Page 1
P-2019
ARC/ZRC
ARC Clutch / ZRC Top Load
Operating Instructions
An Altra Industrial Motion Company
Page 2
ZRC 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-2019 • ZRC
Page 3
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) Deection
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) Deection
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 deection as listed
in the chart.
Figure 6
Warner Electric • 800-825-9050 P-2019 • ZRC 3
Page 4
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 gun, apply lubricant into the
grease zerk.
- Recommended grease: No. 2 Food Grade
Grease
Grease Zerk
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 ZRC style
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-2019 • ZRC
Page 5
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-2019 • ARC/ZRC 5
Figure 13
Continued on page 6.
Page 6
Tool Kit Component Parts Cont.
Figure 14
Figure 15
FIX-0019 – Clutch nut removal
fixture for some ZRC style units.
Not included in tool kits. May be
ordered on an
as-needed basis.
FIX-0005 – Upper assembly nut
removal fixture for ARC style unit.
FIX-0007 – Torque checking
fixture for some ARC models.
Figure 18
Figure 19
YTL3-0009 (Qty 2) &
YTL3-0008 – Adjustable
O.D. Spanner Wrenches
used for adjusting top load
and separating top load and
clutch body.
YTL4-0009, YTL4-0005,
YTL4-0008, YTL4-0010,
YTL4-000 – Open end
wrenches used to install
and remove chucks
on several ARC & ZRC
models.
YTL2-0002 – 1” Face
Spanner Wrench for
adjusting end cap and
setting static torque on
ARC & ZRC units.
Figure 16
Figure 17
FIX-0010 – Torque checking
fixture for some ARC & ZRC
models.
Figure 20
Figure 21
YTL3-0005 – ER-25
Spanner Wrench used for
upper assembly adapter
removal for some ZRC style
units.
6 Warner Electric • 800-825-9050 P-2019 • ARC/ZRC
Page 7
Clutch Rebuild Procedure
Figure 22
Remove set screw between clutch and top load
assembly using a 1/8” 3mm hex wrench. See
Figure 22.
ARC
Figure 25
Remove three socket head cap screws using a
9/64” 3mm hex wrench. See FIgure 25.
FIX-0005
FIX-0003
Figure 23
Separate top load assembly from clutch using two
spanner wrenches (YTL3-0009) and soft hammer.
Sometimes a steel hammer may be required to
loosen this joint. See Figure 23.
Figure 24
Figure 26
Place FIX-0003 in a vice. Place clutch in the fixture
and put FIX-0005 on top. Loosen nut and lift off
housing. See Figure 26.
Figure 27
Remove seal and bearing from housing. See Figure
27.
Figure 28
Remove two set screws using a 3/32” 3mm hex
wrench. Remove third set screw in the slot on the
Remove seal and bearing from housing. See Figure
28.
backside of the housing. See Figure 24.
Warner Electric • 800-825-9050 P-2019 • ARC 7
Page 8
FIX-0002
Figure 29
Press bearing out of housing using FIX-0002 and an
arbor press. See FIgure 29.
FIX-0002
Figure 30
Turn housing over. Press new bearing in housing
using FIX-0002 and an arbor press. See Figure 30.
Figure 33
To replace the magnet on end cap, break the
magnet with a hammer. Remove broken magnet
pieces and old screws. Install new magnet and new
screws. Epoxy magnet holes with epoxy packet from
rebuild kit. Make sure epoxy does not build up on
surface of magnet more than .010” (0.25mm). See
epoxy instructions below (Figure 34)
Figure 34
Figure 35
Install magnet plate into housing. Line up any three
Figure 31
holes and insert screws. See Figure 35.
Put in new seal. See Figure 31.
Figure 32
Separate magnet stack and clean all magnets –
replace as required. Use an alcohol based cleaning
solvent to clean the black driver magnets. Do not
Figure 36
use anything abrasive when wiping the black driver
magnets. Use a Scotch Brite deburr wheel to polish
the hysteresis magnet. See Figure 32.
