Enclosed Tooth Clutches
Contents
1. N Never exceed maximum operating speeds listed for your product See Table 4 TABLE 4 5SH35P E 1350 SHAOP E 1350 TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Control valve malfunction or low air pressure Check system for air leaks or replace control valve Lack of lubrication on the Hub spline or in the Lubricate the Hub spline or check the Air Chamber lubrication of the Air Chamber Failure to Engage Rigid pip or tubing is being used for the air line Use flexible tubing for the air line connections connections A rigid inline coupling is mounted directly to Use Nexen s Flexible Clutch Coupling for the Drive Flange inline applications Never connect a rigid coupling directly to the Drive Flange Unexhausted air due to a control valve Replace the control valve malfunction Broken Return Springs Replace the Return Springs Failure to Disengage Lack of lubrication on the Hub spline or in the Lubricate the Hub spline or check the Air Chamber lubrication of the Air Chamber A rigid inline coupling is mounted directly to Use Nexen s Flexible Clutch Coupling for the Drive Flange inline applications Never connect a rigid coupling directly to the Drive Flange Tooth Wear or Excessive engagement RPM or unintentional Contact Nexen for clutch specifications Clicking Sound disengagement due to torque overload Limit the air pressure to 80 psi Excessive air pressure increases the thrust load on the bearings St2. Ball Bearing into the Cylinder Item 2 18 Remove the Retaining Ring Item 13 from the Piston Item 3 19 Press the old Ball Bearing Item 12 out of the Piston Item 3 20 Clean bearing bore of Piston Item 3 with fresh solvent Make sure all old Loctite residue is removed 21 Apply an adequate amount of Loctite 680 to evenly coat the outer race of the new Ball Bearing Item 12 then press the new Ball Bearing into the Piston Item 3 22 Reinstall the Retaining Ring Item 13 23 Coat o ring contact surfaces of Piston Item 3 and Cylinder Item 2 with a thin film of o ring lubricant 24 Coat the new O ring Seals Items 15 and 16 witha thin film of o ring lubricant NOTE When installing new O ring Seals and Back up Rings make sure the curved surface of the Back up Ring matches surface of O ring Seal The Back up Rings must be installed on the non pressurized side of the O ring Seals 25 Install the new O ring Seals Items 15 and 16 and Back up Rings Items 20 and 21 on the Piston Item 3 and Cylinder Item 2 NOT Use caution when pressing the Piston into the Cylinder to avoid damaging O ring Seals and Back up Rings 26 Press the Piston Item 3 into the Cylinder Item 2 FIGURE 7 11 FIGURE 8 FIGURE 9 FIGURE 10 awe 21 16 s FORM NO L 20203 G 0814 PARTS REPLACEMENT continued REFER TO FIGURES 11 13 27 Slide the Drive Flange It
3. a flexible coupling half The internal construction of 5HPE and Series Clutches will not allow any misalignment tolerances If a coupling is required use the Nexen Clutch Coupling Refer to Nexen Clutch Coupling brochure 20208 NOTE Nexen 5HP E is shaft mounted using a customer supplied full length key REFER TO FIGURE 1 1 Install Nexen Clutch Coupling Bearing Supported Pulley Sprocket or Gear See Table 2 2 Insert customer supplied key into shaft 3 Slide Clutch onto shaft and customer supplied key NOTE Whenever possible arrange the input drive to the clutch through the drive flange to prevent clutch bearings from rotating unnecessarily 4 Using Set Screws tem 18 and 19 secure Clutch to shaft NOTE A locking collar with three set screws is used in 5H80P E models 5 Tighten Set Screws Item 18 and 19 to recommended torque See Table 3 NOTE Align air inlet port to the six o clock down position to allow condensation to drain out of the exhaust port TABLE 2 RECOMMENDED TIGHTENING TORQUES Model Torque Model Torque _ Set Screw tem 18 Customer Supplied Key Set Screw Item 19 Bearing Supported Pulley Sprocket FIGURE 1 or Coupling Item 19 is a locking collar in 5H8OP E models TABLE 3 RECOMMENDED TIGHTENING TORQUES Model Torque Item 18 Torque Item 19 _ 5H50P E 21 in lbs 2 4 Nm 61 in lbs 6 9 Nm 5H60P E 21 in lbs 2 4 Nm 61 i
