Model D4 Differential Shaft User Manual: Tidland
Contents
1. Important e The cartridges are directional and are factory installed relative to customer shaft rotation direction e Determine shaft rotation clockwise or counterclockwise looking toward the machine end of the shaft e fthe shaft is reinstalled on another machine and rotation direction changes the cartridges must be removed reversed and reinstalled Use the images below to help determine which cartridge your shaft uses Refer to shaft assembly details for proper installation e Cartridges installed incorrectly will not grip the cores With Springs Newer shafts feature an updated cartridge design with one or two springs that help the steel balls engage with the cores as they are being loaded onto the shaft allowing immediate core locking action as soon as the winding operation begins The cartridge is held together with two retainer snap rings If your cartridge is assembled with springs you will notice a distinctive wave like pattern around the face of the cartridge This feature will help you orient the cartridges in the correct direction on the shaft See page 17 for shaft assembly details Cartridges engraved with an arrow indicate the direction in ee ed which cartridge should be installed Arrow should point in the direction of shaft rotation Without Springs Cartridges without springs have only one retainer ring which faces toward or away from the machine end of the shaft depending on shaft rotation dire2. Adjusting the Exhaust Bleeder Valve 1 Stop winding operation and shaft rotation 2 To adjust the internal air pressure turn the valve in 1 8 turn increments using a 1 8 hex drive wrench e To increase the pressure turn the valve clockwise e To decrease the pressure turn the valve counterclockwise DO NOT adjust while shaft is spinning To clean or replace the valve see page 10 Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 9 MAINTENANCE Maintaining the Bleeder Valve If maintaining low tension during winding becomes difficult the bleeder valve may require adjustment or cleaning Note The fine threads on the needle and the housing are easy to damage Use care when working with these components Do not attempt to remove the bleeder valve housing from the shaft If repair is necessary return the shaft to Tidland www maxcessintl com returns Location of valve varies due to custom shaft configurations Do not operate the shaft if the valve is missing the orifice is otherwise plugged Cleaning the Exhaust Bleeder Valve 1 NOOO Stop the winding operation and shaft rotation 2 Locate the bleeder valve at the end or on the side of the shaft 3 4 Using a 1 8 hex drive carefully back the needle valve all the way Using a 12 mm socket carefully remove muffler if installed out of its housing counterclockwise Using compre
3. cores do not unlock Cores slipping on cartridges Excessive rattling in shaft Chrome balls are falling out of the cartridge Balls or cartridge races are stuck parts don t move Bladder melting Possible Cause Solution Page Bladder not secure under end Ensure that bladder is pinched under 13 clamps the ridge of the end clamp Fig 6 Ensure that end clamp screws are tightened to 9 10 in Ibs Bladder leak Remove and inspect bladder Replace 12 if necessary Air supply not connected Ensure good connection to air supply Exhaust bleeder valve adjusted See information on adjusting bleeder 8 or installed incorrectly valves Clogged inlet bleeder valve Test inlet bleeder valve for blockage 20 Air fitting in bladder is plugged Remove air fitting Blow air through it 12 to remove debris Bleeder valves incorrectly See information on adjusting bleeder 8 adjusted valves Clogged exit bleeder valve Remove and clean bleeder valve 10 assembly Cartridges installed in the wrong Check shaft rotation direction 15 or 17 direction and ensure cartridges are installed correctly Cartridge races are worn and Replace cartridge 15 or 17 chrome balls are loose Call Tidland 1 800 426 1000 Dust or contamination build up Remove cartridges and clean 14 or 16 in cartridges Dust or contamination build up Remove cartridges and clean 14 or 16 in cartridges Cores too big See core size tolerance requirements 6 If cores are with
