Horton Air Clutch Manual
Contents
1. oil mist into the air chamber Lubricator drip rate is properly set when an oil drop forms in the lubricator sight gauge every twenty cycles of the DPC Clutch Locate the lubricator above and within ten feet of the DPC Clutch OPERATION CAUTION Before placing the DPC Clutch into service verify that all screws are secured to the proper torque See Table 4 The DPC Clutch engages when air pressure is introduced into the C ylinder Drive Disc Air pressure pushes the C ylinder Drive Disc against the Flange Mount Disc and forces the C ylinder Drive Disc in the opposite direction This engages the Friction Facings with the friction surfaces of the Flange Mount Disc and the Friction Disc Torque is transmitted through the C ylinder Drive Disc and Piston Drive Disc Splines to the Splined Hub attached to the S haft with a Q D Bushing Heat generated at the friction surfaces is dissipated by windage created by the fins on the Flange Mount Disc and the Friction Disc W hen air is exhausted from the C ylinder Return Springs pull the Piston to disengaged position CAUTION Never exceed the recommended operating speeds See Table 5 WARNING All parts of the DPC Clutch rotate A guard that will not restrict the flow of cooling air around the DPC Clutch must be installed ifthe DPC Clutch is installed in an area where injury to an operator could occur NOTE Usealow visc2. ESCRIPTION S heave Lockwasher Cap Screw 10 FORM NO L 20070 C 0501 WARRANTIES Warranties Nexen warrants that the Products will be free from any defects in material or workmanship fora period of 12 months from the date ofshipment 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 of the Buyer for any breach of the warranties set out above will be at the sole discretion of Nexen a repair or replacement with new serviceably used or reconditioned Product or issuance of credit in the amount of the purchase price paid to Nexen by the Buyer for the Products Limitation of 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 CONSE
3. QUENTIAL 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 Forall of the purposes hereof the term consequential damages shall include lost profits penalties delay images 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 Limitation of Damages In no event shall Nexen be liable for any consequential indirect incidental or special damages of any nature whatso ever including without limitation lost profits arising from the sale or use of the Products Warranty Claim Procedures To make a claim und
4. alling the Q D Bushing 3 InstallQ D Bushing into S plined Hub aligning untapped holes on Q D Bushing Flange with tapped holes in S plined Hub See Fig 2 CAUTION Do not strike Q D Bushing to SET it in the yon Indicator tapered bore FIGURE 2 4 Loosely insert Pull Up Bolts and Lockwashers into Q D Bushing and tapped holes of S plined Hub See Fig 2 2 FORM NO L 20070 C 0501 NOTE Do not use lubricants or thread locking compounds on Pull Up Bolts 5 Measure runout of Motor Shaft Runout must not exceed 0 002 T I R Total Indicator Reading See Fig 2 6 Insert Key into Motor S haft Keyway 7 Slide DPC Clutch onto Motor S haft 8 Alternately and evenly tighten Pull Up Bolts to recommended torque See Table 1 CAUTION Do not over tighten Pull Up Bolts If excessive tightening torque is applied bursting pressure i created in the Splined Hub NOTE Runoutis minimized if a Dial Indicator is used as the Q D Bushing Pull Up Bolts are tightened Place contact tip of Dial Indicator on the machined surface of the S plined Hub to measure runout Runouton this surface must be within 0 003 T I R when the Pull Up Bolts are tightened S ee Fig 2 SHEAVE MOUNT NOTE The Sheave Clutch is a combination of the Pilot Clutch and Sheave Assembly both shipped ina separate container 1 Slide the S heave Item 26 onto the pilot diameter of the Pilot Clutch Assembly S ee F
