Models SSE-450, SSE-600, SSE-800, and SSE-1000

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Augustus Gaines
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1 Models SSE-450, SSE-00, SSE-00, and SSE

2 In accordance with Nexen s established policy of constant product improvement, specifications contained in this manual are subject change without notice. Technical data listed in this manual are based on latest information available at time of printing and are also subject change without notice. Technical Support: (51) DANGER Read this manual carefully before installation and operation. Follow Nexen s instructions and integrate this unit in 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 original, non-translated, version. Conformity Declaration: In accordance with Appendix II B of CE Machinery Directive (200/42/EC): A Declaration of Incorporation of Partly Completed Machinery evaluation for applicable EU directives was carried out for this product in accordance with 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 in service until machinery in which it is be incorporated has been declared in conformity with applicable provisions of Directive. Nexen Group, Inc. 50 Oak Grove Parkway Vadnais Heights, Minnesota ISO 9001 Certified Copyright 2017 Nexen Group, Inc. 2

3 Table of Contents General Specifications General Safety Precautions Installation Brake Guard Installation Lubrication Air Connections Operation Manual Disengagement Maintenance Troubleshooting Parts Replacement: Friction Facings Bearing, Compression Springs, and O-Ring Seals Replacement Parts List Accessories Facing and Repair Kits Warranty

GENERAL SPECIFICATIONS Specifications: Torque Up 41 Nm (3700 in-lbs) Actuation Pressure 1-5.5 bar (14.5-90 psi) Service Temperature 4.

Use lifting aids and proper lifting techniques when installing, removing, or placing in service. Watch for sharp features when interacting with this product.

4 GENERAL SPECIFICATIONS Specifications: Torque Up 41 Nm (3700 in-lbs) Actuation Pressure bar ( psi) Service Temperature C ( F) Approximate Weight Up 32 kg (70 lbs) GENERAL SAFETY PRES Some product assemblies can exceed 70 lbs. Use lifting aids and proper lifting techniques when installing, removing, or placing in service. Watch for sharp features when interacting with this product. The parts have complex shapes and machined edges. WARNING Ensure proper guarding of product is used. Nexen recommends machine builder design guarding in compliance with OSHA 29 CFR 1910 Occupational Safety and Health Hazards. Use appropriate guarding for moving components. Failure guard could result in serious bodily injury. WARNING This product is capable of emitting a spark if misused refore is not recommended for use in any explosive environment. This product has possible pinch points. Care should be taken when interacting with this product. The temperature limits for product are degree Celsius ( degree F). Use appropriate guarding for moving components. Failure guard could result in serious bodily injury. 4

5 INSTALLATION 1. Before mounting, ensure Cylinder (Item 10) has adequate clearance move freely (See Figure 1 and Table 1). 2. Insert Key (Item 1) in shaft (See Figure 2). FIGURE 1 Friction Disk Hub (Item 1) NOTE: Keep rque pin as short as possible. 3. Position SSE Brake on shaft and rque pin (See Figure 2). 4. Tighten Set Screw (Item 17) secure SSE Brake shaft (See Figure 2 and Table 2). NOTE: Models SSE-450, SSE-00 Mor or Machine Frame Cylinder moves axially engage and disengage. See Table 1 for clearance requirements. Cylinder (Item 10) The key (item 1, Fig. 2) does not clear pisn I.D. Assemble on shaft from finned-hub end of brake. TABLE 1 Mode odel Minimum Clearance for Cylinder (Friction Disc Hub Machine Frame) S SE In. [3.175 mm] S SE In. [3.175 mm] S SE In. [3.175 mm] S SE In. [9.525 mm] FIGURE 2 Friction Disk Hub (Item 1) Set Screw (Item 17) Spring Housing (Item 4) Torque Pin Slot Key (Item 1) Plate See installation note regarding models SSE-450, SSE-00 Check runout with Dial Indicar on Cylinder (Item 10) TABLE 2 Recommended Tightening Torque (Item 17) M odel Tightening Torque s S SE In. Lbs. [5 Nm] S SE In. Lbs. [10 Nm] S SE In. Lbs. [10 Nm] S SE In. Lbs. [37 Nm] 5