4. JOURNAL Fa Ad THRUST WASHER A I 97 AT ASSEMBLY FEMALE Leave 030 060 gap Pt between last WASHER x cartridge and collar CARTRIDGE ASSEMBLY N RETAINER RING POINTS TOWARD MACHINE END THRUST WASHER c MACHINE END SHAFT ROTATION DIRECTION f uns Ty THRUST WASHER A W d 0 63 V AT ASSEMBLY Leave 030 060 gap between last cartridge CARTRIDGE ASSEMBLY f and collar N RETAINER RING POINTS AWAY FROM MACHINE END A 000 0 0 0 0 0000000 THRUST WASHER Pm od FEMALE a 9 SHAFT fj Y ROTATION Tidland Differential D4 Installation Operation and Maintenance 08 11 SS X XS MAINTENANCE Cartridges With Springs Disassembly Tip Work over a shop rag or tray in order to contain the balls during disassembly 1 N Remove one snap ring from the cartridge to free the cartridge outer race It does not matter which ring is removed it is not necessary to remove both rings Note Removing the outer race will allow the balls to fall freely Remove the spring s from the inner race and set aside Remove dust and debris from cartridge parts and clean using a mild solvent such as rubbing alcohol Replace worn parts OTICE Spring constant Ib in is calculated for successful operation of the Tidland D4 shaft Do not replace springs with anything other than Tidland factory parts Assembly 1 2 3 6 T Remov
5. follow the instructions on page 11 to disassemble the shaft and remove the cartridges for cleaning and further inspection 1 Place the cartridge assembly on the work surface with the retainer ring facing up RETAINER RING 2 Align the gap in the retainer ring with any notch in the race Using a small flathead screwdriver carefully pry the retainer ring off the cartridge 3 Remove the first row of six chrome balls and OUTER RACE Ng CHROME BALLS lift off the outer race o 9 eS 4 Remove the remaining six balls 5 Clean all parts mild solvents such as INNER RACE Ser rubbing alcohol are acceptable Replace worn cartridges oo Note e Remove all solvent with a dry cloth before reassembly so parts do not accumulate debris e Petroleum based solvents will destroy bladder material Assembly P ALIGN NOTCHES 1 Place the inner race on the work surface with notches facing up DETER RACE 2 Slide the outer race over the inner race aligning INNER RACE notches as indicated in Fig 1 3 Lift the outer race just enough to insert the chrome O balls in the inner race notches one at a time in six e o places Note If notches are not aligned the balls will not fit into place 4 Letthe outer race slide down into place to secure the first row of chrome balls 5 Insert the rest of the chrome balls in the outer race notches Fig 2 6 Reinstall the retaining ring to secure the assembly F
6. TIDLAND WINDING SOLUTIONS P o Tidland D4 Differential Air Shaft Installation Operation and Maintenance MI 6386721 Q TABLE OF CONTENTS Important Safety Instructions ocio Ph et iiie b tendat Lo ad ener enar deae 3 eri P tenants 3 Tidland Customer Service eessssiessiisesssesee esses senes nnna enne net en nass nnns sn nnns enne inns antenna nnne 4 Recommended tools marear t nter ROREM eth a eee ia A PAA ad ad Fete Phe a ede 4 Maintenance Schedule ccccecccccecceceseeeesseceeaceeeeaaeceaeeeesaeeseaaesaaeeeaaeseaaesaaeeesaaesseaaesaaeeseaeeeeaaeeseaaesaes 4 INI 5 Cartridge Assemblies cree ti iie eli ee ERR HAE Fe ta Saa Fa EL ER n ERR Ro tte HR IER atag 5 With SprihgS 2 et cete react ete desta ved Sas Pee RR eod D ERR ates cash aed eae p ASIE Le ete LR eee augeat gate ae 5 Witho t Spring Siea euet rtu cect escoger ie einer pte carter eed neben RE Eph Sat Rear aH E ob tes cep eaten ees 5 Dimensional amp Quality Recommendations for Cores essssssssssssseseee eee 6 Gote DIMENSIONS iz vitrea ee Earn tests pices Ws Ret EMT pa Oe EN REA ERR Ee EATA RATEN 6 General Gore Quality nitrate kettle ee ete perde bebe Ern RR Ide Fat Bean TANE 6 Gore InstallatiOn 5i teret hc sitet c o cine rette RE ERE Fe Pa ORI EL ERR Sig rd Ren tu I kk ste 6 Operatori sed ese cule Rb LLL a e t UU ES dde 7 Pressure Control Valve System
7. ction Cartridges installed incorrectly will not grip the cores See page 5 e When ordering 3 6 cartridge adapters be sure to confirm your application and load requirements with Tidland Customer Service Use hoist to lift or move the 6 D4 shaft Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 3 TIDLAND CUSTOMER SERVICE 800 426 1000 360 834 2345 www maxcessintl com Visit the Tidland Repair and Return Center online to review our return policies or to submit an electronic Return Material Authorization Request at www maxcessintl com returns RECOMMENDED TOOLS Dow Corning Molykote 557 Silicone Dry Film Lubricant or non petroleum equivalent Hex drive wrenches 1 8 3 16 3mm Tidland Hole Punch Guide P N 647597 Tidland Hole Punch P N 560345 Small flathead screwdriver LOCTITE 242 blue When using Dow Corning 557 Dry Film Lubricant e Apply a very thin film to the shaft body e Do not allow the lubricant to pool in bladder slot or shaft recesses e Allow the lubricant to dry for 30 minutes e Wipe the shaft body down with a clean cloth For more accessories to help with your winding processes visit www maxcessintl com MAINTENANCE SCHEDULE Every 30 Days e Deflate shaft completely and remove cores e Use compressed air to blow out dust and ensure that cartridges turn freely on the shaft e f cartridges are stic
