Nexen AIR CHAMP FWCB User manual

1FORM NO. L-20016-Z-0415
PILOT, COUPLING, AND SHEAVE MOUNT CLUTCH-BRAKE
MODELS FWCB, LWCB, MWCB, AND HWCB

2
FORM NO. L-20016-Z-0415
Copyright 2015 Nexen Group, Inc.
Nexen Group, Inc.
560 Oak Grove Parkway
Vadnais Heights, Minnesota 55127
ISO 9001 Certified
This document is the original, non-translated, version.
Conformity Declaration: In accordance with Appendix II B of CE Machinery Directive (2006/42/EC):
A Declaration of Incorporation of Partly Completed Machinery evaluation for the applicable EU directives was
carried out for this product in accordance with the Machinery Directive. The declaration of incorporation is set
out in writing in a separate document and can be requested if required.
This machinery is incomplete and must not be put into service until the machinery into which it is to be
incorporated has been declared in conformity with the applicable provisions of the Directive.
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, cause injury or death. Comply with
all applicable codes.
DANGER
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

3FORM NO. L-20016-Z-0415
TABLE OF CONTENTS
General Specifications -------------------------------------------------------------------------------------------------------------------------- 4
General Safety Precautions ------------------------------------------------------------------------------------------------------------------- 4
Installation ------------------------------------------------------------------------------------------------------------------------------------------- 5
Lubrication ------------------------------------------------------------------------------------------------------------------------------------------- 7
Air Connections ----------------------------------------------------------------------------------------------------------------------------------- 8
Operation -------------------------------------------------------------------------------------------------------------------------------------------- 9
Troubleshooting ---------------------------------------------------------------------------------------------------------------------------------- 10
Disassembly-Pilot, Coupling, and Sheave Mount ----------------------------------------------------------------------------------- 11
Parts Replacement-Pilot, Coupling, and Sheave Mount -------------------------------------------------------------------------- 13
Reassembly--Pilot, Coupling, and Sheave Mount ----------------------------------------------------------------------------------- 18
Replacement Parts ----------------------------------------------------------------------------------------------------------------------------- 21
Warranty -------------------------------------------------------------------------------------------------------------------------------------------- 29

4
FORM NO. L-20016-Z-0415
GENERAL SPECIFICATIONS
GENERAL SAFETY PRECAUTIONS
CAUTION
Use lifting aids and proper lifting
techniques when installing, removing,
or placing this product in service.
WARNING
This product is capable of emitting
a spark if misused therefore is not
recommended for use in any explosive
environment.
CAUTION
This product has possible pinch
points. Care should be taken when
interacting with this product.
Specifications
Torque: Clutch up to 294 Nm ( 2600 in-lbs)
Brake up to 316 Nm (2800 in-lbs)
Actuation Pressure: 1 - 5.5 bar (14.5 - 80 psi)
Service Temperature: 4.5 - 104 C (40 - 220 F)
Approximate Weight: Up to 64.5 kg (142 lbs)
CAUTION
Use appropriate guarding for moving
components. Failure to guard could
result in serious bodily injury.
CAUTION
Watch for sharp features when
interacting with this product. The parts
have complex shapes and machined
edges.
WARNING
Ensure proper guarding of the product is
used. Nexen recommends the machine
builder design guarding in compliance
with OSHA 29 CFR 1910 “Occupational
Safety and Health Hazards”.
CAUTION
Surface temperature may exceed
safe handling limits during
operation. Do not touch.
CAUTION
Use appropriate guarding for moving
components. Failure to guard could
result in serious bodily injury.

5FORM NO. L-20016-Z-0415
INSTALLATION
PILOT MOUNT CLUTCH-BRAKE
Refer to Figure 1.
NOTE
These are "hub-stop" clutch-brakes. They stop the shaft on
which they are mounted. Therefore, they must be mounted on
the driven shaft.
1. Secure a customer supplied sheave or sprocket to the Clutch-
Brake.
2. Insert the first Key (Item 30) into the shaft.
3. Slide the Clutch-Brake onto shaft and key; then, insert the
second Key (Item 30).
4. Tighten Set Screws (Items 27 and 28) to the recommended
torque (See Table 1).
NOTE
If a bushing for smaller diameter shafts is required, use a
bushing on both ends of the Clutch-Brake.
5. Align air inlet ports to a six o’clock down position to allow
condensation to drain out of exhaust port.
6. Fasten one of the ears of the Clutch-Brake to a fixed member
of the machine.
NOTE
The Piston Air Chamber (Item 7) floats axially approximately
1/16 inch [1.59 mm] during operation. Make sure securing
pin allows 1/16 inch to 1/8 inch [1.59 mm to 3.18 mm]
movement of Piston Air Chamber.
TABLE 1
RECOMMENDED TIGHTENING TORQUES
FIGURE 1
Shaft
Key
(Item 30)
Set Screw
(Item 28)
Set Screw
(Item 27)
Key
(Item 30)
Clutch-Brake
Sheave
or
Sprocket
DESCRIPTION FWCB LWCB MWCB HWCB
35 In. Lbs. 80 In. Lbs. 80 In. Lbs. 23 Ft. Lbs.
Set Screw (Item 27)
[3.9 N•m] [8.9 N•m] [8.9 N•m] [31.2 N•m]
20 In. Lbs. 20 In. Lbs. 80 In. Lbs. — —
Set Screw (Item 28)
[2.2 N•m] [2.2 N•m] [8.9 N•m] — —
.

