tidland g590 lug shaft - · pdf filerecommended tools and supplies ... when lifting a shaft,...

Tidland G590 Lug Shaft Operation and Maintenance

EN 3" Shaft Diameter

MI 746509 1 C

TIDLAND WINDING SOLUTIONS

CONTENTS

www.maxcessintl.com Tidland G590 Lug Shaft MI 746509 1 C

INTRODUCTION 1-1

About these operating instructions ...................................................................... 1-1

Product overview .................................................................................................. 1-2

Model number key ............................................................................................... 1-2

Available models ............................................................................................. 1-2

SAFETY INFORMATION 2-1

Symbols used ....................................................................................................... 2-2

Proper use ............................................................................................................ 2-3

Decommissioning................................................................................................. 2-4

ASSEMBLY DIAGRAM AND PARTS LIST 3-1

Shaft components ................................................................................................ 3-1

Parts list ............................................................................................................... 3-2

INSTALLATION 4-1

Installing the shaft ............................................................................................... 4-1

OPERATION 5-1

Air pressure ......................................................................................................... 5-1

Inflating the shaft ................................................................................................. 5-1

MAINTENANCE 6-1

Maintenance schedule .......................................................................................... 6-1

Recommended tools and supplies ........................................................................ 6-1

Valves .................................................................................................................. 6-2

Removing the rubber tube assembly .................................................................... 6-2

Replacing the air system elements................................................................... 6-3

Rubber tube assembly parts ............................................................................ 6-3

Installing a complete rubber tube assembly .................................................... 6-4

Building the rubber tube assembly .................................................................. 6-5

Torque requirements ........................................................................................... 6-6

TROUBLESHOOTING 7-1

SPECIFICATIONS 8-1

SERVICE AND PARTS 9-1

1-1 INTRODUCTION


About these

operating

instructions

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.maxcessintl.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 G590

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.

1-2 INTRODUCTION


Theory of operation

The Tidland G590 air shaft is a medium to wide web width core

shaft, made of aluminum or steel, with expanding lugs for high

torque transfer to the core. The lugs are actuated by an internal

air bladder to grip the core and are positively retracted with

springs to enable easy, consistent roll or core loading and

removal. 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.

Model number key Shaft series – shaft type – mounting type

Shaft series G – Global

Shaft type 590 = Lug shaft

Mounting type None = drop-in

C = cantilevered

Available models

G590

G590C

2-1 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

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)



Do not carry or lift this product over wet or slippery

surfaces.

Use appropriate mechanical lifting devices, such as a hoist

or 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.

Information about

safety instructions

The safety instructions and symbols described in this section

are used in these operating instructions. They are used to avoid

possible dangers for users and to prevent equipment damage.

SIGNAL WORD

Source of danger and its results

Avoiding dangers

The signal word DANGER refers to the danger of death or

serious bodily injuries.

The signal word WARNING refers to the danger of moderate to

severe bodily injuries.

The signal word CAUTION refers to the danger of slight to

moderate bodily injuries or material damage.

The signal word NOTICE refers to the possibility of damage to

equipment.

Symbols used The following safety identification symbols are used in these

operating instructions.

WARNING/CAUTION – General danger or important note

Reference to general hazards that may result in bodily injuries

or damage to device or material.



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 G590 shaft is intended for the purpose of

clamping cores or rolls to be used for winding or unwinding

web materials (paper, cardboard, plastic film, non-wovens,

textiles, and metal foils).

Improper use

Operation outside the technical specifications

Any other use than the proper use shall be deemed

inappropriate.



Basic safety

information

(continued)

Installation and commissioning

WARNING – Danger of falling down or muscle or skeletal injury

during installation

The larger design shafts are 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 rubber tube outside of the shaft.

Decommissioning

The shaft must be disposed of in accordance with all the

applicable national, state and local regulations.