5. equences of each method Accordingly anyone who uses a procedure that is not recommended by Nexen must first satisfy themselves that neither their safety or the safety of the product will be jeopardized by the service method selected Nexen s DPC Dual Friction Plate Clutches 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 when the DPC Clutch is connected to a bearing supported Flywheel S procket or S heave Five components are combined to install Nexen s DPC Clutch and a Pilot Mount Clutch or as a S heave C lutch FORM NO L 20070 C 0501 The five basic components each sold separately are Pilot Clutch Assembly S heave Rotary Air Union Cap Q D Bushing and Rotary Air Union The inner and outer assembles of the DPC Clutch rotate independently W hen mounted on a through shaft the outer clutch assembly rotates and upon engagement the inner clutch assembly becomes the driven unit W hen mounted on a continually running shaft the inner clutch assembly rotates and upon engagement the outer clutch assembly becomes the driven member Nexen recommends mounting the DPC Clutch with the outer clutch assembly rotating continuously taking advantage of the cooling effect of the fins to dissipate heat generated when the clutch is engaged WARNING This
6. er this warranty the claimant must give written notice of the alleged defect to whom the Product was purchased from and deliver the Product to same within one year of the date on which the alleged defect first became apparent nNexen Nexen Group Inc 800 843 7445 560 Oak Grove Parkway Fax 651 286 1099 Vadnais Heights MN 55127 www nexengroup com ISO 9001 Certified FORM NO L 20070 C 0501 11
7. hers b Insert Pull Up Bolts into tapped Q D Bushing removal holes and alternately and evenly tighten each one until the 5 plined Hub Item 1 is loose on the Q D Bushing 3 Wedge a screwdriver into the sawcut in the Q D Bushing to loosen the Q D Bushing from the S haft then remove the DPC Clutch 4 Remove Cap Screws Item 28 and Lockwashers Item 27 and Sheave Item 26 in mounted on the DPC Clutch See Fig 10 5 Proceed with steps 1 through 7 for the Friction Facing replacement 6 Remove Retaining Ring Item 17 See Fig 10 We WARNING Special attention should be exercised when working with retaining rings Always wear safety goggles when working with spring or tension loaded fasteners or devices 7 Fully supporting the Housing Item 5 press the Hub Item 1 out of the Housing and Bearings See Fig 10 8 Remove Retaining Ring Item 18 See Fig 10 REPLACE MENT PARTS The Item or Balloon Number for all Nexen Products is used for part identification on all Product Parts List Product Price List Unit Assembly Drawings Bills of Materials and Instruction Manuals FORM NO L 20070 C 0501 FIGURE 10 9 Fully supporting the Housing Item 5 push the Bearing Item 16 and Spacer Item 17 out of the Housing See Fig 10 10 Clean bearing contact surfaces of both Housing Item 5 and Hub Item 1 with fresh safety solvent 11 Press ne
8. ig 3 2 Align the mounting holes in the S heave Item 26 with the tapped holes in the Housing Item 5 See Fig 3 3 Install the Cap Screws Item 28 and Lockwashers Item 27 See Fig 3 4 Tighten the Cap Screws Item 28 to the recommended torque See Table 2 5 Proceed with Steps 1 through 8 for Pilot Mount Clutch Installation FORM NO L 20070 C 0501 26 28 27 FIGURE 3 TABLE 2 Recommended Tightening Torques DESCRIPTION DPC 9T DPC 11T Shoulder Screw Item 12 9 ft Ibs 9 ft Ibs Cap Screw Item 15 48 ft Ibs 48 ft lbs Cap Screw Item 24 13 ft Ibs 13 ft Ibs Cap Screw Item 28 48 ft Ibs 48 ft Ibs AIR CONNECTIONS SHAFTEND MOUNTING 1 Install two Elbow Fittings Item 20 into the Rotary Air Union Cap