Nexen AIR CHAMP FWCB User manual

(i) FORM NO. L-20016-U-0305
PILOT, COUPLING, AND SHEAVE MOUNT CLUTCH-BRAKE
MODELS FWCB, LWCB, MWCB, AND HWCB
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

(ii)
InaccordancewithNexen’sestablishedpolicyofconstantproductimprovement,thespecificationscontainedinthis
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 2005 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 ---------------------------------------------------------------------------------------------------- 3
LUBRICATION ------------------------------------------------------------------------------------------------------------- 4
TROUBLESHOOTING -------------------------------------------------------------------------------------------------- 5
DISASSEMBLY—PILOT, COUPLING, AND SHEAVE MOUNT --------------------------------------------- 6
PARTS REPLACEMENT—PILOT, COUPLING, AND SHEAVE MOUNT --------------------------------- 8
REASSEMBLY—PILOT, COUPLING, AND SHEAVE MOUNT ---------------------------------------------13
REPLACEMENT PARTS-----------------------------------------------------------------------------------------------15
PARTS LIST ---------------------------------------------------------------------------------------------------------------16
WARRANTY---------------------------------------------------------------------------------------------------------------24
®
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-20016-U-0305
CLUTCH
END BRAKE END
INSTALLATION
PILOT MOUNT CLUTCH-BRAKE
1. Secure a customer supplied sheave or sprocket to the
Clutch-Brake (See Figure 2).
2. Insert the first Key (Item 30) into the shaft (See Figure 2).
3. Slide the Clutch-Brake onto shaft and key; then, insert the
second Key (Item 30) (See Figure 2).
4. TightenSetScrews(Items27and28)totherecommended
torque (See Table 1 and Figure 2).
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. FastenoneoftheearsoftheClutch-Braketoafixedmember
of the machine (See Figure 2).
NOTE
The Piston Air Chamber (Item 7) floats axially
approximately 1/16 inch [1.59 mm] during operation.
Makesure securing pin allows1/16inchto 1/8 inch[1.59
mm to 3.18 mm] movement of Piston Air Chamber.
INTRODUCTION
TheNexenAirChampClutch-BrakeisanAirChampClutchandan
Air Champ Brake combined into a single unit.
Becauseheatfromboththeclutchandbrakeareabsorbedwithin
theunitduringengagement,cautionmustbeusedwhenaClutch-
Brake is applied on high speed, high cyclic applications. If heat
generated from the clutching and braking of the Clutch-Brake
becomes great enough that the surface temperature of the unit
is 180oF [82.2° C] or higher, the unit may experience excessive
facingwearandareductioninbearingando-ringlife. TheClutch-
Brake must be mounted on a bearing supported, through shaft.
Twoseparateairinletsprovideindependentclutchingandbraking
action. FIGURE 1
AIR TO
CLUTCH
AIR TO
BRAKE
DESCRIPTION FWCB LWCB MWCB HWCB
35In.Lbs. 80In.Lbs. 80In.Lbs. 23Ft.Lbs.
SetScrew (Item27) [3.9N•m] [8.9N•m] [8.9N•m] [31.2N•m]
20In.Lbs. 20In.Lbs. 80In.Lbs. — —
SetScrew (Item28) [2.2N•m] [2.2N•m] [8.9N•m] — —
.
TABLE 1
RECOMMENDED TIGHTENING TORQUES
FIGURE 2
Shaft
Key
(Item 30)
Set Screw
(Item 28)
Set Screw
(Item 27)
Key
(Item 30)
Clutch-Brake
Sheave
or
Sprocket
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
recommendedbyNexenmustfirstsatisfythemselvesthatneithertheirsafetyorthesafetyoftheproductwillbejeopardized
by the service method selected.
WARNING
This unit has rotating parts. A guard that will not restrict the flow of cooling air around the unit must be used if the unit is
installed where injury to an operator could occur, as stated in the Occupational Safety and Health Act (OSHA), Standard
(29 CFR 1910) Section 1910.219K.
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

