Nexen AIR CHAMP Burke E. Porter 5H50P User manual

(i)
Burke E. Porter 5H50P
Multiposition Tooth Clutch
FORM NO. L-20222-G-0501

(ii)
In accordance with Nexen’s established policy of constant product improvement, the specifications contained in this
manual are subject to change without notice. Technical data listed in this manual are based on the latest information
available at the time of printing and are also subject to change without notice.
Technical Support:
800-843-7445
[phone]
www.nexengroup.com
Nexen Group, Inc.
560 Oak Grove Parkway
Vadnais Heights, Minnesota 55127
ISO 9001 Certified
Copyright 2000 Nexen Group, Inc.
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.
WARNING

(iii)
TABLE OF CONTENTS
Introduction---------------------------------------------------------------------------------------------------------------------------------------- 1
Installation ---------------------------------------------------------------------------------------------------------------------------------------- 2
Anti-rotation Clip and Engagement Indicator Switch ----------------------------------------------------------------------------- 2
Air Connections --------------------------------------------------------------------------------------------------------------------------------- 3
Engagement Indicator Switch Adjustment-------------------------------------------------------------------------------------------- 3
Lubrication----------------------------------------------------------------------------------------------------------------------------------------- 3
Troubleshooting---------------------------------------------------------------------------------------------------------------------------------- 4
Parts Replacement ----------------------------------------------------------------------------------------------------------------------------- 5
Replacement Parts ----------------------------------------------------------------------------------------------------------------------------- 8
Parts List ------------------------------------------------------------------------------------------------------------------------------------------- 9
Warranties ---------------------------------------------------------------------------------------------------------------------------------------10

1FORM NO. L-20222-G-0501
INTRODUCTION
Read this manual carefully, making full use of its explanations and instructions. The “Know How” of safe, continuous,
trouble-free operation depends on the degree of your understanding of the system and your willingness to keep all
components in proper operating condition. Pay particular attention to all NOTES, CAUTIONS, and WARNINGS to avoid
the risk of personal injury or property damage. It is important to understand that these NOTES, CAUTIONS, and
WARNINGS are not exhaustive. Nexen cannot possibly know or evaluate all conceivable methods in which service may
be performed, or the possible hazardous consequences of each method. Accordingly, anyone who uses a procedure
that is not recommended by Nexen must first satisfy themselves that neither their safety or the safety of the product will
be jeopardized by the service method selected.

2FORM NO. L-20222-G-0501
INSTALLATION
The 5H50P Tooth Clutch has a drive flange with two
bearings, a pilot diameter, and tapped holes for mounting
Nexen's Flexible Coupling.
NOTE: Nexen recommends using a red anaerobic
thread locking compound on Pilot Mounting
Bolts.
The 5H50P mounts on a full shaft using a full
length Key.
If a Flexible Coupling is to be installed, refer to
INSTALLATION instructions (L-20221) provided
with the Flexible Coupling.
1. Insert the Key into the shaft (See Figure 1).
2. Slide the 5H50P onto the shaft and Key (See
Figure 1).
3. Using Set Screws provided with the 5H50P, secure
the 5H50P to the shaft (See Figure 1).
4. Tighten the Set Screws to 6.6 Ft. Lbs. [8.9 N•m]
torque.
Flex
Coupling
5H50P
50 mm
Machine
Shaft
FIGURE 1
Cap Screws
FIGURE 2
Anti-Rotation
Clip
Anti-Rotation
Dowel Pin
Engagement
Indicator Switch
Dowel Pin
Engagement
Indicator
Switch
Engagement
Indicator
Mounting
Bracket
Engagement
Indicator
Mounting
Plate
ANTI-ROTATION CLIP AND ENGAGEMENT INDICATOR SWITCH
NOTE: The Anti-Rotation Clip may be installed in either
set of tapped holes located on the front of the
Piston (See Figure 2).
1. Install Anti-Rotation Dowel Pin (See Figure 2).
2. Using Cap Screws, secure Anti-Rotation Clip to front
of Piston (See Figure 2).
3. Install Engagement Indicator Dowel Pin (See Figure 2).
4. Using Cap Screws, secure Engagement Indicator
Switch to the tapped Engagement Indicator
Mounting Plate and Engagement Indicator Mounting
Bracket (See Figure 2).
5. Using Cap Screws, secure Engagement Indicator
Mounting Bracket (with Engagement Indicator
Switch) to front of Piston (See Figure 2).
6. Connect the GREEN lead of the Engagement
Indicator Switch to ground.
7. Connect the BLACK lead of the Engagement
Indicator Switch to the power supply.
8. Connect the WHITE lead of the Engagement
Indicator Switch to the engagement light.
9. Connect the RED lead of the Engagement Indicator
Switch to the disengagement light.
Cap Screws

