Warner Electric 5219 Series, 5228 Series, 5218 Series, 5217 Series Installation & Operation Instructions
P-1177-WE
819-0457
Residential, TG-2000 and
Commercial MagStop® Clutch/Brake
Installation & Operation Instructions
This Manual covers Magstop Product Families as outlined below:
Series Reference Name Torque Range
5217 Series RMS 60 & 80 ft-lb.
5218 Series CMS 175 & 200 ft-lb.
5219 Series TG 2000 105 & 125 ft-lb.
5228 Series CMS 250 225 & 250 ft-lb.
Contents
Terminology............................3
MagStop® Components...................4
Mounting Requirements ................5-6
Anti-Rotation Examples ................7-13
Troubleshooting Checklist .............14-15
Electrical Evaluation.....................16
Series Reference Name Torque Range
5217 Series RMS 60 & 80 ft-lb.
5218 Series CMS 175 & 200 ft-lb.
5219 Series TG 2000 105 & 125 ft-lb.
5228 Series CMS 250 225 & 250 ft-lb.
This guide applies to Warner Electric MagStop
®
clutches and clutch/brakes used on power
equipment.
Residential, TG-2000, and Commercial MagStops
are available in a range of torque capacities. The
MagStop® name comes from the permanent
magnet brake (magnetic stopping) rather than
conventional spring activated mechanical brakes.
In addition to these general procedures, any
applicable OEM general and safety procedures
must also be followed.
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.
2 Warner Electric • 800-825-9050 P-1177-WE • 819-0457
MagStop® Bearing Mounted Electric Clutch and Clutch/Brake Assemblies and Operation
Components: (See Figure 1 on page 4.)
1. Rotor Assembly
Generally, the input of the clutch. Includes
a keyed hub which mates with the keyway
in the crank shaft. The rotor transmits the
torque from the crankshaft (driving shaft) to the
armature assembly (output).
2. Armature Assembly
Generally, the output of the clutch. Consists
of a disk, springs and pulley (or output flange).
With power applied the armature transmits
torque from the rotor to the driven load. Power
from the armature disk is transmitted to the
pulley or flange by means of the leaf springs.
3. Field Assembly
The clutch “power” source contains the coil
which generates magnetic attractive force.
4. Brake Poles
The two permanent magnets and plates ffixed
to the field shell provide the brake torque when
the clutch is disengaged. Brake poles are not
present if the assembly is a clutch only.
Optional Washer
A single .250 inch (6.35 mm) minimum thick steel
washer must be used between the clutch and the
crank shaft retaining bolt if the D-drive spacer is
not used.
A washer less than .250 inch
(6.35 mm) thick will deform and allow the
clamping load to be lost, resulting in damage
to the clutch and/or the crankshaft and
possible personal injury due to clutch
separating from the shaft. Multiple thinner
washers are not acceptable.
5. D-drive Spacer
A hub that is inserted into either armature or
field bearing (see Figure 2). The head has flats
that can be held with a wrench to prevent
rotation of the crankshaft when tightening
the mounting bolt (see Figure 5). This hub
also takes the place of the standard retaining
washer.
6. Anti-rotation Slot
Anti-rotation Slot (used with OEM’s anti-
rotation device) prevents MagStop from
rotation with crankshaft. If the field is bolted
rigidly or if its axial movement is restricted the
bearing in the field assembly will be improperly
loaded and may fail. Use OEM supplied antirotation.
Warner Electric • 800-825-9050 P-1177-WE • 819-0457 3
MagStop® Components
Press
Press
Coil
Field
Bearing
1
Rotor
Assembly
3
Field
Assembly
Brake Poles
One piece
Field Assembly
2
Armature
Assembly
4
5
D-drive
Spacer
Armature
Bearing
Armature Leaf
Springs
Optional
Washer
.250 Inch
(6.35 mm)
Minimum
Washer
Thickness.
Washer
Diameter
Must Not
Exceed OD
of Bearing
Inner Race.
Figure 1
6
Anti-
Rotation
Slot
One Piece Field Assembly with
Integral Anti-Rotation Slots
Top View
from Pulley
D-drive Spacer Removal/Installation
D-drive Spacer
Support bearing outer race
D-drive Spacer
D-drive Spacer removal
Figure 2
D-drive Spacer installation
D-drive spacer may be installed on either end of clutch by OEM.
D-drive spacer must be removed or installed using an arbor press or equivalent. On
installation, opposite bearing INNER race must be supported or bearing damage may occur. On
removal, adjacent bearing OUTER race must be supported or bearing damage may occur.
Support bearing
inner race
4 Warner Electric • 800-825-9050 P-1177-WE • 819-0457
REQUIREMENTS
for a Successful Clutch
Application/Installation
Critical Requirements
The two most important requirements for a successful clutch application or installation are:
1. Antirotation device must allow both axial
and radial free-play!
Failure to allow this free-play will result
in field bearing failure. The greater the
restriction the faster the bearing will
fail!
2. Mounting bolt torque to be
minimum of:
• 3/8 -24 UNF use Grade 8 bolt torqued
to 45-49 lb.-ft.
(Grade 5 bolt is unacceptable)
• 7/16-20 UNF Grade 5 or 8 bolt torqued
to 55-60 lb.-ft.
(Grade 5 or 8 bolt is
acceptable)
• M 10 X 1.50 Class 10.9 torqued to
55-65 N-m
Note: All values are for dry (unlubricated)
plated bolts, please consult fastener
manufacturer if any type of locking element
(thread lock compound, patch etc.) is to be
used.
Warner Electric • 800-825-9050 P-1177-WE • 819-0457 5
Failure to adhere to these requirements
will result in the failure of the clutch!
Mounting
Ground drive pulley or spacer
must be chamfered to clear this
radius on the engine shaft
shoulder.
Shaft
Engine Shaft
Note:
Must have faces parallel to each other
(within .003") and be perpendicular
to the bore.
Ground Drive Spacer
(or spacer if no ground
drive used)
round
Shaft end and
D-drive
spacer must
not touch
D-drive Spacer
Always bottom the clutch against a
flat surface; never against radius.
Anti-Rotation
Shaft
Shoulder
Ground
Drive
Pulley
Figure 3
Typical Engine Installation with Ground Drive Pulley
Anti-rotation Slots
Thread size Torque ft.lb. To rque N-m
3/8-24" UNF 45-49 ft.lb. 61-66 N-m
7/16-20" UNF 55-60 ft.lb. 75-81 N-m
M 10 X 1.50 40-48 ft.lb. 55-65 N-m
Note: All values are for dry (unlubricated) plated bolts,
please consult fastener manufacturer if any type of locking
element (thread lock compound, patch etc.) is to be used.
Failure to torque bolt
to requirements will
degrade clamping and
can allow the clutch to
separate from the
shaft, causing risk of
personal injury.
Grade Class
Grade 8
Grade 5 or 8
Grade 10.9
See Anti-Roatation Examples on pages 8-13
its axial movement is restricted, the bearing
in the field assembly will be improperly
loaded and may fail. Use only factory
installed anti-rotation device.
6 Warner Electric • 800-825-9050 P-1177-WE • 819-0457
Figure 4
If the field is bolted rigidly or if
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