6
FORM NO. L-20016-Z-0415
COUPLING MOUNT CLUTCH-BRAKE
Refer to Figure 2.
1. Determine the parallel misalignment of shafts to be coupled
by placing a straight edge across the shafts and measuring
the maximum offset at various points around the periphery
of the shafts. Make the necessary corrections to keep the
shafts within parallel misalignment limits of the clutch coupling
(See Table 2).
NOTE
Before installation, the driving shaft can be fixed but the
driven shaft must be allowed to “float”.
Align the air inlet ports to the six o’clock down position to
allow condensation to drain out of the exhaust port.
2. Insert the first Key (Item 30) into driven shaft.
3. Slide Clutch-Brake Assembly onto the driven shaft.
4. Insert second Key (Item 30).
5. Install and tighten Set Screws (Items 27 and 28) to the
recommended torque (See Table 3).
6. Attach the Coupling Adapter Plate (Item 24) to the Clutch-
Brake pilot using Cap Screws (Item 33) and Lock Washers
(Item 34); then, tighten the Cap Screws to the recommended
torque (See Table 3).
7. Place the Coupling’s Flexible Disc (Item 25) over the pins in
the Coupling Adapter Plate (Item 24).
8. Insert the customer supplied Dodge™ Taper-Lock Bushing
into the Coupling Hub (Item 26).
9. Align the holes (not the threads) and slide the DodgeTM Taper-
Lock Bushing Assembly onto the driving shaft until it is flush
with the shaft.
10. Thread the screws into threaded holes in the DodgeTM Taper-
Lock Bushing and Coupling Hub (Item 26); then, alternately
and evenly tighten the screws to the bushing manufacturer's
specifications.
11. Align the pins in the Coupling Hub (Item 26) with the holes
in the Flexible Disc (Item 25).
12. Push the entire assembly together. Automatic spacing is
accomplished by spacers molded into the Flexible Disc.
13. Fasten one of the ears of the Clutch-Brake to a fixed member
of the machine.
NOTE
The Piston Air Chamber (Item 7) floats laterally approxi-
mately 1/16 inch [1.59 mm] during operation. Make sure
the securing pin allows 1/16 inch to 1/8 inch [1.59 mm to
3.18 mm] movement.
TABLE 2
TABLE 3
RECOMMENDED TIGHTENING TORQUES
FIGURE 2
Driving
Shaft
DodgeTM
Taper-Lock
Bushing
Driven
Shaft
Clutch-Brake
30
30
27
28
26 25
34
33
24
Model Dodge™
Taper-Lock
Poly-Disk
Coupling
Size
Measured Variation
@ Points 180oApart
Axial Float
(Minimum
Value From
Recommended
Initial Spacing)
Parallel
Maximum
Angular
Maximum
FWCB 2-5/8 In.
[66.75mm]
0.015 In.
[0.381 mm]
0.040 In.
[1.016 mm]
+1/8 In.
[+1.375 mm]
LWCB 4 In.
[101.6 mm]
0.015 In.
[0.381 mm]
0.064 In.
[1.625 mm]
+1/8 In.
[+1.375 mm]
MWCB 7 In.
[177.8 mm]
0.015 In.
[0.381 mm]
0.112 In.
[2.845 mm]
+1/8 In.
[+1.375 mm]
HWCB 8 In.
[203.2 mm]
0.015 In.
[0.381 mm]
0.128 In.
[3.251 mm]
+1/8 In.
[+1.375 mm]
Description FWCB LWCB MWCB HWCB
Set Screw
(Item 27)
35 In. Lbs.
[3.9 N.m]
80 In. Lbs.
[8.9 N.m]
80 In. Lbs.
[8.9 N.m]
23 Ft. Lbs.
[3.9 N.m]
Set Screw
(Item 28)
20 In. Lbs.
[2.2 N.m]
20 In. Lbs.
[2.2 N.m]
80 In. Lbs.
[8.9 N.m] — —
Cap Screw
(Item 33)
21 Ft. Lbs.
[28.5 N.m]
21 Ft. Lbs.
[28.5 N.m]
23 Ft. Lbs.
[31.2 N.m]
78 Ft. Lbs.
[105.8 N.m]
INSTALLATION (continued)