8. ction See page 15 for assembly details The figure to the right represents a view of the retainer ring Cartridge type is easy to identify by removing the collar at the operator end of the shaft Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 5 OVERVIEW Dimensional amp Quality Recommendations for Cores for use with D4 Differential Winding Core Dimensions 1 Core ID Range must be between 3 Shafts 3 005 3 040 6 Shafts 6 005 6 060 a If Core I D s are smaller they will be very difficult to load onto shaft If larger they will not lock up properly b Long cores large slit widths and cores with I D defects for example ovality curvature etc will be more difficult to load if they are at the low end of allowable range 2 Core width must be greater than 3 Shafts 0 875 when using narrow 0 75 cartridges 2 00 when using wide 1 25 cartridges 6 Shafts 2 00 when using 1 50 cartridges 3 Core width runout on a single core should be no greater than 0 020 4 Core wall thickness tolerance on a single core should be no greater than 0 010 Variance in the core wall thickness will contribute to increased vibration and reduced roll quality General Core Quality e Surface condition of the Internal Diameter should be smooth for easy installation e Inner edges of cores should be clean and without rough burrs Core Installation
9. d or other safety and functional deficiencies daily before each use 6 Wear safety glasses or proper eye protection when inflating or deflating or otherwise operating the air system 7 Do not remove or otherwise alter any setscrews or fastening devices prior to using this product 8 Do not operate this product if any setscrews or fastening devices are missing 9 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 10 When lifting a shaft use proper lifting techniques keeping back straight and lifting with the legs 11 Do not carry or lift this product over wet or slippery surfaces 12 Use appropriate mechanical lifting devices for heavier shafts such as a hoist or shaft puller 13 Use lifting devices only as designed for this product 14 When performing maintenance or repair procedures do not pressurize the shaft if journal setscrews are loose or missing 15 When performing maintenance procedures do not pressurize the shaft if the journal is missing 16 All replacement parts used on this product should be made to original Tidland specifications 17 All maintenance and repair procedures performed on this product should be done to Tidland specifications by qualified personnel CAUTION e Wear eye protection when using tools or compressed air e The cartridges are directional and are factory installed relative to customer shaft rotation dire
10. d shafts with nose cones remove the nose cone Use a 3 mm hex drive wrench to remove the three setscrews The collar has no setscrews 3 Remove the collar 4 Remove the thrust washer if installed 5 Remove the cartridges washers and remaining thrust washer Note Do not remove the collar at the machine end except to replace the felt strips or bladder 6 To remove bladder see page 12 7 Inspect felt for wear Replace discolored or compressed deformed material 8 Inspect shaft body for wear There should be no signs of galling if scoring or serious wear is detected call Tidland Customer Service for assistance 9 Inspect cartridges for wear and debris buildup Disassemble and clean if necessary without springs page 14 with springs page 16 To reinstall or reverse cartridges see page 15 without springs or page 17 with springs COLLAR oe MACHINE END S SHAFT BODY Va THRUST WASHER CARTRIDGES WASHER JOURNAL CONFIGURATION THRUST WASHER COLLAR vy SHAFT BODY Vig SETSCREW Ny Thrust washer not used on shafts y a with spring loaded cartridges So NOSE CONE cA CAPSCREW 3 PLCS NOSE CONE CONFIGURATION Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 11 MAINTENANCE Removing Felt Strip and Bladder 1 Follow instructions for shaft disassembly on page 11 2 Using 3 16 hex drive wrench remove screws from end clamps and remove th
