Nexen AIR CHAMP DPB-9T User manual

FORM NO. L-20094-E-0914
1
Dual Friction Plate Brakes
Models DPB-9T, DPB-11T, DPB-13T, and
DPB-15T
AIR CHAMP PRODUCTS

2
FORM NO. L-20094-E-0914
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

FORM NO. L-20094-E-0914
3
Table of Contents
General Specifications -------------------------------------------------------------------------------------------------------------------------- 4
General Safety Precautions ------------------------------------------------------------------------------------------------------------------- 4
Introduction ----------------------------------------------------------------------------------------------------------------------------------------- 5
Installation ------------------------------------------------------------------------------------------------------------------------------------------- 5
Lubrication ------------------------------------------------------------------------------------------------------------------------------------------- 7
Air Connections ----------------------------------------------------------------------------------------------------------------------------------- 7
Operation -------------------------------------------------------------------------------------------------------------------------------------------- 8
Parts Replacement ------------------------------------------------------------------------------------------------------------------------------- 9
Replacement Parts ----------------------------------------------------------------------------------------------------------------------------- 11
Warranty -------------------------------------------------------------------------------------------------------------------------------------------- 13

4
FORM NO. L-20094-E-0914
GENERAL SPECIFICATIONS
GENERAL SAFETY PRECAUTIONS
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.
WARNING
This product is capable of emitting
a spark if misused, therefore it is not
recommended for use in any explosive
environment.
Specifications
Torque Up to 4067 Nm (36000 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 115 kg (254 lbs)
CAUTION
Use appropriate guarding for moving
components. Failure to guard could
result in serious bodily injury.
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
This product has possible pinch
points. Care should be taken when
interacting with this product.
CAUTION
Use appropriate guarding for moving
components. Failure to guard could
result in serious bodily injury.
CAUTION
The temperature limits for the
product are 4.5-104 degree
Celsius (40-220 degree F).
CAUTION
This product has possible pinch
points. Care should be taken when
interacting with this product.

FORM NO. L-20094-E-0914
5
INTRODUCTION
Nexen’s DPB (Dual Friction Plate) Brakes are designed to mount on shaft ends, or through shafts using a customer supplied
Q.D. (Quick Detachable) Bushing. The dual friction plate design eliminates thrust loading of bearings.
INSTALLATION
NOTE: All DPB Brake installations require a O.D. (Quick
Detachable) Bushing. Refer to Table 1 for O.D.
Bushing Specifications.
TABLE 1
Q.D. Bushing Specifications
LEDOM GNIHSUB
EPYT EROBXAM
PU-LLUP
GNINETHGIT
EUQROT
T9-BPDKS573.2.sbl.tf51
T11-BPDFS578.2.sbl.tf03
T31-BPDF005.3.sbl.tf57
T51-BPDJ000.4.sbl.tf211
SUPPORT BUSHING
Refer to Figure 1.
NOTE: The Support Bushing provides radial load support
at the shaft, and is used when bore sizes smaller
than standard are required.
1. Place DPB Brake, friction disc side up, and fully support
Flange Mount Disc (Item 5).
2. Insert Support Bushing into bore of Flanged Hub (Item
36).
3. Apply even pressure around entire diameter of Support
Bushing and press Support Bushing into Flanged Hub
(Item 36).
FIGURE 1
5
36
Support
Bushing
CAUTION
Do not use a hammer to install
Support Bushing. A small arbor
press is recommended.

