G890 User Manual: Tidland
Contents
1. Preparing the shaft for operation A Inflating the shaft Deflating the shaft A OPERATION Use only clean dry non lubricated air Shaft operation requires 5 5 8 3 bar 80 120 psil Connect air hose to the air supply When inflating shafts not equipped with a rotary union Tidland recommends the use ofa Tidland Inflation Tool See page 5 1 Do not rotate shaft without a core installed on expansion elements 1 Position the shaft in the core 2 Ensure that all expansion elements are covered by cores or rolls Use the Tidland Inflation Tool to inflate the shaft Hold the nozzle in place until the line pressure air gauge indicates 5 5 8 3 bar 80 120 psil Use an appropriate tool to release air from the shaft Do not use your finger to deflate the shaft The Tidland Air Release Tool is available on request See page 5 1 for part number www maxcessintl com Tidland G890 Shaft MI 746511 1 F 5 1 MAINTENANCE Recommended tools and supplies Hex drive wrenches 2 and 6 mm Tidland inflation tools contact Maxcess for options Tidland air release tool Part No 111630 Tidland valve removal tool North America 745083 wrench 749067 tool bit only Europe M296213 wrench M373530 tool bit only Dow Corning Molykote 55 o ring grease Loctite 222 or equivalent Loctite 243 or equivalent Loctite 545 or equivalent Hole punch guide Tidland Part No 760792 Hole punch tool Tidland Part No2. 760668 This part is a tool bit for use with a torque wrench Using Loctite or equivalent thread locker Always use a thread locker on component threads during reassembly Component Threadlocker sealant Element end clamp fasteners Loctite 222 Air fitting barb Journal or end cap fasteners Loctite 243 Valves Loctite 545 Maintenance schedule Daily Keep shaft clean and dry Remove dust and debris buildup with compressed air Periodically Inspect journals for wear Check for worn or damaged expansion elements www maxcessintl com Tidland G890 Shaft MI 746511 1 F 5 2 MAINTENANCE Removing a journal Drop in shaft AN Deflate shaft and remove core roll Secure the shaft in a round clamping fixture before removing the journal 1 Remove the M8 socket head cap screws 2 Use impact puller to remove the journal 3 Note the o rings in the shaft body Inspect them for wear or damage and replace if necessary Lubricate with o ring grease 1 M8 Soc hd cap screw 2 Shaft body Journal Shaft shown with three expanding elements Reinstalling expansion elements page 5 8 Reinstalling journals page 5 4 www maxcessintl com Tidland G890 Shaft MI 746511 1 F 5 3 MAINTENANCE Removing a journal Cantilevered shaft AN Deflate shaft and remove core roll Machine end 1 Remove shaft from machine 2 Follow the instructions on page 5 2 for rem
3. WA 98607 1 360 834 2345 1 800 426 1000 Please have your shaft serial number available when you call A MAXCESS wesex 7 ED NORTH CENTRAL AND SOUTH AMERICA Tel 1 360 834 2345 Fax 1 360 834 5865 sales maxcessintl com www maxcessintl com INDIA Tel 91 22 27602633 Fax 91 22 27602634 india maxcessintl com www maxcess in EUROPE MIDDLE EAST AND AFRICA Tel 49 6195 7002 0 Fax 49 6195 7002 933 sales maxcess eu www maxcess eu JAPAN Tel 81 43 421 1622 Fax 81 43 421 2895 japan maxcessintl com www maxcess jp CHINA Tel 86 756 881 9398 Fax 86 756 881 9393 info maxcessintl com cn www maxcessintl com cn KOREA TAIWAN AND SE ASIA Tel 65 9620 3883 Fax 65 6235 4818 asia maxcessintl com 2013 Maxcess
4. and safety requirements in your work environment and always work safely Read and understand all instructions and shaft design application limits before operation Never use this product for a purpose or in a machine that it was not specifically designed for See Product Safety Data Sheet PSDS Do not exceed the operation loads for this shaft as noted on its PSDS Product Safety Data Sheet Follow all warnings and instructions marked on the product and on the PSDS Do not use fingers or other objects to deflate the shaft use only the Tidland deflation tool Inspect the shaft for wear and or other safety and functional deficiencies daily before each use Wear safety glasses or proper eye protection when inflating or deflating or otherwise operating the air system Do not remove or otherwise alter any setscrews or fastening devices prior to using this product Do not operate this product if any setscrews or fastening devices are missing Do not lift shaft manually if it is beyond your capacity Loads over 1 3 your body weight may be prohibitive Consult your company safety policy When lifting a shaft use proper lifting techniques keeping back straight and lifting with the legs continued www maxcessintl com Tidland G890 Shaft MI 746511 1 F 2 2 SAFETY INSTRUCTIONS Do not carry or lift this product over wet or slippery surfaces Use appropriate mechanical lifting devices such as a hoist or
