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CLICK on product numbers above
to obtain the product detail sheet
which includes dimensional data
helpful during installation.
Installation & Maintenance Manual
AIR ENGAGED FRICTION CLUTCH MECHANISMS
WITH COUPLINGS
Catalog Products:
M3G2R-STH & M3G2R-STL
M4G2R-STH & M4G2R-STL
M5G2R-STH & M5G2R-STL
M6G2G-STH & M6G2G-STL
And non-catalog variations
of this clutch design.
Mach III Technical Support
Toll Free: 866-291-0849
International: 001-859-291-0849
Email: engineering@machiii.com
www.machiii.com
Detail sheets and 3D models are available on the Mach III website:
http://www.machiii.com/Products/Clutches/Clutch-Couplings/Clutch-Mechanisms-
Couplings-Regular-Duty.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
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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. Clutch Installation
Great care must be exercised to assure proper offset & angular alignment between shafts
to prevent premature clutch failure.
Dimensional diagrams can be obtained by using links on page one of this manual.
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 keys (customer supplied) onto the shafts.
(3) Position clutch mechanism and coupling hub on shafts.
(4) Tighten set screws to secure the clutch and coupling to the shafts.
B. AIR LINE CONNECTION
Refer to the dimensional spec sheet for NPT size to obtain correct fitting. Install fitting using 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. ANTI-ROTATION (REACTION) ARM CONNECTION
The air cylinder portion of a Mach III through shaft style clutch is designed to remain stationary.
Due to friction in the bearing housed in the air cylinder, this member will rotate unless an antirotation arm (a.k.a. reaction arm) is installed. A threaded hole is provided in the cylinder for the
installation of this arm. Please refer to Mach III’s Anti-Rotation (Reaction) Arm Installation
Instructions document for illustrations of proper mounting. This document is available from the
Mach III website: http://www.machiii.com/pdf/ReactionArmInstallation.pdf or by calling Mach III to
have a copy sent by email or fax.
Note that in all cases, the machine frame or bracket should not be tight against the
housing of the clutch as contact may impede piston movement and will shorten bearing
life.
D. FINAL INSPECTION & TESTING
Check alignment of the coupling. 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.
III. 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 bearings.
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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Page 3
O-RING
DRIVE DISC
SPRING
PIN
SCREW
COUPLING
PISTON
FRICTION DISC
CONE
CYLINDER
DRIVE HUB
BEARING
RETAINER RING
IV. Routine Maintenance
Repair Kit:
Part number = Clutch Product Number + “-RPRK” (e.g. M3G2R-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
Tools Required
Hex Wrench Set
Rubber Mallet or similar soft face hammer
Retainer (snap) Ring Pliers
Scraper
Compounds Required
Grease
O-ring Lubricant
Loctite® #609 Retaining Compound
Anti-Seize Lubricant (for re-installation)
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.
V. Parts diagram
VI. Repair Kit Installation Procedure
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A. FRICTION DISC & SPRING REPLACEMENT
(1) Remove clutch from shaft and place in vertical position with drive disc end facing
upward.
(2) Remove retainer ring, drive discs, springs and friction discs.
(3) Drive discs should be clean, dry and free of burrs or nicks.
(4) Reassemble drive & friction disc section according to reference drawing using new
friction discs, springs and steel drive discs as necessary.
(5) Assure that drive discs move freely on the drive hub and that the lugs of the friction
discs move freely in the drive slots of the adapter.
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.
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B. O-RING REPLACEMENT
(1) Remove clutch from shaft and place in vertical position with cylinder end facing upward.
(2) Remove retainer ring from drive hub.
(3) Remove air cylinder with bearing from drive hub. The air cylinder bearing is a slide fit
on the drive hub and is affixed to the drive hub with a thin coating of Loctite
need to strike the hub, or an object inserted in the hub with a rubber mallet or similar
soft face hammer, while pulling the cylinder upwards to break the Loctite® seal.
(4) Remove inner retainer ring from the drive hub.
(5) Next, remove sub-assembly consisting of the piston, bearing & cone. The disc
package (consisting of friction discs, drive discs & springs) will now be accessible.
Note that the first drive disc contains a milled hole. It is important that this disc is
returned to the top during reassembly to line up with the screw in the cone.
(6) Separate cylinder and piston/bearing/cone sub-assembly taking care not to bend the
pins which connect them.
(7) Inspect O-ring seals. If worn, replace using new O-rings that have been lubricated with
an O-ring lubricant such as Dow Corning® #4 Compound or equivalent.
(8) A very thin coat of O-ring lubricant should also be applied to the inner walls of the
cylinder.
®.
C. REASSEMBLY
(1) Place the piston/bearing/cone sub-assembly over drive hub making sure the screw
head in the cone is inserted in the corresponding hole milled in the drive disc. This
prevents the cone from skidding on the drive disc.
(2) Replace the inner retainer ring on the drive hub.
(3) Inspect the inside diameter of the bearing in the air cylinder. If Loctite® residue is
present, gently scrape and assure that the surface is clean.
(4) Place a small amount (dab) of grease (Mantek® Elite Red or equivalent) on the pins
that connect the air cylinder and piston.
(5) Apply a thin coat of Loctite® #609 retainer compound to the inside diameter of the
bearing (applying excessive Loctite® will make future disassembly more difficult), then
slide the air cylinder/bearing sub-assembly over the drive hub making sure the pins of
the cone are aligned with the holes in the cylinder.
(6) Make sure that all components are well seated and replace the outer retainer ring.
(7) 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 859.655.8362
info@machiii.com ● engineering@machiii.com ● www.machiii.com
You may
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