8 Warner Electric • 800-825-9050 P-2019 • ARC
Tighten the three socket head cap screws with a
9/64” 3mm hex wrench. See Figure 36
Page 9
Figure 37
Insert shaft into housing. See Figure 37.
Figure 41
Apply a thin layer of grease to the adjustable end
cap driver magnet. See Figure 41.
Torque Index
Mark
Figure 38
Apply a thin layer of grease to the driver magnet.
See Figure 38.
Figure 39
Install spacer. See Figure 39.
Torque
Settings
Figure 42
With torque settings on the housing and torque
index mark on end cap facing you - place housing
on end cap. Use caution as magnets will attract
to each other. Tap in place with soft hammer if
necessary. See Figure 42.
Install Seal,
Apply Grease
Figure 43
**On newer models install seal and apply a thin layer
of grease to top of seal. If your end cap does not
have a groove in it to accept the seal, skip this step.
See Figure 43.
Figure 40
Install hysteresis magnet. Align on shaft and allow
it to drop carefully down to the spacer. Use caution
as magnets will attract to each other. See Figure
40.
Warner Electric • 800-825-9050 P-2019 • ARC 9
Page 10
Apply Blue
Loctite
Figure 44
Apply a small amount of blue loctite (242
threadlocker) on the inner thread of the nut; screw
into place. See Figure 44.
FIX-0005
FIX-0003
Figure 45
Using FIX-0003 and FIX-0005 to hold the clutch in
place, torque to 45 ft-lbs. (508Ncm). See Figure 45.
Figure 47
Install two ¼” (M6) set screws. 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 47.
Figure 48
Apply grease to top of seal. See Figure 48.
Figure 49
Torque test the unit before re-installing upper
assembly and installing headset on machine. Using
1” face spanner wrench (YTL2-0002) to set the
torque at setting 5. See Figure 49.
Figure 46
Install .472” (12mm) long set screw. See Figure 46.
10 Warner Electric • 800-825-9050 P-2019 • ARC
Page 11
ZRC
Top Load Rebuild Procedure
Figure 48
Remove grease zerk using open-end wrench. See
Figure 47.
Figure 49
Remove spring adjustment rings using two
spanner wrenches (YTL3-0009) and soft hammer.
See Figure 48.
Figure 51
Place top-load in vice, clamping on flats. Using
YTL3-0005 and a soft hammer, loosen spindle
adapter (if applicable) and remove. See Figure 50.
Figure 52
Continue to hold top-load in vice, clamping on flats.
Using a socket and breaker bar, loosen the nut
inside top-load assembly. See Figure 51.
Figure 50
Remove upper spring cover(if applicable), spring,
and lower spring cover (if applicable) from topload assembly. See Figure 49.
Warner Electric • 800-825-9050 P-2019 • ARC 11
Remove the nut inside top-load assembly. See
Figure 52.
Figure 53
Page 12
Figure 54
Remove shaft and inspect both parts for wear,
replace as required. See Figure 53.
Figure 55
Clean all parts. Replace as required. See Figure 54.
Figure 57
Apply grease to bore where pins slide. See Figure
56.
Figure 58
Install shaft in top load assembly. Make sure all four
pins stay engaged during insertion. See Figure 5.
Figure 59
Apply blue loctite on threads of nut; insert into top
Figure 56
load and hand tighten. See Figure 58.
Install new pins; apply grease to shaft and pins. See
Figure 55.
12 Warner Electric • 800-825-9050 P-2019 • ARC
Page 13
Figure 60
Figure 63
Place top load in vice, clamping on flats. Using a
7/8” socket and breaker bar, torque the nut inside
top load assembly to 45 ft-lb (508 Ncm). See
Figure 59.
Apply Blue
Loctite
Figure 61
Apply blue loctite to spindle adapter. See Figure
60.
