Nexen AIR CHAMP II F-450 User manual

1FORM NO. L-20143-M-1216
Air Champ II
F-450, L-600, M-800 and H-1000
AIR CHAMP PRODUCTS

2
FORM NO. L-20143-M-1216
Copyright 2016 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-20143-M-1216
Table of Contents
General Specifications -------------------------------------------------------------------------------------------------------------------------- 4
General Safety Precautions ------------------------------------------------------------------------------------------------------------------- 4
Installation -------------------------------------------------------------------------------------------------------------------------------------------- 5
Friction Facing Admustment ------------------------------------------------------------------------------------------------------------------ 7
Lubrication ------------------------------------------------------------------------------------------------------------------------------------------- 7
Air Connections ------------------------------------------------------------------------------------------------------------------------------------ 8
Operation -------------------------------------------------------------------------------------------------------------------------------------------- 8
Troubleshooting ------------------------------------------------------------------------------------------------------------------------------------ 9
Parts Replacement ----------------------------------------------------------------------------------------------------------------------------- 10
Replacement Parts ----------------------------------------------------------------------------------------------------------------------------- 13
Warranty -------------------------------------------------------------------------------------------------------------------------------------------- 14

4
FORM NO. L-20143-M-1216
GENERAL SPECIFICATIONS
GENERAL SAFETY PRECAUTIONS
Specifications:
Torque 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 37.2 kg (82 lbs)
CAUTION
Use lifting aids and proper lifting
techniques when installing, removing,
or placing this product in service.
CAUTION
Watch for sharp features when
interacting with this product. The
parts have complex shapes and
machined edges.
CAUTION
Use appropriate guarding for moving
components. Failure to guard could
result in serious bodily injury.
WARNING
This product is capable of emitting
a spark if misused therefore is not
recommended for use in any explosive
environment.
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
Use appropriate guarding for moving
components. Failure to guard could
result in serious bodily injury.
CAUTION
The temperature limits for the
product are 4.5-100 degree
Celsius (40-220 degree F).

5FORM NO. L-20143-M-1216
INSTALLATION
Air Champ II
Shaft
19 18
17
16
FIGURE 1
SHEAVE MOUNT AND PILOT MOUNT
Refer to Figure 1.
NOTE: If Air Champ II unit slides with minimal resistance
onto customer supplied shaft use standard
mounting procedure. If Air Champ II clutch binds on
the through shaft when sliding past the adjustment
nut (Item 16) then follow the optional mounting
procedure.
Standard Mounting Procedure.
NOTE: If mounting a customer supplied sheave to the Air
Champ II, the sheave must be mounted to the Air
Champ II first, using bolts that will not bottom out
against the friction material.
1. Insert the Key (Item 19) in the shaft keyway
2. Slide the Air Champ II onto the shaft as far as possible
with the Key fully seated into the Hub
NOTE: Refer to Table 1 for minimum shaft insertion.
3. Tighten the Set Screws (Item 18) to the torque specified
in Table 2.
Optional Mounting Procedure.
NOTE: Some Air Champ II’s may require the (Item 17) Set
Screw to be loosening for through shaft mounting.
If Air Champ II clutch binds on the through shaft
when sliding past the adjustment nut (Item 16)
then follow the procedure below.
1. Insert the Key (Item 19) in the shaft keyway.
2. Loosen Set Screw (Item 17) until Air Champ II
product slides over through shaft.
3. Slide Air Champ II product to desired position on
through shaft. Make sure the key is fully seated in
the hub.
4. Turn the adjustment nut (Item 16) unit the friction facing
gap is between 0.020 inch [0.51 mm] to 0.060 inch
[1.51 mm]. The adjustment nut comes with quantity 1
set screw (Item 17) and must be tightened onto the
hub flat.
NOTE: The Air Champ II comes with a machined flat on
the threaded portion of the hub. Set screw (Item
17) must always be tightened onto this flat (See
Figure 1). Two holes are provided in the adjustment
nut (Item 16) for set screw (Item 17). The set screw
can be installed in either threaded hole, but must
be tightened down over the hub flat. For set screw
(Item 17) Nexen recommends the use of a thread
locking compound in high vibration applications,
(Example: Loctite 242).
5. Once in the desired position over the hub flat, tighten
the set screw (Item 17). (See Table 5 Page 7 for set
screw (Item 17) tightening torque)
6. Tighten the Set Screw (Item 18) to torque specified
in Table 2.
TABLE 1
LEDOM NOITRESNITFAHSMUMINIM
054-F.nI000.2mm08.05
006-L.nI005.2mm05.36
008-M.nI057.3mm52.59
0001-H.nI573.4mm21.111
TABLE 2
LEDOM .ONMETI NOITPIRCSED EUQROT
054-F DTS81
RTM81
02-052.
0.1-6M
.sbL.nI80.43
]mN58.3[
006-L DTS81
RTM81
42-213.
0.1-6M
.sbL.nI80.43
]mN58.3[
008-M DTS81
RTM81
61-573.
5.1-01M
.sbL.nI13.631
]mN4.51[
0001-H DTS81
RTM81
61-573.
5.1-01M
.sbL.nI13.631
]mN4.51[
TABLE 3
LEDOM GNILPUOC
EZIS
NOITAIRAVDERUSAEM
081STNIOPTA
TRAPASEERGED
TAOLFLAIXA
EULAVMUMIXAM(
MORF
DEDNEMMOCER
)GNICAPSLAITINI
LELLARAP
MUMIXAM
RALUGNA
MUMIXAM
054-F .nI8/5-2
]mm57.66[
.nI510.0
]mm183.0[
.nI40.0
]mm610.1[
.nI8/1+
]mm573.1+[
006-L .nI4
]mm6.101[
.nI510.0
]mm183.0[
.nI460.0
]mm526.1[
.nI8/1+
]mm573.1+[
008-M .nI7
]mm8.771[
.nI510.0
]mm183.0[
.nI211.0
]mm548.2[
.nI8/1+
]mm573.1+[
0001-H .nI8
]mm2.302[
.nI510.0
]mm183.0[
.nI821.0
]mm152.3[
.nI8/1+
]mm573.1+[
Disc Screws Torque
10" #10 Flat Head 65 in-lbs
12", 14", 16" .250-20 Flat Head 105 in-lbs
18
Set Screw
Aligned with
Hub Flat

