Warner Electric AT Clutch User Manual

AT Clutch – Major Service

Sizes 25, 55, 115

P-1404
819-0324

Installation Instructions

2

Warner Electric • 800-825-9050 819-0324

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warranty. . . . . . . . . . . . . . . . . . . . . . . back cover

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

AT Clutch – Major Service

A major rebuild of an AT clutch can be accom­plished by following these instructions to
replace the parts furnished in the appropriate
Warner Electric clutch rebuild kit. Part numbers
and component descriptions for these kits are
found on page 11 of this manual. Item numbers
in these instructions refer to clutch components
shown on page 10, exploded view. Proceed as
follows:

1. Turn off all power to the clutch.

2. Disconnect the coil wires from the incoming
control unit wires.

3. Disconnect the field anti-rotation pin or field
restraining arm (Item 16).

4. Loosen the setscrews (Item 6) which hold
the clutch to its shaft.

5. Remove the clutch from its shaft by pulling
and/or gently tapping the hub with a ham­mer and drift.

Note: Do not hit the outer portion of the
clutch outboard of the hub as this may
severely damage it.

6. Remove the retainer ring (Item 11).

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

9. Press the new bearing (Item 9) into the field
assembly by pressing on the bearing outer
race. Do not press on the bearing inner

race or damage to the bearing will result,
making it unusable.

10. Remove the rotor assembly (Item 8) from
the hub (Item 6).

11. Remove the screws (item 8-5) which retain
the friction disc segments (item 8-1).

12. Lift the friction disc segments (item 8-1) off
the rotor, exposing the Autogap assembly.

7. Remove the field assembly (Item 10) and
bearing (Item 9) by locating and supporting
on the rotor outer diameter (Item 8) and
pressing on the hub (Item 6).

8. Remove the bearing (Item 9) from the field
assembly (Item 10) by pressing on the inner
race while supporting the field assembly on
its face.

Note: Use caution to avoid damaging the
epoxy covering the coil.

3

Warner Electric • 800-825-9050 819-0324

4

Warner Electric • 800-825-9050 819-0324

13. Install replacement Autogap components as
follows: Remove plate (item 8-2-size 115
only), and detent ring (item 8-3) to expose
wave spring (item 8-4). Remove and replace
wave spring (item 8-4). Reinstall the detent
ring and plate (items 8-3 and 8-2). Note:

The detent ring lip must point away from
the friction disc. Install the wave spring
with its split 180° from the split in the
detent ring.

14. Clean all foreign matter from rotor mounting
surface. Install the new friction disc seg­ments (Item 8-1) with new screws (Item 8-5)
included with the kit. Note: Use only the

screws included with the kit as any others
may damage the clutch.

Apply a drop of Loctite grade AA or equiva­lent to each screw prior to installation.
Tighten each screw to 18-22 in. lb. torque.

15. Remove the snap ring (Item 3) from the
armature hub assembly.

When installing or remov­ing 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.

Remove the pulley, sheave, or sprocket if it
interferes with removing the cap screws
(Item 7-2).

16. Disassemble the armature hub assembly by
removing cap screws (Item 7-2), lock wash­ers (Item 7-3) and armature segment (Item
7-1).