6
FORM NO. L-20094-E-0914
BRAKE
NOTE
FlangemountingoftheDPBBrakeisnotrecommended.
Tapped holes in the DPB Brake’s Splined Hub (Item
35) are used to connect the brake to a torque pin or
torque arm.
1. Thoroughly inspect tapered bore of Flanged Hub (Item
36) and tapered surface of Q.D. bushing. Remove any
dirt, grease, or foreign material.
NOTE: Do not use lubricants when installing O.D.
bushing.
2. Install Q.D. bushing into flanged hub, aligning untapped
holes in Q.D. bushing flange with tapped holes in flanged
hub.
3. Loosely insert pull-up bolts and lockwashers into Q.D.
bushing and tapped holes of flanged hub.
NOTE: Do not use lubricants or thread locking
compounds on pull-up bolts.
4. Insert customer supplied key into motor shaft.
5. Slide DPB Brake onto motor shaft.
FIGURE 2
Dial Indicator
Q.D. Bushing
Pull-up
Bolts
TORQUE ARM
Refer to Figure 3.
1. Using Cap Screws (Item 42) and Lockwashers (Item
43) secure Torque Arm (Item 37) onto Splined Hub
(Item 35).
2. Tighten Cap Screws (Item 42) to 119 ft. lbs. torque.
3. Using Cap Screws (Item 40) and Lock Nut (Item 44),
secure Extension Arm (Item 37) to Torque Arm (Item
38).
4. Tighten Lock Nut (Item 44) to 70 ft. lbs. torque.
5. Using Cap Screw (Item 41) and Lock Nut (Item 45),
attach Extension Arm (Item 38) to Bracket (Item 39).
6. Tighten Lock Nut (Item 45) to 200 ft. lbs. torque.
7. Using four customer supplied 7/16-UNC bolts, secure
Bracket (Item 39) to a firm support.
42
43
FIGURE 3
37
40
44
38
41
45
39
35
CAUTION
Do not over tighten pull-up bolts. If
excessive tightening torque is applied,
bursting pressure is created in flanged
hub.
CAUTION
Do not strike O.D. bushing to
"set" it in the tapered bore.
6. Alternately and evenly tighten pull-up bolts to
recommended torque (See Table 1).
NOTE: Runout is minimized if a dial indicator is used
as the Q.D. bushing pull-up bolts are tightened.
Place contact tip of dial indicator on smooth
surface of Flange Mount Disc (Item 5) to
measure runout. Runout on this surface must
not exceed 0.003 T.I.R. when pull-up bolts are
tightened (See Fig. 2).
INSTALLATION (continued)

FORM NO. L-20094-E-0914
7
Connect air supply to Adaptor Fittings (Item 16) located
on the Piston/Drive Disc (Item 2).
NOTE: Adaptor Fittings (Item 16) are 1/8 NPT.
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
Do not use rigid pipe or tubing
for air line connections.
Air
Supply
Brake
Inlet
Gauge
Regulator
Filter
Dryer
Brake Control Circuit
Quick Exhaust
Valve
3/2 (3 Way)
N.O. Valve
AIR PRESSURE:
8 BAR (120 PSI) ABSOLUTE MAX
0 BAR (0 PSI) ABSOLUTE MIN
AIR CONNECTIONS
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.
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.

8
FORM NO. L-20094-E-0914
OPERATION
TABLE 2
Recommended Tightening Torques
NOITPIRCSED T9-BPD T11-BPD T31-BPD T51-BPD
)31metI(SWERCSREDLUOHS.sbl.tf9.sbl.tf9.sbl.tf9.sbl.tf9
)02metI(TUNKCOL.sbl.tf23.sbl.tf07.sbl.tf07.sbl.tf07
)12metI(WERCSPAC.sbl.tf84.sbl.tf84.sbl.tf911.sbl.tf911
)24metI(WERCSPAC.sbl.tf911.sbl.tf911.sbl.tf911.sbl.tf911
)44metI(TUNKCOL.sbl.tf07.sbl.tf07.sbl.tf921.sbl.tf921
)54metI(TUNKCOL.sbl.tf002.sbl.tf002.sbl.tf002.sbl.tf002
The DPB Brake engages when air pressure is introduced into
the Cylinder/Drive Disc. Air pressure pushes the Cylinder/
Drive Disc against the Flange/Mount Disc, and forces the
Cylinder/Drive Disc in the opposite direction.
This engages the Friction Facings with the friction surfaces
of the Flange Mount Disc and Friction Disc.
Torque is transmitted through the Cylinder/Drive Disc
and Piston/Drive Disc to the Splined Hub attached to the
Torque Arm.
Heat generated at the friction surfaces is dissipated by
windage created by fins on the Flange Mount Disc and
Friction Disc.
When air is exhausted from the cylinder, return springs pull
the piston to a disengaged position.
MODEL RPMs
DPB-9T 2200
DPB-11T 1800
DPB-13T 1200
DPB15T 900
TABLE 3
Maximum Recommended Operating Speeds
CAUTION
The temperature limits for this
product line are 4.5-104 Degree
Celsius (40-220 Degree F).
CAUTION
Prior to placing DPB Brake into service,
verify that all screws are secured to the
recommended torque (See Table 2).
WARNING
The outer assembly of the DPB Brake
rotates. A guard that will not restrict
the flow of cooling air around the brake
must be installed if the DPB Brake is
installed in an area where injury to an
operator could occur.
WARNING
Never exceed maximum operating
speeds listed for your product.
(See Table 3).
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).

