Autogap Installation for
Size 500 Basic Brakes & Clutches
5200-101-009
Part Number
P-1381
819-0112
Assembly Instructions
Brake or Clutch Coupling Installation
Step 1
Place straight springs over armature boss on back side
of armature.
Step 2
Place armature hub over straight springs assembled in
Step 1.
Installation Instructions
Failure to follow these instructions
may result in product damage, equipment damage,
and serious or fatal injury to personnel.
Be sure that straight springs do not get caught
under shoulder of drive pins.
Step 4
Insert assembled drive pins through armature hub,
through straight springs and into threaded holes in
back of armature. Drive pins require application of
Grade “AA” Loctite®Sealant on threads.
Straight springs must fit into grooves in armature
hub.
Step 3
Compress conical spring against retainer ring by sliding
detent spring towards head of all 3 pins.
Step 5
Draw drive pins up tightly until shoulder of pin is against
face of armature boss, (since threads are class No. 3
fit, pins may seem to bind).
Step 6
Compress the retainers against the armature hub and
check to see that the armature hub is held tightly to the
armature bosses. This position must not be disturbed
during completion of assembly.
Step 7
Slide the armature and armature hub with taperlock
bushing over the shaft. Place armature face
approximately 1/32” from the magnet face and secure
the taperlock bushing to the shaft. This gap will be
automatically maintained throughout the life of the unit.
The unit should be checked for concentricity and
squareness to the shaft by means of a dial indicator.
The unit should be concentric to the shaft within .010
T.I.R. and square to the shaft within .006 T.I.R.
Compressed
A
rmature
Straight Spring
Detent
Spring
R
etainer
C
onical
Spring
Drive Pin
A
rmature Hub
Armature Boss
Autogap Installation for Clutch/Brake
Combination
Step 1
Place straight springs over armature bosses on back
side of both armatures.
Step 2
Compress conical spring against retainer ring by sliding
detent spring towards head of all 6 pins.
Step 4
epeat Step 3 above for the remaining (3) drive pins
R
inserting them from opposite side of armature hub
through remaining (3) holes.
Step 5
Holding the pins in position. Place the armature hub
over one armature. Note: Make sure that the straight
springs on the armature bosses fit into the grooves in
the armature hub. Drive pins require application of
Grade "AA" Loctite Sealant on threads.
Compressed
Step 3
Insert (3) of the compressed drive pins through the
armature hub so that the threaded end of the pins
comes through on the side of the armature hub with
the groove around the hole.
Step 6
Draw these (3) drive pins up tightly until shoulder of pin
is against face of armature boss (since threads are
class No. 3 fit, pins may seem to bind.)
Step 7
Place the armature hub and armature assembled in
steps 5 & 6 over the remaining armature.
Note: Make sure that the three remaining straight
springs on the armature bosses fit into the grooves in
the armature hub. Drive pins require application of
Grade "AA" Loctite Sealant on threads.
2
Warner Electric • 800-825-9050 P-1381 • 819-0112
Step 8
3.356
± .001
Chordal
3
.875
±
.001
Bolt Circle
.
3665 ± .0005 Dia.
5/16 - 24 UNF - 3A
Threads
7
/8 1/16
1-3/8
Draw drive pins up tightly until shoulder of pin is against
face of armature boss, (since threads are class No. 3
it. pins may seem to bind). Note: Rotate tightening of
f
drive pins tightening each drive pin a few turns at a
time.
Step 9
Compress one of the armatures and armature hub
together until the armature hub bottoms on the
armature boss. On each pin, slide the retainer down
tightly against the armature hub. Turn the assembly
over and repeat this procedure for remaining armature.
Note: This position must not be disturbed
during completion of assembly.
tep 10
S
Slide the assembly with taperlock bushing over the shaft.
lace the face of the armature approximately 1/32'’ from
P
the brake magnet face and fix the taperlock bushing to
the shaft.
Step 11
Place the clutch magnet approximately 1/32" from the
armature face, and tighten the taperlock bushing to the
shaft. The unit should then be checked for concentricity
and squareness to the shaft by means of a dial indicator.
The unit should be concentric to the shaft within .010
T.l.R. and square to the shaft within .006 T.l.R. With the
previous steps followed, the autogap will maintain
automatic adjustment for wear throughout the life of the
unit.
Machining Instructions for Gear,
Sprocket, or Pulley
As in the case of a clutch, the customer may wish to
mount the armature to his pulley, hub, etc. These
dimensions must be followed for adaptation to the
armature.
1. The chordal dimension must be held for all chords
between pin holes.
2. Sleeve bearings (Oilite Bronze) must be provided in
the holes of pulley or hub with an I.D. of .376 ±
.001 at the chordal and bolt circle dimensions
shown above.
3. The drive pins must be square with plane of
mounting surface and magnet within .006 T.l.R.
Our standard armature hub may also be used for the
mounting of a gear, sprocket or pulley.
Warner Electric • 800-825-9050 P-1381 • 819-0112
3
Warranty
Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any
product manufactured and sold by it which proves to be defective in material or workmanship within
a period of one (1) year from the date of original purchase for consumer, commercial or industrial
use.
This warranty extends only to the original purchaser and is not transferable or assignable without
Warner Electric LLC’s prior consent.
Warranty service can be obtained in the U.S.A. by returning any defective product, transportation
charges prepaid, to the appropriate Warner Electric LLC factory. Additional warranty information may
be obtained by writing the Customer Satisfaction Department, Warner Electric LLC, 449 Gardner
Street, South Beloit, Illinois 61080, or by calling 815-389-3771.
A purchase receipt or other proof of original purchase will be required before warranty service is
rendered. If found defective under the terms of this warranty, repair or replacement will be made,
without charge, together with a refund for transportation costs. If found not to be defective, you will
be notified and, with your consent, the item will be repaired or replaced and returned to you at your
expense.
This warranty covers normal use and does not cover damage or defect which results from
alteration, accident, neglect, or improper installation, operation, or maintenance.
Some states do not allow limitation on how long an implied warranty lasts, so the above limitation
may not apply to you.
Warner Electric LLC’s obligation under this warranty is limited to the repair or replacement of the
defective product and in no event shall Warner Electric LLC be liable for consequential, indirect,
or incidental damages of any kind incurred by reason of the manufacture, sale or use of any defective
product. Warner Electric LLC neither assumes nor authorizes any other person to give any other
warranty or to assume any other obligation or liability on its behalf.
WITH RESPECT TO CONSUMER USE OF THE PRODUCT, ANY IMPLIED WARRANTIES WHICH
THE CONSUMER MAY HAVE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF
ORIGINAL CONSUMER PURCHASE. WITH RESPECT TO COMMERCIAL AND INDUSTRIAL
USES OF THE PRODUCT, THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL
OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR
OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you. This warranty gives you specific legal rights and
you may also have other rights which vary from state to state.
Changes in Dimensions and Specifications
All dimensions and specifications shown in Warner Electric catalogs are subject to change without
notice. Weights do not include weight of boxing for shipment. Certified prints will be furnished without charge on request to Warner Electric.
Warner Electric
31 Industrial Park Road • New Hartford, CT 06057
815-389-3771 • Fax: 815-389-2582
www.warnerelectric.com
P-1381 819-0112 8/11 Printed in USA
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