Nexen AIR CHAMP DBSE User manual

1FORM NO. L-20017-D-0814
Disc Caliper Brake
Model DBSE
AIR CHAMP PRODUCTS
User Manual

2
FORM NO. L-20017-D-0814
Copyright 2014 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-20017-D-0814
Table of Contents
General Specifications -------------------------------------------------------------------------------------------------------------------------- 4
General Safety Precautions ------------------------------------------------------------------------------------------------------------------- 4
Installation ------------------------------------------------------------------------------------------------------------------------------------------- 5
Lubrication ------------------------------------------------------------------------------------------------------------------------------------------- 7
Air Connections ----------------------------------------------------------------------------------------------------------------------------------- 7
Operation -------------------------------------------------------------------------------------------------------------------------------------------- 8
Troubleshooting ---------------------------------------------------------------------------------------------------------------------------------- 9
Manual Disengagement ------------------------------------------------------------------------------------------------------------------------- 10
Parts Replacement:
Friction Facing Replacement ------------------------------------------------------------------------------------------------------ 10
SealReplacement---------------------------------------------------------------------------------------------------------------------11
Parts List ------------------------------------------------------------------------------------------------------------------------------------------- 12
Warranty -------------------------------------------------------------------------------------------------------------------------------------------- 13

4
FORM NO. L-20017-D-0814
GENERAL SPECIFICATIONS
GENERAL SAFETY PRECAUTIONS
Specifications
Torque: Up to 1200 in-lbs
Disengagement Pressure: 40 psi minimum
Service Temperature: 4.5-104C (40-220F)
Approximate Weight: Up to 20 lbs.
CAUTION
This product has possible pinch
points. Care should be taken when
interacting with this product.
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.
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.
CAUTION
The temperature limits for the
product are 4.5-104 degree
Celsius (40-220 degree F).
CAUTION
This product has possible pinch
points. Care should be taken when
interacting with this product.
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”.
WARNING
This product is capable of emitting
a spark if misused therefore is not
recommended for use in any explosive
environment.

5FORM NO. L-20017-D-0814
INSTALLATION
NOTE
The Brake Disc (ordered separately) may be
mounted to a customer supplied hub or mounted
to the Nexen Disc Brake Hub (also ordered
separately) for use with a Q.D. Bushing.
Refer to Figure 1-2 & Table 1.
1. Apply a drop of Loctite®242 to the threads of the six
Flat Head Hex Socket Cap Screws provided with the
Brake Disc and secure the Brake Disc to the Brake
Disc Hub or to a customer-supplied hub.
2. Alternately and evenly tighten the six Flat Head Hex
Socket Cap Screws to the recommended torque.
3. Thoroughly inspect the tapered bore of the Brake Disc
Hub and the tapered surface of the Q. D. Bushing.
Remove any dirt, grease, or foreign material. Do not
use lubricants for this installation.
4. Assemble the Q.D. Busing into the Brake Disc Hub,
aligning the untapped holes in the Q.D. bushing with
the tapped holes in the Brake Disc Hub.
NOTE
Runout is minimized if a Dial Indicator is used as
the pull-up bolts are tightened. Place the contact
tip of the Dial Indicator on the machined surface of
the Brake Disc to measure runout. Runout should
be less than 0.010-0.015 in. [.254-.381 mm.].
Brake Disc
Brake Disc
Hub Flat Head Hex
Socket Cap
Screw
FIGURE 1
RECOMMENDED TIGHTENING TORQUES
FLAT HEAD HEX SOCKET CAP SCREWS
MODEL TORQUE
10 in. Disc
(Prod. No. 855500)
45 in-lb (5.04 Nm)
12 in. Disc
(Prod. No. 855600)
105 in-lb (11.76 Nm)
14 in. Disc
(Prod. No. 855700)
105 in-lb (11.76 Nm)
16 in. Disc
(Prod. No. 855800)
105 in-lb (11.76 Nm)
Dial Indicator
Brake Disc
FIGURE 2
TABLE 1
CAUTION
If excessive tightening torque is applied, bursting
pressures are created in the Brake Hub. There must
be a gap between the flange of the Q. D. Bushing
and the Brake Disc to ensure a proper fit of the Q. D.
Bushing onto the shaft.