3FORM NO. L-20222-G-0501
AIR CONNECTIONS
Although 5H50P Tooth Clutches are air actuated with a
maximum operating air pressure of 80 psi, use only
enough air pressure to deliver ample torque for the
application. Operating air pressures in excess of 80 psi
will eventually cause bearing and seal damage.
Although an air hose is supplied, for quick response,
locate the control valve as close to the 5H50P as
possible. Air controls having 1/8" ports are
recommended, along with a quick exhaust valve to ensure
rapid disengagement where long air lines are required.
1. Apply air pressure to 5H50P.
2. Rotate 5H50P until fully engaged.
3. Slide Engagement Indicator Switch on Bracket until
Engagement Indicator Switch is fully depressed
against Engagement Indicator Dowel Pin.
4. Slide Engagement Indicator Switch away from
Engagement Indicator Dowel Pin until the
engagement indicator light comes on (See Figure 3).
5. Tighten Cap Screws securing Engagement Indicator
Switch to the Engagement Indicator Mounting
Bracket.
6. Check Engagement Indicator Switch adjustment to
verify lighting of the engagement indicator light when
the 5H50P is engaged.
FIGURE 3
Align air inlet port to the six o’clock down position to
allow condensation in the air chamber to drain out of the
exhaust port. Due to bearing seal drag, the cylinder/
piston assembly will rotate, resulting in hose breakage
when 5H50P is engaged. Attach an Anti-Rotation strap
to the 5H50P, mounting it to the tapped holes provided in
the 5H50P Cylinder to prevent the air hose from
breaking.
Rigid pipe or tubing when connected directly
to the 5H50P will prevent proper actuation of
the 5H50P. Use flexible hose or tubing when
making air line connections to 5H50P.
ENGAGEMENT INDICATOR SWITCH ADJUSTMENT
LUBRICATION
NOTE: Pneumatically actuated devices require clean, pressure regulated, and lubricated air for maximum performance
and long life. The most effective and economical way to lubricate Nexen 5H50P is with an Air Line Lubricator,
which injects oil into the pressurized air, forcing an oil mist into the air chamber.
Locate the lubricator above and within ten feet of the 5H50P, and use a low viscosity oil such as SAE-10.
Synthetic lubricants are not recommended.

4FORM NO. L-20222-G-0501
HUBSPLINE
Although the Hub spline has been lubricated at the
factory with a high temperature, anti-seize lubricating
compound, Nexen recommends periodic lubrication of
this component to ensure smooth 5H50P engagement
and disengagement.
LUBRICATOR DRIP RATE SETTINGS
NOTE: These settings are for Nexen supplied lubricators. If you are not using a Nexen lubricator, calibration must
replicate the following procedure.
1. Close and disconnect the air line from the unit.
2. Turn the Lubricator Adjustment Knob counter-
clockwise three complete turns.
3. Open the air line.
4. Close the air line to the unit when a drop of oil forms
in the Lubricator Sight Gage.
5. Connect the air line to the unit.
6. Turn the Lubricator Adjustment Knob clockwise until
closed.
7. Turn the Lubricator Adjustment Knob counter-
clockwise one-third turn.
8. Open the air line to the unit.
BEARINGS
All 5HP bearings are prelubricated and sealed; therefore,
lubrication of the bearings is not required.
NOTE: The 5H50P must be disassembled in order to
lubricate the Hub spline.
TROUBLESHOOTING
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5FORM NO. L-20222-G-0501
PARTS REPLACEMENT
DISASSEMBLY
Special attention should be exercised when
working with retaining rings. Always wear
safety goggles when working with spring or
tension loaded fasteners or devices.
1. Remove Retaining Ring (Item 11) (See Figure 4).
NOTE: If a press is not available, use a bearing
puller to remove Drive Flange from the Hub.
2. Press Hub (Item 1) out of Drive Flange (See
Figure 4).
NOTE: Backing Plate (Item 6) is initially assembled
with Loctite®680. A bearing puller may be
required to remove it.
3. Remove Backing Plate (Item 6) (See Figure 5).
4. Remove Compression Springs (Item 7) (See
Figure 5).
5. Separate Cylinder (Item 2) and Drive Ring (Item 4),
from Hub (Item 1), Piston (Item 3), and Ball Bearing
(Item 9) (See Figure 6).
NOTE: At this point, the Hub spline (Item 1) can be
lubricated with Never-Seez® without further
disassembly.
6. Remove the O-ring Seals (Items 12 and 13) and the
Backup Ring Seals (Items 21 and 22) from the
Piston (Item 3) and Cylinder (Item 2) (See Figure 6).
Hub
(Item 1)
11
Drive
Flange
FIGURE 4
7
6
FIGURE 5
2
12 13
FIGURE 6
21
22
1
3
9
4
1