2FORM NO. L-20016-U-0305
COUPLING MOUNT CLUTCH-BRAKE
1. Determinetheparallelmisalignmentofshaftstobecoupledby
placinga straightedgeacross theshaftsand measuringthe
maximumoffsetatvariouspointsaroundtheperipheryofthe
shafts. Make the necessary corrections to keep the shafts
withinparallelmisalignmentlimitsoftheclutchcoupling(See
Figure 3 and Table 2).
NOTE
Before installation, the driving shaft can be fixed but the
driven shaft must be allowed to “float” (See Figure 3).
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 (See Figure 3).
3. Slide Clutch-Brake Assembly onto the driven shaft (See
Figure 3).
4. Insert second Key (Item 30) (See Figure 3).
5. Install and tighten Set Screws (Items 27 and 28) to the
recommended torque (See Figure 3 and Table 3).
6. Attach the Coupling Adapter Plate (Item 24) to the Clutch-
Brake pilot using Cap Screws (Item 33) and Lock Washers
(Item34);then,tightentheCapScrewstotherecommended
torque (See Figure 3 and Table 3).
7. Place the Coupling’s Flexible Disc (Item 25) over the pins in
the Coupling Adapter Plate (Item 24) (See Figure 3).
8. Insert the customer supplied Dodge™ Taper-Lock Bushing
into the Coupling Hub (Item 26) (See Figure 3).
9. Aligntheholes(notthethreads)andslidetheDodgeTM Taper-
LockBushing Assemblyonto thedriving shaftuntilit isflush
with the shaft (See Figure 3).
10. ThreadthescrewsintothreadedholesintheDodgeTM Taper-
LockBushing andCoupling Hub(Item 26);then, alternately
andevenlytightenthescrewstothebushingmanufacturer's
specifications.
11. AlignthepinsintheCouplingHub(Item26)withtheholesin
the Flexible Disc (Item 25) (See Figure 3).
12. Push the entire assembly together. Automatic spacing is
accomplished by spacers molded into the Flexible Disc.
13. FastenoneoftheearsoftheClutch-Braketoafixedmember
ofthemachine.
NOTE
The Piston Air Chamber (Item 7) floats laterally
approximately 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.
FIGURE 3
TABLE 2
TABLE 3
RECOMMENDED TIGHTENING TORQUES
Driving
Shaft
DodgeTM
Taper-Lock
Bushing
Driven
Shaft
Clutch-Brake
30
30
27
28
Model
Dodge
TM
Taper-Lock
Poly-Disc
Coupling
Size
Measured Variation
@ Points 180
O
Apart
Axial Float
(Minimum
Value From
Recommended
Initial Spacing)
Parallel
Maximum Angular Maximum
FWCB 2-5/8 In.
[66.75 mm] 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. [31.2 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]
26 25 34
33 24
®
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-20016-U-0305
SHEAVE MOUNT CLUTCH-BRAKE
1. Insert the first Key (Item 30) into the shaft (See Figure 4).
2. Slide the Clutch-Brake onto shaft and key; then, insert the
second Key (Item 30) (See Figure 4).
3. TightenSetScrews(Items27and28)totherecommended
torque (See Table 4 and Figure 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. FastenoneoftheearsoftheClutch-Braketoafixedmember
of the machine (See Figure 4).
NOTE
The Piston Air Chamber (Item 7) floats laterally
approximately 1/16 inch [1.59 mm] during operation.
Makesure securing pin allows1/16inchto 1/8 inch[1.59
mm to 3.18 mm] movement of Piston Air Chamber.
DESCRIPTION FWCB LWCB MWCB HWCB
35In.Lbs. 80In.Lbs. 80In.Lbs. 23Ft.Lbs.
SetScrew (Item27) [3.9N•m] [8.9N•m] [8.9N•m] [31.2N•m]
20In.Lbs. 20In.Lbs. 80In.Lbs. — —
SetScrew (Item28) [2.2N•m] [2.2N•m] [8.9N•m] — —
FIGURE 4
Shaft
Key
(Item 30)
Set Screw
(Item 28
or 48)
Set Screw
(Item 27)
Key
(Item 30)
Clutch-Brake
TABLE 4
RECOMMENDED TIGHTENING TORQUES
AIR CONNECTIONS
NOTE
Forquickresponse,NexenrecommendsaquickexhaustvalveandshortairlinesbetweentheControlValvesandtheclutch/
brake. Align the inlet ports to a down position to allow condensation to drain out of the air chambers.
4-WAY CONTROL VALVE
1. If the brake is to be set when the solenoid is de-energized,
connecttheportmarked2tothebrakeandtheportmarked
4 to the clutch (See Figure 5).
2. Connecttheairsupplylinetotheinletportmarked1(See
Figure 5).
FIGURE 5
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

