Engineering Data Single Reduction Parts List Item # Description Basic Single Reduction Unit 1. Gear Housing 2. Pipe Plug 3. Vent Plug 4. Splash Guard

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21 Engineering Data Single Reduction Parts List Item # Description Basic Single Reduction Unit 1. Gear Housing 2. Pipe Plug 3. Vent Plug 4. Splash Guard 5. Input Cover 6. O-Ring 7. Hex Head Cap Screw 8. Input Oil Seal 9. Input Bearing 10. Input Bearing *11. Retaining Screw 12. Input Shaft 13. Output Cover 14. Output Cover 15. O-Ring 16. Output Cover Gasket (as required) 17. Output Oil Seal 18. Output Bearing 19. Hex Head Cap Screw ***20. Single Output Shaft ***21. Double Output Shaft 22. Gear Spacer 23. Gear Key (only used on size 2-5/8 center distance and larger units) 24. Output Gear (supplied only with output gear on size 1-1/3 through 2-3/8 center distance units) 25. Input Cover (only used on size 4-1/4 center distance and larger units) 26. Input Cover 27. Input Oil Seal *28. Retaining Ring - Shaft 29. Double Input Shaft 170. Internal Pressure Compensation Chamber (optional) 171. Internal Pressure Compensation Chamber Stem Plug 172. Internal Pressure Compensation Chamber Stem Nut *not used on 4-1/4 center distance and larger units Quill Motor Flange Unit 30. Double Input Shaft 40. Quill Motor Flange 41. Input Oil Seal 42. Hex Head Cap Screw 43. Retaining Ring - Shaft 44. Retaining Ring - Housing (only used on size 4-1/4 center distance and larger units) 45. Quill Input Shaft Hollow Output Shaft Unit 50. Gear Housing 51. Output Cover 52. Output Oil Seal 53. Output Bearing 54. Gear Spacer ***55. Output Shaft 56. Setscrew 57. Gear Key (only used on size 2-5/8 center distance and larger units) 157 Item # Description 58. Output Gear (supplied only with output shaft on size 11/3 through 2-3/8 center distance units) Mounting Bracket Options 70. Horizontal Mounting Foot 71. Cap Screw 72. High and Low Riser Bracket 73. Hex Head Cap Screw 74. J Mount Bracket 75. Output Flange 76. Machine Faced Output Cover (only used on size 2-3/8 center distance and larger solid output shaft units) 77. Hex Head Cap Screw 78. Torque Bracket 79. Hex Head Cap Screw Extended Bearing Unit 90. Flange 91. Output Shaft 92. Bearing 93. Output Oil Seal 94. Hex Head Cap Screw 95. Pipe Plug 96. Expansion Plug *97. Flange Cover *98. Gasket *99. Hex Head Cap Screw *only used on size 5-1/4 center distance and larger units Long Motor Flange and Coupling Kit 110. C Face Motor Flange 111. Hex Head Cap Screw 112. Coupling Key - Reducer Shaft 113. Setscrew - Reducer Shaft 114. Coupling Gear - Reducer Shaft 115. Coupling Sleeve 116. Setscrew - Motor Shaft 117. Coupling Gear - Motor Shaft 118. Coupling Key - Motor Shaft Vertical Shaft Required Parts (Supplied only when mounting position involves a vertical shaft.) *129. Output Cover *130. Output Cover *131. Output Bearing Grease Retainer 132. Grease Fitting 133. Sealed Ball Bearing (only used on size 1-3/4 through 2-5/8 center distance units) **134. Input Cover **136. Input Bearing Grease Retainer * Only used on size 4-1/4 center distance and larger units. ** Only used on size 3 center distance and larger units. *** Supplied only with output gear on size 1-1/3 through 2-3/8 center distance units CA IN

30 ! WARNING Read this manual carefully before installation and operation. Follow the 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. Comply with all applicable codes.