11. e During both installation and removal a slight twist against the spring helps make it easier to slide the cores on and off Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 6 OPERATION egg 04 9 Before beginning the winding operation please read and understand the following Pressure Control Valve System Successful operation of the Tidland Differential Shaft series depends upon proper internal air pressure Each of the Differential Shaft models can be equipped with a pressure control system comprising two bleeder valves Used with your applied air pressure these valves allow the operator to adjust and maintain internal air pressure which is critical in low tension winding applications where the required internal pressure is very low and the pressure range is very small Variable pressure is required in order to control the air pressure on the tension segments as the roll diameter increases As the roll diameter grows the required rate of pressure increase will diminish due to the weight of the roll and friction between the roll and shaft These parameters will vary based on your application How It Works As operating air pressure is applied to the shaft the factory set inlet valve causes a drop in pressure as air enters the bladder The exhaust bleeder valve controls the amount of that pressure drop The larger the exhaust opening the greater the pressure drop r
12. e all solvent with a dry cloth before reassembly to reduce accumulation of dust on cartridges and shaft There should be one snap ring installed on the inner race before beginning reassembly Install the spring s securely in the groove s provided in the cartridge inner race On a flat work surface place the inner race inside the outer race If there is an arrow engraved on the outer race ensure that it points in the direction of spring compression installed in the inner race Install a row of balls in the slots next to the snap ring Lift up on the outer race which helps hold the balls in place and turn the cartridge over Install the remaining balls in the slots Note Spring s must be compressed to allow the ball s to fit properly in the slot s 8 9 10 Install the remaining snap ring Before installing the cartridges a Apply a very thin film of Dow Corning 557 Silicone Dry Film Lubricant to the shaft body Avoid spraying the felt strip b Allow the lubricant to dry for 30 minutes c Wipe the shaft body down with a clean cloth Reinstall cartridges according to the diagram on page 17 Tidland Differential D4 Installation Operation and Maintenance 01 12 16 SPRING SNAP RING INNER OUTER RACE www maxcessintl com 360 834 2345 MAINTENANCE Reinstalling or Reversing Cartridges With Springs Important e Correct installation of cartridges depends upon shaft rotation dir
13. e clamps from wy SCREWS each end of the shaft ENS BLAMP 3 Remove the felt strip Z 4 Pull the air fittings from their locations in the slot and remove the bladder from the slot carefully FELT so as not to damage the air fittings f FITTING 5 Remove the air fittings from the bladder BLADDER 6 Inspect the bladder and replace if necessary T un Tidland recommends replacing the bladder x and felt strip components at the same time O S Replacing Felt Strip and Bladder Tidland recommends replacing both components at the same time 1 Follow the instructions for shaft disassembly on page 11 2 Remove both of the air fittings from the old bladder and set aside 3 Clean the slot with a soft cloth A rag damp with mild solvent such as rubbing alcohol is acceptable Caution e Make sure all parts are completely dry before reassembling the shaft Bladder and felt strip material supplied for replacement will be longer than the required finished length Do not cut to length until instructed in Steps 0 and 0 Fig 4 00 7 HOLE PUNCH TOOL A F 460 BLADDER a BLADDER AIR FITTING HOLE PUNCH GUIDE 4 Cut one end of the bladder square Bladders cut at any angle are at risk for leakage 5 Insert the Tidland Hole Punch Guide into the bladder and with the Tidland Hole Punch Tool punch a hole in one wall only of the bladder Fig 4 6 Insert air fitting into the bladder Fig 5 Tidland Diff