4FORM NO. L-20016-U-0305
5-WAY CONTROL VALVE
1. IfthebrakeistobesetandtheclutchistobeOFFwhenthe
solenoidis de-energized, connectthe portmarked4 to the
brake and the port marked 2 to the clutch (See Figure 6).
2. Connect the brake air supply line to the port marked5 and
theclutchairsupplylinetotheportmarked3(SeeFigure6).
3-WAY CONTROL VALVES
1. Connecta3-WayN.O.Controlintothebrakeinletportand
a 3-Way N.C. Control into the clutch inlet port (See Figure
7).
2. Connect an air supply line to the inlet port (marked IN) on
the top of the 3-Way N.O. Control and an air supply line to
the inlet port (marked IN) on the side of the 3-Way N.C.
Control (See Figure 7).
NOTE
When a 3-Way N.O. Control is de-energized, air flows
directly to the brake. When a 3-Way N.O. Control is
energized, air exhausts from the brake.
When a 3-Way N.C. Control is de-energized, air exhausts
from the clutch. When a 3-Way N.C. Control is energized,
air flows to the clutch.
FIGURE 6
FIGURE 7
3-Way
N.C. Control
3-Way
N.O. Control
Air to
Brake
Air to
Clutch
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 Clutch-Brakes 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 Clutch-Brake, and use a low viscosity oil such as SAE-10.
Synthetic lubricants are not recommended.
LUBRICATOR DRIP RATE SETTINGS
NOTE
TheseinstructionsandsettingsareforNexensuppliedlubricatorsonly. TheydonotapplytolubricatorsnotsuppliedbyNexen.
1. Close and disconnect the air line from the unit.
2. TurntheLubricatorAdjustmentKnobcounterclockwisethree
complete turns.
3. Open theair line.
4. Close the air line when a drop of oil forms in the Lubricator
Sight Gage.
6. TurntheLubricatorAdjustmentKnobclockwiseuntilclosed.
7. TurntheLubricatorAdjustmentKnobcounterclockwiseone-
third turn.
8. Open the air line to the unit.
5. Connect the air line to the unit.
®
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-20016-U-0305
FIGURE 8
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
PROBLEM PROBABLE CAUSE SOLUTION
Failure to engage.
Air not getting to the 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 malfunction. 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 the application.
Overlap or simultaneous engagement of
the 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 the valve and the Clutch-
Brake. Shorten air line between the valve and Clutch- Brake.
Air pressure too high. Reduce the air pressure.
Lack of quick exhaust valves. Install quick exhaust valves.
TROUBLESHOOTING
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

6FORM NO. L-20016-U-0305
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
1. Loosen the SetScrew(Item 47)andremovethe HubCollar
(Item 46) from the Clutch-Brake (See Figure 9).
WARNING
Specialattention should be exercisedwhenworkingwith
retainingrings. Alwayswearsafetygoggleswhenworking
with spring or tension loaded fasteners or devices.
2. RemovetheRetainingRing(Item37)fromtheClutch-Brake
(See Figure 9).
3. PresstheDriveDiscAssemblyortheSheaveAssemblyoffthe
Hub (Item 1) (See Figure 10).
4. SlidetheCompressionSpring(Item11)offtheHub(Item
1) (See Figure 10).
5. Slide the Clutch Assembly off the Hub (Item 1) (See Figure
11).
6. Remove the old O-ring Seals (Items 19 and 21) (See
Figure 11).
7. Remove the Key (Item 35) (See Figure 11).
8. Remove the Retaining Ring (Item 37) (See Figure 12).
9. LoosentheSetScrew(Item29)andremovetheLockingNut
(Item26)andslidetheBrakeFrictionDisc(Item2)offtheHub
(Item 1) (See Figure 12).
10. Press the Brake Assembly off the Hub (Item 1) (See Figure
12).
47
46
37
FIGURE 9
FIGURE 10
FIGURE 11
FIGURE 12
Sheave
Assembly
Drive Disc
Assembly
11
Hub
(Item 1)
Clutch
Assembly
19
21
35
Brake
Assembly
37
12
26
Brake
Assembly
29
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

7
FORM NO. L-20016-U-0305
LWCB AND MWCB
1. LoosentheSetScrews(Items28and29);then,removethe
Locking Nut (Item 26) and the Brake Friction Disc (Item 2)
(See Figure 13).
2. Remove the Spacer (Item 16) (See Figure 13).
3. Press the Brake Assembly off the Hub (Item 1) (See Figure
13).
4. Remove the O-ring Seals (Items 19 and 21) (See Figure
13).
5. Slide the Clutch Assembly off the Hub (Item 1) (See Figure
14).
6. SlidetheCompressionSpring(Item11)offtheHub(Item
1) (See Figure 14).
7. PresstheDriveDiscAssemblyortheSheaveAssemblyoffthe
Hub (Item 1) (See Figure 14).
HWCB
WARNING
Specialattention should be exercisedwhenworkingwith
retainingrings. Alwayswearsafetygoggleswhenworking
with spring or tension loaded fasteners or devices.
1. RemovetheRetainingRing(Item45)fromtheClutch-Brake
(See Figure 15).
2. Loosen the Set Screw (Item 28) and the Socket Head Cap
Screw(Item47)securingtheLockingCollar(Item46);then,
remove the Locking Collar (Item 46) and the Brake Friction
Disc (Item 44) (See Figure 15).
3. Remove the Spacer (Item 16) (See Figure 15).
4. PresstheBrakeAssemblyofftheHub(Item43)(SeeFigure
15).
5. Remove the O-ring Seals (Items 19 and 21) (See Figure
15).
6. SlidetheClutchAssemblyofftheHub(Item43)(SeeFigure
16).
7. SlidetheCompressionSpring(Item11)offtheHub(Item
43) (See Figure 16).
8. PresstheDriveDiscAssemblyortheSheaveAssemblyoffthe
Hub (Item 43) (See Figure 16).
FIGURE 13
FIGURE 14
Hub
(Item 1)
19
21
Brake
Assembly
16
2
26
28 29
Clutch
Assembly
Sheave
Assembly
Drive Disc
Assembly
1
11
FIGURE 15
Hub
(Item 43)
19
21
Brake
Assembly
16
44 46
45
28 47
FIGURE 16
43
Drive Disc
Assembly
Sheave
Assembly
Clutch
Assembly
11
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