31 INSTALLATION FMBES-CC NOTE The following sections are arranged by model. Verify that you are in the correct section for your model. 1. Remove the six Socket Head Cap Screws (Item 11) and separate the two halves of the FMBES-CC. 2. Using four Socket Head Cap Screws (Item 34) and Lock Washers (Item 35), secure the Female Pilot (Item 6) to the motor. Tighten the Socket Head Cap Screws to the recommended torque (See Figure 1 and Table 1). 29 Customer supplied key Install the customer supplied key into the motor shaft (See Figure 1). 4. Reassemble the two halves of the FMBES-CC (See Figure 1). 5. Apply a drop of Loctite 242 to the threads of the six Socket Head Cap Screws (Item 11) (See Figure 1). 6. Reinstall the six Socket Head Cap Screws (Item 11); then, alternately and evenly tighten them to 65 In. Lbs. [7.3 N m] torque (See Figure 1). 7. Remove Pipe Plug (Item 30) (See Figure 1). 8. Tighten the Set Screw (Item 29) to lock the customer supplied key. Reinstall the Pipe Plug (Item 30) (See Figure 1). 11 FIGURE 1 TABLE /35 Motor RECOMMENDED TORQUE MODEL ITEM Ft. Lbs. [65.5 N m] Ft. Lbs. [65.5 N m] Ft. Lbs. [161.0 N m] Ft. Lbs. [161.0 N m] AIR CONNECTIONS NOTE For quick response, install a quick exhaust valve and short air lines between the Control Valves and the FMBES. Align the air inlet port to a down position to allow condensation to drain out of the Air Chamber of the FMBES. In high-cyclic applications, Nexen recommends a 50 ms delay between the solenoid valve and the motor starter. 1 FORM NO. L D-0300

LUBRICATION NOTE Pneumatically actuated devices require clean, pressure regulated, and lubricated air for maximum performance and long life.

32 LUBRICATION NOTE Pneumatically actuated devices require clean, pressure regulated, and lubricated air for maximum performance and long life. The most effective and economical way to lubricate the FMBES is with an Air Line Lubricator, which injects oil into the pressurized air, forcing an oil mist into the air chamber. Locate the lubricator above and within ten feet of the FMBES, and use a low viscosity oil such as SAE-10. Synthetic lubricants are not recommended. LUBRICATOR DRIP RATE SETTINGS NOTE These settings are for Nexen supplied lubricators. If you are not using a Nexen lubricator, calibration must replicate the following procedure. 1. Close and disconnect the air line from the unit. 2. Turn the Lubricator Adjustment Knob clockwise three complete turns. 3. Open the air line. 4. Close the air line to the unit when a drop of oil forms in the Lubricator Sight Gage. 5. Connect the air line to the unit. 6. Turn the Lubricator Adjustment Knob counterclockwise until closed. 7. Turn the Lubricator Adjustment Knob clockwise onethird turn. 8. Open the air line to the unit. MANUAL RELEASE OPERATION NOTE The Manual Release Set Screws (Item 26) must be alternately and evenly tightened to insure proper operation of the Manual Release feature. 1. Loosen the Jam Nuts (Item 27) until they are flush with the tops of the two Set Screws (Item 26) (See Figure 2). NOTE Count and record the number of turns required for the Set Screws (Item 26) to disengage the FMBES. 2. Alternately and evenly turn the Set Screws (Item 26) clockwise 1/2 turn at a time until the FMBES is released; then, secure the two Set Screws (Item 26) by turning the Jam Nuts (Item 27) until they are flush with the Housing of the FMBES (See Figure 2). 3. To engage the FMBES alternately and evenly turn the Set Screws (Item 26) counterclockwise the same number of turns required to release the FMBES; then, secure the Set Screws with the Jam Nuts (Item 27) (See Figure 2). FIGURE 2 Set Screw (Item 26) and Jam Nut (Item 27) FORM NO. L-20323D