Install lower spring cover(if applicable), spring, and
upper spring cover (if applicable) onto top-load
assembly. Thread lower spring adjustment ring onto
top-load assembly. See Figure 62.
Figure 64
Thread upper spring adjustment ring onto top-load
assembly using face spanner wrench (YTL2-0002) to
tighten. See Figure 63.
Figure 62
Figure 65
Continue to hold top-load in vice, clamping on
flats. Using YTL3-0005 and a soft hammer, tighten
spindle adapter (if applicable). See Figure 61.
Tighten spring adjustment rings using two spanner
wrenches (YTL3-0009) and soft hammer. See Figure
64.
Warner Electric • 800-825-9050 P-2019 • ARC/ZRC 13
Page 14
Figure 66
Install grease zerk using open-end wrench. See
Figure 65.
Figure 67
Install new o-ring on adapter base. See Figure 66.
Figure 69
Tighten set screw with 1/8” 3mm hex wrench.
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 68.
Figure 70
Compress top load assembly to ensure that it
moves freely. See Figure 69.
Figure 68
Install top load assembly on to clutch and tighten
using spanner wrenches (YTL3-0009 & YTL3-0008).
See Figure 67.
14 Warner Electric • 800-825-9050 P-2019 • ARC/ZRC
Page 15
Rebuild Kits and Rebuild
Exchange Programs
Warner Electric Capping Headsets
Magnetic Headset Rebuild Kits
End-users can purchase rebuild kits to rebuild the
magnetic headsets themselves. It is recommended
that the end-user keep both bearing and magnetic
kits on hand in order to reduce maintenance
downtime.
Factory Rebuild Program
End-users can ship their headsets back to Warner
Electric for a full factory rebuild and certification.
Upon receipt, Warner Electric will rebuild and factory
certify headsets. Typical turnaround for headsets is
1-2 weeks. Expedited services are available upon
request. Additional fees will apply. End-user will be
invoiced for the rebuilt headset when the rebuilt
headset is shipped. The end-user is responsible for
freight to and from factory.
Headset Exchange Program (TWO YEAR
AGREEMENT):
Once end-users own Warner Electric headsets, they
have the option of signing up for a Warner Electric
Headset Exchange Program for rebuilt headsets. In
this case, end-users would receive rebuilt headsets
from Warner Electric at a predetermined time during
the year in exchange for their used Warner Electric
headsets. End-user signs an agreement for the
headset exchange program for 2 years. Pricing for
the headset exchange program will be paid once per
year, on the date the agreement is signed and on
the agreement anniversary date. At the beginning of
the agreement period, the end-user must specify the
headset model, how many heads are to be rebuilt,
and what time(s) during the year rebuilt headsets are
expected. Warner Electric will ship rebuilt headsets
to end-user at the predetermined date. Within two
weeks from receipt of rebuilt headsets, the end-user
is required to return their used headsets. The enduser is responsible for freight to and from the factory.
Headset Lease Exchange Program
(3 YEAR AGREEMENT)
Warner Electric offers an option for end-users to
receive factory rebuilt Warner Electric headsets at
no initial purchase fee if they sign up for a 3 year
headset exchange program with Warner Electric. At
the end of the 3 year agreement period, the end-user
will own their Warner Electric headsets.
End-user signs an agreement for the headset
exchange program for 3 years. Pricing for the
headset exchange program will be paid once per
year, on the date the agreement is signed and on the
agreement anniversary dates. At the beginning of
the agreement period, the end-user must specify the
headset model, how many heads are to be rebuilt
and what time(s) during the year rebuilt headsets are
expected. Upon receipt of initial payment, Warner
Electric will ship rebuilt headsets to the end-user. On
the predetermined rebuild dates, Warner Electric will
ship rebuilt headsets to end-user. Within two weeks
from receipt of rebuilt headsets, the end-user is
required to return their used headsets. At the end of
the 3 year agreement period, the end-user will own
their magnetic headsets. The end-user is responsible
for all freight to and from the factory.
