Nexen Air Champ BC 288 User manual

(i) FORMNO.L-20066-B-0402
BC Brake Caliper
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

(ii)
In accordance with Nexen’s established policy of constant product improvement, the specifications contained in this
manualaresubjecttochangewithoutnotice. Technicaldatalistedinthismanualarebasedonthelatestinformation
available at the time of printing and are also subject to change without notice.
Technical Support: 800-843-7445
[phone]
www.nexengroup.com
Copyright 1999 Nexen Group, Inc.
NexenGroup,Inc.
560 Oak Grove Parkway
Vadnais Heights, Minnesota 55127
ISO 9001 Certified
Read this manual carefully before installation and operation.
Follow Nexen's instructions and integrate this unit into your system with care.
This unit should be installed, operated and maintained by qualified personnel ONLY.
Improper installation can damage your system or cause injury or death.
Comply with all applicable codes.
DANGER
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

(iii)
Table of Contents
Introduction----------------------------------------------------------------------------------------------------------------------------------------1
Installation -----------------------------------------------------------------------------------------------------------------------------------------1
Air Connections--------------------------------------------------------------------------------------------------------------------------------- 1
Operation ------------------------------------------------------------------------------------------------------------------------------------------2
Maintenance and Repair --------------------------------------------------------------------------------------------------------------------3
Replacement Parts List ----------------------------------------------------------------------------------------------------------------------4
Warranty -------------------------------------------------------------------------------------------------------------------------------------------5
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

1
FORM NO. L-20066-B-0402
INTRODUCTION
INSTALLATION
1. Air Actuated Brake Caliper: Connect an air supply
to the 1/8 NPT air inlet ports located in the end
caps (Item 2) in both caliper halves.
2. Spring Actuated Brake Caliper: Air cylinders are
connected in tandem with push lock fittings and a
nylon tube.
Install one Elbow Fitting (Item 22) in the inlet port
located at the bottom of one Brake Caliper Cylinder
(Item 1). Install the Tee Fitting (Item 23) in the other
cylinder air port. Push the ends of the 1/4 inch
Polyethylene Tube (Item 24) into the fittings and
tighten the fitting nuts. Connect an air supply to the
tee with the extra tube and elbow fitting.
AIR CONNECTION
Models BC288 and BC425 Brake Calipers are available with either air or spring actuation. Caliper spacing is moveable to
fit 3/16 to 1-1/2 inch wide rotating discs or linear traveling devices.
Shoe travel of the spring actuated Brake Caliper adjusts for maintaining constant “new facing” torque as the facing wears
and the springs extend. This adjustment mechanism also manually releases the spring actuated Brake Caliper when
turned counter clockwise.
1. Assemble the two Brake Caliper halves together
with the Connecting Rods (Item 7) and Hex Nuts
(Item 17). At this time, adjust the space between
the Friction Facings (Item 5) to the thickness of the
disc or linear device used. Add 1/16 inch for facing
clearance. Tighten the Hex Nuts to the torque
recommended in Table 1.
NOTE: Before mounting the Spring-Actuated Brake
Caliper: Be sure the brake is in the manual released
position (See paragraph two of the OPERATION
SECTION); and Install the air connection fittings
and tube (See step two in the AIR CONNECTIONS
section).
2. Mount the Brake Caliper assembly on a support
that is capable of sustaining the loads produced
during braking. See the mounting cap screw size
and tightening torque recommendations in Table 1.
3. Position the brake so there is 1/32 inch between
both sides of the disc and the facings. The outside
radius of the disc should run approximately 1/16
inch below the radius of the friction facing. The
friction facings should be as parallel to the disc as
possible to minimize facing wearing time,
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TABLE 1
3. Pneumatically actuated devices require clean
pressure regulated and lubricated air for maximum
performance and long life. Nexen recommends that
a filter, regulator and lubricator be used on the air
line ahead of the air controls.
4. Connect the air controls as close to the unit as
possible for faster engagement and disengagement.
Use a quick exhaust valve where long air lines are
required.
5. Check all connections for leaks.
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