33 FORM NO. L D TROUBLESHOOTING FIGURE 3 Ball Bearing Female Pilot Friction Facing Rotor Disc Plate Set Screw Jam Nut O-ring Seal Wave Spring Ball Bearing Shaft Compression Spring Housing Piston Friction Disc TYPICAL FMBES-CC ROBLEM P E ROBABLE CAUS P N SOLUTIO engage. to ailure F. Springs Compression weak or roken B. Springs Compression the Replace disengage. to Failure a to FMBES due the to getting not Air malfunction. valve control and malfunction valve control a for Check necessary. if valve control the replace Seals. O-ring leaking or orn W. Seals O-ring the Replace in or spline Hub the on lubrication of Lack Chamber. Air the Air and/or spline Hub the Lubricate Chamber. torque. of Loss Facings. Friction contaminated or orn W. Facings new Friction Install engaged. Release anual M. mechanism Release Manual Disengage

34 PARTS REPLACEMENT NOTE The following sections are arranged by model. Verify that you are in the correct section for your model. FRICTION FACING FMBES-CC 1. Remove the six Socket Head Cap Screws (Item 11) (See Figure 4). 2. Remove the Pipe Plug (Item 30); then, loosen the Set Screw (Item 29) (See Figure 4) Separate the two halves of the FMBES-CC (See Figure 4). 6 CAUTION The Disc Plate (Item 8) is under pressure from the Compression Springs (Item 14). Alternately and evenly remove the Socket Head Cap Screws (Item 10). Always wear safety goggles when working with spring or tension loaded fasteners or devices. 4. Remove the six Socket Head Cap Screws (Item 10); then, remove the Disc Plate (Item 8) from the Piston (Item 5) (See Figure 4). 11 FIGURE NOTE The Flat Head Machine Screws (Item 13) are assembled with an anaerobic thread locking compound. Inserting a properly fitting screwdriver into the head of the Flat Head Machine Screw and striking the end of the screwdriver with a hammer will break the crystalline structure of the locking compound and allow removal of the Flat Head Machine Screws. Never use an impact wrench to remove the Flat Head Machine Screws. 5. Remove the six Flat Head Machine Screws (Item 13) and the worn Friction Facing (Item 3) from the Rotor (Item 2) (See Figure 4). 7 FIGURE Press the Shaft (Item 1), Ball Bearing (Item 9), and Rotor (Item 2) from the Housing (Item 7) (See Figure 5). 7. Remove the six Flat Head Machine Screws (Item 13) and the worn Friction Facing (Item 3) from the Friction Disc (Item 4) (See Figure 5). 8. Install the new Friction Facing (Item 3) to the Friction Disc (Item 4) using the six new Flat Head Machine Screws (Item 13). Tighten the six Flat Head Machine Screws (Item 13) to 20 In. Lbs. [2.2 N m] torque (See Figure 5). 9. Carefully align the O.D. of the Ball Bearing (Item 9) with the bore of the Housing (Item 7); then, press the Shaft (Item 1), Ball Bearing (Item 9), and Rotor (Item 2) back into the Housing (Item 7) (See Figure 5). 10. Install the new Friction Facing (Item 3) to the Rotor (Item 2) using the six new Flat Head Machine Screws (Item 13); then, alternately and evenly tighten the six Flat Head Machine Screws (Item 13) to 20 In. Lbs. [2.2 N m] torque (See Figure 6) FIGURE FORM NO. L D

35 11. Secure the Disc Plate (Item 8) to the Piston (Item 5) using the six Socket Head Cap Screws (Item 10); then, alternately and evenly tighten the six Socket Head Cap Screws (Item 10) to 40 In. Lbs. [4.5 N m] torque (See Figure 7). 12. Reinstall the FMBES-CC, referring to Steps 3 through 8 of INSTALLATION (See Page 1). BALL BEARINGS, COMPRESSION SPRINGS, WAVED SPRING, AND O-RING SEALS FMBES-CC 1. Remove the six Socket Head Cap Screws (Item 11) (See Figure 7). 2. Remove the Pipe Plug (Item 30); then, loosen the Set Screw (Item 29) (See Figure 7) Separate the two halves of the FMBES-CC (See Figure 7). 29 CAUTION The Disc Plate (Item 8) is under pressure from the Compression Springs (Item 14). Alternately and evenly remove the Socket Head Cap Screws (Item 10). Always wear safety goggles when working with spring or tension loaded fasteners or devices Remove the six Socket Head Cap Screws (Item 10); then, remove the Disc Plate (Item 8) from the Piston (Item 5) (See Figure 7). FIGURE 7 5. Press the Shaft (Item 1), Ball Bearing (Item 9), and Rotor (Item 2) from the Housing (Item 7) (See Figure 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 Remove the Retaining Ring (Item 16) from the Shaft (Item 1) (See Figure 9). 7. Press both old Ball Bearings (Item 9) off the Shaft (Item 1) (See Figure 9) Remove the Retaining Ring (Item 15) from the Shaft (Item 1) (See Figure 9). FIGURE 8 9. Slide the Washer (Item 18) and Waved Spring (Item 17) from the Shaft (Item 1); then, install the new Waved Spring and reinstall the Washer (See Figure 9). 5 FORM NO. L D-0300