5. shaft puller for heavier shafts When performing maintenance or repair procedures do not pressurize the shaft if journal setscrews are loose or missing When performing maintenance procedures do not pressurize the shaft if the journal is missing All replacement parts used on this product should be made to original Tidland specifications All maintenance and repair procedures performed on this product should be done to Tidland specifications by qualified personnel Basic safety information To ensure safe and problem free installation of the winding shaft the shaft must be properly transported and stored professionally installed and placed in operation Proper operation and maintenance will ensure a long service life of the shaft Only persons who are acquainted with the installation commissioning operation and maintenance of the system and who possess the necessary qualifications for their activities may work on the shaft Proper use The Tidland G890 shaft is intended to be used on unwind or rewind machines Improper use Operation outside the technical specifications Any other use than the proper use shall be deemed inappropriate www maxcessintl com Tidland G890 Shaft MI 746511 1 F 2 3 Basic safety information continued A A SAFETY INSTRUCTIONS Installation and commissioning WARNING Danger of falling down or muscle or skeletal injury during installation The larger design shafts ar
6. www maxcessintl com Tidland G890 Shaft MI 746511 1 F 1 2 Theory of operation Model number key Available models INTRODUCTION The Tidland G890 air shaft is a medium to wide web width core shaft made of aluminum or steel with external expanding elements External bladders activate the expanding elements rubber or aluminum strips to grip the core The bladders are ultrasonically sealed and secured with screw clamps Air is delivered to the shaft through a valve located in the end or on the side of the shaft body or through a rotary union Shaft series shaft type mounting style Shaft series G Global Shaft type 890 External element shaft Mounting type None drop in C cantilevered E extruded body G890 G890C G890E www maxcessintl com Tidland G890 Shaft MI 746511 1 F SAFETY INSTRUCTIONS Safety Information When using this Tidland product always follow basic safety precautions to reduce the risk of personal injury Your company s safety instructions and procedures should always be followed When using this product with any other equipment or machinery all safety requirements stipulated by that equipment or machinery manufacturer must be followed Compliance with local state and federal safety requirements is your responsibility No part of these or the following instructions should be construed as conflicting with or nullifying the instructions from other sources Be familiar with the hazards
7. 7 TTN MAXCESS Tidland G890 External Element Shaft Operation and Maintenance EN 3 Shaft Diameter MI 746511 1 F CONTENTS INTRODUCTION 1 1 About these operating instructions ooccccocncocacnccnnnnonnnnnnanncnnnnnnnncncnnnnnnnncnenannnennnnns 1 1 Product overview oi it re 1 2 Model number keria ia 1 2 Available Models umi a 1 2 SAFETY INFORMATION 2 1 PLONE dial eect senacs eel E T 2 2 DECOMMISSIONING ia abate 2 3 ASSEMBLY DIAGRAM AND PARTS LIST 3 1 Drops a a dea 3 1 Cantilevered shafts E E nenne nnnnn nenne nennen 3 3 INSTALLATION 4 1 Installing the Shaina o iR Bi 4 1 OPERATION 4 1 Air pressure une een Eee 4 1 MAINTENANCE 5 1 Recommended tools and supplies oocccccccnccncnconnnnncncnconnnnnnncncnnnnnonnnnnnnnncnnnnnnnnnncnns 5 1 Maintenance schedules atien a a a a a 5 1 R mo ving ajournal es ae ee Dial 5 2 Drop air Shaft tenno e ee ee Di 5 2 Cantilevered sha ia a En lek 5 3 Reinstalling a journal odia ea la 5 4 Replacing expansion elements c ccooccccocnncnncnccnoncnnnnnnnncnconnnnonnrnonannnnnnnnnrarnrnnanenanncnns 5 5 Using bulk bladder material cccconncoonncccccncconnconacinonnnononnnonarnnnonnnonncnnnannnnnnns 5 6 W ve SPENGO S ui A een TG 5 9 Ain SyS AAA AA A 5 10 RE placing the Valve aves ii A A EDS 5 10 OTIS aia ee A AREA 5 10 Replacing the internal air hose oooccocccccncnnocncnccnnnnonacncnonononacncnnnnnnnnrnnnananennnnns 5 11 TROUBLESHOOTING 7 1 SPECIFIC