6
FORM NO. L-20017-D-0814
5. Insert the pull-up bolts and alternately and evenly tighten
them to 15 ft–lb [20.3 Nm] torque.
6. To remove the Q.D. Bushing, remove the pull-up bolts
and reinsert them into the threaded holes of the Q.D.
Bushing. Tighten the pull-up bolts to push out the Q.D.
Bushing.
7. Mount the Caliper Brake so the radius of the Disc runs
approximately 0.06 in [1.6 mm] below the outside radius
of the Friction Facing Assembly (Item 1), and with an
equal distance between the Disc and Friction Facing
Assemblies (See Figure 3).
0.06
FIGURE 3
Brake Disc
Friction Facing
Assemblies
(Item 1)
FIGURE 4
Customer
supplied 3/8"
bolts
"T" Support
(Item 12)
8. Use customer-supplied 3/8 in. bolts to mount the "T"
support (Item 12) to a solid base (See Figures 3 and
4).
9. The Caliper Brake can be flush-mounted. The 3/8-16
mounting bolts can secure the Caliper Brake to a
solid mounting surface. The recommended mounting
hole pattern includes a .125-27 NPT thread to
relocate the breather fitting and allow access for
manual disengagement (See Figure 5).
1.156
2.312
.125–27 NPT
Ø0.406
2x
2.125
0.875
FIGURE 5
INSTALLATION (continued)

7FORM NO. L-20017-D-0814
AIR CONNECTIONS
Air Pressure (Gage) Limits
6.9 Bar (100 PSI) Absolute Max.
0 Bar (0 PSI) Absolute Min.
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.
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.
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.
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.
TABLE 2
Air
Supply
Brake
Inlet
Gauge
Regulator
Filter
Dryer
Typical Brake Control Circuit
3/2 (3 Way)
N.C. Valve
Quick
Exhaust Valve

8
FORM NO. L-20017-D-0814
OPERATION
TABLE 3
WARNING
Never exceed maximum operating speeds
listed for your product. (See Table 3).
CAUTION
The temperature limits for this product
line are 4.5-104 Degree Celsius (40-220
Degree F).
DBSE Disc Size Max RPM
10 Inch O.D. 4500
12 Inch O.D. 3800
14 Inch O.D. 3200
16 Inch O.D. 2800
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”.
WARNING
This product is capable of emitting
a spark if misused therefore is not
recommended for use in any explosive
environment.

9FORM NO. L-20017-D-0814
Symptom Probable Cause Solution
Failure to engage
Air not being exhausted due to a control valve malfunc-
tion. Replace the control valve.
Broken compression spring Replace the compression springs.
Internal contamination or corrosion. Align the exhaust port to the six-o'clock down position to allow
condensation to drain out of the exhaust port.
Failure to disengage
Los or lack of air pressure.
Check for control valve malfunction and replace it if necessary.
Check for air leaks in the air lines and around the o-ring seals.
Replace the air lines or o-ring seals if necessary.
Internal contamination or corrosion. Align the exhaust port to the six-o'clock down position to allow
condensation to drain out of the exhaust port.
Loss of torque Worn or dirty Facings. Replace Friction Facings.
TROUBLESHOOTING
U-cup Seal (5)
Friction
Facing (1)
Piston (3)
Flat Washer (14)
Hex Nut (10)
Lock Washer (9)
"T" Support (12)
Pin (4)
Spacer (13)
O-ring Seal (15)
Cylinder (2)
Cap
Screw (8)
Breather (18)
Spring (11)
Flat Screw (17)
FIGURE 8