6 BRAKE GUARD INSTALLATION NOTE: Refer Figure Align mounting holes of Brake Guard with four tapped holes in SSE Mounting Flange. 2. Using four Phillips Head Pan Screws, secure Brake Guard SSE. Tighten 35 in-lbs [4 Nm]. 3. If Brake Guard is not through shaft mounting, place End Cap over front of Brake Guard and bend tabs around Brake Guard hold End Cap in place. Brake Guard End Cap SSE Mounting Flange FIGURE 3 LUBRICATION NOTE 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 cusmers prefer use an air line lubricar, which injects oil in pressurized air, forcing an oil mist in air chamber. This is acceptable, but care must be taken ensure once an air mist lubrication system is used, it is continually used over life of product as oil mist may wash free facry installed lubrication. Locate lubricar above and within ten feet of product, and use low viscosity oil such as SAE-10. Syntic lubricants are not recommended. Nexen product's bearings are shielded and pre-lubricated, and require no furr lubrication. LUBRICATOR DRIP RATE SETTINGS 1. Close and disconnect air line from unit. 2. Turn Lubricar Adjustment Knob counterclockwise three complete turns. 3. Open air line. These settings are for Nexen supplied lubricars. If you are not using a Nexen lubricar, calibration must follow manufacturer's suggested procedure. 4. Close air line unit when a drop of oil forms in Lubricar Sight Gage. 5. Connect air line unit.. Turn Lubricar Adjustment Knob clockwise until closed. 7. Turn Lubricar Adjustment Knob counterclockwise one-third turn.. Open air line unit.

7 AIR CONNECTIONS NOTE: Refer Figure 4. Never operate brake without Restricr installed. Restricr (Item 22) NOTE: The Restricr is provided prevent Shoulder Bolt (Item ) fatigue from impact during operation. 1. Connect Flexible Hose (Item 19) Restricr (Item 22) (See Figure 4). NOTE: The Auxiliary Cooling Option has been removed from all standard Nexen S, T and TSE series brakes. It is a passage for compressed air be connected for increased rmal capacity. If you desire this feature or are replacing a brake that has this feature, please contact Nexen at All Nexen pneumatically actuated devices require clean and dry air, which meet or exceeds ISO 573.1:2001 Class quality. NOTE For quick response, Nexen recommends a quick exhaust valve and short air lines between Control Valves and product. Align air inlet ports a down position allow condensation drain out of air chambers of product. Low air pressure will cause slippage and overheating. Excessive air pressure will cause abrupt starts and sps, reducing product life. FIGURE 4 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 be used with this product must be designed following ISO 4414 guidelines. Air Supply Typical Brake Control Circuit Filter Dryer AIR PRESSURE: BAR (120 PSI) ABSOLUTE MAX 0 BAR (0 PSI) ABSOLUTE MIN Regular 3/2 (3 Way) N.C. Valve Quick Exhaust Valve Brake Inlet Gauge 7

OPERATION WARNING Never exceed maximum operating speeds listed for your product. (See Table 3). TABLE 3 Sizes: Max RPM SSE 450-1000 *100 *Consult Nexen for high speed applications.

8 OPERATION WARNING Never exceed maximum operating speeds listed for your product. (See Table 3). TABLE 3 Sizes: Max RPM SSE *100 *Consult Nexen for high speed applications. Never exceed life of facing material. Facing life depends on volume of material and tal energy over life of unit. Expected life (in hrs) can be found by: Time=Volume/(Power*Wear Rate). The temperature limits for this product line are Degree Celsius ( Degree F). The SSE Brake will remain engaged until sufficient air pressure is applied release it. Depending upon length of air lines and type of controls used, amount of release air may vary. Do not use more air pressure than required release brake (100 psi maximum). WARNING Ensure proper guarding of product is used. Nexen recommends machine builder design guarding in compliance with OSHA 29 CFR 1910 Occupational Safety and Health Hazards. Apply increasing amounts of air pressure brake until Friction Disc Hub turns freely. MANUAL DISENGAGEMENT 1. To manually release SSE Brake, remove three Shoulder or Socket Head Cap Screws (Item ) and replace m with cusmer supplied cap screws (See Table 4). 2. Tighten cap screws alternately and evenly draw Plate (Item 3) and Friction Facing (Item 5) away from Friction Disc Hub (Item 1). TABLE 4 Model Cap Screw Size SSE x 1-1/2 SSE-00 5/1-1 x 1-3/4 SSE-00 3/-1 x 2 SSE /-1 x 2-1/4 MAINTENANCE Periodically inspect all mounting bolts and air line fittings make sure y are securely tightened. Pay particular attention Shoulder Screws or Socket Head Cap Screws (Item ). If se screws are loose, Cylinder (Item 10) travel will increase, causing O-Ring Seals leak air. Tighten Shoulder Screws or Socket Head Cap Screws (Item ) recommended rque (See Table 5). Inspect Friction Facings (Item 5) for signs of wear and replace if worn down where Machine Screws (Item 14) may score Friction Disc Hub. TABLE 5 Model SSE-450 SSE-00 SSE-00 SSE-1000 Tightening Torques 4 In. Lbs. [5.0 Nm] In. Lbs. [2 Nm] In. Lbs. [50. Nm] 3.0 In. Lbs. [43. Nm]