3-1 ASSEMBLY DIAGRAM AND PARTS LIST


Shaft components

Shaft and journals

Internal parts

Rubber tube assembly

3-2 ASSEMBLY DIAGRAM AND PARTS LIST


Parts list

Tidland G590 Lug Shaft configurations vary; replacement parts

are dependent upon number of lugs, length of rubber tube

assembly, valve location(s) and body material.

Parts are listed for reference. To order parts, call Tidland

Customer Service. Please have your shaft serial number

available.

Item Description

Shaft and Journals

* 1 Valve, large (side or end location)

* 2 Valve gasket, large (Note 1)

* 3 Valve, small (end location only)

3a Valve gasket, small (Note 2)

4 Journal

5 Shaft body

6 Set screw, M10

Internal parts

* 7 Lug (without stubs)

* 8 Lug (with stubs)

9 Separator

* 10 Poron springs (2 per lug)

11 Rubber tube assembly

Rubber tube assembly

* 12 Rubber tube material

13 Tube fitting

14 Tube fitting cap

15 Jam nut

16 O-ring connector

17 O-rings (2)

18 Gasket (sealing ring)

* Recommended spare parts

Note 1:

Note 2:

Large valve gasket must be ordered separately if replacing the large valve.

Small valve is supplied with a gasket. The gasket is also available separately.

4-1 INSTALLATION


Installing the shaft

Upon receipt

Before placing in service, visually inspect shaft for any

damage due to shipping or mishandling. Track each shaft

by recording its serial number and the date it was placed

in service.

See Maintenance Schedule (Section 6-1) for shaft

inspection guidelines.

General

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.

When using chucks on this shaft, always locate chucks as

shown.

Improper placement of chucks will reduce life cycle

of the shaft.

Questions about installation, application or load

calculations? Call Tidland Customer Service.

5-1 OPERATION


Operation

Use only clean, dry, non-lubricated air.

WARNING – Danger of entanglement or pinching during

operation

Keep hands and loose clothing away from rotating shaft.

WARNING – Danger of high-speed projectile injury

Do not inflate rubber tube assembly outside of the shaft. Tube

fittings could disengage from assembly and become dangerous

projectiles.

Air pressure

Shaft operation requires 5.5-8.3 bar [80-120 psi].

Inflating the shaft

Use the Tidland Inflation Tool. Push the air nozzle firmly into

the valve receiver, depressing both the valve button and the tip

of the inflation tool.

Do not exceed 8.3 bar [120 psi].

Deflating the shaft

WARNING – Danger of high pressure injection injury

Do not use finger to deflate the shaft.

Using the Tidland air release tool, push in the quick release air

valve allowing the air to escape through the hole in the center

of the button.

6-1 MAINTENANCE


Maintenance

schedule

If any of these problems are found, remove the shaft from

service and call Tidland Customer Service. These guidelines do

not in any way extend or modify the Tidland Product Warranty.

Specific shaft life is determined by actual operating conditions.

These inspection intervals may be adjusted.

General

Keep shaft clean and dry.

Between every roll change, use compressed air to remove dust

and debris buildup.

Note: When not in use, always store the shaft fully deflated to

prevent cold flowing of the air bladder.

Before each use

Check for damage or excessive wear (see inspection section).

Check for missing or loose fasteners.

Inflate and deflate the shaft without a core installed and verify

that each lug is expanding and retracting correctly.

After one year

Body

Inspect lug slots for excessive wear. Inspect for squaring at the

corners of the lug slots where cracks can develop. Dry polish

with an abrasive pad around the ends of the suspect slots to

expose any possible cracks.

(continued)

6-1 MAINTENANCE


Maintenance schedule

(continued)

Composite body

Inspect the integrity of the outer fiberglass skin; if delamination

is present or cracks* are visible, remove the shaft from service.