On-site Service Support
Warner Electric Capping Headsets
On-site service support is available for installation
of new Warner headsets, rebuild support of existing
Warner headsets, training, etc. Our factory-trained
and certified service department with over 50 years
combined experience can help prevent costly delays
and down time of your capping operation.
Precision Tork is the ONLY Service Group
that is factory authorized to work on
the Warner Electric headsets.
Services Provided:
• Installation of new equipment
• Machine audits and troubleshooting
• Service and repair of filling and capping
equipment
• Consulting: New Installations-existing issues for
filling and capping
• Develop new design for efficient production
• Assist with planning of preventative maintenance
programs
• Operator and mechanical training
• Highly qualified trained field engineers ready to
work on the following bottling equipment:
• Alcoa • Zalkin • Fowler • AROL
Precision Tork Service Benets:
• We manufacture the headsets!
• Most up-to-date designs available only through
Precision Tork.
• Our service technicians are trained to rebuild
your headsets to their existing revision level OR
upgrade them to the latest technology.
Warner Electric • 800-825-9050 P-2019 • ARC/ZRC 15
Page 16
• Component parts and rebuild kits on hand so
you do not incur downtime.
• Coming soon…secure website for headset
information and parts ordering with a credit card.
To schedule a certied Warner Service
Technician contact Melissa Bottke at
1-888-350-1891
Upgrade Kits
Warner Electric Capping Headsets
Benets of upgrading your M4.5 Headsets:
1. Eliminate setscrew stripping during torque
adjustment
• Larger adjustment screws in housing makes
it easier to adjust the torque and helps prevent
stripping of the screw head. Old setscrew in a
10-32 utilizing a 3/32” wrench. The new
setscrew is a 1/4-28 utilizing a larger 1/8”
wrench.
2. Longer bearing and magnet life
• Bottom seal in end cap helps to prevent water
and other contaminants from getting inside of
the headset. Easy to retrofit in the field.
Material Requirements
Anti-Seize Compound
• Apply to spindle at time of headset installation
Cleaning Solution
• Alcohol based cleaning solvent used to wipe
and clean parts during rebuild.
Grease
• Citgo Clarion Food Grade Grease, HTEP NLGI
No. 2 Grade used to lubricate headset.
Loctite
• Blue Removable - 242 threadlocker used to
secure components within the headset.
Epoxy
• Five minute epoxy – Amber, Devcon dev-pak
adhesive 14270 used to fill counter-bores in
the magnet plate.
Information for Ordering
Spare Parts
It is important to stock spare parts on hand to avoid
unnecessary downtime. Warner recommends that
you stock at least two spare headsets per machine
and a few bearing and magnet rebuild kits so that
you have the necessary parts on hand if you need
them.
Here’s how to order:
1. Find the headset part number or serial number
engraved on the housing body.
2. Call 1-888-350-1891
3. See Cross-reference list below for part number
Information.
4. Parts are in stock and ready for immediate
delivery.
5. Step-by-step instrucitons available.
How to order spare parts – required information:
1. Purchase Order Number.
2. Warner headset model number/part number OR
serial number (only on models manufactured July
2007 and later).
3. Warner Component or Kit Part Number.
4. Preferred distributor to order from. All orders will be
routed through local distribution. Pricing and lead
time can be quoted by calling the Manufacturing
Facility at (888) 350-1891.
16 Warner Electric • 800-825-9050 P-2019 • ARC/ZRC
Page 17
NOTES
Warner Electric • 800-825-9050 P-2019 • ARC/ZRC 17
Page 18
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 Specications
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.
www.warnerelectric.com
31 Industrial Park Road
New Hartford, CT 06057
800-389-3771
Fax: 815-389-2582
P-2019-WE 3/14 Printed in USA
An Altra Industrial Motion Company
www.altramotion.com
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