Nexen AIR CHAMP BD Caliper Brake User manual

(i) FORMNO.L-20271-E-0300
Spring-Engaged/Hydraulically-Released
BD Caliper Brake
®
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 2000 Nexen Group, Inc.
NexenGroup,Inc.
560 Oak Grove Parkway
Vadnais Heights, Minnesota 55127
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]

(iii)
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 may cause injury and death.
Comply with all applicable codes.
WARNING
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

(iv)
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

(v)
Table of Contents
Installation ------------------------------------------------------------------------------------------------------------------------ 1
Friction Facing Clearance Adjustment ------------------------------------------------------------------------------------ 3
Maintenance ---------------------------------------------------------------------------------------------------------------------3
Lubrication------------------------------------------------------------------------------------------------------------------------ 4
Parts Replacement ------------------------------------------------------------------------------------------------------------ 4
Replacement Parts ------------------------------------------------------------------------------------------------------------ 7
Parts List ------------------------------------------------------------------------------------------------------------------------- 7
Warranty ------------------------------------------------------------------------------------------------------------------------10
®
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MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

(vi)
-NOTES-
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DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

1FORMNO.L-20271-E-0300
ACTUATOR
NOTE
This BD Caliper Brake is spring engaged and
hydraulically disengaged. To release the spring
pressure, remove the Vent, then lubricate and insert a
Grade 5, 3/8-16 x 9'' Threaded Rod into the back of the
Actuator;then,usingaFlatWasherandNut,tightenthe
Nut to release the spring pressure (See Figure 4). A
Manual Release Kit (Product No. 933596) containing
these items is available from Nexen.
The actuator may be mounted on either side of the
brake.
1. Remove the Detent Pins (Item 16) to release the Shoes
(Item 3) and the Belleville Disc Springs (Item 29) (See
Figure 2).
NOTE
Two Belleville Disc Springs (Item 29) are compressed
between the Brake Arm (Item 2) and the Shoe (Item 3).
When the Shoe is removed, the Belleville Disc Springs
will fall free from the Brake Arms.
2. Remove the Shoes (Item 3) and Belleville Disc Springs
(Item 29) (See Figure 2).
3. Remove four Cap Screws (Item 24) (See Figure 2).
INSTALLATION
DISC
1. Thoroughly inspect the tapered bore of the disc hub and
thetaperedsurfaceoftheQ.D.bushing. Removeanydirt,
grease, or foreign material. Do not use lubricants for this
installation.
2. AssembletheQ.D. bushing intothedischub, aligningthe
untapped holes in the bushing flange with the tapped
holes in the disc hub.
3. Insert the pull-up bolts and alternately and evenly tighten
to the recommended torque (See Tables 1 and 2).
NOTE
Runout is minimized if a Dial Indicator is used as the
pull-up bolts are tightened. Place the contact tip of the
Dial Indicator on the machined surface of the rotor to
measure runout. Runout should be .010 - .015 In.
[2.5 - 3.8 mm] (See Figure 1).
CAUTION
If excessive tightening torque is applied, bursting
pressures are created in the hub. There must be a gap
betweentheflangeoftheQ.D.bushingandthedischub
toensureaproperpressfitoftheQ.D.bushingontothe
shaft.
Dial
Indicator
4. RemovePivotPinRetainingPlate(Item6)(SeeFigure2).
5. Press out Pivot Pins (Item 7) (See Figure 2).
6. SlideBrakeArms(Item2)outofMainFrame(Item1)(See
Figure 2).
7. Position the Brake Arms and Actuator as desired.
8. Slide the Brake Arms (Item 2) back into the Main Frame
(Item 1) (See Figure 2).
24 24
2
6
1
7
16
29
3
7
16
29
FIGURE 2
3
FIGURE 1
4. ToremovetheQ.D.bushing,removethepull-upboltsand
reinsertinto thethreadedholes. Tighten thepull-up bolts
to push the disc hub off the Q.D. bushing.
RECOMMENDED TIGHTENING TORQUES
DIA. PART NO. QD BUSHING TORQUE
12" 934201 SF 30 Ft. Lbs. [40.5 N m]
14" 934202 E60 Ft. Lbs. [81 N m]
16" 932203 E60 Ft. Lbs. [81 N m]
18" 934204 J133 Ft. Lbs. [182.5 N m]
20" 934205 J133 Ft. Lbs. [182.5 N m]
22" 934206 J133 Ft. Lbs. [182.5 N m]
24" 934207 J133 Ft. Lbs. [182.5 N m]
TABLE 1
PULL-UP BOLT TORQUES FOR NON-VENTILATED DISCS
RECOMMENDED TIGHTENING TORQUES
DIA. PART NO. QD BUSHING TORQUE
18.25" 934200 J 135 Ft. Lbs. [182.5 N m]
21" 934300 J 135 Ft. Lbs. [182.5 N m]
24" 934400 J 135 Ft. Lbs. [182.5 N m]
TABLE 2
PULL-UP BOLT TORQUES FOR VENTILATED DISCS
®
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MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