8FORM NO. L-20016-U-0305
PARTS REPLACEMENT—PILOT, COUPLING, AND SHEAVE MOUNT
WARNING
Specialattention should be exercisedwhenworkingwith
retainingrings. Alwayswearsafetygoggleswhenworking
with spring or tension loaded fasteners or devices.
1. Remove the Retaining Ring (Item 41) from the Sheave
(Item 12) or Pilot Drive Disc (Item 33) (See Figure 17 or
18).
2. PresstheoldBallBearing(Item13)outoftheSheave(Item
12) or old Ball Bearing (Item 34) out of the Pilot Drive Disc
(Item 33) (See Figure 17 or 18).
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
DriveDisc(Item33)withfreshsafetysolvent,makingsure
all old Loctite residue is removed (See Figure 17 or 18).
4. ApplyanadequateamountofLoctite®680toevenlycoatthe
outerraceofthenewBallBearing(Item13or34)(SeeFigure
17 or 18).
5. Support the Sheave (Item 12) or the Pilot Drive Disc (Item
33)and pressingon theouter raceof thenew BallBearing
(Item13 or34),press thenewBall Bearing(Item13 or34)
into the Sheave or Pilot Drive Disc (See Figure 17 or 18).
6. Reinstall the Retaining Ring (Item 41) (See Figure 17 or 18).
NOTE
The Flat Head Machine Screws are assembled with an
anaerobic locking compound. Inserting a properly fitting
screwdriverintotheheadoftheFlatHeadMachineScrew
andstrikingtheendofthe screwdriverwithahammerwill
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)
securingtheFrictionFacing(Item4)totheSheave(Item12)
or Pilot Drive Disc (Item 33) (See Figure 17 or 18).
8. Remove the old Friction Facing (Item 4) (See Figure 17
or 18).
9. Install thenewFriction Facing(Item 4)and tightenthe new
FlatHeadMachineScrews(Item24)to26In.Lbs.[2.9N•m]
torque (See Figure 17 or 18).
FIGURE 17
SHEAVE MOUNT
FIGURE 18
PILOT MOUNT
41
34
12
4
24
41
13
33
4
24
NOTE
The following sections are arranged by model. Verify that you are in the correct section for your model.
FWCB
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

9
FORM NO. L-20016-U-0305
10. FullysupporttheAirChamber(Item8)andpresstheClutch
FrictionDisc(Item9)outoftheAirChamber(SeeFigure19).
NOTE
IftheBallBearing(Item14)comesoutoftheAirChamber
(Item 8), use a bearing puller to remove it from the Clutch
FrictionDisc(Item9). IftheBallBearingremainsintheAir
Chamber(Item8),useadieremovertoremoveitfromthe
Air Chamber.
11. CleanthebearingboreoftheAirChamber(Item8)withfresh
safetysolvent,makingsurealloldLoctite®residueisremoved
(See Figure 19).
12. ApplyanadequateamountofLoctite®680toevenlycoatthe
outerraceofthenewBallBearing(Item14).(SeeFigure19).
13. CarefullyaligntheO.D.ofthenewBallBearing(Item14)with
theboreoftheAirChamber(Item8)andpressthenewBall
Bearing into place (See Figure 19).
14. CarefullyalignthehuboftheClutchFrictionDisc(Item9)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) (See Figure 19).
15. Remove the old Flat Head Machine Screws (Item 24) and
FrictionFacing(Item4)fromthePiston(Item3)(SeeFigure
20).
16. Remove the old Shoulder Bolts (Item 5), Shoulder Bolt O-
rings (Item 22), and Compression Springs (Item 6) (See
Figure 20).
17. Separatethe PistonAir Chamber (Item 7) andPiston (Item
3) (See Figure 20).
18. Remove the old O-ring Seals (Items 18 and 20) from the
PistonAirChamber(Item7)andPiston(Item3)(SeeFigure
20).
19. Remove the Retaining Ring (Item 17) (See Figure 20).
20. Press the old Ball Bearing (Item 13) out of the Piston Air
Chamber (Item 7) (See Figure 20).
21. Clean the bearing bore of the Piston Air Chamber (Item 7)
withfreshsafetysolvent,makingsurealloldLoctite®residue
is removed (See Figure 20).
22. ApplyanadequateamountofLoctite®680toevenlycoatthe
outerraceofthenewBallBearing(Item13)(SeeFigure20).
23. CarefullyaligntheO.D.ofthenewBallBearing(Item13)with
the bore of the Piston Air Chamber and press the new Ball
Bearing into place.
24. Reinstall the Retaining Ring (Item 17) (See Figure 20).
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. LubricatethenewO-ring Seals(Items 18,20,and22)with
fresho-ring lubricantand installthe newO-ringSeals (See
Figure 20).
27. Pressthe Piston(Item3) intothePiston AirChamber (Item
7) (See Figure 20).
28. Apply Loctite®242 to the threads of the Shoulder Bolts
(Item5);then,installthenewCompressionSprings(Item6)
andShoulderBolts(Item5)withnewO-ringSeals(Item22)
(See Figure 20).
29. TightentheShoulderBolts(Item5)to43In. Lbs.[4.8N•m]
torque (See Figure 20).
30. Installthe newFriction Facing(Item 4)and tightenthenew
FlatHeadMachineScrews(Item24)to26In.Lbs.[2.9N•m]
torque (See Figure 20).
FIGURE 19
FIGURE 20
9
14
8
7
13
17
20
18 3
6522
424
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