4. ay within specified speed limits as specified in the OPERATIONS SECTION Use Nexen s Flexible Clutch Coupling for inline applications Never connect a rigid coupling Bearing Failure directly to the Drive Flange Avoid applying excessive overhung loads to Pilot Mount Clutches Wide pulleys or sprockets which extend beyond the end of the clutch will increase the radial load and reduce bearing life Rotary Seal MOOD Cylinder OE AI Piston Ball Ball Bearing i Back up l gt Ring Compression Spring yi Enclosure O ring Seal FIGURE 2 6 FORM NO L 20203 G 0814 PARTS REPLACEMENT Working with spring loaded or tension loaded fasteners and devices can cause injury Wear safety glasses and take the appropriate safety precautions REFER TO FIGURES 3 6 1 Remove the Set Screws Item 18 and 19 Hub and NIE Piston Cylinder A Locking collar with three set screws is used Assembly in 5H80P E models 2 Remove the Retaining Ring Item 14 ad Fully supporting the lip of Drive Flange Assembly press the Hub Item 1 and Piston Cylinder Assembly out of the Drive Flange Assembly Cylinder Piston Assembly 4 Remove the old Rotary Seal Item 4 5 Remove the Retaining Ring Item 14 O Fully supporting the Cylinder Piston Assembly press th
5. conformity with the applicable provisions of the Directive Nexen Group Inc 560 Oak Grove Parkway Vadnais Heights Minnesota 55127 ISO 9001 Certified Copyright 2014 Nexen Group Inc FORM NO L 20203 G 0814 il TABLE OF CONTENTS General SPCC Ca et oa AO OG 1 General Safety Precautions 0 n0nnnnnnn nnn EE EE EE EE EE EE Ee EE EE EE EE EE ee ee 1 INIROGUIG HOG GO AA EE 2 Else EE AA AA AE AA AE Ee 3 Bielie ve AE EA AE OE AE AE 4 Air Connections a aaa a a na 5 Bee eaae aea 5 Troubleshooting ae Ge Handed Oe ek 6 Bad AE OE OE AA EE ER a 7 Repair Kits 22 c0nn Eea macnn EE EE Ee EE ee EE EE EE EE ee Ee EE Ee ee 9 Kepler Parts EER RE ER EO IE ER RR GEE AE EE DR RR ARE ER OE ER Ee EE ee ee 10 EER AE AE 11 iii FORM NO L 20203 G 0814 GENERAL SPECIFICATIONS Specifications Up to 3730 Nm 83000 in lbs 1 5 5 bar 14 5 80 psi 4 5 104 C 40 220 F Approximate Weight Up to 33 6 kg 74 Ibs GENERAL SAFETY PRECAUTIONS Use appropriate guarding for moving Use lifting aids and proper lifting components Failure to guard could result in serious bodily injury Watch for sharp features when interacting with this product The parts have complex shapes and machined edges techniques when installing removing or placing this product in service This product is capable of emitting a spark if misused therefore is not recommended for use in any explosive environment E
6. e Hub ltem 1 out of the Cylinder Piston Assembly FIGURE 4 7 Remove the old Compression Springs Item 8 8 Remove the Retaining Ring Item 13 9 Press the old Ball Bearings Item 12 out of the Drive Flange Assembly 10 Clean bore of Drive Flange Assembly with fresh solvent making sure all old Loctite residue is removed Drive Flange Assembly NOTE When installing new Ball Bearings carefully align the Ball Bearing O D with Drive Flange FIGURE 5 Assembly bore to prevent Ball Bearing misalignment 11 Apply an adequate amount of Loctite 680 to evenly coat the outer race of the new Ball Bearings Item 12 then press the new Ball Bearings into the Drive Flange Assembly 12 Reinstall the Retaining Ring Item 13 13 Remove the Drive Flange Item 22 from the Piston Cylinder Assembly Cylinder Piston Assembly FIGURE 6 FORM NO L 20203 G 0814 7 PARTS REPLACEMENT continued REFER TO FIGURES 7 10 14 Separate Piston Item 3 from Cylinder tem 2 15 Remove the old O ring Seals Items 15 and 16 and Back Up Seals Items 20 and 21 from the Piston Item 3 and Cylinder Item 2 16 Press Ball Bearing Item 11 out of Cylinder Item 2 17 Clean the bearing bore of the Cylinder Item 2 with fresh solvent making sure all old Loctite residue is removed 18 Apply an adequate amount of Loctite 680 to evenly coat the outer race of the new Ball Bearing Item 11 then press the new