7FORM NO. L-20016-Z-0415
NOTE
Nexen pneumatically actuated devices require clean, pressure regulated air for maximum performance and
life. All seals in Nexen pneumatically operated devices are lubricated for life, and do not require additional
lubrication.
However, some customers prefer to use an air line lubricator, which injects oil into the pressurized air, forcing
an oil mist into the air chamber. This is acceptable, but care must be taken to ensure once an air mist lubrication
system is used, it is continually used over the life of the product as the oil mist may wash free the factory
installed lubrication.
Locate the lubricator above and within ten feet of the product, and use low viscosity oil such as SAE-10.
Synthetic lubricants are not recommended.
Nexen product's bearings are shielded and pre-lubricated, and require no further lubrication.
LUBRICATOR DRIP RATE SETTINGS
SHEAVE MOUNT CLUTCH-BRAKE
Refer to Figure 3.
1. Insert the first Key (Item 30) into the shaft.
2. Slide the Clutch-Brake onto shaft and key; then, insert the
second Key (Item 30).
3. Tighten Set Screws (Items 27 and 28) to the recommended
torque (See Table 4).
NOTE
If a bushing for smaller diameter shafts is required, use
a bushing on both ends of the Clutch-Brake.
4. Align air inlet ports to a six o’clock down position to allow
condensation to drain out of exhaust port.
5. Fasten one of the ears of the Clutch-Brake to a fixed member
of the machine.
NOTE
The Piston Air Chamber (Item 7) floats laterally approxi-
mately 1/16 inch [1.59 mm] during operation. Make sure
securing pin allows 1/16 inch to 1/8 inch [1.59 mm to 3.18
mm] movement of Piston Air Chamber.
FIGURE 3
Shaft
Key
(Item 30)
Set Screw
(Item 28
or 48)
Set Screw
(Item 27)
Key
(Item 30)
Clutch-Brake
TABLE 4
RECOMMENDED TIGHTENING TORQUES
INSTALLATION (continued)
DESCRIPTION FWCB LWCB MWCB HWCB
35 In. Lbs. 80 In. Lbs. 80 In. Lbs. 23 Ft. Lbs.
Set Screw (Item 27)
[3.9 N•m] [8.9 N•m] [8.9 N•m] [31.2 N•m]
20 In. Lbs. 20 In. Lbs. 80 In. Lbs. — —
Set Screw (Item 28)
[2.2 N•m] [2.2 N•m] [8.9 N•m] — —
1. Close and disconnect the air line from the unit.
2. Turn the Lubricator Adjustment Knob counterclockwise
three complete turns.
3. Open the air line.
LUBRICATION
CAUTION
These settings are for Nexen supplied
lubricators. If you are not using a Nexen
lubricator, calibration must follow the
manufacturer's suggested procedure.
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 counterclockwise
one-third turn.
8. Open the air line to the unit.

8
FORM NO. L-20016-Z-0415
Typical Clutch-Brake Control Circuit
Air
Supply
Filter
Dryer
Regulator
Gauge
Quick Exhaust
Valve
Quick Exhaust
Valve
Brake
Inlet
Clutch
Inlet
4/2 (4 Way)
Valve
Air
Supply
Filter
Dryer
Gauge
Quick Exhaust
Valve
Quick Exhaust
Valve
Brake Inlet
Gauge
Regulator
Filter
Dryer
Air
Supply
Clutch Inlet
Regulator
Dual Supply Clutch-Brake Control Circuit
3/2 (3 Way)
N.C. Valve
3/2 (3 Way)
N.O. Valve
Brake Supply Circuit Clutch Supply Circuit
3/2 (3 Way) 4/2 (4 Way)
5/2 (4 Way) 5/2 (5 Way)
AIR CONNECTIONS
NOTE
For quick response, Nexen recommends a quick exhaust
valve and short air lines between the Control Valves and
the product. Align the air inlet ports to a down position
to allow condensation to drain out of the air chambers of
the product.
CAUTION
Low air pressure will cause slippage and
overheating. Excessive air pressure will
cause abrupt starts and stops, reducing
product life.
All Nexen pneumatically actuated devices require clean
and dry air, which meet or exceeds ISO 8573.1:2001
Class 4.4.3 quality.
Air Pressure (Gage) Limits
6.9 Bar (100 PSI) Absolute Max.
0 Bar (0 PSI) Absolute Min.
Typical Clutch-Brake Control Circuit
Air
Supply
Filter
Dryer
Regulator
Gauge
Quick Exhaust
Valve
Quick Exhaust
Valve
5/2 (4 Way)
Valve
Brake
Inlet
Clutch
Inlet
Air
Supply
Filter
Dryer
Gauge
Quick
Exhaust
Valve
Quick Exhaust Valve
5/2 (5 Way)
Valve
Brake Inlet
Gauge
Regulator
Filter
Dryer
Air
Supply
Clutch Inlet
Regulator
Dual Supply Clutch-Brake Control Circuit
Brake Supply Circuit
Clutch Supply Circuit
The following are common air supply schemes used with
this product. These are examples and not an all-inclusive
list. All air circuits to be used with this product must be
designed following ISO 4414 guidelines.

9FORM NO. L-20016-Z-0415
WARNING
Never exceed maximum operating
speeds listed for your product.
(See Table 5).
OPERATION
TABLE 5
CAUTION
The temperature limits for this
product line are 4.5-100 Degree
Celsius (40-220 Degree F).
CAUTION
Never exceed life of facing material. Facing
life depends on the volume of material and
the total energy over the life of the unit.
Expected life (in hrs) can be found by:
Time=Volume/(Power*Wear Rate).
Sizes Max RPM
FWCB 1,800
LWC B 1,800
MWCB 1,800
HWCB 1,800
WARNING
Ensure proper guarding of the product is
used. Nexen recommends the machine
builder design guarding in compliance
with OSHA 29 CFR 1910 “Occupational
Safety and Health Hazards”.