6
FORM NO. L-20143-M-1216
COUPLING MOUNT
Refer to Figures 2 & 3.
1. Determine the parallel misalignment of the shafts to be
coupled.
NOTE: Before installation, the Driving Shaft can be fixed
but the Driven Shaft must be allowed to float.
a. Place a straight edge across the shafts and measure
the maximum offset of various points around the
outside of the shafts.
b. Make the necessary corrections to keep within the
parallel misalignment limits of the coupling (See
Table 3).
2. Attach the Adapter Plate (Item 24) to the Air Champ II,
using Cap Screws (Item 33) and Lock Washers (Item
34) .
3. Tighten the Cap Screws (Item 33) to the recommended
torque (See Table 4).
4. Slide the Air Champ II complete with the Coupling
Adapter Plate onto the Driving Shaft until the Coupling
Adapter Plate is flush with the end of the Driving Shaft.
5. Insert the Key (Item 19) into the Driving Shaft keyway.
6. Tighten the Set Screws (Item 18) to the recommended
torque (See Table 2).
7. Place the Flexible Ring (Item 25) over the pins of the
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 Dodge
Taper-Lock®bushing onto the Driven Shaft until it is
flush with the shaft.
TABLE 4
FIGURE 3
LEDOM .ONMETI NOITPIRCSED EUQROT
054-F 5202-052.]mN05.82[.sbL.tF12
006-L 5202-052.]mN05.82[.sbL.tF12
008-M 5281-213.]mN81.13[.sbL.tF32
0001-H 5261-573.]mN57.501[.sbL.tF87
24
25
26
34
33
19
18
Driving Shaft
Driven
Shaft
Dodge Taper-Lock®
Bushing
Air Champ II
FIGURE 2
INSTALLATION (continued)
10. Thread the screws supplied with the Dodge Taper-
Lock®bushing into the threaded holes of the 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 Ring (Item 25) and push the entire
assembly together.
NOTE: Automatic spacing isaccomplished by aspacer
molded into the Flexible Ring (Item 25).
12. Secure the Driven Shaft.
CALIPER DISC MOUNT
1. Air Champ II clutches have brake disc-mounting features
on the face of the drive disc or sheave. Select disc sizes
are offered for each of the four clutch models. The
combination of a disc, DB Caliper Brake / T-Bracket
and clutch create a clutch-disc-caliper brake.
2. Each disc comes with six flat head cap screws to
assemble the disc to the drive disc or sheave. Place the
disc on the larger pilot and secure with flat head cap
screws. Tighten cap screws with appropriate tightening
torque. It is recommended the disc run out be within
0.010 inch (0.25mm) or optimum performance.