6FORM NO. L-20222-G-0501
DRIVE FLANGE BALL BEARINGS (Item 9)
Special attention should be exercised when
working with retaining rings. Always wear
safety goggles when working with spring or
tension loaded fasteners or devices.
1. Remove Retaining Ring (Item 10) (See Figure 7).
2. Push the Ball Bearings (Item 9) out of Drive Flange
(Item 15) (See Figure 7).
3. Clean inside bore of Drive Flange with fresh safety
solvent.
4. Apply Loctite® 680 to O.D. of new Bearings and
press new Bearings into Drive Flange.
NOTE: When installing new Ball Bearings, carefully
align Ball Bearing O.D. with Drive Flange
bore in order to prevent bearing
misalignment.
5. Install Retaining Ring (Item 10).
CYLINDER BALL BEARING (Item 8)
1. Press Drive Ring (Item 4) out of Ball Bearing (Item 8)
(See Figure 8).
2. Remove Ball Bearing (Item 8) from Cylinder (Item 2)
(See Figure 8).
3. Clean Cylinder bearing bore with fresh safety solvent.
NOTE: When installing new Ball Bearings into the
aluminum Cylinder, carefully align the Ball
Bearings in the Cylinder bearing bore to
prevent slivers of aluminum from becoming
trapped under the Ball Bearing and causing
bearing misalignment.
4. Apply Loctite ®680 to O.D. of the new Ball Bearing
and press new Ball Bearing into Cylinder.
CAUTION
Do not press on the Drive Ring face teeth.
Pressing on the Drive Ring face teeth will
damage them.
5. Fully supporting inner race of the Ball Bearing, press
the Drive Ring into the Ball Bearing.
10
15
9
FIGURE 7
4
8
2
FIGURE 8

7FORM NO. L-20222-G-0501
PISTON BALL BEARING (Item 9)
Special attention should be exercised when
working with retaining rings. Always wear
safety goggles when working with spring or
tension loaded fasteners or devices.
1. Remove Retaining Ring (Item 11) (See Figure 9).
2. Press Hub (Item 1) out of Piston (Item 3) and Ball
Bearing (Item 9) (See Figure 9).
3. Remove the Ball Bearing (Item 9) from Piston (Item 3).
4. Clean Piston bearing bore with fresh safety solvent.
NOTE: When installing new Ball Bearings into the
aluminum Piston, carefully align the Ball
Bearing in the Piston bearing bore to prevent
slivers of aluminum from becoming trapped
under the Ball Bearing and causing bearing
misalignment.
5. Apply Loctite® 680 to O.D. of the new Ball Bearing
and press new Ball Bearing into Cylinder.
6. Fully supporting inner race of Ball Bearing, press
Hub into Ball Bearing.
7. Install Retaining Ring (Item 11).
REASSEMBLY
1. Coat O-ring Seal contact surfaces of Piston (Item 3)
and Cylinder (Item 2) with a thin film of O-ring
lubricant (See Figure 10).
2. Coat O-ring Seals (Items 12 and 13) with a thin film
of O-ring lubricant (See Figure 10).
3. Install O-ring Seals (Items 12 and 13) and Back-up
Ring Seals (Items 21 and 22) on Piston (Item 3) and
Cylinder (Item 2) (See Figure 10).
4. Coat Hub spline teeth with Never-Seez® (See
Figure 10).
5. Making sure not to damage O-ring Seals (Items 12
and 13), press the Piston (Item 3) into the Cylinder
(Item 2) (See Figure 10).
3
2
12 13
Hub
Spline
Teeth
21
22
FIGURE 10
FIGURE 9
93
11 1