10
FORM NO. L-20016-Z-0415
TROUBLESHOOTING
PROBLEM PROBABLE CAUSE SOLUTION
Failure to engage.
Air not getting to clutch-brake due to a control
valve malfunction.
Check for control valve malfunction and replace
valve if necessary.
Air leaks. Replace air lines.
Lack of lubrication on the hub spline or in the
air chamber.
Lubricate hub spline and/or air chamber.
Rigid piping instead of flexible air lines. Replace rigid piping with flexible air lines.
Failure to disengage.
Unexhausted air due to a control valve mal-
function.
Check for control valve malfunction and replace
if necessary.
Friction lock due to a lack of lubrication on the
hub spline or in the air chamber.
Lubricate hub spline and/or air chamber.
Rigid piping instead of flexible air lines. Replace air lines with flexible air line tubing.
Weak or broken compression springs. Replace compression springs.
Loss of torque.
Air leaks. Replace air lines.
Overheating (fading). Check manufacturing specifications to be certain
clutch-brake is suitable for application.
Overlap or simultaneous engagement of clutch
and brake when switching. Overlap can be
verified by motor amperage readings when
cycling with the clutch-brake versus clutch
(brake disconnected). Higher draw with the
clutch-brake indicates overlap.
Inadequate controls. Install controls meeting the specification of
clutch-brake.
Air line too long between valve and clutch-
brake.
Shorten air line between valve and clutch-brake.
Air pressure too high. Reduce the air pressure.
Lack of quick exhaust valves. Install quick exhaust valves.
FIGURE 4
TYPICAL CLUTCH-BRAKE
Sheave
Ball
Bearing
Hub
Compression
Spring
Friction
Disc
Friction
Facing
Ball
Bearing
Air
Chamber
O-Ring
Seals
Friction
Disc
Ball
Bearing
Piston Air
Chamber
Friction
Facing
Piston
Compression
Spring
Shoulder
Bolt

11 FORM NO. L-20016-Z-0415
DISASSEMBLY—PILOT, COUPLING, AND SHEAVE MOUNT
NOTE
The following sections are arranged by model. Verify that you are in the correct section for your model.
FWCB
Refer to Figures 5 - 8.
1. Loosen the Set Screw (Item 47) and remove the Hub Collar
(Item 46) from the Clutch-Brake.
2. Remove the Retaining Ring (Item 37) from the Clutch-
Brake.
3. Press the Drive Disc Assembly or the Sheave Assembly off
the Hub (Item 1).
4. Slide the Compression Spring (Item 11) off the Hub (Item
1).
5. Slide the Clutch Assembly off the Hub (Item 1).
6. Remove the old O-Ring Seals (Items 19 and 21).
7. Remove the Key (Item 35).
8. Remove the Retaining Ring (Item 37).
9. Loosen the Set Screw (Item 29) and remove the Locking
Nut (Item 26) and slide the Brake Friction Disc (Item 2) off
the Hub (Item 1).
10. Press the Brake Assembly off the Hub (Item 1).
FIGURE 8
47
46
37
FIGURE 5
FIGURE 6
Sheave
Assembly
Drive Disc
Assembly
11
Hub
(Item 1)
FIGURE 7
Clutch
Assembly
19
21
35
Brake
Assembly
Brake
Assembly
37
1
2
26 29
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.

12
FORM NO. L-20016-Z-0415
LWCB AND MWCB
Refer to Figures 9 & 10.
1. Loosen the Set Screws (Items 28 and 29); then, remove the
Locking Nut (Item 26) and the Brake Friction Disc (Item 2).
2. Remove the Spacer (Item 16).
3. Press the Brake Assembly off the Hub (Item 1).
4. Remove the O-Ring Seals (Items 19 and 21).
5. Slide the Clutch Assembly off the Hub (Item 1).
6. Slide the Compression Spring (Item 11) off the Hub (Item
1).
7. Press the Drive Disc Assembly or the Sheave Assembly off
the Hub (Item 1).
HWCB
Refer to Figures 11 & 12.
1. Remove the Retaining Ring (Item 45) from the Clutch-
Brake.
2. Loosen the Set Screw (Item 28) and the Socket Head Cap
Screw (Item 47) securing the Locking Collar (Item 46); then,
remove the Locking Collar (Item 46) and the Brake Friction
Disc (Item 44).
3. Remove the Spacer (Item 16).
4. Press the Brake Assembly off the Hub (Item 43).
5. Remove the O-Ring Seals (Items 19 and 21).
6. Slide the Clutch Assembly off the Hub (Item 43).
7. Slide the Compression Spring (Item 11) off the Hub (Item
43).
8. Press the Drive Disc Assembly or the Sheave Assembly off
the Hub (Item 43).
FIGURE 9
Hub
(Item 1)
19
21
Brake
Assembly
16
2
26
28 29
FIGURE 10
Clutch
Assembly
Sheave
Assembly
Drive Disc
Assembly
1
11
FIGURE 11
Hub
(Item 43)
19
21
Brake
Assembly
16
44
46
45
28 47
FIGURE 12
43
Drive Disc
Assembly
Sheave
Assembly
Clutch
Assembly
11
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.
DISASSEMBLY—PILOT, COUPLING, AND SHEAVE MOUNT (continued)