14. ection e Before reinstalling cartridges a Apply a very thin film of Dow Corning 557 Silicone Dry Film Lubricant to the shaft body Avoid spraying the felt strip b Allow the lubricant to dry for 30 minutes c Wipe the shaft body down with a clean cloth e When reinstalling collars make sure that setscrew holes align with flats on shaft body and that the bleeder valve hole is aligned for access during reinstallation of the valve e Make sure there is a washer in between each cartridge and or collar e Push all cartridges to the fixed end and install the remaining collar To prevent cartridges from seizing leave a 030 060 gap between the last cartridge installed and the collar Note wave direction on cartridge COLLAR If there is an arrow engraved on the outer race it must point in the direction of shaft rotation WEB TRAVEL ETAR N SHAFT ROTATION 9 SHAFT BODY SHAFT CB 7 DIRECTION i Jj AT ASSEMBLY Leave Ac 030 060 gap between Ly Ye last cartridge and collar WASHER Je O 0 KZ CARTRIDGE WITH SPRINGS S C COLLAR Note wave direction on cartridge If there is an arrow engraved on the outer race it must point in the direction of shaft rotation WEB TRAVEL SHAFT ROTATION NM SHAFT n ROTATION UJ AT ASSEMBLY Leave DIRECTION P 030 060 gap between f 06h Oo last cartridge and collar Tidland Differential D4 Installation Ope
15. erential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 12 MAINTENANCE Replacing Felt Strip and Bladder continued 7 8 9 10 11 12 14 15 16 Lay the bladder in the slot and insert the air fitting into the shaft Lay the new felt strip on top of the bladder as shown in Fig 6 Apply a small amount of Loctite 242 to the end clamp screw threads and secure both components with one end clamp Note Only the bladder end is pinched under the ridge on the underside of the clamp The felt strip is secured by the end clamp as shown in Fig 6 Using 3mm hex drive wrench tighten end clamp screws to 9 10 in lbs END CLAMP FELT STRIP BLADDER N AIR FITTING To cut the bladder to the required length install it along the length of the slot Do not stretch the bladder Mark the bladder at a point 0 140 from the end clamp screw hole centers Fig 7 Lift the bladder out of the slot and cut square across its end 0 140 gt H BLADDER SLOT SCREW HOLE 0 30 gt FELT STRIP Using the Tidland Hole Punch Guide and Tool punch a hole in one wall of the bladder Insert the remaining air fitting into the bladder Reinstall the bladder along the length of the slot and insert the air fitting into the shaft Before installing felt strip a Apply a very thin film of Dow Corning 557 Silicone Dry Film Lubricant to the shaft body Do not allow the lubrican
16. esulting in lower internal bladder pressure Reducing the exhaust opening increases the internal air pressure If you are unable to achieve optimal tension control by adjusting your applied air pressure use the exhaust bleeder valve to improve the resolution of your tension controller CAUSES A PRESSURE DROP SHOULD NOT REQUIRE ADJUSTMENT OUTLET SUPPLY AIR ATMOSPHERIC APPLIED AP P iNTERNAL P PRESSURE PRESSURE DROP AFFECTS THE INTERNAL AIR PRESSURE CONTROL THE PRESSURE DROP BY ADJUSTING THE OUTLET EXHAUST BLEEDER VALVE PAGE 8 Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 7 OPERATION Cores Installing and Removing Refer to page 6 for core dimension and quality recommendations 1 Inflate the shaft to lock the inner race of the cartridges to the shaft 45 psi max 2 Install the cores twisting them in the direction of the arrow engraved on the cartridge outer race This will help the cores slide onto the shaft more easily 3 Adjust core positions and attach the web 4 Resume normal pressure control once winding starts To remove the cores inflate the shaft to maximum pressure and twist the cores in the direction of the arrow while sliding them off of the shaft e 6 2 For maximum operating air pressure refer to the chart below Winding The Tidland D4 differential shaft is designed for rewind applications If you would like
17. ig 3 7 Before installing the cartridges a Apply a very thin film of Dow Corning 557 Silicone Dry Film Lubricant to the shaft body Avoid spraying the felt strip b Allow the lubricant to dry for 30 minutes c Wipe the shaft body down with a clean cloth 8 Reinstall cartridges according to the diagram on page 15 RETAINER RING Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 14 MAINTENANCE Reinstalling or Reversing Cartridges Without Springs Important e Correct installation of cartridges depends upon shaft rotation direction e Before reinstalling cartridges a Apply a very thin film of Dow Corning 557 Silicone Dry Film Lubricant to the shaft body Avoid spraying the felt strip b Allow the lubricant to dry for 30 minutes c Wipe the shaft body down with a clean cloth e Mount thrust washer with the flat side against the collar 2 places e When reinstalling collars make sure that setscrew holes align with flats on shaft body and that the bleeder valve hole is aligned for access during reinstallation of the valve e Make sure there is a washer in between each cartridge and or collar e Push all cartridges to the fixed end and install the remaining collar To prevent cartridges from seizing leave a 030 060 gap between the last cartridge installed and the collar MACHINE END SHAFT BODY SHAFT ROTATION DIRECTION p FLATS SETSCREW Mu
