Nexen AIR CHAMP FC-605 Bedienungsanleitung

(i)

Fluid Coupling

FC-605, FC-607, FC-707, FC-709, FC-809,

FC-811, FC-911, and FC-913

FORM NO. L-20177-F-0501

AIR CHAMP PRODUCTS

User Manual

(ii)

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

Nexen Group, Inc.

560 Oak Grove Parkway

Vadnais Heights, Minnesota 55127

ISO 9001 Certified

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 or cause injury or death.

Comply with all applicable codes.

WARNING

(iii)

TABLE OF CONTENTS

Introduction---------------------------------------------------------------------------------------------------------------------------------------- 1

Installation ---------------------------------------------------------------------------------------------------------------------------------------- 2

Fluid Coupling Oil Levels -------------------------------------------------------------------------------------------------------------------- 3

Operation ------------------------------------------------------------------------------------------------------------------------------------------ 4

Parts Replacement ----------------------------------------------------------------------------------------------------------------------------- 4

Parts List ------------------------------------------------------------------------------------------------------------------------------------------- 7

Repair Kit Numbers ---------------------------------------------------------------------------------------------------------------------------- 8

Replacement Parts ----------------------------------------------------------------------------------------------------------------------------- 8

Warranties ----------------------------------------------------------------------------------------------------------------------------------------- 9

1FORM NO. L-20177-F-0501

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 consequences 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.

2FORM NO. L-20177-F-0501

INSTALLATION

1. Coat the threads of the Socket Head Cap Screws

(Item 9) with Loctite®242 and secure Mounting Pilot

(Item 7) to NEMA C-Faced Motor (See Figure 1).

2. Tighten the Socket Head Cap Screws (Item 9) to the

recommended torque (See Table 1).

3. Insert customer supplied key into motor shaft (See

Figure 1).

4. Slide Fluid Coupling and Housing onto motor shaft.

5. Coat the threads of the Socket Head Cap Screws

(Item 8) with Loctite®242 and secure Housing (Item

3) and Fluid Coupling (Item 1) to Mounting Pilot (Item

7) (See Figure 1)

6. Tighten the Socket Head Cap Screws (Item 8) to

recommended torque (See Table 2).

7. Install Housing Guard (Item 10) onto Fluid Coupling

and secure with Screws, Lock Washers, and Nuts

provided with Housing Guard.

8. Insert customer supplied key into Fluid Coupling’s

output shaft (See Figure 1).

9. Slide Fluid Coupling’s output shaft into gear reducer

or driven unit (See Figure 1).

10. Coat the threads of the customer supplied socket

head cap screws with Loctite®242 (See Table 1)

and secure Fluid Coupling to the gear reducer or

driven unit (See Figure 1).

11. Tighten the socket head cap screws to the

recommended torque (See Table 1).

Customer

supplied

key

Socket Head

Cap Screw

(Item 8)

Customer

supplied

socket head

cap screw

Socket Head

Cap Screw

(Item 9)

Mounting

Pilot

(Item 7)

Fluid Coupling and

Housing

(Items 1 and 3)

Customer

supplied

key

FIGURE 1

Housing

Guard

(Item 10)

TABLE 1

MODEL CAP SCREW TORQUE

FC605 3/8-16 30 Ft. Lbs. [40.6 N•m]

FC607 3/8-16 30 Ft. Lbs. [40.6 N•m]

FC707 3/8-16 30 Ft. Lbs. [40.6 N•m]

FC709 1/2-13 75 Ft. Lbs. [101.7 N•m]

FC809 1/2-13 75 Ft. Lbs. [101.7 N•m]

FC811 1/2-13 75 Ft. Lbs. [101.7 N•m]

FC911 1/2-13 75 Ft. Lbs. [101.7 N•m]

FC913 1/2-13 75 Ft. Lbs. [101.7 N•m]

TABLE 2TABLE 2

TABLE 2

MODEL CAP SCREW TORQUE

FC605 5/16-18 17 Ft. Lbs. [23 N•m]

FC607 5/16-18 17 Ft. Lbs. [23 N•m]