13 FORM NO. L-20016-Z-0415
NOTE
The following sections are arranged by model. Verify that you are in the correct section for your model.
FWCB
PARTS REPLACEMENT—PILOT, COUPLING, AND SHEAVE MOUNT
Refer to Figures 13 - 16.
1. Remove the Retaining Ring (Item 41) from the Sheave (Item
12) or Pilot Drive Disc (Item 33).
2. Press the old Ball Bearing (Item 13) out of the Sheave (Item
12) or old Ball Bearing (Item 34) out of the Pilot Drive Disc
(Item 33).
NOTE
Do not reuse the old ball bearings. Applying force on the
inner race of a ball bearing to remove a ball bearing held
by the outer race causes damage to the bearing.
3. Clean the bearing bore of the Sheave (Item 12) or Pilot Drive
Disc (Item 33) with fresh safety solvent, making sure all old
Loctite residue is removed.
4. Apply an adequate amount of Loctite®680 to evenly coat
the outer race of the new Ball Bearing (Item 13 or 34).
5. Support the Sheave (Item 12) or the Pilot Drive Disc (Item
33) and pressing on the outer race of the new Ball Bearing
(Item 13 or 34), press the new Ball Bearing (Item 13 or 34)
into the Sheave or Pilot Drive Disc.
6. Reinstall the Retaining Ring (Item 41).
NOTE
The Flat Head Machine Screws are assembled with an
anaerobic locking compound. Inserting a properly fitting
screwdriver into the head of the Flat Head Machine Screw
and striking the end of the screwdriver with a hammer will
break the crystalline structure of this locking compound
and allow removal of the Flat Head Machine Screws. Never
use an impact wrench to remove the Flat Head Machine
Screws.
7. Remove the old Flat Head Machine Screws (Item 24) securing
the Friction Facing (Item 4) to the Sheave (Item 12) or Pilot
Drive Disc (Item 33).
8. Remove the old Friction Facing (Item 4).
9. Install the new Friction Facing (Item 4) and tighten the new
Flat Head Machine Screws (Item 24) to 26 In. Lbs. [2.9 Nm]
torque.
FIGURE 13
SHEAVE MOUNT
41
34
12
4
24
FIGURE 14
PILOT MOUNT
41
13
33
4
24
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.

14
FORM NO. L-20016-Z-0415
10. Fully support the Air Chamber (Item 8) and press the Clutch
Friction Disc (Item 9) out of the Air Chamber.
NOTE
If the Ball Bearing (Item 14) comes out of the Air Chamber
(Item 8), use a bearing puller to remove it from the Clutch
Friction Disc (Item 9). If the Ball Bearing remains in the
Air Chamber (Item 8), use a die remover to remove it from
the Air Chamber.
11. Clean the bearing bore of the Air Chamber (Item 8) with
fresh safety solvent, making sure all old Loctite®residue is
removed.
12. Apply an adequate amount of Loctite®680 to evenly coat
the outer race of the new Ball Bearing (Item 14).
13. Carefully align the O.D. of the new Ball Bearing (Item 14)
with the bore of the Air Chamber (Item 8) and press the new
Ball Bearing into place.
14. Carefully align the hub of the Clutch Friction Disc (Item 9)
with the bore of the new Ball Bearing (Item 14) and press
the Clutch Friction Disc into the new Ball Bearing and Air
Chamber (Item 8).
15. Remove the old Flat Head Machine Screws (Item 24) and
Friction Facing (Item 4) from the Piston (Item 3).
16. Remove the old Shoulder Bolts (Item 5), Shoulder Bolt
O-Rings (Item 22), and Compression Springs (Item 6).
17. Separate the Piston Air Chamber (Item 7) and Piston (Item
3).
18. Remove the old O-Ring Seals (Items 18 and 20) from the
Piston Air Chamber (Item 7) and Piston (Item 3).
19. Remove the Retaining Ring (Item 17).
20. Press the old Ball Bearing (Item 13) out of the Piston Air
Chamber (Item 7).
21. Clean the bearing bore of the Piston Air Chamber (Item 7)
with fresh safety solvent, making sure all old Loctite®residue
is removed.
22. Apply an adequate amount of Loctite®680 to evenly coat
the outer race of the new Ball Bearing (Item 13).
23. Carefully align the O.D. of the new Ball Bearing (Item 13)
with the bore of the Piston Air Chamber and press the new
Ball Bearing into place.
24. Reinstall the Retaining Ring (Item 17).
25. Clean all O-Ring grooves and O-Ring contact surfaces with
fresh safety solvent and lubricate the O-Ring grooves and
contact surfaces with fresh O-Ring lubricant.
26. Lubricate the new O-Ring Seals (Items 18, 20, and 22) with
fresh O-Ring lubricant and install the new O-Ring Seals.
27. Press the Piston (Item 3) into the Piston Air Chamber (Item
7).
28. Apply Loctite®242 to the threads of the Shoulder Bolts (Item
5); then, install the new Compression Springs (Item 6) and
Shoulder Bolts (Item 5) with new O-Ring Seals (Item 22).
29. Tighten the Shoulder Bolts (Item 5) to 43 In. Lbs. [4.8 Nm]
torque.
30. Install the new Friction Facing (Item 4) and tighten the new
Flat Head Machine Screws (Item 24) to 26 In. Lbs. [2.9 Nm]
torque.
FIGURE 15
9
14
8
FIGURE 16
7
13
17
20
18
3
65
22
424
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.
PARTS REPLACEMENT—PILOT, COUPLING, AND SHEAVE MOUNT (continued)