7. em 22 into the Cylinder Item 2 and Ball Bearing tem 11 28 Install new Compression Springs Item 8 29 Coat the spline teeth of the Hub tem 1 with NEVER SEEZ and slide the Hub Item 1 into the Drive Flange 30 Reinstall the Retaining Ring Item 14 NOTE The back of the Rotary Seal must be installed facing the Drive Flange Assembly end of the clutch 31 Install the new Rotary Seal Item 4 into the groove in Cylinder NOTE Use caution when sliding Drive Flange Assembly onto Cylinder Piston Assembly to avoid damage to Rotary Seal REPAIR KITS Number Number FORM NO L 20203 G 0814 Cylinder Piston Assembly FIGURE 12 Rotary Seal Item 4 FIGURE 13 REPLACEMENT PARTS LIST 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 1g 12 og 17 109S we VA ODO Item 19 is a locking collar in 5H80P E models When ordering replacement parts specify model designa tion item number part description and quantity Purchase replacement parts through your local Nexen Distributor QUANTITY 1 ee ere eee ME EEN ioio ae aa f OO N OE 2 EN tt ME N Pt tt 4 EEN RotaySel oon tt mm mk mk i 7 1 Repair Kit Items mm ml mk mm ml mk vio gt AAR FE i Item 19 is a l
8. ement 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 t
9. he 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 80 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 act
10. hen tooth velocity and air pressure settings are too high i e a smaller clutch has a lower tooth velocity at any given RPM and a small clutch has less driver inertia V 10 P 22 WK Where N Differential RPM Limit Clutch V Constant for Clutch See Table 1 P Operational Pressure P S I WK referred Inertia Lb e Ft EXAMPLE The required differential engagement speed using a Model 5H45P E clutch at 60 psi is 150 RPM Clutch rotating at 1250 machine component at 1100 The referred inertia is 3 Lb es Ft The differential RPM limit for the clutch is 1 4 10 p 60 22 V 3 N 213 RPM 150 RPM is within the limit of the 5H45P E operating at 60 psi with a load of 3 Lb Ft TABLE 1 CONSTANTS FOR CLUTCHES NOTE The Differential Speed Formula does not estimate RPM which prevents ratcheting e acceleration time e tooth stress after engagement If differential speed exceeds the clutch limitations ratcheting of the teeth can occur and shorten clutch life FORM NO L 20203 G 0814 INSTALLATION Nexen SHPE Series clutches have a drive flange with two bearings a pilot diameter and tapped holes for mounting a pulley sprocket or the Nexen Clutch Coupling Refer to Sales Brochure L 21479 See Table 2 for recommended tightening torgues NOTE Nexen recommends using a red anaerobic thread locking compound on Pilot Mounting Bolts Do not connect in line without the use of
11. ion 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 ne gt lt en 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 20203 G 0814 11
12. n lbs 6 9 Nm 5H80P E 21 in lbs 2 4 Nm 61 in lbs 6 9 Nm In severe use applications the clutch may tend to move axially along the shaft To prevent axial movement confine the clutch between shoulders clamp collars or insert spring pins through the shaft Mounting positions of Tooth Clutches may be horizontal or vertical Nexen recommends the Drive Flange faces up to en hance the spring return when mounting tooth clutches in the vertical position FORM NO L 20203 G 0814 LUBRICATION 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 4 Close the air line to the unit when a drop of oil forms in the Lubricator Sight Gage The
13. nes lt en AIR CHAMP PRODUCTS User Manual 22 Enclosed Tooth Clutches 5HP E Series CE RoHS ee al FORM NO L 20203 G 0814 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 651 484 5900 www nexengroup com DANGER 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 This document is the original non translated version Conformity Declaration In accordance with Appendix Il 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 incorpo rated has been declared in