Item 25 See Fig 4 Install an Adaptor Fitting Item 19 and Elbow Fitting Item 20 into each air inlet or the Piston Drive Disc Item 2 See Fig 4 Using Cap Screws Item 24 attach the Rotary Air Union C ap Item 25 to the tapped holes of the Splined Hub Item 1 See Fig 4 NOTE The Rotary Air Union Cap air outlets must be aligned at approximately 60 to the Piston Drive Disc air inlets for proper Hose Item 22 connection Tighten the Cap Screws Item 24 to the recommended torque See Table 3 Install Hoses Item 22 See Fig 4 Install the Rotary Air Union Item 21 Connect air supply to the Rotary Air Union NOTE Do not use rigid p
9. ipe or tubing for this connection For fast engagement and disengagement connect air controls as close to the DPC Clutch as possible W here long air lines are required use a quick exhaust valve THROUGH SHAFT MOUNTING 1 Drill a 3 8 diameter hole into the center of the shaft deep enough to reach the desired air outlets See Fig 5 NOTE Airoutlets should be approximately 3 8 from the end ofthe Hub Tap the end ofthe Shaft 5 8 18 by 5 8 deep See Fig 5 Drilla 11 32 diameter air outlet hole through the shaft intersecting the air inlet hole approximately 3 8 from the end ofthe Hub See Fig 5 Tap both air outlet holes 1 8 27 NPT by 5 8 deep See Fig 5 Install two Elbow Fittings Item 20 into each air outlet hole FIGURE 4 TABLE 3 Recommended Tightening Torques DESCRIPTION DPC 9T DPC 11T Cap Screw Item 24 13 ft Ibs 13 ft Ibs 5 8 18 NF TAP 5 8 DEEP 11732 DRILL THRU 17 8 NPT BOTH ENDS 80 APART 90 FROM KWY FIGURE 5 4 FORM NO L 20070 C 0501 Install an Adaptor Fitting Item 19 and Elbow Fitting Item 20 into each air inlet of the Piston Drive Disc Item 2 Install Hoses Item 22 Install the Rotary Air Union Item 21 See Fig 5 Connect air supply to the Rotary Air Union NOTE Do not use rigid pipe or tubing for this connection For fast engagement and disengagement connect air controls as close to the DPC Clutch as possible W here long ai
10. locking compound 9 Reverse Steps 1 through 7 to reassemble the DPC Clutch noting chalk alignment marks and tighten all screws to the recommended torque See Table 6 O RINGS Items 8 amp 9 NOTE Replace O rings Items 8 amp 9 if there are noticeable air leaks ora loss of torque 1 Proceed with Steps 1 through 7 for the Friction Facing Replacement 2 Remove O rings Items 8 amp 9 and clean o ring contact surfaces with fresh safety solvent S ee Fig 9 3 Lubricate new O rings and o ring contact surfaces with fresh o ring lubricant 4 Install new O rings Items 8 amp 9 See Fig 9 5 Revers Step 1 to reassemble the DPC Clutch noting chalk alignment marks and tighten all screws to the recommended torque S ee Table 6 KE NI TAN w SE AAS Re ZILI LES SSI Rood FIGURE 8 A MN Ses gee KO KERK XN g EE Boos el A koul kr oo hy CHE SANS FIGURE 8 FORM NO L 20070 C 0501 BEARINGS Item 16 NOTE DPC Clutch Bearings are prelubricated sealed and do not require further lubrication 1 Disconnect the air supply line and Hose Assemblies at the Piston Drive Disc Elbow Fittings NOTE Ifthe DPC Clutch is shaft mounted remove the Rotary Air Union C ap Item 25 On through shaft installation remove the Elbow Fittings Item 20 from the shaft 2 Loosen the Q D Bushing a remove Q D Bushing Pull Up Bolts and Lockwas
11. nexen AIR CHAMP PRODUCTS User Manual 29292 Models DPC 9T and DPC 11T 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 S upport 800 843 7445 651 484 5900 www nexengroup com WARNING 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 O N LY Improper installation can damage your system or cause injury or death Comply with all applicable codes Nexen Group Inc 560 Oak Grove Parkway Vadnais Heights Minnesota 55127 Copyright 2000 Nexen Group Inc ISO 9001 Certified ii TABLE OF CONTENTS INtrodUCtION ereeeereennooo one ennnoecnnoaconnornnroonnnnoounrcoounoouonoerennacounoconnrccuurocounocouunocnvorennoncunnoounocounonconreannnesoue 1 Installation eeeeeeeneeeecnononnnocnonoconnonconnoucnnoccunoocunceoonrocouroconnreouunocounorennrooonnooonnocuunocoonneonunccouroaunracounocconoconn 2 Air CONNECTIONS eeverereenereeooooooonoonnnoornnnoonunoccenoecunnoconncooenocuunnoonuveounnecoonoorenrooouneoonnoeouncoevnreoovresonnecouncennnen 4 Lubrication eeeeereereeonoorrorooenroronnooonnnoo
