1N1526 .048" - .064" Actual Avg.
4100/4100A 7.00 2.50 1.50" 1J329 1J199 .023" - .038" Backlash in
4100TS/BOSS 5.00 2.63 1.50" R37179 R32245 .026" - .048" Rear Mesh
4100XPB 5.25 2.72 1.50" R37179 R32245 .026" - .048" *(E + F + G + H) / 2
.033

Formulas for hand calculations: Final Check of Lead Error Across Gear Face (Load Side):
Maximum Permissible
Shim Sidestand Horizontally By: (- A + B - C + D + E - F + G - H) x Horizontal Factor Model Lead Error **
(Greater Than Zero = Towards Front) (- .0159 +.0154 - .0181 + .0195 + .017 - .0174 + .0147 - .0133) x 5.25 = .010 2300XPA .003" Actual Lead Actual Lead
(Less Than Zero = Towards Rear) 2300XPB .003" Error (front) Error (rear)
2800XPA/XPB .004" *[ A - B ] *[ E - F ]
4100/4100A .004" .001 .001
Shim Sidestand Vertically By: (A - B - C + D - E + F + G - H) x Vertical Factor 4100TS/BOSS .004"
(Greater Than Zero = Up) (.0159 - .0154 - .0181 + .0195 - .017 + .0174 + .0147 - .0133) x 2.72 = .0101 4100XPB .004"
(Less Than Zero = Down) *Note: Use 2nd BL measurements
** If unobtainable contact Engineering

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 Figure 3 - Applying Solder to Front Pinion
Note: Points A & B are on the Load Side. Points C & D are on the NON-Load Side

Figure 4 - Measuring Solder Thickness on Front Pinion

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 Figure 5 - Applying Solder to Rear Pinion
Note: Points E & F are on the Load Side. Points G & H are on the NON-Load Side

Figure 6 - Measuring Solder Thickness on Rear Pinion

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 Figure 7 - Applying Bluing Compound
(Load side of tooth on front pinion shown)
NOTE: Load side of top tooth faces toward front of machine on both pinions

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Note: Use copy machine to increase scale of this sheet to fit 11 x 17 paper

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