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FORM 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

Summary of Contents for AIR CHAMP DBSE

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

Page 2: ...ce 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...

Page 3: ...eral 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...

Page 4: ...esult 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 t...

Page 5: ...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 P...

Page 6: ...istance 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 su...

Page 7: ...r 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...

Page 8: ...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 g...

Page 9: ...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 co...

Page 10: ...at 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 It...

Page 11: ...l 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 Ca...

Page 12: ...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 C...

Page 13: ...TURE 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 SU...

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