10
FORM NO. L-20017-D-0814
PARTS REPLACEMENT - FRICTION FACING REPLACEMENT
Refer to Figure 6.
1. Remove the two Hex Head Screws (Item 8), Hex Head
Nuts (Item 10), Lock Washers (Item 9), and Flat Washers
(Item 14). Then remove the two Cylinders (Item 2) from
the "T" Support (Item 12).
2. Separate the two Cylinders (Item 2).
3 Remove the Flat Head Cap Screws (Item 6) securing
the old Friction Facing Assemblies (Item 1) to the Piston
(Item 3).
4. Apply Loctite®242 to the threads of the Flat Head
Screws (Item 6); then secure the new Friction Facing
Assemblies (Item 1) to the Pistons (Item 3).
5. Tighten the Flat Head Cap Screws (Item 6) to 62–81
in-lb (7.0–9.2 Nm).
6. Using the two Hex Head Screws (Item 8), Hex Nuts
(Item 10), Lock Washers (Item 9), and Flat Washers
(Item 14), secure the two Cylinders (Item 2) to the "T"
Support (Item 12).
FIGURE 6
8
10
9
14
2
2
12
6
1
3
MANUAL DISENGAGEMENT
For manual disengagement of the brake, remove the
breather fittings. Insert a 5/16-18 x 1-1/2 bolt or cap
screw through the breather port. Screw into the piston
until the caliper brake is disengaged.
5/16-18
THREADED HOLE
BREATHER FITTING
5/16-18 X 1-1/2" LONG
CAP SCREW

11 FORM NO. L-20017-D-0814
Refer to Figure 7.
1. Remove the two Hex Head Cap Screws (Item 8), Hex
Head Nuts (Item 10), Lockwashers (Item 9) and Flat
Washers (Item 14). Then remove the two Cylinder
Assemblies (Item 2) from the “T” Support (Item 12).
(See Figure 6).
2. Separate the two Cylinder Assemblies (Item 2) and
set the Spacers (Item 13) and Pin (Item 4) aside. (See
Figure 6).
3. Remove the Flat Head Cap Screws (Item 6) securing
the Shoe Facings (Item 1) to the Piston (Item 3).
PARTS REPLACEMENT - SEAL REPLACEMENT
4. Remove the Flat Head Cap Screws (Item 17), End Cap
(Item 16) and Springs (Item 11) from both Cylinders
(item 2).
5. Push Pistons (Item 3) out of both Cylinders (Item 2).
6. Remove old U-Cup Seals (Item 5) and O-Rings (Item
15) from both Pistons (item 3).
7. Clean the O-Ring grooves of the Pistons (Item 3); then,
lubricate the new U-Cup Seals and O-Rings and contact
surfaces with a thin film of fresh o-ring lubricant.
8. Install the new U-Cup Seals (Item 5) and O-Rings (Item
15) onto both Pistons (Item 3).
9. Place Springs (Item 11) into spring pockets of Pistons
(Item 3).
10. Attach End Caps (Item 16) to Cylinders (Item 2) with
Flat Head Cap Screws (Item 17).
Note
Orientation of mounting holes in End Cap must
match mounting holes in Cylinder. Alternately and
evenly tighten Flat Head Cap Screws to 178–232
in-lbs (20.1–26.2 Nm).
11. Apply Loctite 242 to the threads of the Flat Head Cap
Screws (Item 6); then secure the Friction Facings (Item
1) to the Pistons (Item 3). Tighten Flat Head Cap Screws
(Item 6) to 62–81 in-lbs (7.0–9.2 Nm).
12. Using the two Hex Head Cap Screws (Item 8), Hex Nuts
(Item 10), Lock Washers (Item 9) and Flat Washers
(Item 14), secure the two Cylinder assemblies (Item
2) with the Spacers (Item 13) and Pin (Item 4) to the
“T” support (Item 12).
2
1
6
15
5
3
11
17
16
FIGURE 7
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.
CAUTION
Orientation of U-Cup Seal is important.
Open side of U-Cup Seal should face into
the Cylinder (Item 2).

12
FORM NO. L-20017-D-0814
ITEM DESCRIPTION QTY
1 Friction Facing Assembly 2
2 Cylinder 2
3 Piston 2
4 Pin 1
5 U-Cup Seal 2
6 Cap Screw 4
8 Hex. Head Screw 2
9 Lock Washer 2
10 Hex. Nut 2
PARTS LIST
ITEM DESCRIPTION QTY
11 Compression Spring 12*
12 "T" Support 1
13 Spacer 2
14 Flat Washer 2
15 O-Ring 2
16 End Cap 2
17 Flat Cap Screw 8
18 Breather Fitting Plug 2
* Varies by unit.
18
1
2
16
4
12
6
9
11
13
15
10
8
17
3
5
14
2
35
11 16
17
FIGURE 9