2
FORMNO.L-20271-E-0300
9. Press in the Pivot Pins (Item 7) (See Figure 2).
10. Reinsert the Pivot Pin Retaining Plate (Item 6) (See
Figure 2).
11. Reinstall the four Cap Screws (Item 24) and tighten to
40-50 In. Lbs. [4.5-5.6 N•m] torque.
NOTE
When reinstalling the Shoe (Item 3), first place the
Belleville Disc Springs (Item 29) into the recesses
provided in the Brake Arm (Item 2). The Belleville Disc
Springs should be inserted with their concave side
toward the Brake Arm.
12. Reinstall the Shoes (Item 3) and Belleville Disc Springs
(Item 29) (See Figure 2).
13. Reinsert the Detent Pins (Item 16) to secure the Shoes
(Item 3) and Belleville Disc Springs (Item 29) (See
Figure 2).
14. Loosen the Nut to manually reset the brake.
15. Remove the Threaded Rod, Nut, and Washer.
16. ScrewtheVent(Item17)intothebackoftheActuatoruntil
handtight andcontinueto tightenoneand one-halfturns.
MAIN FRAME
NOTE
SetScrews(Item27)andHex.Nuts(Item28)areprovided
toholdBrakeArms(Item2)inplacewhentheBDCaliper
Brake is used on vertical shaft installations (See
Figure 3).
1. Locate the BD Caliper Brake in the desired position in
relation to the disc.
NOTE
This BD Caliper Brake is spring engaged and
hydraulically disengaged. To release the spring
pressure, remove the Vent, then lubricate and insert a
Grade 5, 3/8-16 x 9'' Threaded Rod into the back of the
Actuator;then,usingaFlatWasherandNut,tightenthe
Nut to release the spring pressure (See Figure 4). A
Manual Release Kit (Product No. 933596) containing
these items is available from Nexen.
2. Alignthe customersupplied supportwiththe MainFrame
(Item 1) mounting holes.
NOTE
The support must be capable of sustaining loads
producedduringbraking.
IfshimsareusedundertheMainFrame(Item1)mounting
pads,caremustbetakentopreventwarpingoftheMain
Frame when tightening the customer supplied 5/8''-11
cap screws (See Figure 3).
WARNING
Thecustomersupplied5/8''-11capscrewsmustsustain
theloadsproducedbythebrakingpreloadproducedby
mounting torque. The torque rating specified above
allows a significant load safety factor. DO NOT OVER
TORQUE CAP SCREWS.
3. Tighten the customer supplied 5/8''-11 cap screws to
150 Ft. Lbs. [203.4 N•m] torque.
4. Remove the Threaded Rod, Nut, and Washer.
5. ScrewtheVent(Item17)intothebackoftheActuatoruntil
handtight andcontinueto tightenoneand one-halfturns.
Actuator
Flat Washer
Nut
Grade 5
3/8-16 x 9''
Threaded Rod
FIGURE 3
2
27
1
Customer supplied
5/8''-11 cap screws
and lock washers
28
FIGURE 4
NOTE
The Vent in the Rear Cylinder prevents debris from
entering the Belleville Spring stack and relieves any
pressure built up by the reciprocating action of the
Piston.
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