FORM NO. L-20094-E-0914
9
FIGURE 5
12
11
420
7
11
16
10
35
13
14
2
3
FRICTION FACING (Item 4)
Inspect Friction Facings for wear, and replace when they
are approximately 9/32" thick. Friction Facings can be
replaced without removing DPB Brake from motor shaft.
Refer to Figures 4 & 5.
1. Disconnect air supply lines from Adaptor Fittings (Item
16).
2. Remove Cap Screws (Item 42), Lockwashers (Item 43),
and swing Torque Arm (Item 37) clear of DPB Brake.
3. Remove Cap Screws (Item 12) and Locknuts (Item 20).
4. Remove Friction Disc (Item 7).
5. Remove Shoulder Screws (Item 13) and Springs (Item
14).
6. Slide Piston/Drive Disc (Item 2) off Splined Hub (Item
35).
7. Remove Retaining Ring (Item 10).
8. Slide Cylinder/Drive Disc (Item 3) off Splined Hub (Item
35).
9 Remove Machine Screws (Item 11), and replace worn
Friction Facings (Item 4).
PARTS REPLACEMENT
FIGURE 4
Alignment
Mark
Alignment
Mark
Alignment
Mark
Alignment Mark
NOTE: On some models of the DPB Brake, the
Machine Screws (Item 11) are assembled with
a green anaerobic thread locking compound.
If removal is difficult, strike end of screwdriver
with a hammer to break crystalline structure of
locking compound before attempting to remove
screws. Machine Screws (Item 11) furnished
with newFriction Facings have a locking patch
and do not require the use of a thread locking
compound.
10. Reverse Steps 1 through 8 to reassemble the DPB
Brake, noting chalk alignment marks, and tighten all
screws to recommended torque (See Table 2).
CAUTION
The Nexen DPB Brake has been balanced
at the factory. During disassembly, mark
components with chalk alignment marks
to insure correct alignment and balance as
the DPB Brake is reassembled (See Fig. 4).
When reassembling the Nexen DPB Brake,
make sure all screws are tightened to the
recommended torque (See Table 2).
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.

