Page 1
CLICK on product numbers
above to obtain the product detail
sheet which includes dimensional
data helpful during installation.
Installation & Maintenance Manual
COMBINATION AIR ENGAGED FRICTION CLUTCH-
SPRING ENGAGED FRICTION BRAKES
STOP & START THE BRONZE BUSHING PILOT (SPROCKET)
Catalog Products:
W3B2H-STH
W4B2H-STH
W5B2H-STH
W6B2G-STH
And non-catalog variations
of this clutch-brake 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/Clutch-Brakes/Stop-Start-Pilot-Sprocket-Clutch-
Brakes-Bronze-Bushing.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
Page 2
I. New Clutch-Brake Torque
New clutch or brake 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-Brake 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-brake onto
the shaft. Hammering on the clutch-brake 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-brake 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 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-brake.
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 sprocket or pulley. Cycle the clutch-brake 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.
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Page 3
RACE
BUSHING
RETAINER RING
BEARING
O-RING
DRIVE DISC
SPRING
PIN
SCREW
SLEEVE
PISTON
FRICTION DISC
CONE
CYLINDER
DRIVE HUB
BRAKE DRIVE
DISC
BRAKE FRICTION
DISC
IV. Clutch-Brake Operation
Repair Kit:
Part number = Clutch-Brake Product Number + “-RPRK” (e.g. W3B2H-STHRPRK).
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.
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 or brake may either seize
up entirely or lose torque capacity. If friction discs become contaminated, they should be
replaced. See repair kit ordering information below.
V. Routine Maintenance
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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Page 4
VII. Repair Kit Installation Procedure
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)
A. CLUTCH FRICTION DISC & SPRING REPLACEMENT
(1) Remove clutch-brake from shaft and place in vertical position with sleeve end facing
upward.
(2) Remove retainer ring, race, sleeve and secondary race.
(3) Two remaining retainer rings should now be accessible. Remove the first retainer ring.
(4) The last retainer ring is under pressure from the springs. It may be necessary to
use an arbor press to compress the springs to remove this last retainer ring.
(5) Remove the drive discs, springs and friction discs.
(6) Drive discs should be clean, dry and free of burrs or nicks.
(7) 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 sleeve.
(8) Reassemble drive & friction disc section according to reference drawing using new
friction discs, springs and steel drive discs as necessary. Note that the first drive disc
contains a milled hole. It is important that this disc is replaced first during
reassembly to line up with the screw in the cone. After installing remaining friction
discs, drive discs and springs it may be necessary to use an arbor press to compress
the springs to replace retainer ring.
(9) Replace retainer rings, races, and sleeve according to reference drawing.
(10) If the cylinder is to be disassembled omit steps 8 & 9.
B. CYLINDER DISASSEMBLY
(1) Place clutch-brake in vertical position with cylinder end facing upward.
(2) Remove retainer ring from drive hub.
(3) Remove air cylinder sub-assembly consisting of the piston, bearing & cone 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
inserted in the hub with a rubber mallet or similar soft face hammer, while pulling the
cylinder upwards to break the Loctite® seal.
C. O-RING & BRAKE FRICTION DISC REPLACEMENT
(1) Separate cylinder and piston/bearing/cone/brake friction disc sub-assembly.
(2) Remove & inspect O-ring seals.
(3) Remove Brake friction disc.
(4) Remove any grease from piston and replace brake friction disc.
(5) Replace O-rings that have been lubricated with an O-ring lubricant such as Dow
Corning® #4 Compound or equivalent. Be careful not to contaminate brake friction
disc with O-ring lubricant.
(6) A very thin coat of O-ring lubricant should also be applied to the inner walls of the
cylinder.
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®.
You may need to strike the hub, or an object
Page 5
D. REASSEMBLY
(1) Replace the piston/bearing/cone/brake friction disc sub-assembly into cylinder.
(2) 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.
(3) Apply a thin coat of Loctite® #609 retainer compound to the inside diameter of the
bearing, then slide the air cylinder/bearing sub-assembly over the drive hub. Applying
excessive Loctite® will make future disassembly more difficult.
(4) Replace the outer retainer ring. Invert clutch-brake and seat cylinder sub-assembly
firmly against retainer ring.
(5) Replace drive discs, friction discs and springs according to “CLUTCH FRICTION DISC
& SPRING REPLACEMENT” portion of these instructions.
(6) Replace the sleeve, races and retainer rings according to reference drawing. It may be
necessary to apply enough air pressure (15-25 PSI) to obtain a neutral position
between the clutch and the brake to allow all the friction discs to float easily into the
slots in the sleeve.
(7) See “CLUTCH INSTALLATION” portion of these instructions for the proper procedure
for reinstalling the clutch-brake.
Technical assistance is available by contacting Mach III Clutch, Inc.
Toll free 866.291.0849 ● International 859.291.0849 ● Fax 859.655.8362
info@machiii.com ● engineering@machiii.com ● www.machiii.com
Mach III Product Warranty
http://www.machiii.com/Resources/Warranty-Info.asp
Mach III Clutch, Inc.
101 Cummings Drive ● Walton, KY 41094
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