15 FORM NO. L-20016-Z-0415
LWCB AND MWCB
Refer to Figures 17 - 20.
1. Remove the Retaining Ring (Item 41) from the Sheave (Item
12) or Pilot Drive Disc (Item 33).
2. Press the old Ball Bearing (Item 15) out of the Sheave (Item
12) or Ball Bearing (Item 34) out of the Pilot Drive Disc (Item
33).
NOTE
Do not reuse the old ball bearings. Applying force on the
inner race of a ball bearing to remove a ball bearing held
by the outer race causes damage to the bearing.
3. Clean the bearing bore of the Sheave (Item 12) or Pilot Drive
Disc (Item 33) with fresh safety solvent, making sure all old
Loctite®residue is removed.
4. Apply an adequate amount of Loctite®680 to evenly coat
the outer race of the new Ball Bearing (Item 15 or 34).
5. Support the Sheave (Item 12) or the Pilot Drive Disc (Item
33) and pressing on the outer race of the new Ball Bearing
(Item 15 or 34), press the new Ball Bearing (Item 15 or 34)
into the Sheave or Pilot Drive Disc.
6. Reinstall the Retaining Ring (Item 41).
NOTE
The Flat Head Machine Screws are assembled with an
anaerobic locking compound. Inserting a properly fitting
screwdriver into the head of the Flat Head Machine Screw
and striking the end of the screwdriver with a hammer will
break the crystalline structure of this locking compound
and allow removal of the Flat Head Machine Screws. Never
use an impact wrench to remove the Flat Head Machine
Screws.
On the LWCB, the Flat Head Machine Screws securing the
Friction Facing (Item 10) are Item 24. On the MWCB, the
Flat Head Machine Screws securing the Friction Facing
(Item 10) are Item 25.
7. Remove the old Flat Head Machine Screws (Item 24 or 25)
securing the Friction Facing (Item 10) to the Sheave (Item
12) or Pilot Drive Disc (Item 33).
8. Remove the old Friction Facing (Item 10).
9. Install the new Friction Facing (Item 10) and tighten the new
Flat Head Machine Screws (Item 24 or 25) to 26 In. Lbs. [2.9
Nm] torque.
10. Fully support the Air Chamber (Item 8) and press the Clutch
Friction Disc (Item 9) out of the Air Chamber.
FIGURE 17
SHEAVE MOUNT
41
15
12
10
24/25
FIGURE 18
PILOT MOUNT
41
34
33
10
24/25
FIGURE 19
9
14
8
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.
PARTS REPLACEMENT—PILOT, COUPLING, AND SHEAVE MOUNT (continued)

16
FORM NO. L-20016-Z-0415
NOTE
If the Ball Bearing (Item 14) comes out of the Air Chamber
(Item 8), use a bearing puller to remove it from the Clutch
Friction Disc (Item 9). If the Ball Bearing remains in the
Air Chamber (Item 8), use a die remover to remove it from
the Air Chamber.
11. Clean the bearing bore of the Air Chamber (Item 8) with
fresh safety solvent, making sure all old Loctite®residue is
removed.
12. Apply an adequate amount of Loctite®680 to evenly coat
the outer race of the new Ball Bearing (Item 14).
13. Carefully align the O.D. of the new Ball Bearing (Item 14)
with the bore of the Air Chamber (Item 8) and press the new
Ball Bearing into place.
14. Carefully align the hub of the Clutch Friction Disc (Item 9)
with the bore of the new Ball Bearing (Item 14) and press
the Clutch Friction Disc into the new Ball Bearing and Air
Chamber (Item 8).
15. Remove the old Flat Head Machine Screws (Item 24) and
Friction Facing (Item 4) from the Piston (Item 3).
16. Remove the Shoulder Bolts (Item 5), Shoulder Bolt O-Rings
(Item 22), and Compression Springs (Item 6).
17. Separate the Piston Air Chamber (Item 7) and Piston (Item
3).
18. Remove the old O-Ring Seals (Items 18 and 20) from the
Piston Air Chamber (Item 7) and Piston (Item 3).
19. Remove the Retaining Ring (Item 17).
20. Press the old Ball Bearing (Item 13) out of the Piston Air
Chamber (Item 7).
21. Clean the bearing bore of the Piston Air Chamber (Item 7)
with fresh safety solvent, making sure all old Loctite®residue
is removed.
22. Apply an adequate amount of Loctite®680 to evenly coat
the outer race of the new Ball Bearing (Item 13).
23. Carefully align the O.D. of the new Ball Bearing (Item 13)
with the bore of the Piston Air Chamber and press the new
Ball Bearing into place.
24. Reinstall the Retaining Ring (Item 17).
25. Clean all O-Ring grooves and O-Ring contact surfaces with
fresh safety solvent and lubricate the O-Ring grooves and
contact surfaces with fresh O-Ring lubricant.
26. Lubricate the new O-Ring Seals (Items 18, 20, and 22) with
fresh O-Ring lubricant and install the new O-Ring Seals.
27. Press the Piston (Item 3) into the Piston Air Chamber (Item
7).
28. Apply Loctite®242 to the threads of the Shoulder Bolts (Item
5); then, install the new Compression Springs (Item 6) and
Shoulder Bolts (Item 5) with new O-Ring Seals (Item 22).
29. Tighten the Shoulder Bolts (Item 5) to 43 In. Lbs. [4.8 Nm]
torque.
30. Install the new Friction Facing (Item 4) and tighten the new
Flat Head Machine Screws (Item 24) to 26 In. Lbs. [2.9 Nm]
torque.
FIGURE 20
713
17 18
20 3
65
22
424
PARTS REPLACEMENT—PILOT, COUPLING, AND SHEAVE MOUNT (continued)
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.