36 10. Reinstall the Retaining Ring (Item 15) (See Figure 9). 11. Pressing on the inner race of the two new Ball Bearings (Item 9), press the new Ball Bearings (Item 9) onto the Shaft (Item 1) (See Figure 10). 12. Reinstall the Retaining Ring (Item 16) (See Figure 9). WARNING The Friction Disc (Item 4) is spring loaded. Use 'C' clamps to maintain pressure on the Friction Disc (Item 4) while removing the six Socket Head Cap Screws (Item 12). After the six Socket Head Cap Screws have been removed, slowly release the pressure on the 'C' clamps. Always wear safety goggles when working on spring or tension loaded fasteners or devices FIGURE Alternately and evenly remove the six Socket Head Cap Screws (Item 12) (See Figure 10) Slowly release the pressure on the 'C' clamps; then, remove the 'C' clamps. 15. Remove the Friction Disc (Item 4) and old Compression Springs (Item 14) from the Piston (Item 5) (See Figure 10). WARNING Do not apply excessive air pressure to slide the Piston (Item 5) out of the Housing (Item 7). Excessive air pressure may result in personal injury or damage to the Piston and Housing. 16. Gently apply air pressure to slide the Piston (Item 5) out of the Housing (Item 7) (See Figure 10). 7 FIGURE Remove the old O-ring Seals (Items 20 and 21) from the Piston (Item 5) (See Figure 10). 18. Clean the o-ring grooves of the Piston (Item 5) and o- ring contact surfaces of the Housing (Item 7) with fresh safety solvent (See Figure 10). 19. Lubricate the new O-ring Seals (Items 20 and 21) with fresh o-ring lubricant; then, install the new O-ring Seals into the Piston (Item 5) (See Figure 10). 20. Slide the Piston (Item 5) and new O-ring Seals (Items 20 and 21) into the Housing (Item 7) (See Figure 10). NOTE Repair Kit No contains nine Compression Springs (Item 14). Refer to Table 3 for the correct number of Compression Springs required for your Model FMBES-CC and the required output torque. 21. Install the new Compression Springs (Item 14) into the Piston (Item 5) (See Figure 10). 22. Place the Friction Disc (Item 4) on the Piston (Item 5) and Compression Springs (14); aligning the holes in the Friction Disc with the tapped holes in the Housing (See Figure 10). FORM NO. L D

37 23. Using 'C' clamps, press the Friction Disc (Item 4) onto the Piston (Item 5) (See Figure 10). 24. Apply a drop of Loctite 242 to the threads of the six Socket Head Cap Screws (Item 12) (See Figure 10). 25. Install the six Socket Head Cap Screws (Item 12); then, alternately and evenly tighten the Socket Head Cap Screws (Item 12) to 30 In. Lbs. [3.4 N m] torque. Remove the 'C' clamps (See Figure 10). 26. Carefully align the O.D. of the Ball Bearing (Item 9) with the bore of the Housing (Item 7); then, press the Shaft (Item 1), Ball Bearing (Item 9), and Rotor (Item 2) back into the Housing (Item 7) (See Figure 12). NOTE Apply Loctite 680 to the outer race of the Ball Bearing (Item 9). 27. Apply a drop of Loctite 242 to the threads of the six Socket Head Cap Screws (Item 10) (See Figure 12). 28. Secure the Disc Plate (Item 8) to the Piston (Item 5) using the six Socket Head Cap Screws (Item 10); then, alternately and evenly tighten the six Socket Head Cap Screws (Item 10) to 40 In. Lbs. [4.5 N m] torque (See Figure 12). MODEL FMBES-CC 625 FMBES-CC 625 FMBES-CC 875 FMBES-CC 875 FMBES-CC 875 FMBES-CC 1125 FMBES-CC 1375 TABLE 3 7 PRODUCT NO. OUTPUT TORQUE (In. Lbs.) REQUIRED NUMBER OF SPRINGS In. Lbs In. Lbs In. Lbs In. Lbs In. Lbs In. Lbs In. Lbs Reinstall the FMBES-CC, referring to Steps 3 through 8 of INSTALLATION (See Page 1). 9 2 FIGURE FIGURE FORM NO. L D-0300