10 FORM NO. L-20016-U-0305
LWCB AND MWCB
WARNING
Specialattention should be exercisedwhenworkingwith
retainingrings. Alwayswearsafetygoggleswhenworking
with spring or tension loaded fasteners or devices.
1. Remove the Retaining Ring (Item 41) from the Sheave
(Item 12) or Pilot Drive Disc (Item 33) (See Figure 21 or
22).
2. PresstheoldBallBearing(Item15)outoftheSheave(Item
12)orBallBearing(Item34)outofthePilotDriveDisc(Item
33) (See Figure 21 or 22).
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 (See Figure 22).
4. ApplyanadequateamountofLoctite®680toevenlycoatthe
outerraceofthenewBallBearing(Item15or34)(SeeFigure
21 or 22).
5. Support the Sheave (Item 12) or the Pilot Drive Disc (Item
33)and pressingon theouter raceof thenew BallBearing
(Item15 or34),press thenewBall Bearing(Item15 or34)
into the Sheave or Pilot Drive Disc (See Figure 21 or 22).
6. Reinstall theRetaining Ring (Item41) (SeeFigure 21or22).
NOTE
The Flat Head Machine Screws are assembled with an
anaerobiclockingcompound. Inserting aproperlyfitting
screwdriver into the head of the Flat Head Machine
Screw and striking the end of the screwdriver with a
hammerwillbreakthecrystallinestructureofthislocking
compound and allow removal of the Flat Head Machine
Screws. Never use an impact wrench to remove the Flat
Head Machine Screws.
OntheLWCB,theFlatHeadMachineScrewssecuringthe
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) (See Figure 21 or
22).
8. Removetheold FrictionFacing(Item 10)(SeeFigure 21
or 22).
9. InstallthenewFrictionFacing(Item10)andtightenthenew
FlatHeadMachineScrews(Item24or25)to26In.Lbs.[2.9
N•m] torque (See Figure 21 or 22).
10. FullysupporttheAirChamber(Item8)andpresstheClutch
FrictionDisc(Item9)outoftheAirChamber(SeeFigure23).
FIGURE 21
SHEAVE MOUNT
FIGURE 22
PILOT MOUNT
FIGURE 23
41 15
12
10
24/25
41
34
33 10
24/25
9
14
8
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