9 9 TROUBLESHOOTING FIGURE 5 Friction Facing Pisn Plate Compression Spring O-Ring Seals Air Inlet Pisn Bearing Friction Disc Hub Cylinder Shoulder Screw Compression Spring Housing/Pin Assembly ympm S e robable Caus P n Solutio Failure engage. control a due exhausted being not Air malfunction. valve valve. control Replace Springs. Compression roken B. Springs Compression Replace corrosion. or contamination nternal I k o'cloc six port exhaust Align allow condensation position down port. exhaust of out drain Failure disengage. pressure. air of lack ow or L d an malfunction valve control for Check necessary. if it replace and lines air in leaks air for Check Replace Seals. O-rings around necessary. if Seals O-ring or lines air corrosion. or contamination nternal I k o'cloc six port exhaust Align allow condensation position down port. exhaust of out drain of Loss rque. Facings. Friction dirty or orn W. Facings Friction Replace

10 PARTS REPLACEMENT FRICTION FACINGS NOTE: Refer Figure. 1. Align holes in Friction Disc Hub (Item 1) with Machine Screws (Item 14) holding split Friction Facing (Item 5). 2. Remove old Machine Screws (Item 14). FIGURE Friction Facing (Item 5) Align holes in Friction Disc Hub (Item 1) with Machine Screws. 3. Remove old split Friction Facings (Item 5). 4. Install new split Friction Facings (Item 5). 5. Secure new split Friction Facings (Item 5) using new Machine Screws (with locking patch) (Item 14).. Tighten new Machine Screws recommended rque (See Table ). Machine Screw (Item 14) TABLE Recommended Tightening Torque (Item 14) M odel Tightening Torque s S SE In. Lbs. [2.5 Nm] S SE In. Lbs. [2.5 Nm] S SE-00 0 In. Lbs. [.7 Nm] S SE In. Lbs. [.7 Nm] BEARING, COMPRESSION SPRINGS, AND 0-RING SEALS Item 1 Item 14 Item 5 Item 3 Item 15 Item 13 Item 4 Item Item 9 Item 2 Item 12 Item 11 Item 10 FIGURE 7 Item 13 Item 7 Item 1 Item NOTE: Refer Figure 7. Shoulder and Socket Head Cap Screws are spring loaded. Always wear safety goggles when working with spring or tension loaded fasteners or devices. 1. Alternately and evenly remove Shoulder or Socket Head Cap Screws (Item ). 2. Remove Cylinder (Item 10). 3. Remove Compression Springs (Item 7). 4. Remove O-ring Seals (Items 11 and 12). Spring Housing and Pisn Plate are spring loaded. Spring Housing and Pisn Plate can spring apart, resulting in personal injury if Spring Housing and Pisn Plate are not clamped ger. 10