8. ATIONS 8 1 SERVICE AND PARTS 9 1 www maxcessintl com Tidland G890 Shaft MI 746511 1 F 1 1 About these operating instructions INTRODUCTION All of the information herein is the exclusive proprietary property of Maxcess International and is disclosed with the understanding that it will be retained in confidence and will neither be duplicated nor copied in whole or in part nor be used for any purpose other than for which disclosed Copyright 2012 all rights reserved Periodically there will be updates to this manual The latest version is available at www maxcess nt com or by calling your regional office listed on the back page of this publication These instructions are designed to help put the external element winding shafts into service and provide important notes for the proper use of the shaft These instructions are valid for following shaft series Series G890 and G890C These instructions are important for the machine manufacturer end user machine operator and maintenance personnel Read and understand these instructions before installing and operating the shaft The instructions must be read and used by all persons who have the responsibility of installing and maintaining these shafts These instructions must be retained and incorporated in the technical documentation for the machine or partly completed machinery into which the shaft is installed These are the original instructions written in English
9. Punch through one wall only 1 Hole locater guide 2 Tidland hole punch 3 Punch mark See page 5 1 for part numbers continued www maxcessintl com Tidland G890 Shaft MI 746511 1 F 5 7 MAINTENANCE Installing the expansion elements AN Do not use lubricants between the bladder and the protection strip These components must be clean dry and free of debris 1 Air fitting 2 Bladder 3 Top clamp w set screws 4 Bottom clamp 5 Protection strip www maxcessintl com Tidland G890 Shaft MI 746511 1 F 5 8 MAINTENANCE Installing expansion elements 1 Install the expansions element in the slot If using aluminum strips see page 5 9 to install wave springs 6 End clamp in slot 7 Journal or nose cone 8 Outboard set screw 9 Inboard set screw 2 Install the remaining end clamp assembly and torque the end clamp set screws in the following order 1 Outboard screw 1 Nm 9 in Ibs 2 Inboard screw 1 5 Nm 13 in Ibs 3 Outboard screw 1 5 Nm 13 in lbs 3 Reinstall the end cover and torque set screws to 1 5 Nm 13 in Ibs 4 lf installing a journal torque socket head cap screws to 20 Nm 177 in lbs See page 5 4 www maxcessintl com Tidland G890 Shaft MI 746511 1 F 5 9 MAINTENANCE Wave springs Position the two wave springs 1 on the aluminum strip 2 one along each side with th
10. company lockout tagout procedure before removing shaft from machine Note Use Loctite 222 on all threads during reassembly Follow manufacturer s instructions for best results 1 Deflate shaft and remove roll core Remove shaft from the machine Remove both journals page 5 2 detach the air hose during disassembly 4 If you are using bulk air hose material use the following formula to measure and cut to length for your shaft air hose length body length 64 mm 2 5 5 Reconnect the air hose at each journal during reassembly 6 Torque journal socket head cap screws to 20 Nm 177 in Ibs 7 Torque nose cone or body end cover 1 5 Nm 13 in Ibs www maxcessintl com Tidland G890 Shaft MI 746511 I F 7 1 Problem Cores slipping TROUBLESHOOTING Possible Cause Low air pressure Recommended Solution Operate shaft at 5 5 bar 80 psi minimum for optimal performance Check for leaks See Shaft will not inflate or hold air in the list below Wrong core diameter Shaft is designed to support core diameter of 76 2 76 mm 3 00 03 External elements worn Inspect elements for excessive wear or damage and replace as necessary Call Maxcess Customer Service for parts Web tension out of spec Check your winding process Shaft will not inflate or hold air Journals wear prematurely Bladder leak Listen for leaks or spray with soapy water to determine which element i