* greater than 1.5 mm [.0625"] deep and 13 mm [.500"] long

Journals

Check for reductions in transitional radii between journal

diameter steps. If wear is observed, check for cracks. Use

magnetic-particle or dye-penetrant, or an equivalent procedure,

to detect surface cracks. Measure diameters at those locations

where journal, or body, rides on bearings. Measure diameter at

those locations where the edges of mounted rolls ride on the

shaft body, watching for diameter reduction of 0.015" (0.4 mm)

or more.

Recommended

tools and supplies

Hex drive wrenches: 5 mm

Socket wrench: 19 mm [3/4 in.]

Tidland inflation tools (contact Customer Service for options)

Tidland air release tool (Tidland 111630)

Tidland valve removal tool (for use with the small valve only):

Part No. (North America) 745083 (wrench)

749067 (tool bit only)**

Part No. (Europe) M296213 (wrench)

M373530 (tool bit only)**

Dow Corning Molykote® 55 o-ring grease

Loctite® 243 (or equivalent medium-strength threadlocker)

** This part is a tool bit for use with a torque wrench. (Recommended)

6-2 MAINTENANCE


Valves

Valve may be located at end or side of shaft, or at both ends for

dual air systems.

Valve(s) must be removed before removing the valve journal.

Small valves: Use the recommended Tidland valve removal tool.

Large valves: Use socket wrench – 19 mm [3/4"].

Reinstalling a valve

Replace gasket when reinstalling a valve.

Apply a thread sealant (according to the manufacturer's

directions) to threads of the valve (unless the sealant is pre-

applied).

NOTE: Valves with pre-applied thread sealant are good for

multiple uses. Always inspect the valve threads for sufficient

sealant; do not reuse more than six times.

Screw the valve into the shaft; see Section 6-6 for torque

requirements for each valve size.

Removing the rubber

tube assembly

Remove the journal

1. Inflate the shaft to raise the lugs.

2. Insert retainer clips in each lug and deflate the shaft.

3. Remove the valve.

4. Match-mark the body and journal; remove the journal.

5. Pull the rubber tube assembly from the shaft.

end view - retainer clips

6-3 MAINTENANCE


Replacing the air

system elements

WARNING – Danger of high-speed projectile injury

Do not inflate rubber tube assembly outside of the shaft. Tube

fittings could disengage from assembly and become dangerous

projectiles.

To prevent damage to the shaft and lugs, use a round clamping

fixture to secure shaft during maintenance.

Rubber tube

assembly parts

Some assemblies include a tube stiffener: tubes 11/16" and under

include a wooden dowel inside the tube to aid in loading the

assembly into the shaft.

All fittings can be reused with new rubber tube material. If parts

are rusted or worn, Tidland recommends replacing the entire

rubber tube assembly.

Valve-end fittings are bored through for air passage; non-valve

fittings are solid.

1 Valve journal

2 O-ring connector

3 Jam nut

4 End cap

5 Tube fitting

6 Tube stiffener

7 Rubber tube

12

34

5

6

7

6-4 MAINTENANCE


Reinstalling a

complete rubber

tube assembly

1. Apply o-ring grease to the connector o-rings.

2. Push the valve end tube fitting into the journal until firmly

seated.

3. Insert the non-valve end of the rubber tube assembly into the

shaft until fitting is fully seated in the socket.

(Shaft not shown.)

4. Apply o-ring grease to valve journal fit area; align match marks

and reinstall the valve journal.

5. Apply Loctite 243 to the journal set screws; reinstall and

tighten according to chart in Section 6-6.

6. Reinstall the valve; Section 6-2.

1 Valve journal

2 O-ring connector and o-rings

3 Rubber tube assembly (valve end)

4 Journal fit area

5 Rubber tube assembly (non-valve end)

6 Socket

7 Non-valve journal

Note: If replacing o-ring connector (item 2), see torque requirements

in Section 6-6.

1

2

3

4

5

6

7

6-5 MAINTENANCE


Building the rubber tube

assembly

1. Cut rubber tube square at each end.

2. Install the end cap (1) on the rubber tube and mark

its position on the tube (2). Remove the end cap.