11 5. Remove Socket Head Cap Screws (Item 1).. Remove Pisn (Item 2). 7. Using C-Clamps, compress Spring Housing (Item 4) against Pisn Plate (Item 3). Special attention should be exercised when working with Retaining Rings. Always wear safety goggles when working with spring or tension loaded fasteners or devices.. Remove Retaining Ring (Item 9). 9. Press Friction Disc Hub (Item 1) out of Bearing (Item ). 10. Slowly unclamp Spring Housing (Item 4) and Pisn Plate (Item 3). 11. Using a bearing puller, remove Bearing (Item ) from Spring Housing (Item 4). 12. Clean bearing bore of Spring Housing (Item 4), Pisn Plate (Item 3), and Compression Springs (Item 15) with fresh safety solvent remove all old Loctite residue. 13. Apply an adequate amount of Loctite 0 evenly coat O.D. of new Bearing (Item ) and press new Bearing in Spring Housing (Item 4). 14. Equally space Compression Springs (Item 15) in spring pockets of Spring Housing (Item 4). 15. Slide Pisn Plate (Item 3) on Dowel Pins (Item 13) of Spring Housing (Item 4). 1. Using C-clamps, compress Pisn Plate (Item 3) against Compression Springs (Item 15) and Spring Housing (Item 4). 17. Press Friction Disc Hub (Item 1) in new Bearing (Item ). 1. Reinstall Retaining Ring (Item 9). 19. Remove C-clamps securing Spring Housing against Pisn Plate. 20. Press Pisn (Item 2) in Spring Housing (Item 4). 21. Apply Loctite 242 entire length and under heads of Socket Head Cap Screw (Item 1). Alternately and evenly tighten Socket Head Cap Screws recommended rque (See Table 7). NOTE: Loctite must seal all air gaps between Socket Head Cap Screws (Item 1) and clearance holes. 22. Reinstall Compression Springs (Item 7). 23. Clean O-ring grooves of Pisn (Item 2) and Cylinder (Item 10); n, lubricate new O-rings and O-Ring contact surfaces with a thin film of fresh O-Ring lubricant. NOTE: Avoid pinching of O-Ring Seals when assembling Pisn and Cylinder. 24. Install new O-Ring Seals (Items 11 and 12). 25. Slide Cylinder (Item 10) on Pisn (Item 2). 2. SSE-450 and SSE-00: Apply Loctite 242 threads of Socket Head Cap Screws or Shoulder Screws (Item ); n, alternately and evenly tighten m recommended rque (See Table 7). SSE-00: Alternately and evenly tighten Socket Head Cap Screws (Item ) recommended rque (See Table ). Do not use lubricants or thread locking compounds on Socket Head Cap Screws (Item ). SSE-1000: Lubricate tapped holes in Pisn Plate (Item 3) with a light machine oil before installing Shoulder Screws (Item ); n, alternately and evenly tighten m recommended rque (See Table 7). TABLE 7 Recommended Tightening Torque (Items and 1) Model Item Item 1 SSE-450 SSE-00 SSE-00 SSE-1000 The SSE-1000 uses Nexen Shoulder Screws only. The Shoulder Screws are specifically designed for high stress and prevailing rque capabilities In. Lbs. [5.0 Nm] In. Lbs. [2.0 Nm] In. Lbs. [34.0 Nm] 3.0 In. Lbs. [43. Nm] 0.0 In. Lbs. [.7 Nm] 0.0 In. Lbs. [.7 Nm] 90.0 In. Lbs. [10.7 Nm] 90.0 In. Lbs. [10.7 Nm] 11

12 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. When ordering replacement parts, specify model designation, item number, part description, and quantity. Purchase replacement parts through your local Nexen Distribur. Item 1 Item 17 Item 5 Item 3 Item 15 Item 13 Item 4 Item Item 9 Item 2 Item 12 Item 11 Item 10 FIGURE Item 14 Item 13 Item 7 Item 1 Item ITEM DESCRIPTION QTY 1 Friction Disc Hub 1 2 Pisn 1 3 Pisn Plate Spring Housing Friction Facing 1 1,2 Shoulder or Socket Head Cap Screw 3 7 Compression Spring 3 1 Bearing 1 9 Retaining Ring 1 10 Cylinder O-Ring Seal (Small) O-Ring Seal (Large) Dowel Pin Machine Screw 15 3 Compression Spring Cap Screw Set Screw 3 1 Key (Not Shown) 1 19 Hose Assembly (Not Shown) 1 22 Restricr Valve Housing (Not Shown) 1 23 Restricr Valve (Not Shown) 1 24 Air Inlet Adapr (Not Shown) 1 1 Denotes repair kit items. 2 : Model SSE-1000 uses Nexen Shoulder Screws only. 3 See Table for product number and quantity. 4 SSE-450 and SSE-00: Qty 5. SSE-00 and SSE- 1000: Qty 3. 5 Order Air Chamber Assembly in place of Spring Housing (Item 4) and Dowel Pin (Item 13) (See Table 9). TABLE M odel P roduct No. Qty. SSE-450 SSE-00 SSE-00 SSE Facing Kit: One split Friction Facing and six Machine Screws Repair Kit: Facing Kit plus one Bearing, three Shoulder Screws (Socket Head Cap Screws for SSE-00), three Retaining Rings, and two O-Ring Seals. Specify model and kit product number when ordering facing and repair kits (See Table 11). 12