12. osity petroleum base oil such as SAE10 Synthetic lubricants are not recommended Fora DPC Clutch cycled infrequently apply two or three drops of oil into the air inlet every two weeks TABLE 4 Recommended Tightening Torques DPC 9T DPC 11T DESCRIPTION Shoulder Screw Item 12 9 ft Ibs 9 ft Ibs Cap Screw Item 15 48 ft Ibs 48 ft Ibs Cap Screw Item 24 13 ft Ibs 13 ft Ibs Cap Screw Item 28 48 ft Ibs 48 ft Ibs Pull Up Bolts 15 ft Ibs 30 ft Ibs TABLE 5 Recommended Tightening Torques OUTER MODEL ASSEMBLY INNER ASSEMBLY DPC 9T 2200 RPM 3000 RPM DPC 11T 1800 RPM 2500RPM FORM NO L 20070 C 0501 PARTS REPLACEMENT TABLE 6 Recommended Tightening Torques Alignment Alignment Mark CAUTION The Nexen DPC Clutch has been balanced at the factory During disassembly mark components with chalk alignment marks to insure correct alignment and balance as the DPC Clutch is reassembled See Fig 7 When reassembling the Nexen DPC Clutch make sure all screws are tightened to the recommended torque See Table 6 Alignment gp ZR e ZAM N y INM Alignment Alignment Mark Mark FIGURE 7 FRICTION FACING Item 4 NOTE Inspect Friction Facings for wear and replace when they are appropriately 9 32 thick Friction Facings can be replaced without removing the DPC Clutch from the motor shaft 1 Disconnect the air s
13. r lines are required use a quick exhaust valve THROUGH SHAFT MOUNTING 1 Drill a 3 8 diameter hole into the center of the shaft deep enough to reach the desired air outlets See Fig 5 NOTE Airoutlets should be approximately 3 8 from the end of the Hub Tap the end of the Shaft 5 8 18 by 5 8 deep See Fig 6 Drill a 11 32 diameter air outlet hole through the shaft intersecting the air inlet hole approximately 3 8 from the end of the Hub See Fig 6 Tap both air outlet holes 1 8 27 NPT by 5 8 deep See Fig 6 Install two Elbow Fittings Item 20 into each air outlet hole Install an Adaptor Fitting Item 19 and Elbow Fitting Item 20 into each air inlet of the Piston Drive Disc Item 2 Install Hoses Item 22 Install the Rotary Air Union Item 21 See Fig 6 Connect air supply to the Rotary Air Union NOTE Do not use rigid pipe or tubing for this connection For fast engagement and disengagement connect air controls as close to the DPC Clutch as possible W here long air lines are required use a quick exhaust valve FORM NO L 20070 C 0501 7 3 H MIN e 5 8 18 NF TAP 5 8 DEEP 11732 DRILL THRU IZ8 NPT BOTH ENDS 180 APART 90 FROM KWY FIGURE 6 LUBRICATION The most effective and economical way to lubricate the DPC Clutch is with an air line lubricator Available from Nexen the lubricator injects oil into the pressurized air forcing a constant
14. unit has rotating parts A guard that will not restrict the flow of cooling air around the unit must be used if the unitis installed in an area where injury to an operator could occur INSTALLATION NOTE All DPC Clutch installations require a Q D Quick Detachable Bushing Referto Table 1 for Q D Bushing Specifications TABLE 1 Q D Bushing Specifications BUSHING PULL UP BOLT MODED BORE TIGHTENING TORQUE DPC 9T 2 375 15 ft Ibs DPC 1 wig is i re SUPPORT BUSHING NOTE The Support Bushing provides radial load support at the shaft and is used when bore sizes smaller than standard are required 1 Place DPC Clutch Friction Disc side down and support large end of Splined Hub Item 