3FORMNO.L-20271-E-0300
FRICTION FACING CLEARANCE ADJUSTMENT
1. RemovetheVent (Item17)fromthebackoftheActuator.
2. Using the Nexen Manual Release Kit (Product No.
933596), manually release the brake by inserting the
Grade 5, 3/8-16 x 9'' Threaded Rod into the back of the
Actuator;then,usingtheFlatWasherand Nut,tightenthe
Nut to release the brake (See Figure 5).
3. LoosentheadjustmentscrewSpannerNut(Item12)(See
Figure 6).
4. Loosen the Set Screws (Item 27) and the Hex. Nuts
(Item 28) on the Main Frame (Item 1) (See Figure 6).
5. TurntheAdjustmentScrew(Item8)outuntil1/32''[0.8 mm]
spacers can be slid between each of the Friction Facings
(Item 4) and the Friction Disc (See Figure 6).
6. Turn the Adjustment Screw (Item 8) in until the spacers
can be just pulled out.
7. Tighten the Spanner Nut (Item 12) to 10-15 Ft. Lbs.
[13.6-20.3 N•m] torque.
8. AdjusttheSetScrews(Item27)untiltheytouchtheBrake
Arms (Item 2) and tighten the Hex. Nuts (Item 28) on the
Main Frame (Item 1).
9. Loosen the Nut to manually reset the brake.
10. Remove the Threaded Rod, Nut, and Washer.
11. ScrewtheVent(Item17)intothebackoftheActuatoruntil
handtight andcontinueto tightenoneand one-halfturns.
NOTE
The vent in the Rear Cylinder prevents debris from
entering the Belleville Spring stack and relieves any
pressure built up by the reciprocating action of the
Piston.
Flat Washer
Nut
Actuator
FIGURE 5
Grade 5
3/8-16 x 9''
Threaded Rod
Adjustment
Screw (Item 8)
Spanner Nut
(Item 12)
Friction Disc
FIGURE 6
Vent
(Item 17)
28
27
MAINTENANCE
1. Adhere to the following bolt torques (See Table 3).
DANGER
Never use your hand to check the condition of the
hydrauliclines. Ifhydraulicfluidpenetratestheskin,get
medicalhelpimmediately. Failuretogetpropermedical
helpmayresultinlossoflimbor life. The safest way to
check hydraulic lines for leaks is by holding a piece of
cardboard next to the hydraulic line.
3. Inspect friction facings for wear. Replace if worn to
approximately 5/32" [4 mm] thick.
4. Lubricate items requiring lubrication (See
LUBRICATION).
2. Checktightnessandconditionofhydrauliclines. Replace
hydraulic lines if signs of deterioration exist. TABLE 3
1
1/32" [0.8 mm]
spacer between
each of the
FrictionFacings
(Item 4) and
FrictionDisc.
METINOITPIRCSEDEUQROT
42wercSpaC]m•N1.5-5.4[.sbL.nI54-04
21tuNrennapS]m•N3.02-6.31[.sbL.tF51-01
81wercSenihcaM]m•N51-21[.sbL.tF21-8
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]

4
FORMNO.L-20271-E-0300
LUBRICATION
All pivot points on the BD Caliper Brake use self-lubricated
high PV Sleeve Bearings.
For tension control applications where the disc is held at
elevated temperatures for extended periods, use a light
machine oil on Sleeve Bearings (Items 14, 15 and 30) (See
Figure 7).
The sliding spherical contact between the Adjustment Screw
(Item 8) and the spherical shaft end should be lubricated with
a molybdenum disulfide based grease (See Figure 7).
Adjustment
Screw (Item 8)
Sleeve
Bearing
(Item 15)
FIGURE 7
PARTS REPLACEMENT
FRICTION FACINGS
NOTE
When replacing Friction Facings, inspect the Friction
Disc for scoring or grooves. If necessary, the Friction
Disc may be turned. A total of 0.030'' [0.762 mm] may
be removed from each side of the Friction Disc before
it is necessary to replace the Friction Disc.
1. Remove the Vent (Item 17) from the back of the Actuator
(See Figure 8).
2. Using the Nexen Manual Release Kit (Product No.
933596) manually release the brake by inserting the
Grade 5, 3/8-16 x 9'' Threaded Rod into the back of the
Actuator; then, using a Flat Washer and Nut, tighten the
Nut to release the brake (See Figure 9).
NOTE
Two Belleville Disc Springs (Item 29) are compressed
between the Brake Arm (Item 2) and the Shoe (Item 3).
When the Shoe is removed, the Belleville Disc Springs
will fall free from the Brake Arms.
3. RemoveDetentPins(Item16)toreleaseFrictionFacings
(Item 4), Shoes (Item 3), and Belleville Disc Springs
(Item 29) from Brake Arms (Item 2) (See Figure 8).
4. RemoveFrictionFacings(Item4)fromtheShoes(Item3)
by removing the old Machine Screws (See Figure 8).
5. Install new Friction Facings (Item 4) using new Machine
Screws (Item 18).
6. TightentheMachineScrews(Item18)to8-12Ft.Lbs.[12-
15 N•m] torque. NOTE
When reinstalling the Shoe (Item 3), first place the
Belleville Disc Springs (Item 29) into the recesses
provided in the Brake Arm (Item 2). The Belleville Disc
Springs should be inserted with their concave side
toward the Brake Arm.
2
8
12
17 16
29
3
FIGURE 8
Spherical
Shaft End
Sleeve
Bearing
(Item 14 and 30)
4
Flat Washer
Nut
Grade 5
3/8-16 x 9''
Threaded Rod
Actuator
FIGURE 9
7. Loosen adjustment screw Spanner Nut (Item 12) and
back out Adjustment Screw (Item 8) until the Friction
Facings, Shoes, and Belleville Disc Springs will slide
back onto the Brake Arms (Item 2) (See Figure 8).
8. Replace the Detent Pins (Item 16) (See Figure 8).
9. Perform Friction Facing adjustment (See FRICTION
FACING CLEARANCE ADJUSTMENT).
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31 QRO (442) 1 95 72 60
MTY (81) 83 54 10 18 [email protected]