13 TABLE 9 M odel Spring Housing Assembly w. Pi n SSE-450 Prod. No SSE-00 Prod. No SSE-00 Prod. No SSE-1000 Prod. No ACCESSORIES TABLE 10 Brake Guards M odel Product No. SSE SSE SSE SSE FIGURE 9 Brake Guard FACING AND REPAIR KITS TABLE 11 Model Facing Kit Repair Kit w/out Facing Kit Repair & Facing kit SSE SSE SSE SSE *22571 *27703 * Use this repair kit for SSE-1000's with serial numbers higher than

14 WARRANTY Warranties Nexen warrants that Products will (a) be free from any defects in material or workmanship for a period of 12 months from date of shipment, and (b) will meet and perform in accordance with specifications in any engineering drawing specifically for Product that is in Nexen s current product catalogue, or that is accessible at Nexen website, or that is attached this Quotation and that specifically refers this Quotation by its number, subject in all cases any limitations and exclusions set out in 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) Product has been installed, used and maintained in accordance with any applicable Nexen installation or maintenance manual for Product; (b) alleged defect is not attributable normal wear and tear; (c) Product has not been altered, misused or used for purposes or than those for which it was intended; and (d) Buyer has given written notice of alleged defect Nexen, and delivered allegedly defective Product Nexen, within one year of date of shipment. Exclusive Remedy The exclusive remedy for Buyer for any breach of any warranties provided in connection with this agreement will be, at election of Nexen: (a) repair or replacement with new, serviceably used, or reconditioned parts or products; or (b) issuance of credit in amount of purchase price paid Nexen by Buyer for Products. Agent's Authority Buyer agrees that no agent, employee or representative of Nexen has authority bind Nexen any affirmation, representation, or warranty concerning Products or 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 purposes hereof, term "consequential damages" shall include lost profits, penalties, delay damages, liquidated damages or or damages and liabilities which Buyer shall be obligated pay or which Buyer may incur based upon, related or arising out of its contracts with its cusmers or or 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 which a breach of contract has been determined exist. The parties expressly agree that price for Products and services was determined in consideration of limitation on damages set forth herein and such limitation has been specifically bargained for and constitutes an agreed allocation of risk which shall survive 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 or failures conform se terms and conditions which are reasonably discoverable upon arrival without opening any carn or box in which Products are contained. Such notice shall be sent within 14 days following arrival. All notifications shall be accompanied by packing slips, inspection reports and or documents necessary support Buyer's claims. In addition foregoing obligations, in event that Buyer receives Products that Buyer did not order, Buyer shall return erroneously shipped Products Nexen within thirty (30) days of date of invoice for such Products; Nexen will pay reasonable freight charges for timely return of erroneously shipped Products, and issue a credit Buyer for returned Products at price Buyer paid for m, including any shipping expenses that Nexen charged Buyer. All shortages, overages and nonconformities not reported Nexen as required by this section will be deemed waived. Limitation on Actions No action, regardless of form, arising out of any transaction which se terms and conditions are applicable may be brought by Buyer more than one year after cause of action has accrued. Nexen Group, Inc. 50 Oak Grove Parkway Vadnais Heights, MN Fax: ISO 9001 Certified 14

Disc Caliper Brake Model DBSE

AIR CHAMP PRODUCTS User Manual Disc Caliper Brake Model DBSE i In accordance with Nexen s established policy of constant product improvement, the specifications contained in this manual are subject to