FORM NO. L-20066-B-0402
2
OPERATION
MAINTENANCE AND REPAIR
3. Release the hold-off pressure to engage the spring
actuated Brake Caliper.
Friction Facing Wear Adjustment:
1. To maintain new facing torque levels, periodic
adjustments for facing wear is necessary. Optimum
torque is derived with a 1/32 inch gap on each side
of the disc.
2. Apply 90 PSI hold-off air pressure at the air inlet
and inspect the gap between the friction facing and
the disc.
3. Loosen the set screw hex nut (item #17) and turn
the set screw CW until a 1/32 inch spacer can be
slid between the facing and the disc.
4. Remove the spacer and retighten the hex nut.
NOTE: Periodically inspect all airline connections
for leaks. Inspect all fasteners to make sure they are
tightened to the torques recommended in Table 1.
NOTE: Depending upon the Brake Caliper
accessibility, friction facing replacement and piston
seal maintenance can be performed without
removing the brake from it’s mounting.
2. Replace the Friction Facings (Item 5) when they are
approximately 3/16 inch thick:
a. Spring Actuated Unit: Apply 90 PSI hold-off
pressure at the air inlet or manually release the
brake as described in paragraph B.1 of the
OPERATIONsection.
b. All models: Remove the Shoulder Screws (Item 11).
Remove the facing/shoe assembly (Items 4 & 5)
and Spacer (Item 6). Remove the Machine Screws
(Item 9) and replace the Friction Facings.
c. All models: Reassemble the Spacer, Shoe/Facing
assembly, Springs and Shoulder screws. Tighten the
Shoulder Screws to the torque recommended in
Table 1.
d. Spring Actuated Unit: Reset as described in
paragraph B.2 of the OPERATION section.
3. Air Actuated U-cup and O-ring replacement (Items
10 & 14):
a. Disconnect the air supply to both cylinders.
b. Remove the clamps (Item 8) and end caps (Item 2).
c. Pull the Pistons (Item 3) out of the Cylinders (Item
1) and remove the U-cups (Item 10). Inspect the
Sleeve Bushings (Item 15) for wear and replace if
necessary.
d. Lubricate the new u-cups with O-ring lube and
place them, with the seal lip upward, over the small
diameters of the pistons and into the grooves. Slide
the pistons into the cylinders.
e. Lubricate the new O-rings (Item 14) with 0-ring
lube, place them into the end cap grooves and
reinstall the end caps and clamps. Tighten the
clamp bolts to the torque recommended in Table 1.
4. Spring Actuated u-cup and O-ring replacement
(Items 10 & 21):
a. Disconnect the air supply from the air inlet.
b. Manually release the Brake Caliper as described in
Section IV, paragraph 2.
AIR ACTUATED UNIT
This unit engages when air is applied to both calipers.
Return Springs (Item 12) disengage the calipers when air
exhausts from the cylinders.
SPRING ACTUATED UNIT
Manual Release:
1. Loosen the Hex Nut (Item 17) attached to the Set
Screw (Item 20). Use an Allen wrench to turn the
Set Screw CCW until the Return Springs (item
#12) pull the Shoe/Facing assembly back against
the cylinder (Item 1).
2. Adjust the caliper halves for the space requirements
as described in the INSTALLATION section.
Reset:
1. Apply 90 PSI hold-off air pressure at the air inlet.
2. Turn the Set Screws CW until the Shoe/Facing
assembly just starts to move towards the disc;
tighten the Hex Nuts.
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

3
FORM NO. L-20066-B-0402
c. Loosen the clamp bolt and carefully remove the
Clamp (Item 8) The actuating springs will push the
End Cap (Item 2) away from the cylinder. Remove
the Springs (Item 19).
d. Slide the Piston, Spacer, Set Screw and Hex Nut
assembly (Items 3, 18, 20, 17) out of the Cylinder
and remove the U-cups and O-rings.
e. Lubricate the new U-cups with O-ring lube and
place them, with the seal lip upward, over the small
diameter of the pistons and into the grooves.
f. Lubricate the new O-rings (Item 21) with O-ring
lube and install in the O-ring grooves.
g. Slide the Piston, Spacer, Set Screw and Hex Nut
assembly back into the Cylinder. Install the springs
and place the end caps on top of the springs. Push
down on the end caps until they are flush with the
Cylinder Flange; install the clamp and tighten the
clamp bolt to the torque recommended in Table 1.
NOTE: A ‘C’ clamp, used to compress the End Cap
against the Cylinder Flange, will facilitate assembly.
h. Reset as described in the OPERATION section.
WARNING
Always wear safety
goggles when
working with spring
or tension loaded
devices such as
retaining rings.
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