38 PARTS LIST FIGURE 13 FMBES-CC, 625 AND FMBES-CC, 625 ITEM DESCRIPTION QTY 1 Shaft 1 2 Rotor 1 3 1,2 Friction Facing 2 4 Friction Disc 1 5 Piston 1 6 Female Pilot 1 7 Housing 1 8 Disc Plate Ball Bearing 2 10 Socket Head Cap Screw 6 11 Socket Head Cap Screw 6 12 Socket Head Cap Screw ,2 Flat Head Machine Screw Compression Spring 3, 6 15 Retaining Ring (Ext.) 2 16 Retaining Ring (Ext.) Waved Spring 1 18 Washer O-ring Seal O-ring Seal 1 24 Key (Not Shown) 1 26 Set Screw 2 27 Jam Nut 2 29 Set Screw 1 30 Pipe Plug 1 34 Socket Head Cap Screw 4 35 Lock Washer 4 1 Denotes Facing Kit item. Facing Kit Product No Denotes Repair Kit item. Repair Kit Product No FMBES-CC, 875 ITEM DESCRIPTION QTY 1 Shaft 1 2 Rotor 1 3 1,2 Friction Facing 2 4 Friction Disc 1 5 Piston 1 6 Female Pilot 1 7 Housing 1 8 Disc Plate Ball Bearing 2 10 Socket Head Cap Screw 6 11 Socket Head Cap Screw 6 12 Socket Head Cap Screw ,2 Flat Head Machine Screw Compression Spring 3, 6, 9 15 Retaining Ring (Ext.) 2 16 Retaining Ring (Ext.) Waved Spring 1 18 Washer O-ring Seal O-ring Seal 1 24 Key (Not Shown) 1 26 Set Screw 2 27 Jam Nut 2 29 Set Screw 1 30 Pipe Plug 1 34 Socket Head Cap Screw 4 35 Lock Washer 4 1 Denotes Facing Kit item. Facing Kit Product No Denotes Repair Kit item. Repair Kit Product No FORM NO. L D

40 RAM P/N AG04714R MANUAL CONTROL VALVE 4 Way 3 Position Manual Control Valve Body Assembly 1 ¼ Ports Hand Lever Assembly SA For 1 ¼ Valves Spring-Center Cap Assembly

41 RAM P/N AG04713C PILOT OPERATED VALVE 4 Way 3 Position Pilot Control *** For Remote Control with Pendant Controller *** Valve Body Assembly 1 ¼ Ports SA Pilot Spring Center Cap Assembly

42 CONTROL VALVE PLATE ASSEMBLY ITEM No. PART No. DESCRIPTION QTY Valve Sub-Plate O-Ring Sandwich Plate O-Ring Thread Inlet Bushing O-Ring Adapter Hex Hd. Cap Screw 3/8 x 1 1/ /8 Lock Washer Allen Hd. 3/8 x 7/8 Cap Screw /8 Lock Washer Allen Hd. 3/8 x 3/4 Cap Screw /8 Lock Washer Air Motor Neopr. Spacer Ring 2

ACCESSORIES SHUTTLE VALVES a range of Shuttle Valves in different sizes, made from Brass or 316 Stainless Steel General Description VERSA Shuttle Valves are constructed of solid Brass or 316