1 See Fig 1 Support Bushing 2 Insert Support Bushing into bore of Splined Hub Item 1 See Fig 1 3 Apply even pressure around the entire diameter of the Support Bushing and press the Support B ushing into the S plined Hub Item 1 See Fig 1 CAUTION Do not use a hammer to install Support FIGURE 1 Bushing Nexen recommends a small arbor press NOTE On DPC 9T the Support Bushing fits flush with the end of the Splined Hub PILOT MOUNT CLUTCH 1 Install Support Bushing if required 2 Thoroughly inspect tapered bore of the Splined Hub AL and tapered surface of the Q D Bushing Remove L Si any dirt grease or foreign material S ee Fig 2 NOTE Do notuse lubricants when inst
15. unncenonocounoeoonnoocunecconreonunaconnoceonnocunnocennoecunnooouncoconocuuneorencevnnecevnoosenne 6 Operation 6 Parts Replacement 7 Replacement P arts 7 9 ACCESSOT ES 7 7 nna one annan nna 10 Warranties erereereeeonooeeonoooonouornooonnnoooouroounocoounorenncocuunocooncouuoneccncncnunocvouoocnovooconoconnrocnurocouncononceconcocnnrocone 11 iii INTRODUCTION 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 cons
16. upply and Hose Assemblies at the Piston Drive Disc Elbow Fittings NOTE Ifthe DPC Clutch is shaft end mounted remove the Rotary Air Union C ap Item 25 On through shaft installation remove the Elbow Fittings Item 20 from the shaft 2 Remove the Cap Screws Item 15 and Lockwashers Item 14 See Fig 8 3 Remove the Friction Disc Item 6 See Fig 8 4 Remove the Shoulder Screws Item 12 and Springs Item 13 See Fig 8 FORM NO L 20070 C 0501 7 5 Slide the Piston Drive Disc Item 2 off of the Splined Hub Item 1 See Fig 8 6 Remove the Retaining Ring Item 10 See Fig 8 WARNING Special attention should be exercised when working with retaining rings Always wear safety goggles when working with spring or tension loaded fasteners or devices 7 Slide the Cylinder Drive Disc Item 3 off of the Splined Hub Item 1 See Fig 8 8 Remove the Machine Screws Item 11 and replace worn Friction Facings Item 4 S ee Fig 8 NOTE Onsome models of the DPC 9T and DPC 11T the Machine Screws Item 11 are assembled with a green anaerobic thread locking compound If remove is difficult strike the end of the screwdriver with a hammer to break the crystalline structure of this locking compound before attempting to remove the screws The Machine Screws Item 11 that are furnished with new Friction Facings have a locking patch and do not require the use of a thread
17. w Bearings Item 16 and Spacer Item 7 into the Housing Item 5 See Fig 10 NOTE When installing new Bearings carefully align the Bearing O D with the Housing bore Apply Loctite RC 601 or equivalent to the outer race of the new Bearings 12 Install Retaining Ring Item 18 See Fig 10 13 Fully supporting the inner race of the new Bearings press the Hub Item 1 into the Bearings and Housing 14 Install Retaining Ring Item 17 See Fig 10 15 Reverse Steps 1 through 5 to reassemble the DPC Clutch noting the chalk alignment marks and tighten all screws to the recommended torque See Table 6 W hen ordering replacement parts specify model designation item number part description and quantity Purchase replacement parts through your local Nexen Distributor PARTS LIST 7 AN fen 14 15 ry Wy FIGURE 11 CLUTCH ASSEMBLY Hub Piston Drive Disc C ylinder D rive Disc MG FAR L LAT kis BRZII IN DA Friction Facing Housing Friction Disc Spacer O ring Seal Large O ring S eal S mall Retaining Ring Machine Screw Shoulder S crew S pring Lockwasher Cap Screw Bearing Retaining Ring Retaining Ring Adapter Fitting Elbow Fitting Rotary Air Union Hose Assembly Not Shown Hose Assembly Not S hown e NIe BNR rFND DD SS ROTARY AIR UNION CAP ITEM DESCRIPTION 24 Rotary Air Union Cap 1 25 Cap Screw 3 SHEAVE ITEM D
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