11. crew M4 x 6 mm 3 per body end cover 6 739345 M141619 6 O rings Parker 2 129 4 520007 M192279 7 Shaft body 1 Custom Custom 8 Soc hd cap scr M8 x 20 mm zinc plate 6 739337 M127702 9 Bladder material a r 739338 M193425 10 Air fitting a r 739339 M250318 11 End clamp bottom a r 740602 M237218 12 End clamp top a r 740601 M237217 13 Set screw M4 x 6 mm 2 per clamp assembly a r 130304 M141619 14 Protection strip a r 739340 M245285 15 Rubber element 10 3 mm high in shafts after 05 2013 a r 759684 n a 16 Poron spring a r 740605 M272799 17 Aluminum strip option a r 740599 M112710 18 Wave spring 2 per aluminum strip a r 740600 M246628 Optional Calibration tape 1 Custom Custom Valve gasket is available separately Tidland 745181 Europe M284758 Shafts stamped Fife Tidland GmbH use element 8 7 mm high Tidland 739341 Europe M326848 www maxcessintl com Tidland G890 Shaft MI 746511 1 F 3 3 ASSEMBLY DIAGRAM AND PARTS LIST Cantilevered shafts Free end Fixed end Note Expansion element components are common to both shafts See pages 3 1 and 3 2 for part numbers T Tidland Europe Item Description Oty Part No Part No 20 Air plug free end use with items 21 22 1 744481 M367153 20a Journal with collar use with items 21 23 1 Custom Custom 20b Journal with should
12. e end of the spring pointing as shown below A Do not reinstall broken wave springs Call Maxcess Customer Service for replacement parts www maxcessintl com Tidland G890 Shaft MI 746511 1 F 5 10 MAINTENANCE Air system Replacing a valve 1 Stop the winding operation and deflate the shaft 2 Using the recommended tool see page 5 1 remove the valve 3 If a patch lock thread sealant is not already pre applied apply Loctite 545 to the valve threads and install torque to 5 Nm 44 in Ibs Note If you are reinstalling your existing valve inspect the gasket for wear cracks or delamination and replace if damaged See page 3 2 Item 2 note for gasket part number Ensure that there is a gasket in place on the valve when installing New valves are supplied with a gasket O rings 1 Stop the winding operation and deflate the shaft 2 Remove the journal feature see page 6 3 3 Note the two o rings in the shaft body Inspect them for wear or damage and replace if necessary Lubricate o rings with Dow Corning Molykote 55 o ring lubricant Note There are no o rings used in the machine end of the cantilever shaft Reinstalling journals page 5 4 www maxcessintl com Tidland G890 Shaft MI 746511 1 F 5 11 Air System Replacing the internal air hose MAINTENANCE Cantilevered shafts with a rotary union valve deliver air to the expansion elements through an internal air hose AN Follow your
13. e heavy Appropriate equipment is to be used and the safety rules of the company must be observed Operation WARNING Danger of entanglement or pinching during operation Keep hands and loose clothing away from rotating shaft Maintenance and repair WARNING Danger of entanglement or pinching Maintenance and repair tasks on the shaft must be performed only when the machine has been stopped and has been secured from being turned on again WARNING Danger of bodily injury or damage to hearing Do not inflate bladders without the leaves installed Decommissioning The shaft must be disposed of in accordance with all the applicable national state and local regulations www maxcessintl com Tidland G890 Shaft MI 746511 1 F 3 1 ASSEMBLY DIAGRAM AND PARTS LIST Drop in shafts Typical both ends except for valve www maxcessintl com Tidland G890 Shaft MI 746511 1 F 3 2 ASSEMBLY DIAGRAM AND PARTS LIST Parts list Recommended spare parts a r as required er Tidland Europe Item Description Qty Part No Part No End plug for use with side valve location 128045 M1 86986 ER 2 Valve G1 8 located in end or side 1 739343 M266978 3 Journal 1 Custom Custom 3a Journal with shoulder items 4 5 not used 1 Custom Custom 3b Journal with shoulder valve items 4 5 not used 1 Custom Custom 4 Body end cover 2 744219 M257917 5 Set s
14. er 1 Custom Custom 21 Set screw M4 x 6 mm 6 739345 M141619 22 Nose cone use with items 20a 21 1 744480 M265884 23 Nose cone simple use with items 20a 21 1 744874 M263932 24 Soc hd cap scr M8 x 20 mm zinc plate 6 739337 M127702 25 O rings Parker 2 129 2 520007 M192279 26 Hose barb fitting 2 745111 M229812 27 Gasket 2 133720 M188639 28 Airhose required for rotary union valve a r 128898 M187226 x 29 Journal machine end 1 Custom Custom 29a Journal with shoulder machine end 1 Custom Custom 30 Core stop optional For 3 elements 1 747295 M269348 For 4 elements 1 747297 M369650 Shafts built in April May 2012 use an adapter with gasket in this journal www maxcessintl com Tidland G890 Shaft MI 746511 1 F 4 1 INSTALLATION Installing the shaft MN WARNING Danger of falling down or muscle or skeletal injury during installation The longer shafts are heavy Appropriate equipment is to be used and the safety rules of the company must be observed General 1 Install shaft as required for your machine application 2 Adjust core stop if installed 3 Slide the core onto the shaft Installing a core stop 1 Loosen the M8 bolt in the core stop 2 Move the core stop to the desired position on the shaft body and tighten the bolt to 20 Nm 177 in lbs For 3 elements For 4 elements www maxcessintl com Tidland G890 Shaft MI 746511 1 F 4 1 Operation Air pressure A