17 FORM NO. L-20016-Z-0415
HWCB
Refer to Figures 21 - 24.
1. Remove the Retaining Ring (Item 41) from the Sheave (Item
12) or Pilot Drive Disc (Item 33).
2. Press the old Ball Bearings (Item 15) out of the Sheave (Item
12) or the Pilot Drive Disc (Item 33).
NOTE
Do not reuse the old ball bearings. Applying force on the
inner race of a ball bearing to remove a ball bearing held
by the outer race causes damage to the bearing.
3. Clean the bearing bore of the Sheave (Item 12) or Pilot Drive
Disc (Item 33) with fresh safety solvent, making sure that all
old Loctite®residue is removed.
4. Apply an adequate amount of Loctite®680 to evenly coat
the outer race of the new Ball Bearings (Item 15).
5. Support the Sheave (Item 12) or the Pilot Drive Disc (Item
33) and pressing on the outer race of the new Ball Bearings
(Item 15), press the new Ball Bearings (Item 15) into the
Shave or Pilot Drive Disc.
6. Reinstall the Retaining Ring (Item 41)
NOTE
The Flat Head Machine Screws are assembled with an
anaerobic locking compound. Inserting a properly fitting
screwdriver into the head of the Flat Head Machine Screw
and striking the end of the screwdriver with a hammer will
break the crystalline structure of this locking compound
and allow removal of the Flat Head Machine Screws. Never
use an impact wrench to remove the Flat Head Machine
Screws.
7. Remove the old Flat Head Machine Screws (Item 24) securing
the Friction Facing (Item 10) to the Sheave (Item 12) or Pilot
Drive Disc (Item 33).
8. Remove the old Friction Facing (Item 10).
9. Install the new Friction Facing (Item 10) and tighten the new
Flat Head Machine Screws (Item 24) to 43 In. Lbs. [4.8 Nm]
torque.
10. Fully support the Air Chamber (Item 8) and press the Clutch
Friction Disc (Item 9) out of the Air Chamber.
NOTE
If the Ball Bearing (Item 14) comes out of the Air Chamber
(Item 8), use a bearing puller to remove it from the Clutch
Friction Disc (Item 9). If the Ball Bearing remains in the
Air Chamber (Item 8), use a die remover to remove it from
the Air Chamber.
FIGURE 23
9
14
8
FIGURE 22
PILOT MOUNT
41
15
33
10
24
11. Clean the bearing bore of the Air Chamber (Item 8) with
fresh safety solvent, making sure all old Loctite®residue is
removed.
12. Apply an adequate amount of Loctite®680 to evenly coat
the outer race of the new Ball Bearing (Item 14).
13. Carefully align the O.D. of the new Ball Bearing (Item 14)
with the bore of the Air Chamber (Item 8) and press the new
Ball Bearing into place.
14. Carefully align the hub of the Clutch Friction Disc (Item 9)
with the bore of the new Ball Bearing (Item 14) and press
the Clutch Friction Disc into the new Ball Bearing and Air
Chamber (Item 8)
.
41
15
12
10
24
FIGURE 21
SHEAVE MOUNT
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.
PARTS REPLACEMENT—PILOT, COUPLING, AND SHEAVE MOUNT (continued)

18
FORM NO. L-20016-Z-0415
NOTE
The following sections are arranged by model. Verify that you are in the correct section for your model.
15. Remove the old Flat Head Machine Screws (Item 24) and
Friction Facing (Item 4) from the Piston (Item 3).
16. Remove the Shoulder Bolts (Item 5), Shoulder Bolt O-Rings
(Item 22), and Compression Springs (Item 6).
17. Separate the Piston Air Chamber (Item 7) and Piston (Item
3).
18. Remove the old O-Ring Seals (Items 18 and 20) from the
Piston Air Chamber (Item 7) and Piston (Item 3).
19. Remove the Retaining Ring (Item 17).
20. Press the old Ball Bearing (Item 13) out of the Piston Air
Chamber (Item 7).
21. Clean the bearing bore of the Piston Air Chamber (Item 7)
with fresh safety solvent, making sure all old Loctite®residue
is removed.
22. Apply an adequate amount of Loctite®680 to evenly coat
the outer race of the new Ball Bearing (Item 13).
23. Carefully align the O.D. of the new Ball Bearing (Item 13)
with the bore of the Piston Air Chamber and press the new
Ball Bearing into place.
24. Reinstall the Retaining Ring (Item 17).
25. Clean all O-Ring grooves and O-Ring contact surfaces with
fresh safety solvent and lubricate the O-Ring grooves and
contact surfaces with fresh O-Ring lubricant.
26. Lubricate the new O-Ring Seals (Items 18, 20, and 22) with
fresh O-Ring lubricant and install the new O-Ring Seals.
27. Press the Piston (Item 3) into the Piston Air Chamber (Item
7).
28. Apply Loctite®242 to the threads of the Shoulder Bolts (Item
5); then, install the new Compression Springs (Item 6) and
Shoulder Bolts (Item 5) with new O-Rings Seals (Item 22).
29. Tighten the Shoulder Bolts (Item 5) to 205 In. Lbs. [23.1 Nm]
torque.
30. Install the new Friction Facing (Item 4) and tighten the new
Flat Head Machine Screws (Item 24) to 43 In. Lbs. [4.8 Nm]
torque.
REASSEMBLY—PILOT, COUPLING, AND SHEAVE MOUNT
FWCB
Refer to Figures 25 - 28.
1. Press the Brake Assembly onto the Hub (Item 1) and reinstall
the Retaining Ring (Item 37).
2. Slide the Brake Friction Disc (Item 2) onto the Hub and install
the Locking Nut (Item 26).
3. Reinstall and tighten the Set Screws (Item 29) to 20 In. Lbs.
[2.2 Nm] torque.
FIGURE 24
7
20 313 17
6522
4
24
18
FIGURE 25
Brake
Assembly
37
1
12
26 29
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.
4. Lubricate the new O-Ring Seals (Items 19 and 21) with fresh
O-Ring lubricant; then, install the new O-Rings Seals onto
the Brake and Clutch Assemblies.
5. Reinstall the Key (Item 15).
PARTS REPLACEMENT—PILOT, COUPLING, AND SHEAVE MOUNT (continued)