FORM NO. L-20066-B-0402
4
PARTS LIST
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AIR ACTUATED BRAKE CALIPER
SPRING ACTUATED BRAKE CALIPER
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

5
FORM NO. L-20066-B-0402
WARRANTY
WarrantiesWarranties
WarrantiesWarranties
Warranties
Nexen warrants that the Products will be free from any defects in material or workmanship for a period of 12 months
from the date of shipment. NEXEN MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND ALL IMPLIED
WARRANTIES,INCLUDINGWITHOUTLIMITATION, IMPLIEDWARRANTIESOFMERCHANTABILITY AND FIT-
NESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. This warranty applies only if (a) the
Product has been installed, used and maintained in accordance with any applicable Nexen installation or maintenance
manual for the Product; (b) the alleged defect is not attributable to normal wear and tear; (c) the Product has not been
altered, misused or used for purposes other than those for which it was intended; and (d) Buyer has given written
notice of the alleged defect to Nexen, and delivered the allegedly defective Product to Nexen, within one year of the
date of shipment.
Exclusive RemedyExclusive Remedy
Exclusive RemedyExclusive Remedy
Exclusive Remedy
The exclusive remedy of the Buyer for any breach of the warranties set out above will be, at the sole discretion of
Nexen, a repair or replacement with new, serviceably used or reconditioned Product, or issuance of credit in the
amount of the purchase price paid to Nexen by the Buyer for the Products.
Limitation of Nexen’s LiabilityLimitation of Nexen’s Liability
Limitation of Nexen’s LiabilityLimitation of Nexen’s Liability
Limitation of Nexen’s Liability
TO THE EXTENT PERMITTED BY LAW NEXEN SHALL HAVE NO LIABILITY TO BUYER OR ANY OTHER PERSON
FOR INCIDENTAL DAMAGES, SPECIAL DAMAGES, CONSEQUENTIAL DAMAGES OR OTHER DAMAGES OF
ANY KIND OR NATURE WHATSOEVER, WHETHER ARISING OUT OF BREACH OF WARRANTY OR OTHER
BREACH OF CONTRACT, NEGLIGENCE OR OTHER TORT, OR OTHERWISE, EVEN IF NEXEN SHALL HAVE
BEEN ADVISED OF THE POSSIBILITY OR LIKELIHOOD OF SUCH POTENTIAL LOSS OR DAMAGE. For all of
the purposes hereof, the term “consequential damages”shall include lost profits, penalties, delay images, liquidated
damages or other damages and liabilities which Buyer shall be obligated to pay or which Buyer may incur based
upon, related to or arising out of its contracts with its customers or other third parties. In no event shall Nexen be liable
for any amount of damages in excess of amounts paid by Buyer for Products or services as to which a breach of
contract has been determined to exist. The parties expressly agree that the price for the Products and the services was
determined in consideration of the limitation on damages set forth herein and such limitation has been specifically
bargained for and constitutes an agreed allocation of risk which shall survive the determination of any court of compe-
tent jurisdiction that any remedy herein fails of its essential purpose.
Limitation of DamagesLimitation of Damages
Limitation of DamagesLimitation of Damages
Limitation of Damages
In no event shall Nexen be liable for any consequential, indirect, incidental, or special damages of any nature whatso-
ever, including without limitation, lost profits arising from the sale or use of the Products.
Warranty Claim ProceduresWarranty Claim Procedures
Warranty Claim ProceduresWarranty Claim Procedures
Warranty Claim Procedures
To make a claim under this warranty, the claimant must give written notice of the alleged defect to whom the Product
was purchased from and deliver the Product to same within one year of the date on which the alleged defect first
became apparent.
Nexen Group, Inc.
560 Oak Grove Parkway
Vadnais Heights, MN 55127
800.843.7445
Fax: [phone]
www.nexengroup.com
ISO 9001 Certified
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]