Nexen AIR CHAMP FC-605 User manual

(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
[phone]
www.nexengroup.com
Nexen Group, Inc.
560 Oak Grove Parkway
Vadnais Heights, Minnesota 55127
ISO 9001 Certified
Copyright 2000 Nexen Group, Inc.
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 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.
8
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
1a
FIGURE 5
Remove nuts.
1
2

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
1b
1c
Rear
Bearing
Carrier
Front
Bearing
Carrier
FIGURE 7

7FORM NO. L-20177-F-0501
PARTS LIST
7
8
9
1
2
4
5
3
6
10
FIGURE 8
FLUID COUPLING
1e
1d 1b
1c
1f
1a
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