FC707 5/16-18 17 Ft. Lbs. [23 N•m]

FC709 5/16-18 17 Ft. Lbs. [23 N•m]

FC809 3/8-16 30 Ft. Lbs. [40.7 N•m]

FC811 3/8-16 30 Ft. Lbs. [40.7 N•m]

FC911 3/8-16 30 Ft. Lbs. [40.7 N•m]

FC913 3/8-16 30 Ft. Lbs. [40.7 N•m]

3FORM NO. L-20177-F-0501

Rotate Fluid

Coupling until X

mark is in twelve

o'clock up position

FIGURE 2

X Mark

FIGURE 3

Fusible

Plug

TABLE 3

RECOMMENDED OILS FLASH POINT

Chevron HYDRAULIC Oil 32 374oF [190oC]

Mobil HYDREX AW32 375o F [190.6oC]

Texaco RANDO HD32 385oF [196.1oC]

Do not use any oil with a flash point below 370oF

[187.8oC].

FLUID COUPLING OIL LEVELS

NOTE: Nexen Fluid Couplings are shipped dry (not filled

with oil).

1. With Fluid Coupling mounted in the horizontal

position, rotate coupling until Xmark cast in Housing

is in the twelve o’clock up position (See Figures 2

and 3).

2. Remove Fusible Plug (See Figure 3).

3. Rocking the Fluid Coupling on its axis to excess air is

vented from the filler hole, fill Fluid Coupling with

recommended oil (See Table 3).

CAUTION

Never use transmission fluid in the Fluid

Coupling. Use of transmission fluid will

cause overheating and result in increased

slip and potential unit failure.

NOTE: Under normal conditions, use SAE-10-W. At

low ambient temperatures, SAE-5-W may be

used. Synthetic lubricants are not

recommended.

4. Install Fusible Plug.

NOTE: Different oil fill levels can be selected at the

users judgment. With X as maximum fill, the

Fluid Coupling will operate with minimal slip

and maximum efficiency, and the starting

torque will be at maximum. By decreasing

Fluid Coupling oil fill level (1-2-3-4 marks on

the Coupling), the starting torque decreases.

CAUTION

High values of slip decrease Fluid

Coupling efficiency and will cause the

oil to overheat.

4FORM NO. L-20177-F-0501

OPERATION

1. Start and stop motor several times to verify

performance of Fluid Coupling.

2. Check oil level and Socket Head Cap Screws

securing Fluid Coupling after the first 20 days of

operation.

NOTE: Oil must be at room temperature when

checking oil level.

3. Check oil level and Socket Head Cap Screws

securing Fluid Coupling on a monthly basis.

4. Change oil in Fluid Coupling after every 4,000 hours

of operation.

The Fluid Coupling is supplied with a Fusible Plug rated at 293O F [145O C] to protect the machine

from damage in an overload situation. The Fusible Plug is designed to allow hot oil 293O F [145O C]

to be discharged from the Fluid Coupling in an overload condition. If there is any chance an

operator could come in contact with the hot oil, additional shielding must be provided by the

customer. Isolate oil from all surfaces where temperatures may exceed 300o F [145O C].

An overload may be caused by any of the following conditions:

1. Insufficient oil

2. Absorbed power is greater than the motor rated power

3. High ambient temperature

4. Excessive or frequent starts

5. Prolonged starting time

6. Inadequate ventilation restricting cooling of Fluid Coupling. If Fluid Coupling is operated

in restricted areas, adequate ventilation must be provided

Maximum operating temperatures should not exceed 194O F [90O C]. If higher operating

temperatures are required, contact Nexen for information concerning the use of special seals.

PARTS REPLACEMENT

HOUSING BEARING (Item 4)

1. Remove Socket Head Cap Screws (Item 8) and

separate Mounting Pilot (Item 7) from Housing (Item

3) (See Figure 4).

NOTE: Mounting Pilot (Item 7) may be left installed

on drive unit or motor.

7123465

FIGURE 4

5FORM NO. L-20177-F-0501

2. Remove Retaining Ring (Item 5) (See Figure 4).

Special attention should be exercised when

working with retaining rings. Always wear

safety goggles when working with spring or

tension loaded fasteners or devices.

