What can be a consequence of incorrectly set up dials in Millwright alignment?

When dials used in Millwright alignment are not correctly set up, one of the primary consequences is that the shimming process can become more complex. This complexity arises because inaccurate dial readings may lead to improper measurements of the machine's current alignment status. Consequently, compensating for these errors usually requires additional calculations, adjustments, and potentially more shims to achieve correct alignment.

An improperly set dial can create a feedback loop of misalignment, meaning each corrective action taken based on faulty readings may lead to further inaccuracies. This complication can significantly extend the time and effort needed to align the machinery properly, as the technician may need to revisit and reevaluate each step of the process repeatedly, leading to a less efficient workflow.

While it is true that misalignment may also affect how the coupling behaves and may necessitate more frequent adjustments, the immediate and direct impact of incorrectly set up dials manifests most clearly in the complexity of the shimming required to correct the alignment. Hence, the shimming process is likely to be the most evident consequence in this scenario.