11
FORM NO. L-20016-U-0305
NOTE
IftheBallBearing(Item14)comesoutoftheAirChamber
(Item 8), use a bearing puller to remove it from the Clutch
FrictionDisc(Item9). IftheBallBearingremainsintheAir
Chamber(Item8),useadieremovertoremoveitfromthe
Air Chamber.
11. CleanthebearingboreoftheAirChamber(Item8)withfresh
safetysolvent,makingsurealloldLoctite®residueisremoved
(See Figure 23).
12. ApplyanadequateamountofLoctite®680toevenlycoatthe
outerraceofthenewBallBearing(Item14)(SeeFigure23).
13. CarefullyaligntheO.D.ofthenewBallBearing(Item14)with
theboreoftheAirChamber(Item8)andpressthenewBall
Bearing into place (See Figure 23).
14. CarefullyalignthehuboftheClutchFrictionDisc(Item9)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) (See Figure 23).
15. Remove the old Flat Head Machine Screws (Item 24) and
FrictionFacing(Item4)fromthePiston(Item3)(SeeFigure
24).
16. RemovetheShoulderBolts(Item5),ShoulderBoltO-rings
(Item 22), and Compression Springs (Item 6) (See Figure
24).
17. Separatethe PistonAir Chamber (Item 7) andPiston (Item
3) (See Figure 24).
18. Remove the old O-ring Seals (Items 18 and 20) from the
PistonAirChamber(Item7)andPiston(Item3)(SeeFigure
24).
19. Remove the Retaining Ring (Item 17) (See Figure 24).
20. Press the old Ball Bearing (Item 13) out of the Piston Air
Chamber (Item 7) (See Figure 24).
21. Clean the bearing bore of the Piston Air Chamber (Item 7)
withfreshsafetysolvent,makingsurealloldLoctite®residue
is removed (See Figure 24).
22. ApplyanadequateamountofLoctite®680toevenlycoatthe
outerraceofthenewBallBearing(Item13)(SeeFigure24).
23. CarefullyaligntheO.D.ofthenewBallBearing(Item13)with
the bore of the Piston Air Chamber and press the new Ball
Bearing into place.
24. Reinstall the Retaining Ring (Item 17) (See Figure 24).
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. LubricatethenewO-ring Seals(Items 18,20,and22)with
fresho-ring lubricantand installthe newO-ringSeals (See
Figure 24).
27. Pressthe Piston(Item3) intothePiston AirChamber (Item
7) (See Figure 24).
28. Apply Loctite®242 to the threads of the Shoulder Bolts
(Item5);then,installthenewCompressionSprings(Item6)
andShoulderBolts(Item5)withnewO-ringSeals(Item22)
(See Figure 24).
29. TightentheShoulderBolts(Item5)to43In. Lbs.[4.8N•m]
torque (See Figure 24).
30. Installthe newFriction Facing(Item 4)and tightenthenew
FlatHeadMachineScrews(Item24)to26In.Lbs.[2.9N•m]
torque (See Figure 24).
FIGURE 24
713
17 18
20 3
6522
424
HWCB
WARNING
Specialattention should be exercisedwhenworkingwith
retainingrings. Alwayswearsafetygoggleswhenworking
with spring or tension loaded fasteners or devices.
1. RemovetheRetainingRing(Item41)fromtheSheave(Item12)
or Pilot Drive Disc (Item 33) (See Figure 25 or 26).
2. PresstheoldBallBearings(Item15)outoftheSheave(Item
12) or the Pilot Drive Disc (Item 33) (See Figure 25 or 26).
41
15
12
10
24
FIGURE 25
SHEAVE MOUNT
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

12 FORM NO. L-20016-U-0305
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. CleanthebearingboreoftheSheave(Item12)orPilotDrive
Disc(Item33)withfreshsafetysolvent,makingsurethatall
old Loctite®residue is removed (See Figures 25 or 26).
4. ApplyanadequateamountofLoctite®680toevenlycoatthe
outerraceofthenewBallBearings(Item15)(SeeFigure25
or 26).
5. Support the Sheave (Item 12) or the Pilot Drive Disc
(Item33)andpressingontheouterraceofthenewBall
Bearings (Item 15), press the new Ball Bearings (Item
15) into the Shave or Pilot Drive Disc (See Figure 25
or 26).
6. Reinstall the Retaining Ring (Item 41) (See Figure 25 or
26).
NOTE
The Flat Head Machine Screws are assembled with an
anaerobic locking compound. Inserting a properly fitting
screwdriverintotheheadoftheFlatHeadMachineScrew
andstrikingtheendofthe screwdriverwithahammerwill
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) (See Figure 25 or 26).
8. Removetheold FrictionFacing(Item 10)(SeeFigure 25
or 26).
9. InstallthenewFrictionFacing(Item10)andtightenthenew
FlatHeadMachineScrews(Item24)to43In.Lbs.[4.8N•m]
torque (See Figure 25 or 26).
10. FullysupporttheAirChamber(Item8)andpresstheClutch
FrictionDisc(Item9)outoftheAirChamber(SeeFigure27).
NOTE
IftheBallBearing(Item14)comesoutoftheAirChamber
(Item 8), use a bearing puller to remove it from the Clutch
FrictionDisc(Item9). IftheBallBearingremainsintheAir
Chamber(Item8),useadieremovertoremoveitfromthe
Air Chamber.
FIGURE 27
9
14 8
FIGURE 26
PILOT MOUNT
41
15
33
10
24
11. CleanthebearingboreoftheAirChamber(Item8)withfresh
safetysolvent,makingsurealloldLoctite®residueisremoved
(See Figure 27).
12. ApplyanadequateamountofLoctite®680toevenlycoatthe
outerraceofthenewBallBearing(Item14)(SeeFigure27).
13. CarefullyaligntheO.D.ofthenewBallBearing(Item14)with
theboreoftheAirChamber(Item8)andpressthenewBall
Bearing into place (See Figure 27).
14. CarefullyalignthehuboftheClutchFrictionDisc(Item9)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) (See Figure 27).
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