10
FORM NO. L-20094-E-0914
FIGURE 6
8
9
O-RINGS (Items 8 & 9)
Refer to Figure 6.
Replace O-rings (Items 8 &, 9) if there are noticeable air
leaks or loss of torque.
1. Proceed with Steps 1 through 8 for Friction Facing
replacement.
2. Remove O-rings (Items 8 & 9) and clean o-ring contact
surfaces.
3. Lubricate new O-rings (Items 8 & 9) and o-ring contact
surfaces with O-ring lubricant.
4. Install new O-rings.
5. Reverse Step 1 to reassemble DPB Brake, noting chalk
alignment marks,and tighten all screwsto recommended
torque (See Table 2).
BEARINGS (Item 25)
Refer to Figure 7.
DPB Brake Bearings (Item 25) are prelubricated, sealed,
and do not require further lubrication.
1. Disconnect air supply lines from Adaptor Fittings (Item
16).
2. Remove Cap Screws (Item 42), Lockwashers (Item 43),
and swing Torque Arm (Item 37) clear of DPB Brake.
3. Loosen Q.D. Bushing.
a. Remove Q.D. Bushingpull-upbolts and lockwashers.
b. Insert pull-up bolts into tapped Q.D. bushing removal
holes and progressively tighten each one until
Flanged Hub (Item 36) is loose on Q.D. bushing.
4. Wedge a screwdriver into saw cut in Q.D. bushing to
loosen Q.D. bushing from shaft and remove DPB Brake.
5. Proceed with Steps 3 through 8 for Friction Facing
replacement.
6. Remove Cap Screws (Item 21) (See Fig. 7).
7. Separate Flange Mount Disc (Item 5) from Flanged
Hub (Item 36) and Splined Hub (Item 35).
8. Remove Retaining Ring (Item 27).
9. Fully supporting Splined Hub (Item 35), press Flanged
Hub (Item 36) out of Bearings (Item 25).
10. Remove Retaining Ring (Item 26) (See Fig. 7).
11. Fully supporting Splined Hub (Item 35), press Bearings
(Item 25) out of Splined Hub.
12. Clean bearing contact surfaces of Flanged Hub (Item
36), and Splined Hub (Item 35) with safety solvent.
13. Press new Bearings (Item 25) into Splined Hub (Item
35).
NOTE: When installing new bearings, carefully align
bearing O.D. with bore of splined hub. Apply
Loctite 601 or equivalent to outer race of new
bearings.
(continued...)
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 (continued)

FORM NO. L-20094-E-0914
11
FIGURE 7
21
5
36
Q.D. Bushing
16
35
27
25
26
Pull-up
Bolts
REPLACEMENT PARTS
The item or balloon number for all Nexen products is used
for part identification on all product parts lists, product
price lists, unit assembly drawings, bills of materials, and
instruction manuals.
When ordering replacementparts, specify modeldesignation,
item number, part description, and quantity. Purchase
replacement parts through your local Nexen Distributor.
TORQUE ARM
FIGURE 8
37 42
43
38
39
41
45
40
44
ITEM DESCRIPTION QTY.
37 Arm, Torque 1
38 Bar, Extension 1
39 Bracket 1
40 Screw, Cap 1
41 Screw, Cap 1
42 Screw, Cap 3
431Lock washer 3
441Nut, Lock 1
45 Nut, Lock 1
1Qty. 4: DPB-15T
14. Install Retaining Ring (Item 26).
15. Press Flanged Hub (Item 36) into Bearings (Item 25)
and Splined Hub (Item 35).
16. Install Retaining Ring (Item 27).
17. Reverse Steps 1 through 7 to reassemble DPB Brake,
noting chalk alignment marks, and tighten all screws to
recommended torque (See Table 2).
PARTS REPLACEMENT (continued)

12
FORM NO. L-20094-E-0914
ITEM DESCRIPTION QTY.
2 Piston/Drive Disc 1
3 Cylinder/Drive Disc 1
4 Facing, Friction 2
5 Disc, Flange Mount 1
6 Housing 1
7 Disc, Friction 1
8 O-ring (Large) 1
9 O-ring (Small) 1
10 Ring, Retaining 1
11 Screw, Machine 16
12 Screw, Cap *
13 Screw, Shoulder **
14 Spring **
15 Fitting, Adapter 2
ITEM DESCRIPTION QTY.
20 Nut, Lock *
21 Screw, Cap 6
25 Bearing 2
26 Ring, Retaining 1
27 Ring, Retaining 1
35 Hub, Splined 1
36 Hub, Flanged 1
DPB BRAKE
MODEL *QTY. **QTY.
DPB-9T 6 4
DPB-9T 6 6
DPB-9T 8 8
DPB-9T 10 8
FIGURE 9
11 4 8 20
11
7
16
35
Support
Bushing
27
25
13
14
2
6
3
9
26
5
Pull-up
Bolts
Q.D.
Bushing
36
21
10
12 4
REPLACEMENT PARTS (continued)

FORM NO. L-20094-E-0914
13
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.