3. Insert the tube fitting (3) deep inside the rubber

tube.

4. Fit the end cap (4) over the tube.

5. Squeeze the tube (5) to force the tube fitting back

toward the end.

6. Apply Loctite 243 to the tube fitting threads and

install the nut (6). Do not tighten.

7. Secure the shaft in a round clamping fixture.

8. Tighten the nut to draw the tube fitting out until

fully seated in the end cap.

9. Tighten the nut to torque specified in Section 6-6.

10. The end cap must be within 2 mm of the mark on

the rubber tube. Tube fitting threads should be

perpendicular to the rubber tube. If crooked, loosen

the nut and repeat the procedure.

11. Repeat the procedure for the non-valve end.

Reinstalling the rubber tube assembly; Section 6-4.

90°

2 mm[1/16"]

2

3

6 45

1

6-6 MAINTENANCE


Torque

requirements

Set screw torque

Size Steel Body Aluminum Body

M10 30-32 Nm [22-24 ft·lbs] 10-11 Nm [7-8 ft·lbs]

Tube fitting assembly torque

Tube O.D.

1-3/8 inch 51-54 Nm [38-40 ft·lbs]

1-5/8 inch 58-61 Nm [43-45 ft·lbs]

O-ring connector

Item 2

(Section 6-4) 11 Nm [97 in·lbs]

Valve

Valve size

Small (end location) 5 Nm [44 in·lbs]

Large (end or side location) 17 Nm [150 in·lbs]

7-1 TROUBLESHOOTING


Problem Possible Cause Recommended Solution

Shaft will not inflate or

hold air

Leaking rubber tube

assembly

Disassemble shaft and replace rubber tube

assembly.

Valve leaking Remove valve and inspect for thread sealant

applied to threads.* Add thread sealant and

reinstall. Tighten according to specifications in

Section 6-6.

Replace valve if necessary.

O-ring connector

loose

Disassemble shaft and reinstall o-ring connector

using Loctite 243 on the threads.

Lugs fall through slots No tube stiffener

Call Tidland for recommendation. Rubber tube lies flat

when not inflated.

Cores slipping Low air pressure Operate shaft at 80 psi minimum (5.5 bar) for

optimal performance.

Air leak See "shaft will not inflate or hold air" at the top

of this list.

Journals wear

prematurely

High loads or speeds Check PSDS specifications for your shaft

application.

Verify that journals are hardened.

Excessive shaft

vibration

Shaft imbalance Inspect shaft for missing components or

fasteners.

* Valves with pre-applied thread sealant (from manufacturer) can be re-used up to six times.

8-1 SPECIFICATIONS


Specifications

WARNING – Do not use the devices outside of their rated

specifications.

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 38º C [100º F]

Core diameter 76.2 ± .76 mm [3.00" ± .03"]

Core types Fiber or plastic

9-1 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.

Maxcess

2305 SE 8th Avenue

Camas WA 98607

1.360.834.2345

1.800.426.1000

Please have your shaft serial number available when you call.

NORTH, CENTRAL AND SOUTH AMERICA

Tel +1.360.834.2345

Fax +1.360.834.5865

[email protected]

www.maxcessintl.com

EUROPE, MIDDLE EAST AND AFRICA

Tel +49.6195.7002.0

Fax +49.6195.7002.933

[email protected]

www.maxcess.eu

CHINA

Tel +86.756.881.9398

Fax +86.756.881.9393

[email protected]

www.maxcessintl.com.cn

INDIA

Tel +91.22.27602633

Fax +91.22.27602634

[email protected]

www.maxcess.in

JAPAN

Tel +81.43.421.1622

Fax +81.43.421.2895

[email protected]

www.maxcess.jp

KOREA, TAIWAN, AND SE ASIA

Tel +65.9620.3883

Fax +65.6235.4818

[email protected]

© 2013 Maxcess

tidland g590 lug shaft - · pdf filerecommended tools and supplies ... when lifting a shaft,...

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