18. in spec contact Tidland Customer Service Cartridge races are worn and Replace cartridge 15 or 17 chrome balls are loose Cartridge races are worn Replace cartridge 15 or 17 Dust or contamination build up Remove cartridges Disassemble and 14 or 16 in cartridges clean parts Apply a very thing film of silicone dry film lubricant spray or equivalent to shaft body before reinstalling cartridges Let dry 30 minutes before wiping the shaft body clean with a clean cloth Avoid spraying felt strip or letting the lubricant pool in shaft recesses Excessive overspeed rpms Reduce speed 8 Tidland Differential D4 Installation Operation and Maintenance 19 01 12 www maxcessintl com 360 834 2345 TROUBLESHOOTING Air Leaks oo Test the inlet bleeder valve first to make sure your shaft is inflating properly Shut off air supply to shaft and remove shaft from machine Remove all of the cartridges p 11 Lift the felt strip out of the slot It should pull out easily from the end clamps Slowly apply 10 psi max to the shaft the bladder should begin to inflate WARNING Body hazard Excessive air pressure may cause bladder to explode Apply 10 psi maximum air pressure if cartridges are not installed If the bladder does not inflate the inlet bleeder valve may be clogged and will need to be removed for inspection and cleaning Determine the adjustment of the inlet bleeder valve you will need this infor
19. king follow the instructions on page 11 to disassemble the shaft e Inspect felt for wear Replace discolored or compressed deformed material page 12 e Inspect shaft body for wear There should be no signs of galling if scoring or serious wear is detected call Tidland Customer Service for assistance e Inspect cartridges for wear and debris buildup Disassemble cartridges and clean thoroughly e Before reinstalling cartridges a Apply a very thin film of Dow Corning 557 Silicone Dry Film Lubricant to the shaft body Do not allow the lubricant to pool in bladder slot or shaft recesses b Allow the lubricant to dry for 30 minutes c Wipe the shaft body down with a clean cloth Every 6 Months e Disassemble clean and lubricate the shaft page 11 Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 4 OVERVIEW Cartridge Assemblies The cartridge on the D4 Differential shaft is designed to spin on the shaft even after web tension causes it to grip and lock the core Slippage is between the shaft body and the cartridge not the core so dust is not generated by core wear Independent cartridges allow for winding multiple cores of different roll widths and roll diameters at the same tension The Tidland D4 differential shaft is designed for rewind applications If you would like to use a D4 for an unwind operation please contact Tidland Customer Service at 1 800 426 1000
20. l Free 800 639 3433 Tel 49 6195 7002 0 Tel 86 756 881 98398 AND SE ASIA Tel 1 405 755 1600 Fax 449 6195 7002 933 Fax 86 756 881 9393 Tel 65 9620 3883 Fax 41 405 755 8425 sales maxcess eu sales Q9 maxcessintl com cn Fax 65 6235 4818 sales Q9 maxcessintl com WWW maxcess eu www maxcessintl com cn asia maxcessintl com www maxcessintl com SOUTH AMERICA INDIA JAPAN yo gt Tel 55 11 3959 0990 Tel 91 22 27602633 Tel 81 43 421 1622 Fax 55 11 3856 0990 Fax 491 22 27602634 Fax 81 43 421 2895 southamerica maxcessintl com india maxcessintl com japan Q maxcessintl com www maxcessintl com br www maxcess in www maxcess jp 2011 Maxcess
21. mation for reinstallation a Close the valve all the way down clockwise and note how far it turns Factory setting is 1 4 turn for most applications Use 1 8 hex drive wrench b Remove the valve completely from the shaft Inspect the valve and remove any debris Reinstall and adjust the valve a Close the needle valve completely clockwise and then back off one quarter turn b Retest for inflation 10 psi max If bladder does not inflate the bladder air fitting may be clogged a Remove element end clamps and air fittings from the bladder b Clean and reinstall the air fittings and clamps then retest for inflation If the shaft appears to be leaking air when the bladder is inflated test the bladder and end clamps 1 2 3 Close the exit bleeder valve all the way With the bladder inflated 10 psi max spray the end clamps and the length of the bladder with soapy water Watch for bubbles that indicate air leakage If air is leaking at the end clamps make sure that the bladder is completely sealed under the clamp and that the clamp is tightened to 9 10 in Ibs If the leak is somewhere along the length of the bladder install a new bladder p 12 and retest for leaks All rights reserved No part of this publication may be reproduced transmitted transcribed or translated into any language in any form by any means without the written permission of Tidland NORTH AMERICA EUROPE CHINA KOREA TAIWAN n Tol
