Warner Electric Advanced Technology Tension Clutches User Manual

Advanced Technology Tension

Clutches

P-220
819-0339

Installation Instructions

Contents

Clutch Installation

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Clutch Repair – On the Shaft . . . . . . . . . . . . . . . . . . 4

Clutch Service – Major . . . . . . . . . . . . . . . . . . . . . . . 7

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Exploded View and Parts List. . . . . . . . . . . . . . . . . 18

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . Back Page

Failure to follow these
instructions may result in product damage, equip­ment damage, and serious or fatal injury to per­sonnel.

The Warner Electric Advanced Technology Tension
(ATT) clutch you have purchased has been designed
to provide long and trouble-free service. It is a
rugged and durable unit that is rebuildable with both
friction face replacement and complete clutch rebuild
kits discussed in this service manual. The friction
face replacement kit renews the friction surfaces,
while the complete clutch rebuild kit includes new
bearings, components and hardware in addition to
the friction faces.

1. Remove your ATT Clutch from its shipping carton
and inspect it thoroughly to ensure that it has
arrived in good condition.

An accessory kit included with your clutch con­tains a key, retaining ring, and coil wire retainer.
In addition, you may have ordered the optional
sheave or timing belt pulley and field restraining
strap.

2. Install the factory-ordered sheave or pulley by
first inserting the key in its keyway. Place the
sheave or pulley so it will fit onto the hub, align­ing the keyway with the key and keeping the
sheave tapped holes facing away from the
clutch. (See Figure 1)

This service manual includes instructions required for
installation, repair on the shaft, and major rebuilding,
as well as troubleshooting information, specifications,
dimensions, an exploded view and parts list. Please
refer to the Table of Contents above for the section
page numbers.

All installation and repair involving clutches must be
carried out in accordance with the procedures speci­fied in the service manual. All stated or implied man­ufacturer warranties are voided if this product is not
installed and serviced in accordance with these
instructions.

Figure 1

Gently tap the sheave or pulley until it seats
against the hub shoulder.

Note: Do not force the pulley or sheave onto the
hub if it will not go. Check alignment to assure it
is going on evenly. Customer furnished sheaves,
pulleys and sprockets must be machined per
instructions found on page 16 of this manual
prior to installation. After machining, install per

Figure 2

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the above instructions. (See Figure 2)

3. Install the furnished sheave or pulley retaining
ring with retaining ring pliers.
(See Figure 3)

Figure 3

6. Tighten the hub setscrews into the shaft (See
Figure 5) to the appropriate torque for your size
unit:

Size Torque

25 80 in.lbs.
55 160 in.lbs.

When installing this or other
retaining rings, be sure to hold the ring with
one hand so it will not spring away, endanger­ing personnel and property, should the pliers
lose their grip on the ring. Safety glasses
should always be worn when installing or
removing retaining rings.

4. If used, install the Warner Electric conduit box in
accordance with its furnished instructions.

5. Place the ATT clutch onto its shaft, making sure
it is properly positioned over the shaft key. (See
Figure 4)

Figure 5

115 275 in.lbs.

Figure 6

Assure proper alignment of driving and driven
sheave, pulley or sprocket before tightening the
setscrews.

Figure 4

Note: The Warner Electric special furnished key
must be used with ATTC-25-7/8” bore units.

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Figure 7

7. Install the field restraining arm. (See Figure 6)

Note: The field must retain a degree of move­ment freedom to compensate for bearing and
shaft alignment tolerances.

8. When using a Warner Electric tension con­trol, follow the connection diagram supplied
with the control. (See Figure 7)

Complete Clutch Repair - On the Shaft

The new ATT design incorporates the latest in
advanced technology providing a rugged, durable,
patented design for long life, and maximum heat dis­sipation. Patented, easy to replace, friction surfaces
extend the design life for continued like-new per­formance. The ATT offers complete repair on the
shaft following ten easy steps. The repair can be
completed utilizing the parts in the friction face
replacement kit.

1. Move the clutch rotor towards the field for disas­sembly and reassembly. (See Figure 8)

Note: If a Warner Electric TCS-210, -220, -310,
or – 320 control is used, add a 68 ohm, 25 watt
resister or a dummy coil (part no. 275-3843)
across the current sense circuit. Although the
TCS series controls are recommended, a MCS
control can be used with normal hook-up.

9. Your ATT clutch is now ready for its static test.
Apply DC voltage to the clutch coil through the
clutch control. The armature should pull against
the friction material face.

10. Install the drive belt or chain.

11. Run the clutch under its operating load.

12. Your ATT clutch may not achieve its full torque
until after a short “break-in” period. To break in
the clutch, cycle it on and off under full load at
operating speed a minimum of ten times in quick

Figure 8

2. Remove hex head capscrews, washers and lock­washers to loosen the armature segments from
the cast iron carrier.
(See Figure 9)

Figure 9

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3. Lift out the two worn armature segments.
(See Figure 10)

Figure 10

Note: Although an AT brake is shown in these
instructions, identical procedures apply to a
clutch.

4. Remove the screws that attach the friction mate­rial segments to the clutch rotor through the
appropriate access holes. (See Figure 11)

6. Insert two new friction material segments. The
recessed holes should be facing away from the
magnet body. (See Figure 13)

Figure 13

7. Attach the new friction material segments to the
clutch rotor or brake magnet with screws through
the appropriate access holes. Apply one drop of
Loctite®(grade AA or equivalent) to each screw.
(See Figure 14)

Figure 14

Note: Use only the screws included with the

Figure 11

5. Lift out the worn friction material segments. (See
Figure 12)

repair kit since any other screws may damage
the unit. Tighten screws to 18 to 22 inch pounds
torque.

Figure 12

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Figure 15

8. Insert the two new armature segments. (See
Figure 15)

10. Reset the gap by moving the clutch rotor away
from the field or brake armature toward the mag­net. (See Figure 17)

Figure 17

9. Attach the new armature segments to the cast
iron carrier with hex head capscrews, lockwash­ers and washers. Apply one drop of Loctite
(grade AA or equivalent) to each screw. (See
Figure 16) Tighten to the appropriate torque for
your size unit.

Figure 16

Size Torque

ATT 25 29-35 in.-lbs.
ATT 55 60-84 in.-lbs.
ATT 115 60-84 in.-lbs.

11. Your ATT clutch is now ready for its static test.
Apply DC voltage to the clutch coil through the
clutch control. The armature should pull against
the friction material face.

12. Install the drive belt or chain.

13. Run the clutch under its operating load.

14. Your ATT clutch many not achieve its full torque
until after a short “break-in” period. To break in
the clutch, cycle it on and off under full load at
operating speed a minimum of ten times in quick
succession.

Your ATT clutch is now ready to run.

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