15. oving journal from a drop in shaft Note There are no o rings in the machine end Operator end 1 Remove the M4 set screws from the end cover 2 Carefully pull the journal feature from the shaft and detach the air hose 3 Note the two o rings inside the shaft body Inspect them for wear or damage and replace if necessary Lubricate with o ring grease Shaft body M4 Soc hd cap screw Air hose Air plug or journal Set screw OJU JA w N End cover Reinstalling expansion elements page 5 8 Reinstalling journals page 5 4 Replacing the air hose page 5 11 www maxcessintl com Tidland G890 Shaft MI 746511 1 F 5 4 MAINTENANCE Reinstalling a journal Drop in shafts Drop in shaft journals require a press fit 1 Apply o ring grease to the fit area and press fit the journal into the shaft body 2 Reinstall and torque the socket head cap screws to 20 Nm 177 in lbs Cantilever shafts The machine end journal requires a press fit Note There are no o rings in the machine end of a cantilever shaft If using rotary union you will need to reconnect the air hose to both journals during reassembly 1 Apply o ring grease to the fit area and press fit the journal into the shaft body 2 Reinstall and torque the socket head cap screws to 20 Nm 177 in lbs The operator end journal feature is designed with a slip fit Lubricate o rings with o ring grease 1 Insert the jou
16. rnal feature into the shaft body reinstall and torque the socket head cap screws to 20 Nm 177 in Ibs 2 Reinstall the end cover and torque the set screws to 1 5 Nm 13 in Ibs www maxcessintl com Tidland G890 Shaft MI 746511 1 F 5 5 MAINTENANCE Air system Replacing a bladder 1 Remove three M4 set screws from the end cover If your shaft uses a journal with shoulder you will need to remove the journal to access the expansion elements See page 5 2 2 Loosen do not remove the M4 set screws in both end clamps 3 Remove clamps and expansion elements from shaft End cover Set screw End clamp assembly Expansion element with wave springs Sealed bladder assembly diu a WIN Protection strip External elements Inspect elements for excessive wear or damage and replace as necessary Call Maxcess Customer Service for replacement parts for your shaft Please have your shaft serial number available continued www maxcessintl com Tidland G890 Shaft MI 746511 1 F 5 6 MAINTENANCE Cutting the new bladder Using bulk bladder material If you use bulk bladder material instead of a sealed bladder assembly use the following formula to determine the correct replacement bladder length for your shaft bladder length body length 2 mm 079 XXX 1 mm X XX 0 04 22 0 mm 0 87 9 9 mm 0 39 3 18 mm 9 0 125
17. s leaking replace the bladder See page 5 7 Valve is leaking Use soapy water to test the valve for leaks Replace valve if necessary See page 5 10 Excessive shaft vibration Bad o rings in body end plug Internal air hose is leaking or kinked High loads or speeds Incorrect shaft mounting Shaft imbalance Remove nose cone and body end plug to inspect o rings for damage or wear Replace o rings See page 5 10 Disassemble shaft and check the air hose Replace if necessary See page 5 11 Check PSDS specifications for your shaft application Check shaft at installation mounting points Contact Maxcess Customer Service 1 360 834 2345 1 800 426 1000 www maxcessintl com Tidland G890 Shaft MI 746511 1 F 8 1 SPECIFICATIONS Specifications specifications MN WARNING Do not use the devices outside of their rated Refer to your Product Safety Data Sheet PSDS for your custom shaft specifications Operating air pressure 5 5 8 3 bar 80 120 psi Ambient operating temperature 38 C 100 F Core diameter 76 2 76 mm 3 00 03 Core types Fiber or plastic www maxcessintl com Tidland G890 Shaft MI 746511 1 F 9 1 PARTS AND SERVICE Service requests and replacement parts To request service or to get replacement parts contact Tidland or one of the locations listed on the back page of this publication Tidland 2305 SE 8th Avenue Camas
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