3. Fully supporting Housing (Item 3), press Stub Shaft

(Item 2) and Fluid Coupling (Item 1) out of Bearing

(Item 4) and Housing (Item 3) (See Figure 4).

4. Remove Retaining Ring (Item 6) (See Figure 4).

5. Fully supporting Housing, press old Bearing out of

Housing.

6. Clean bearing bore of Housing (Item 3), removing all

traces of old Loctite®; then, coat the outer race of the

new Bearing with Loctite 680® and press new

Bearing (Item 4) into place.

7. Install Retaining Ring (Item 6).

NOTE: If Fluid Coupling Seals are to be replaced,

proceed with PARTS REPLACEMENT,

FLUID COUPLING SEALS.

8. Fully supporting inner race of Bearing (Item 4), press

Stub Shaft (Item 2) and Fluid Coupling (Item 1) into

Bearing (Item 4).

9. Install Retaining Ring (Item 5).

10. Install Fluid Coupling (See INSTALLATION).

FLUID COUPLING SEALS (Items 1a, 1b, 1c, 1d, and 1e)

1. Remove Nuts securing Stub Shaft (Item 2) to Fluid

Coupling (Item 1); then, remove Stub Shaft from

Fluid Coupling (See Figure 5).

2. Remove Socket Head Caps Screws holding Fluid

Coupling halves together (See Figure 6).

3. Separate two halves of Fluid Coupling and remove

the old O-ring Seal (Item 1a) (See Figure 6).

FIGURE 6

FIGURE 5

Remove nuts.

6FORM NO. L-20177-F-0501

4. Press Impeller out of Fluid Coupling covers (See

Figure 7).

5. Remove Socket Head Cap Screws securing Front

Bearing Carrier (See Figure 7).

6. Remove Front Bearing Carrier (See Figure 7).

7. Remove the old Gasket (Item 1b) and Seal (Item 1c)

(See Figure 7).

8. Install new Seal and Gasket, and install the Front

Bearing Carrier.

9. Remove Socket Head Cap Screws securing Rear

Bearing Carrier (See Figure 7)

10. Remove Rear Bearing Carrier. (See Figure 7).

11. Remove old Gasket (Item 1d) and Seal (Item 1e)

(See Figure 7).

12. Install new Seal and Gasket, and install the Rear

Bearing Carrier.

13. Fully supporting bearings, press Impeller into

Housing.

14. Install new O-ring Seal (Item 1a) and assemble Fluid

Coupling (See Figure 6).

15. Assemble Fluid Coupling and Housing (See PARTS

REPLACEMENT, HOUSING BEARING, Steps 8 - 10).

Impeller

1e 1d

Rear

Bearing

Carrier

Front

Bearing

Carrier

FIGURE 7

7FORM NO. L-20177-F-0501

PARTS LIST

FIGURE 8

FLUID COUPLING

1d 1b

Rear

Bearing

Carrier ImpellerImpeller

ImpellerImpeller

Impeller

ITEM DESCRIPTION QTY

1a2O-Ring Seal 1

1b2Gasket 1

1c2Seal 1

2Denotes repair kit item.

Front

Bearing

Carrier

ITEM DESCRIPTION QTY

1d2Gasket 1

1e2Seal 1

1f2Fusible Plug 1

ITEM DESCRIPTION QTY

8 Socket Head Cap Screw (5/16-18) 6

9 Socket Head Cap Screw (3/8-16 or 1/2-13) 4

10 Housing Guard 1

11 Housing Guard Screw (Not Shown) 2

12 Housing Guard Lock Washer (Not Shown) 2

13 Housing Guard Nut (Not Shown) 2

ITEM DESCRIPTION QTY

11Fluid Coupling 1

2 Stub Shaft 1

3 Housing 1

42Bearing 1

5 Retaining Ring 1

6 Retaining Ring 1

7 Mounting Pilot 1

1Refer to Coupling Assembly parts list for repair kit items.

2Denotes repair kit item.

FIGURE 9

FLUID COUPLING ASSEMBLY

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