7FORM NO. L-20143-M-1216
FRICTION FACING ADJUSTMENT
Refer to Figure 4.
1. Ensure the Set Screw (Item 17) that locks the Adjustment
Nut (Item 16) is released to allow the Adjustment Nut to
be rotated on the Hub.
2. Using a 0.020 In. [0.508 mm] and a 0.060 In. [1.514
mm] feeler gauge, check the gap between the Friction
Disc and the Friction Facing.
a. If the gap is less than 0.020 In. [0.508 mm], rotate
the Adjustment Nut counterclockwise until one set
screw hole is over the flat on the Hub and the 0.020
In. [0.508 mm] feeler gauge can be inserted.
b. If the gap is greater than 0.060 In. [1.514 mm],
rotate the Adjustment Nut clockwise until one set
screw hole is over the flat on the Hub and the 0.060
In. [1.514 mm] feeler gauge can not be inserted.
3. Tighten the Set Screw to the recommended torque (See
Table 5).
NOTE: Do not adjust the gap to less than 0.020 In.
[0.508 mm]. The Air Champ II will not disengage
if the gap is closed. Always tighten Set Screw
(Item 17) on Hub Flat.
17
16
Check Friction
Facing gap here.
FIGURE 4
TABLE 5
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
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.
MODEL ITEM NO. DESCRIPTION TORQUE
F-450 17 STD
17 MTR
.190-32
M4-0.7
37 in-lbs
4.18 Nm
L-600 17 STD
17 MTR
.190-32
M4-0.7
37 in-lbs
4.18 Nm
M-800 17 STD
17 MTR
.250-28
M6-1.0
80 in-lbs
9.04 Nm
H-1000 17 STD
17 MTR
.250-28
M6-1.0
80 in-lbs
9.04 Nm

8
FORM NO. L-20143-M-1216
AIR CONNECTIONS
An Air Line (Item 20) is furnished and air controls with 1/8
NPT ports are recommended. Where long air lines are
required, a Quick Exhaust Valve (Product No. 945100) is
recommended to ensure rapid disengagement.
NOTE: Because of the necessary movement of the air
chamber and Air Line upon engagement, flexible
tubing or air lines must be used on the Air Champ
II.
Due to bearings seal drag, the outer portion or the Air
Champ II will rotate when it is engaged. Rest the air line
against a support that is parallel to the centerline of the Air
Champ II to stop this rotation.
NOTE: Pressure should be regulated to the minimum
required for sufficient torque to maximize bearing
life.
Air
Supply
Brake or
Clutch
Gauge
Regulator
Filter
Dryer
Typical Clutch or Brake Control Circuit
3/2 (3 Way)
N.C. Valve
Quick
Exhaust Valve
AIR PRESSURE:
8 BAR (120 PSI) ABSOLUTE MAX
0 BAR (0 PSI) ABSOLUTE MIN
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.
The following is a common air supply scheme used with
this product. This is an example and not an all-inclusive
list. All air circuits to be used with this product must be
designed following ISO-4414 guidelines.
OPERATION
WARNING
Never exceed maximum operating
speeds listed for your product.
(See Table 6).
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).
TABLE 6
Size Max RPM
F-450 3,600
L-600 3,600
M-800 1,800
H-1000 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”.

9FORM NO. L-20143-M-1216
TROUBLESHOOTING
Drive
Disc
Friction
Facing
Cylinder
Piston
Friction
Disc
Set
Screw
Set
Screw
Adjustment
Nut
Bearing
O-ring Seal
O-ring Seal
Air Inlet
Port Bearing
Compression
Spring
Bearing
Hub
Key
FIGURE 5
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10
FORM NO. L-20143-M-1216
PARTS REPLACEMENT
Refer to Figures 6, 7, & 8.
1. Loosen the Set Screw (Item 17) and unscrew the
Adjustment Nut (Item 16).
2. Slide the Cylinder, Piston, Compression Spring, Friction
Disc, and Adjustment Nut (Item 16) off the Hub.
3. Apply low air pressure to separate the Piston (Item 13)
from the Cylinder (Item 11) and Friction Disc (Item 9).
4. Remove the two old O-ring Seals (Items 14 and 15)
from the Piston (Item 13).
5. Press the Adjustment Nut (Item 16) out of the Ball
Bearing (Item 10).
6. Press the old Ball Bearing (Item 10) out of the Piston
(Item 13).
7. Clean the bearing bore of the Piston with fresh safety
solvent, making sure all old Loctite®residue has been
removed.
8. Apply Loctite® 680 to evenly coat the outer race of the
new Ball Bearing (Item 10) and align it with the bore of
the Piston (Item 13); then, pressing on the outer bearing
race, press the new Ball Bearing into the Piston.
9. Press the Adjustment Nut (Item 16) into the new Ball
Bearing (Item 10).
10. Using a bearing puller, remove the Cylinder (Item 11)
from the Ball Bearing (Item 10) and Friction Disc (Item
9).
11. Using a bearing puller, remove the old Ball Bearing (Item
10) from the Friction Disc (Item 9).
12. Clean the bearing bore of the Cylinder (Item 11) with
fresh safety solvent, making sure all old Loctite®residue
has been removed.
13. Apply an adequate amount of Loctite®680 to the outer
race of the new Ball Bearing (Item 10) and align it with
the bore of the Cylinder (Item 11); then, press the new
Ball Bearing (Item 10) into the Cylinder (Item 11).
FIGURE 8
10
13
11
10
9
16
FIGURE 7
13
11
9
14
15
Hub
16
FIGURE 6
17
Cylinder, Piston,
Friction Disc, and
Compression Spring
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.