22. ng Cartridges sssssssssseees eene 17 Assembly Diagram and Parts List 2 tete eee ctt fee Rabe e UII TO eene ne chin 18 Troubleshootlrig s iie Ph ete teen aient eae eA aite ee ea p e eade aues 19 SNAIL Ei 19 AFLEI a EE 20 Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 2 IMPORTANT SAFETY INSTRUCTIONS When using this Tidland product follow basic safety 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 1 Read and understand all instructions and shaft design application limits before operation 2 Never use this product for a purpose or in a machine that it was not specifically designed for See Product Safety Data Sheet PSDS 3 Do not exceed the operation loads for this shaft as noted on its PSDS 4 Follow all warnings and instructions marked on the product and on the PSDS 5 Inspect the shaft for wear an
23. ration and Maintenance 01 12 www maxcessintl com 360 834 2345 17 ASSEMBLY DIAGRAM AND PARTS LIST NOT SHOWN Pp Parts are not to scale m 2b a 2I 3 EST cu f P d NEEDLE SETSCREW KNURL CUP PT 3 1 4 20NC X 1 4 LG 4 565567 REEXEN SETSCREW KNURL CUP PT 3 8 16NC X 5 8 LG 561656 6 cwmRoeASSEBLY STP CCS T wmusmmGsUme Wb 7 799 wmusmmGszeWpg 7 742 1 wmusmmGs s Wog r REPLACEMENT SPRING 77 58 535 582808 Cartridge Width so ens es 8 THRUST WASHER WALE iia o ommon oso oo 1 a 808786 508 38 14 130815 130815 6 BINSOC HD SCREW B M4 X 0 7 X 12M a OSE CONE NOSE CONE SETSCREW CUSTOM CUSTOM CUSTOM CUSTOM Tidland Differential D4 Installation Operation and Maintenance 01 12 18 www maxcessintl com Number of cartridges and washers is dependent upon shaft length ff nose cone is installed Not used with spring loaded cartridges Spring constant is calculated use only Tidland factory parts 360 834 2345 TROUBLESHOOTING Shaft To troubleshoot an air leak see page 20 Problem Shaft leaking air when bleeder valve is closed Bladder does not inflate properly Air does not escape shaft Cartridges do not expand fully cores do not lock Cartridges do not collapse fully
24. se the exhaust bleeder valve to improve the resolution of your tension controller For the majority of applications no adjustment is required for the exhaust bleeder valve For higher internal pressure adjust to a smaller opening in the valve For lower internal pressure adjust to a larger opening Adjustments are made with a 1 8 hex key e The restrictor valve at the inlet should not require adjustment e Donot operate shaft with missing valves e Amuffler may be installed on the exhaust bleeder valve outlet to reduce noise A slight hiss may be audible this indicates that the Pressure Control Valve System is functioning allowing air to escape from the shaft as designed The muffler must be removed 12 mm socket before attempting to adjust or remove the bleeder valve See Replacing the Bleeder Valves page 10 Not available on all Differential shaft designs Exhaust Bleeder Valve Function e The purpose of this graph is to illustrate the characteristics of bleeder valve function The 0 60 4 tension values displayed are arbitrary 1 VALVE CLOSED e Actual winding tension will differ by variables 0 50 J such as bladder length shaft speed roll specs a is 3 1 8 TURN OPEN width diameter and weight and core material z We 9 2 0 30 4 ul 4 E J 8 0 204 a 1 4 TURN OPEN 0 10 4 0 00 T T T T T T T 0 0 5 0 10 0 15 0 20 0 25 0 30 0 35 0 40 0 APPLIED AIR PRESSURE PSI
25. ssed air blow dust and debris out of the valve Carefully reinstall the needle valve in the housing Close the valve down until it just bottoms out in the housing and then adjust as required for your application Resume winding operation Adjust the bleeder valve incrementally to achieve required internal pressure Not available on all Differential shaft designs Replacing the Exhaust Bleeder Valve 1 Stop the winding operation and shaft rotation 2 Locate the bleeder valve at the end or on the side of the shaft 3 Using a 12 mm socket carefully remove muffler if installed 4 Using a 1 8 hex drive carefully back the needle all the way out of its housing counterclockwise 5 Carefully reinstall the needle valve in the housing 6 Close the valve down until it just bottoms out in the housing and then adjust as required for your application 7 Resume winding operation 8 Adjust the bleeder valve incrementally to achieve required internal pressure Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 10 MAINTENANCE To Disassemble the Shaft Removing Collar and Cartridges Pay close attention to the orientation of the cartridges and washers when removing components from the shaft body Proper reinstallation depends on shaft rotation 1 Loosen do not remove the setscrews 3 16 hex drive holding the collar at the journal end of the shaft body Note On cantilevere