14. nsure proper guarding of the product is used Nexen recommends the machine builder design guarding in compliance with OSHA 29 CFR 1910 Occupa tional Safety and Health Hazards This product has possible pinch points Care should be taken when interacting with this product The temperature limits for this product are 4 5 100 C 40 220 F Use appropriate guarding for moving components Failure to guard could result in serious bodily injury FORM NO L 20203 G 0814 1 INTRODUCTION Nexen 5HP E Multi Position Tooth Clutches are designed for applications that require a high starting torque without slipping Tooth clutches are normally engaged when stationary In certain circumstances such as low RPM tooth clutches can be engaged at differential soeeds up to 150 RPM The allowable engagement speed depends on the rotational inertia of the mass being accelerated and the air pressure applied If the tooth clutch is to be engaged in other than static conditions solve the following Differential Soeed Formula to make sure the application s speed is within the limits of the selected clutch DIFFERENTIAL SPEED FORMULA Use the Differential Soeed Formula to find the allowable engagement speed N at a specific air pressure setting P with a given inertia load WK This formula expresses the relationship of the variables involved that effect the impact of the face teeth during engagement Tooth damage can occur w
15. ocking collar in 5H80P E models FORM NO L 20203 G 0814 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 agre
16. ooth Clutch will prevent proper actuation of the Tooth Clutch Although Nexen 5HP E Enclosed Tooth Clutches are air actuated with a maximum operating air pressure of 80 psi use only enough air pressure to deliver ample torque for the application Operating air pressures over 80 psi will eventually cause bearing and seal damage Due to bearing seal drag the cylinder piston assembly will rotate resulting in hose breakage when clutch is engaged Resting the hose against a support mounted parallel to the clutch centerline stops this rotation and will prevent the hose from breaking OPERATION Ensure proper guarding of the product is used Nexen recommends the machine builder design guarding in compliance with OSHA 29 CFR 1910 Occupa tional Safety and Health Hazards The temperature limits for this product line are 4 5 100 C 40 220 F FORM NO L 20203 G 0814 Low air pressure will cause slippage and overheating Excessive air pressure will cause abrupt starts and stops reducing product life The following is acommon 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 Brake Control Circuit Filter Gauge Dryer Eg er J SS 3 2 3 Way TING Valve Ouick Exhaust AIR PRESSURE 8 BAR 120 PSI ABSOLUTE MAX O BAR 0 PSI ABSOLUTE MIN N N
17. se settings are for Nexen supplied lubricators If you are not using a Nexen SE Er EO RE AE lubricator calibration must follow the manufacturer s suggested procedure 6 Turn the Lubricator Adjustment Knob clockwise until 1 Close and disconnect the air line from the unit closed 2 Turn the Lubricator Adjustment Knob 7 Turn the Lubricator Adjustment Knob counterclockwise three complete turns counterclockwise one third turn 3 Open the air line 8 Open the air line to the unit SPLINE Although the Spline has been lubricated at the factory with a high temperature anti seize lubricating compound Nexen recommends periodic lubrication of this component to ensure smooth clutch engagement and disengagement FACE TEETH Periodically lubricate Drive Flange Assembly Face Teeth and Drive Ring Item 17 with NEVER SEEZ NOTE Clutch must be disassembled to lubricate Spline and Face Teeth 4 FORM NO L 20203 G 0814 AIR CONNECTIONS All Nexen pneumatically actuated devices require clean and dry air which meets 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 unit Align the air inlet ports to a down position to allow condensation to drain out of the air chambers of the product NOTE Use only flexible hose or tubing when making air line connections Rigid pipe or tubing connected directly to the T
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