Mach III Clutch C6D2G-STH, C6D2G-STL User Manual

CLICK on product numbers above

to obtain the product detail sheet

which includes dimensional data

helpful during installation.

Installation & Maintenance Manual

AIR ENGAGED FRICTION CLUTCHES

END OF SHAFT MOUNT- BALL BEARING PILOT

Catalog Products:

C3D2R-STH & C3D2R-STL
C4D2R-STH & C4D2R-STL
C5D2R-STH & C5D2R-STL

C6D2G-STH & C6D2G-STL

And non-catalog variations

of this clutch design.

Mach III Technical Support

Toll Free: 866-291-0849

International: 001-859-291-0849

Email: [e-mail]

www.machiii.com

Detail sheets and 3D models are available on the Mach III website:

http://www.machiii.com/Products/Clutches/Industrial-Friction-Clutches/End-of-Shaft-

Pilot-Mount-Clutches-Ball-Bearing.asp

Please contact Mach III to obtain assembly and parts list drawings.

This product includes rotating equipment and should be guarded according to

OSHA requirements and other Federal, State and local regulations. It is the

responsibility of the user to provide necessary guarding.

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© Mach III Clutch, Inc. All Rights Reserved

I. New Clutch Torque

New clutch torque is approximately 40% less than rated design torque until the friction
and drive discs are worn in (lapped, burnished). The length of time for wear-in to occur
depends upon the application.

II. Installing a Sprocket or Pulley

Mach III units are typically shipped from the factory with the required sprocket or pulley
preinstalled. This section pertains only to those who need to install or replace a pulley or
sprocket in the field. Please use the links on page one of this document to obtain the
detail sheet for your unit. This sheet will include the pilot diameter and other dimensions
needed to machine the sprocket or pulley.

Bore the sprocket or pulley for clearance (slide fit) over pilot and drill standard clearance
holes for the number and type of screws on corresponding bolt circle. The cap screws
used to attach the sprocket or pulley should not be longer than the sum of the depth of
the threaded hole plus the thickness of the sprocket or pulley. Otherwise, the cap screws
may bottom out. Tighten all screws to uniform torque based on screw size and use
proper Loctite® (or equivalent) compound to assure a permanent mount.

III. Clutch Installation

A. SHAFT PREPARATION & MOUNTING

Mach III Clutch products are bored to fit a precision plug gauge for the specified bore size and
should slide fit the mating shaft. Make certain that the shaft is free of burrs or nicks. It may be
necessary to file or sand the shaft to assure a slide fit. Never hammer the clutch onto the
shaft. Hammering on the clutch may cause evident damage or subtle injury that will shorten the
wear life of the unit, and will void the warranty.

(1) Apply the anti-seize (E-Z Break®) lubricant from the packet provided, or equivalent, to

the shaft.
(2) Insert key (customer supplied) onto the shaft.
(3) Slide clutch over key on the shaft, align the sprocket or pulley.
(4) Tighten set screws to secure the clutch to the shaft.

B. AIR LINE CONNECTION

Refer to the dimensional spec sheet for NPT or TUBING size. If installing an NPT fitting use a
thread sealing compound to prevent air leakage. Connect a flexible air line to the fitting. Do not
use rigid piping. Air supply should be both filtered and regulated. Contamination in the air
supply may damage the clutch.

C. FINAL INSPECTION & TESTING

Check alignment of the sprocket or pulley. Cycle the clutch with the machine off to check for air
leaks and to ensure proper engagement and release. After a short run, check set screws and
alignment.

IV. Clutch Operation

The maximum operating pressure should not exceed 80 PSI. Operation at pressures
greater than that required for proper function will decrease the life of the air seal.

Special Note Regarding Friction Disc Contamination:

The friction material used in this product will absorb oil, water, chemicals and other
contaminants. Depending on the type of contamination, clutch may either seize up
entirely or lose torque capacity. If friction discs become contaminated, they should be
replaced. See repair kit ordering information below.

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V. Routine Maintenance

Repair Kit:

Part number = Clutch Product Number + “-RPRK” (e.g. C3D2R-STH-RPRK)

Additional
Parts:

Contact Mach III to obtain a complete listing of additional parts kits available for

your specific clutch. Please reference product number when calling or e-mailing.

Repair
services:

Factory repair is available. A return materials authorization (RMA) number must

be obtained prior to sending any unit in for repair

BEARING

RETAINER RING

DRIVE DISC

SPRING

SLEEVE

PISTON

FRICTION DISC

CYLINDER

DRIVE HUB

AIR SEAL

RETAINER RING

O-RING

When installed and operated according to the preceding guidelines, Mach III Clutch
products should require little or no routine maintenance. A repair kit is available which
contains all parts subject to typical wear: friction discs, springs and O-rings.

VI. Parts diagram

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VII. Repair Kit Installation Procedure

Tools Required

Hex Wrench Set
Retainer (snap) Ring Pliers

Compounds Required

Grease
O-ring Lubricant
Anti-Seize Lubricant (for re-installation)

A. DISASSEMBLY

(1) Remove clutch from shaft and place in vertical position with cylinder end facing upward.
(2) Remove outer retainer ring.
(3) Remove air cylinder with Piston from drive hub.
(4) The disc package (consisting of friction discs, drive discs & springs) will now be

accessible.

B. FRICTION DISC & SPRING REPLACEMENT

(1) Remove the drive discs, springs and friction discs.
(2) Drive discs should be clean, dry and free of burrs or nicks.
(3) Reassemble drive & friction disc section according to reference drawing using new

friction discs, springs and steel drive discs as necessary.
(4) Assure that drive discs move freely on the drive hub and that the lugs of the friction disc

discs move freely in the drive slots of the sleeve.

Note Regarding Wave Spring Alignment:

The beginning of the coil of each spring should be placed in the same relative (O-Clock)
position to the drive hub to assure equal separation of the drive disc.

C. O-RING REPLACEMENT

(1) Separate cylinder and piston.
(2) Inspect O-ring seals (in piston and on drive hub). If worn, replace using new O-rings

that have been lubricated with an O-ring lubricant such as Dow Corning® #4 Compound

or equivalent.
(3) A very thin coat of O-ring lubricant should also be applied to the inner walls of the

cylinder.

D. REASSEMBLY

(1) Replace the piston.
(2) Lubricate bore of cylinder with an O-ring lubricant such as Dow Corning® #4 Compound

or equivalent.
(3) Slide the air cylinder/piston sub-assembly over the drive hub.
(4) Make sure that all components are well seated and replace the outer retainer ring.
(5) See “Clutch Installation” portion of these instructions for the proper procedure for

reinstalling the clutch.

Technical assistance is available by contacting Mach III Clutch, Inc.

Mach III Product Warranty

http://www.machiii.com/Resources/Warranty-Info.asp

Mach III Clutch, Inc.

101 Cummings Drive ● Walton, KY 41094

Toll free 866.291.0849 ● International 859.291.0849 ● Fax [phone]

[e-mail] ● [e-mail] ● www.machiii.com

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