13
FORM NO. L-20016-U-0305
15. Remove the old Flat Head Machine Screws (Item 24) and
FrictionFacing(Item4)fromthePiston(Item3)(SeeFigure
28).
16. RemovetheShoulderBolts(Item5),ShoulderBoltO-rings
(Item 22), and Compression Springs (Item 6) (See Figure
28).
17. Separatethe PistonAir Chamber (Item 7) andPiston (Item
3) (See Figure 28).
18. Remove the old O-ring Seals (Items 18 and 20) from the
PistonAirChamber(Item7)andPiston(Item3)(SeeFigure
28).
19. Remove the Retaining Ring (Item 17) (See Figure 28).
20. Press the old Ball Bearing (Item 13) out of the Piston Air
Chamber (Item 7) (See Figure 28).
21. Clean the bearing bore of the Piston Air Chamber (Item 7)
withfreshsafetysolvent,makingsurealloldLoctite®residue
is removed (See Figure 28).
22. ApplyanadequateamountofLoctite®680toevenlycoatthe
outerraceofthenewBallBearing(Item13)(SeeFigure28).
23. CarefullyaligntheO.D.ofthenewBallBearing(Item13)with
the bore of the Piston Air Chamber and press the new Ball
Bearing into place.
24. Reinstall the Retaining Ring (Item 17) (See Figure 28).
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. LubricatethenewO-ring Seals(Items 18,20,and22)with
fresho-ring lubricantand installthe newO-ringSeals (See
Figure 28).
27. Pressthe Piston(Item3) intothePiston AirChamber (Item
7) (See Figure 28).
28. Apply Loctite®242 to the threads of the Shoulder Bolts
(Item5);then,installthenewCompressionSprings(Item6)
and Shoulder Bolts (Item 5) with new O-rings Seals (Item
22) (See Figure 28).
29. TightentheShoulderBolts(Item5)to60In. Lbs.[6.8N•m]
torque (See Figure 28).
30. Installthe newFriction Facing(Item 4)and tightenthenew
FlatHeadMachineScrews(Item24)to43In.Lbs.[4.8N•m]
torque (See Figure 28).
FIGURE 28
718 20 313 17
6522 4
24
REASSEMBLY—PILOT, COUPLING, AND SHEAVE MOUNT
FWCB
WARNING
Specialattention should be exercisedwhenworkingwith
retainingrings. Alwayswearsafetygoggleswhenworking
with spring or tension loaded fasteners or devices.
1. PresstheBrakeAssemblyontotheHub(Item1)andreinstall
the Retaining Ring (Item 37) (See Figure 29).
2. SlidetheBrakeFrictionDisc(Item2)ontotheHubandinstall
the Locking Nut (Item 26) (See Figure 29).
3. ReinstallandtightentheSetScrews(Item29)to20In.Lbs.
[2.2 N•m] torque (See Figure 29).
FIGURE 29
Brake
Assembly
37
112
26 29
NOTE
The following sections are arranged by model. Verify that you are in the correct section for your model.
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

14 FORM NO. L-20016-U-0305
4. LubricatethenewO-ringSeals(Items19and21)withfresh
o-ringlubricant;then,installthenewO-ringsSealsontothe
Brake and Clutch Assemblies (See Figure 30).
5. Reinstall the Key (Item 15) (See Figure 30).
6. Slide the Clutch Assembly onto the Hub (Item 1) and Key
(Item 15) (See Figure 30).
7. AligntheSpringPin(Item23)locatedontheBrakeAssembly
with the hole in the Clutch Assembly and press the Clutch
Assembly onto the Hub (Item 1) (See Figure 30).
8. SlidetheCompressionSpring(Item11)ontotheHub(Item
1); then, pressing on the inner bearing race, press the
Sheave or Drive Disc Assembly onto the Hub (See Figure
31).
9. ReinstalltheRetainingRing(Item37)andHubCollar;then,
reinstall the Set Screw (Item 47) (See Figure 32).
47
46
37
FIGURE 32
FIGURE 31
FIGURE 30
Sheave
Assembly
Drive Disc
Assembly
1111
1111
11
Hub
(Item 1)
Clutch
Assembly
19
21
15
23 Brake
Assembly
LWCB AND MWCB
1. Fully supporting the inner bearing race, press the Hub
(Item 1) into the Sheave or Drive Disc Assembly (See
Figure 33).
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) (See Figure 33).
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 (See Figure 34).
4. Align the Spring Pin (Item 23) located on the Brake
AssemblywiththeholeintheClutchAssemblyandpress
the Brake Assembly onto the Hub (Item 1) (See Figure
34).
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 (See Figure 34).
6. Reinstall the Locking Nut (Item 26) and tighten the Set
Screws (Item 29) to 20 In. Lbs. [2.2 N•m] torque for the
LWCB and 35 In. Lbs. [3.9 N•m] torque for the MWCB
(See Figure 34).
FIGURE 33
Clutch
Assembly
Sheave
Assembly
Drive Disc
Assembly
1
11
FIGURE 34
Hub
(Item 1)
19
21
Brake
Assembly
16
2
26
28 29
23
Clutch
Assembly
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

