Warner Electric ARC 2000 User Manual

P-2016
ARC

ARC

Magnetic Capping Headsets

Service & Installation Instructions

An Altra Industrial Motion Company

ARC Installation Procedure

Wrench ats

Customer
Supplied
Chuck

Figure 1

Install chuck (not supplied). Use appropriate open­end wrench (YTL4-0009 or YTL4-0007) depending
on headset model to hold headset output.
See Figure 1.

Spanner
Holes

Jam Nuts

Figure 2

Knock-out Rod

Spring

Spring Seat

Figure 4

Apply anti-seize compound to spindle shaft.
Install spring seat and spring (not supplied) if
required. See Figure 4.

Set the top-load assembly using provided spring
setting chart. Lock the jam nuts using O.D. spanner
wrench (YTL3-0009). See Figure 2.

Set Screws

Face
Spanner
Wrench

Figure 3

Set the preliminary static torque using provided
torque setting chart. Loosen set screws with hex
key wrench, turn end cap with face spanner wrench
(YTL2-0002), tighten set screws to 8-10 lb-in. Over
tightening is not necessary and will strip the screws
or possibly damage the housing body. See Figure 3.

Spring Seat

Figure 5

Install headset on spindle. Turn onto threaded
spindle until headset is fully seated on spindle.
Tighten headset securely using O.D. Spanner
wrench (YTL3-0009). See Figure 5.

2 Warner Electric • 800-825-9050 P-2016 • ARC

Setting Top Load Spring Force

1. Determine initial spring setting from spring
force chart below.

2. Compress the spring with the locking ring just
enough to allow the adjustment ring into its
correct setting.

3. Move the adjustment ring to the desired
setting. Bring the locking ring down and jam
the rings together with a spanner wrench.

4. For optimum results check download force
with a force scale.

5. Set headset on the scale and manually
compress the spring downward 5mm. Take
the force reading at this position. The lines on
the spring cover are .100” (2.5mm) apart, so
two lines equal the recommended .200” (5mm)
compression.

Top Load Spring Force

Setting Chart

Spring Force at 0.200” (5mm) Deection

Standard

Spring

Setting

lb Kg lb Kg lb Kg

1.0 34 15 24 11 50 23

1.5 39 18 27 12 58 26

2.0 44 20 31 14 66 30

2.5 49 22 34 15 73 33

Max 54 24 38 17 80 37

Spring

YTP1-0010

Plain

Spring Force at 0.100” (2.5mm) Deection

Standard

Spring

Setting

Spring

YTP1-0010

Plain

Low

Spring

YTP1-0003

Grey

Low

Spring

YTP1-0003

Grey

High

Spring

YTP1-0008

Black

High

Spring

YTP1-0008

Black

Top Load Settings

lb Kg lb Kg lb Kg

1.0 29 13 20 9 43 20

1.5 34 15 24 11 50 23

2.0 39 18 27 12 58 26

2.5 44 20 31 14 66 30

Max 49 22 34 15 73 33

NOTE: The charts above provide actual spring
loads without any added load due to the
weight of the headset. These spring loads are
valid for any headset. Not all headsets have
the full range of settings; some headsets do
not have a ‘3.0’ setting, other headsets do not
have ‘1.0’ or ‘1.5’ settings. The spring loads
are calculated at the given deection as listed
in the chart.

Figure 6

Warner Electric • 800-825-9050 P-2016 • ARC 3

Setting Application Torque

1. Determine initial clutch setting from torque chart
below.

Recommended Maintenance

Schedule

Lubricate the upper assembly every 500
hours of run time.

2. Loosen the torque adjustment screws. Rotate the
adjustment ring using the face spanner wrench to
the desired setting and then retighten the torque
adjustment screws. Do not use the set screw in
the slot on the backside of the housing for torque
adjustment. Tighten set screws to 8-10 lb-in.
Over tightening is not necessary and will strip the
screws or possibly damage the housing body.

3. For optimum results, check setting with a torque
wrench and FIX-0007 or FIX-0010.

Application
Torque Setting

Figure 7

- Using a grease injector needle, apply lubricant
into the grease port.

- Recommended grease: No. 2 Food Grade
Grease

Grease Port

Figure 8

Disassemble, clean, and replace all wearing
parts in the headset every 7000 hours of
machine run time.

Application Torque Setting Charts

Application

Clutch

Setting

lb-in Ncm lb-in Ncm

0.00 2.00 22.5 2.5 28.2

0.50 3.50 39.5 4.0 45.2

1.00 5.00 56.5 5.0 56.5

1.50 8.50 96.0 8.5 96.0

2.00 10.50 118.6 11.0 124.3

2.50 13.50 152.5 15.0 169.5

3.00 16.00 180.7 18.5 209.0

3.50 17.50 197.7 22.0 248.5

4.00 18.50 209.0 24.0 271.1

4.50 19.00 214.6 25.5 288.1

5.00 19.50 220.3 26.0 293.7

Torque-Low

Inertia

Magnet

Application

Torque

(Ncm)

Standard

Magnet

- See rebuild instructions for detailed information
on disassembly and assembly of Warner
headsets.

- Dependent upon machine speed and
washdown procedure, some environments
may require more frequent rebuilds.

Rebuild Kits available:

• M4.5-BK (Bearing and Hardware Rebuild Kit)

• M4.5-MK (Magnet Rebuild Kit)

• M4.5-PK (Push rod Rebuild Kit)

• M4.5-TL (Replacement Top Load Assembly)

*Contact customer service for the exact kit part

number for your specific headset model.

4 Warner Electric • 800-825-9050 P-2016 • ARC

Installation Tools and Fixtures

FIX-0001 – Bearing installation

and removal fixture for the ZRC
style bearings.

FIX-0003 – Use to hold the
output of ARC style unit during
disassembly. Earlier revision levels
with a larger output dimension

Figure 10

Figure 12

FIX-0002 – Bearing installation

and removal fixture for the ARC

that will not fit in this fixture can
be clamped directly in a vice.

FIX-0004 – Upper assembly nut
removal fixture for ZRC style unit.

style bearing.

Figure 11

Warner Electric • 800-825-9050 P-2016 • ARC 5

Figure 13

Continued on page 6.