26. ssssssssssssssssee eene nennen nnne nnn sin nrnr innen nnns nr nn enne 7 Cores Installing and Removing ssesssssssssssseeeee ener entente enn nnns nnne nnns 8 Winding iei etude ne Om at titt nuda tedio T i ee ette ue 8 Bleeder Valves 2 iso eain adeat diee tin ad Rhea bise em ext t ash ed enata 9 Mete OM UR A P DE 9 Adjusting the Exhaust Bleeder Valve ssssssssssssseeeeneeeene nennen ener nnn nnns 9 Mantenan E e Let rd os Udo at dedu ota teo tas ai aad is 10 Exhaust Bleeder Valve ide dee ded c a e eis 10 Cleanirig axo th esca nec ai dE uin c a Lue Led En 10 Hoplaging s e hee een e ce ot tea atta A e T eee dan 10 To Disassemble the Shaft ccecccccesceseeeeceenceceeeeeeaeseseneecaeeeeaaesseaaesgaeeeceaeeeeaaeseeaeesseeeseaaeseeneeenaees 11 Collar and Cartridges asrini iiaiai dienian e Ge ede ede el betel ee ct dada 11 Felt Strip and Bladder tent d ec tee Ae e e s 12 REMOVING EP D 12 Replacing dL ETT 12 Cartridges PT 14 Without Springs aod eei dico Cape eap Ld Og dob Ld A e RR d og etum a 14 DISASSOMDIY scr 2 6 t e c o EC C tg d def ec dp d C p dn 14 Assembly 4 45 gp en ter de Capit de dida eoe He es dod e cas 14 Reinstalling or Reversing Cartridges ssssesssseeeneenenneneen nnne 15 With Springs 2 23 25 1 nannaa Heic ut e utt d rede p AN e a i D dap ee 16 Disassembly ier een E REC qe I et d e det e o dp e Cd aeu et dens 16 DECIDE 16 Reinstalling or Reversi
27. t to pool in the bladder slot or shaft recesses b Allow the lubricant to dry for 30 minutes c Wipe the shaft body down with a clean cloth Make sure to wipe the slot also d Proceed to Step O To cut the felt strip to the required length install it along the length of the slot Stretch the felt strip using 1 1 5 Ibs of force and mark a point 0 30 from the end clamp screw hole centers Lift the end of the felt strip out of the slot and cut it square across the end where marked Lay the felt strip back in the slot and stretch it until the end covers the air fitting Secure bladder and felt strip with the remaining end clamp as shown in Fig 6 Use small amount of Loctite 242 on the screw threads Tighten clamps to 9 10 in lbs 17 Push all cartridges toward the fixed end and reinstall the collar To prevent cartridges from seizing leave a 030 060 gap between the last cartridge installed and the collar Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 13 MAINTENANCE Cartridges Without Springs Disassembly The cartridge assembly is made up of an inner race an outer race and twelve chrome balls held together by a retainer ring The cartridge assembly may be disassembled for cleaning Inspect the cartridges on the shaft once a month for wear or dust buildup Use compressed air to blow out dust and ensure that cartridges turn freely on the shaft If the cartridges stick
28. to use a D4 for an unwind operation please contact Tidland Customer Service at 1 800 426 1000 1 Begin the winding operation at 0 5 psi for low tension winding 2 During winding observe the tension controller readout and adjust the applied air pressure as needed Adjusting the exhaust bleeder valve may improve the effectiveness of the tension controller See page 9 D4 Pressure Overspeed Limits Maintaining Safe Temperature for Plastic Components 70 Ambient Overheating or seizing will occu E a a ul ul n o t ul 2 o Recommended operatio 25 30 PRESSURE psi Tidland Differential D4 Installation Operation and Maintenance 08 11 www maxcessintl com 360 834 2345 8 OPERATION Bleeder Valves As operating air pressure is applied to the shaft the factory set inlet valve causes a drop in pressure as air enters the bladder The exhaust bleeder valve controls the amount of that pressure drop The larger the exhaust opening the greater the pressure drop resulting in lower internal bladder pressure Reducing the exhaust opening increases the internal air pressure e Both valves are factory set according to customer operating specifications roll specs width diameter and weight and web tension PLI e f you are unable to achieve optimal tension control by adjusting your applied air pressure u
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