15
FORM NO. L-20016-U-0305
HWCB
1. Fullysupportingtheinnerbearingrace,presstheHub(Item
43)intotheSheaveofDriveDiscAssembly(SeeFigure35).
2. Slide the Compression Spring (Item 11) onto the Hub
(Item 43); then, supporting the inner bearing race, press
theClutch Assemblyontothe Hub(Item43) (SeeFigure
35).
3. LubricatethenewO-ringSeals(Items19and21)withfresh
o-ringlubricant;then,installthenewO-ringsSealsontothe
Brake and Clutch Assemblies (See Figure 36).
4. AligntheSlottedSpringPin(Item 23) locatedon the Brake
AssemblywiththeholeintheClutchAssemblyandpressthe
Brake Assembly onto the Hub (Item 43) (See Figure 36).
5. Slide the Spacer (Item 16) onto the Hub (Item 43); then,
slide the Brake Friction Disc (Item 44) onto the Hub (See
Figure 36).
6. AlignthetwoholesintheLockingCollar(Item46)withthetwo
holesintheHub(Item43);then,reinstalltheLockingCollarand
tightentheSocket HeadCapScrew(Item 47)to300In. Lbs.
[33.6 N•m] torque (See Figure 36).
FIGURE 35
43
Drive Disc
Assembly
Sheave
Assembly
Clutch
Assembly
11
FIGURE 36
Hub
(Item 43)
19
21
Brake
Assembly
16
44 46
45
28 47
23
Clutch
Assembly
REPLACEMENTPARTS
TheitemorballoonnumberforallNexenproductsisusedforpartidentificationonallproductpartslists,productpricelists,unitassembly
drawings, bills of materials, and instruction manuals.
Whenorderingreplacementparts, specify modeldesignation,itemnumber,partdescription,and quantity. Purchasereplacement parts
through your local Nexen Distributor.
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

16 FORM NO. L-20016-U-0305
PARTS LIST
FWCB—SHEAVE MOUNT
ITEM DESCRIPTION QTY
1 Hub 1
2 FrictionDisc 1
3 Piston 1
41Friction Facing 2
51Shoulder Bolt 3
61Compression Spring 3
7 Piston Air Chamber 1
8 Air Chamber 1
9 FrictionDisc 1
111Compression Spring 1
12 Sheave 1
131BallBearing 2
141BallBearing 1
171Retaining Ring (Int.) 1
181O-ring Seal 1
191O-ring Seal 1
201O-ring Seal 1
ITEM DESCRIPTION QTY
211O-ring Seal 1
221O-ring Seal 3
231Slotted Spring Pin 1
241Flat Head Machine Screw 12
26 LockingNut 1
27 Set Screw 1
28 Set Screw 3
29 Set Screw 2
30 Key 2
32 Air Line (Not Shown) 2
351Key 1
361Retaining Ring (Ext.) 1
371Retaining Ring (Ext.) 2
41 Retaining Ring (Int.) 1
46 Hub Collar 1
47 Set Screw 2
FIGURE 37
46
47 37 41 13
12 424 914
11
8
19 21
23
7
37 13 17
27 130
35 28
20 18 3
6522
4
36
24 2
26
29
1Denotes Repair Kit item.
Repair Kit Product No. 847800. NOTE
Repair Kit Product No. 847800 includes only one Ball
Bearing (Item 13).
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

17
FORM NO. L-20016-U-0305
FWCB—PILOT AND COUPLING MOUNT
ITEM DESCRIPTION QTY
1 Hub 1
2 FrictionDisc 1
3 Piston 1
41Friction Facing 2
51Shoulder Bolt 3
61Compression Spring 3
7 Piston Air Chamber 1
8 Air Chamber 1
9 FrictionDisc 1
111Compression Spring 1
131BallBearing 1
141BallBearing 1
171Retaining Ring (Int.) 1
181O-ring Seal 1
191O-ring Seal 1
201O-ring Seal 1
211O-ring Seal 1
ITEM DESCRIPTION QTY
221O-ring Seal 3
231Slotted Spring Pin 1
241Flat Head Machine Screw 12
26 LockingNut 1
27 Set Screw 1
28 Set Screw 3
29 Set Screw 2
30 Key 2
32 Air Line (Not Shown) 2
33 PilotDriveDisc 1
34 BallBearing 1
351Key 1
361Retaining Ring (Ext.) 1
371Retaining Ring (Ext.) 2
41 Retaining Ring (Int.) 1
46 Hub Collar 1
47 Set Screw 2
FIGURE 38
46 47 37 41 34
33
424
11
914
8
19 21
23
7
37 13 17
27 1
30
35 28
20
18
3
4
36
226
29
6522
24
1Denotes Repair Kit item.
Repair Kit Product No. 847800.
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]