A typical schematic is shown below: Materials 1 2 3 Type: Brass Stainless Steel Body: Brass 316 Stainless Steel Shuttle: Nylon(Zytel) 316 Stainless Steel Seals: NBR (Nitrile) FKM (Fluorocarbon)

43 ACCESSORIES SHUTTLE VALVES a range of Shuttle Valves in different sizes, made from Brass or 316 Stainless Steel General Description VERSA Shuttle Valves are constructed of solid Brass or 316 Stainless Steel, with resilient seals providing tight shut off. Shuttle valves are 3/2 valves, primarily used to charge and discharge a pressure line or chamber from two - or more - sources. A typical schematic is shown below: Materials Type: Brass Stainless Steel Body: Brass 316 Stainless Steel Shuttle: Nylon(Zytel) 316 Stainless Steel Seals: NBR (Nitrile) FKM (Fluorocarbon) Screws: Plated Steel 316 Stainless Steel Functional Description Shuttle Valves have a free moving shuttle that blocks one of two inlet ports while the other inlet port is connected to the (common) outlet port. When a pressure signal enters the port blocked by the shuttle, it will cause the shuttle to shift over to close the opposite inlet port. The shuttle will stay there while the line or chamber connected to the outlet port is charged and/or discharged and will only shift when pressure is applied to the inlet port it is blocking at that time. In logic terms a shuttle valve is an 'OR' - function. Pressures Pressure range Pneumatic: 5 to 200 psi (0.35 to 14 bar) Hydraulic: 5 to 500 psi (0.35 to 35 bar) Symbol Mounting IN OUT IN Preferably with the centerline of the two inlet ports horizontal. As shown in the drawing above. Sizes/Connections/Types/Dimensions/Weights *Porting Product Number Dimensions in inch (mm) Flow Cv (Kv) Weights in lbs (kg) 'P' brass st. steel 'A' 'B' 'C' brass st. steel brass st. steel 1/8 NPT SV (51) 1.5 (38) 1.0 (25) 0.8 (12) 0.57 (0.26) 1/4 NPT SV-3 SV (51) 1.5 (38) 1.0 (25) 0.8 (12) 0.5 (7) 0.57 (0.26) 0.33 (0.15) 3/8 NPT SV (64) 1.9 (48) 1.3 (32) 1.6 (23) 1.10 (0.50) 1/2 NPT SV (64) 1.9 (48) 1.3 (32) 2.1 (30) 1.10 (0.50) 3/4 NPT SV (89) 2.8 (70) 1.5 (38) 6.5 (84) 2.16 (0.98) * For Subplate Mounting Shuttle Valves Consult Factory conforms to NACE standard MR

46 RAM P/N LB80040R FILTER Specifications Pipe Size 1 1/4 Net Bowl Capacity oz. (cm 3 ) 6.1 (180) Weight lbs. (kgf) 6.94 (3.15) Proof Pressure psig (Mpa) 220 (1.5) Max. Operating Pressure psig (Mpa) 150 (1.0) Operating Temperature Range 23 ~ 140 F (-5 ~ 60 C) Filtration 40 µm Flow Characteristics

50 RAM P/N LB80045R LUBRICATOR Specifications Proof Pressure psig (Mpa) 220 (1.5) Max. Operating Pressure psig (Mpa) 145 (1) Operating Temperature Range 40 ~ 140 (5 ~ 60 C) Recommended Lubricant Turbine Oil #1 (ISO VG32) Pipe Size 1 ½ NPT Oil Capacity (cm3) 500 Flow Rate /n/min 12500

AIR CHAMP PRODUCTS. FMBES-CC Models 625, 875, 1125, and 1375 FORM NO. L E-0714 FORM NO. L E-0714

AIR CHAMP PRODUCTS. FMBES-CC Models 625, 875, 1125, and 1375 FORM NO. L E-0714 FORM NO. L E-0714 AIR CHAMP PRODUCTS Models 5, 85, 5, and 5 In accordance with Nexen s established policy of constant product improvement, the specifications contained in this manual are subject to change without notice.