19 FORM NO. L-20016-Z-0415
6. Slide the Clutch Assembly onto the Hub (Item 1) and Key
(Item 15).
7. Align the Spring Pin (Item 23) located on the Brake Assembly
with the hole in the Clutch Assembly and press the Clutch
Assembly onto the Hub (Item 1).
8. Slide the Compression Spring (Item 11) onto the Hub (Item
1); then, pressing on the inner bearing race, press the Sheave
or Drive Disc Assembly onto the Hub.
9. Reinstall the Retaining Ring (Item 37) and Hub Collar; then,
reinstall the Set Screw (Item 47).
47
46
37
FIGURE 28
FIGURE 27
Sheave
Assembly
Drive Disc
Assembly
11
Hub
(Item 1)
FIGURE 26
Clutch
Assembly
19
21
15
23
Brake
Assembly
LWCB AND MWCB
Refer to Figures 29 & 30.
1. Fully supporting the inner bearing race, press the Hub (Item
1) into the Sheave or Drive Disc Assembly.
2. Slide the Compression Spring (Item 11) onto the Hub (Item
1); then, supporting the inner bearing race, press the Clutch
Assembly onto the Hub (Item 1).
3. Lubricate the new O-Ring Seals (Items 19 and 21) with fresh
O-Ring lubricant; then, install the new O-Ring Seals onto the
Brake and Clutch Assemblies.
4. Align the Spring Pin (Item 23) located on the Brake Assembly
with the hole in the Clutch Assembly and press the Brake
Assembly onto the Hub (Item 1).
5. Slide the Spacer (Item 16) onto the Hub (Item 1); then, align
the three holes in the Brake Friction Disc (Item 2) with the
three holes in the Hub and slide the Brake Friction Disc (Item
2) onto the Hub.
6. Reinstall the Locking Nut (Item 26) and tighten the Set Screws
(Item 29) to 20 In. Lbs. [2.2 Nm] torque for the LWCB and
35 In. Lbs. [3.9 Nm] torque for the MWCB.
FIGURE 29
Clutch
Assembly
Sheave
Assembly
Drive Disc
Assembly
1
11
FIGURE 30
Hub
(Item 1)
19
21
Brake
Assembly
16
2
26
28 29
23
Clutch
Assembly
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.
REASSEMBLY—PILOT, COUPLING, AND SHEAVE MOUNT (continued)

20
FORM NO. L-20016-Z-0415
HWCB
Refer to Figures 31 & 32.
1. Fully supporting the inner bearing race, press the Hub (Item
43) into the Sheave of Drive Disc Assembly.
2. Slide the Compression Spring (Item 11) onto the Hub (Item
43); then, supporting the inner bearing race, press the Clutch
Assembly onto the Hub (Item 43).
3. Lubricate the new O-Ring Seals (Items 19 and 21) with fresh
O-Ring lubricant; then, install the new O-Rings Seals onto
the Brake and Clutch Assemblies.
4. Align the Slotted Spring Pin (Item 23) located on the Brake
Assembly with the hole in the Clutch Assembly and press
the Brake Assembly onto the Hub (Item 43).
5. Slide the Spacer (Item 16) onto the Hub (Item 43); then,
slide the Brake Friction Disc (Item 44) onto the Hub.
6. Align the two holes in the Locking Collar (Item 46) with the
two holes in the Hub (Item 43); then, reinstall the Locking
Collar and tighten the Socket Head Cap Screw (Item 47) to
100 In. Lbs. [11.3 Nm] torque.
FIGURE 31
43
Drive Disc
Assembly
Sheave
Assembly
Clutch
Assembly
11
FIGURE 32
Hub
(Item 43)
19
21
Brake
Assembly
16
44
46
45
28
47
23
Clutch
Assembly
REASSEMBLY—PILOT, COUPLING, AND SHEAVE MOUNT (continued)