13 FORM NO. L-20017-D-0814
Nexen Group, Inc.
560 Oak Grove Parkway
Vadnais Heights, MN 55127
800.843.7445
Fax: [phone]
www.nexengroup.com
ISO 9001 Certified
WARRANTY
Warranties
Nexen warrants that the Products will (a) be free from any defects in material or workmanship for a period of 12 months
from the date of shipment, and (b) will meet and perform in accordance with the specifications in any engineering drawing
specifically for the Product that is in Nexen’s current product catalogue, or that is accessible at the Nexen website, or that is
attached to this Quotation and that specifically refers to this Quotation by its number, subject in all cases to any limitations
and exclusions set out in the drawing. NEXEN MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND ALL
IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. This warranty applies only if: (a) the Product has
been installed, used and maintained in accordance with any applicable Nexen installation or maintenance manual for the
Product; (b) the alleged defect is not attributable to normal wear and tear; (c) the Product has not been altered, misused or
used for purposes other than those for which it was intended; and (d) Buyer has given written notice of the alleged defect
to Nexen, and delivered the allegedly defective Product to Nexen, within one year of the date of shipment.
Exclusive Remedy
The exclusive remedy for the Buyer for any breach of any warranties provided in connection with this agreement will be,
at the election of Nexen: (a) repair or replacement with new, serviceably used, or reconditioned parts or products; or (b)
issuance of credit in the amount of the purchase price paid to Nexen by the Buyer for the Products.
Agent's Authority
Buyer agrees that no agent, employee or representative of Nexen has authority to bind Nexen to any affirmation, representation,
or warranty concerning the Products other than those warranties expressly set forth herein.
Limitation on Nexen’s Liability
TO THE EXTENT PERMITTED BY LAW NEXEN SHALL HAVE NO LIABILITY TO BUYER OR ANY OTHER PERSON
FOR INCIDENTAL DAMAGES, SPECIAL DAMAGES, CONSEQUENTIAL DAMAGES OR OTHER DAMAGES OF ANY
KIND OR NATURE WHATSOEVER, WHETHER ARISING OUT OF BREACH OF WARRANTY OR OTHER BREACH
OF CONTRACT, NEGLIGENCE OR OTHER TORT, OR OTHERWISE, EVEN IF NEXEN SHALL HAVE BEEN ADVISED
OF THE POSSIBILITY OR LIKELIHOOD OF SUCH POTENTIAL LOSS OR DAMAGE. For all of the purposes hereof, the
term "consequential damages" shall include lost profits, penalties, delay damages, liquidated damages or other damages
and liabilities which Buyer shall be obligated to pay or which Buyer may incur based upon, related to or arising out of its
contracts with its customers or other third parties. In no event shall Nexen be liable for any amount of damages in excess of
amounts paid by Buyer for Products or services as to which a breach of contract has been determined to exist. The parties
expressly agree that the price for the Products and the services was determined in consideration of the limitation on damages
set forth herein and such limitation has been specifically bargained for and constitutes an agreed allocation of risk which
shall survive the determination of any court of competent jurisdiction that any remedy herein fails of its essential purpose.
Inspection
Buyer shall inspect all shipments of Products upon arrival and shall notify Nexen in writing, of any shortages or other failures
to conform to these terms and conditions which are reasonably discoverable upon arrival without opening any carton or
box in which the Products are contained. Such notice shall be sent within 14 days following arrival. All notifications shall be
accompanied by packing slips, inspection reports and other documents necessary to support Buyer's claims. In addition
to the foregoing obligations, in the event that Buyer receives Products that Buyer did not order, Buyer shall return the
erroneously shipped Products to Nexen within thirty (30) days of the date of the invoice for such Products; Nexen will pay
reasonable freight charges for the timely return of the erroneously shipped Products, and issue a credit to Buyer for the
returned Products at the price Buyer paid for them, including any shipping expenses that Nexen charged Buyer. All shortages,
overages and nonconformities not reported to Nexen as required by this section will be deemed waived.
Limitation on Actions
No action, regardless of form, arising out of any transaction to which these terms and conditions are applicable may be
brought by the Buyer more than one year after the cause of action has accrued.