Advanced Technology AT Clutches
P-217-1
819-0372
Installation Instructions
Contents
Introduction
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clutch Installation . . . . . . . . . . . . . . . . . . . . . . 3
AT Clutch Troubleshooting Guider. . . . . . . . . . 6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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 (AT)
clutch you have purchased has been designed
to provide long and trouble-free service. It is
a rugged and durable unit which is rebuildable
with both friction face replacement and
complete clutch rebuild kits offered in this
service manual. The friction face replacement
kit renews the friction surfaces, while the
complete clutch rebuild kits includes new
TM
bearings, Autogap
components and hardware
in addition to the fruction faces.
This service manual includes instructions
required for installation, as troubleshooting
information, specifications.
For friction material replacement refer to manual
819-0341.
For complete rebuilt refer to manual 819-0324.
Installation of AT clutches must be carried out
in accordance with the procedures specified
in the installation manual. All stated or implied
manufacturer warranties are voided if this
product is not installed in accordance with
these instructions.
Warner Electric • 800-825-9050 P-217-1 • 819-0372
2
Clutch Installation
1. Remove your AT 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.
Two methods for fastening pulleys and sheaves
are offered. For key mounting, follow the
instructions in 2. below; for through bolt
mounting, go to instruction 3.
Note: For high cycle rate applications
with potential pulley misalignment,
apply Loctite to the I.D. of the pulley to
eliminate the possibility of keyway wear.
b. 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.
Check for burrs or ridges on the shaft
and remove any which may be present
with a file.
c. Install the furnished retaining ring with
retaining ring pliers. Ensure that the
retaining ring is fully seated around its
periphery.
2. Key and Snap Ring Mounting
a. Install the factory ordered sheave or pulley
by first inserting the factory furnished key
into its keyway in the clutch hub. Position
the sheave or pulley so it will fit onto the
hub, aligning the keyway with the key. Be
sure to keep the tapped pulley removal
holes accessible.
When installing this or other
retaining rings, be sure to hold the ring with
one hand so it will not spring away should the
pliers lose their grip on the ring. Always wear
safety glasses when installing or removing
retaining rings.
Warner Electric • 800-825-9050 P-217-1 • 819-0372
3
3. Through Bolt Mounting
Note: This method is suitable for pulleys and
sheaves with adequate radial wall thickness
to accommodate through holes.
a. Drill holes through the pulley or sheave
to match the tapped holes on the hub
shoulder of the clutch. The correct bolt
pattern can be found on page 7.
b. Align the through holes in the sheave or
pulley with the tapped holes on the hub
shoulder and gently tap until it seats
against the shoulder.
Note: Installing the keyway and snap ring
are not necessary if the sheave or pulley
is held in place by the through bolt
method.
c. Secure the pulley with capscrews, using
lockwashers or Loctite to assure thread
retention.
6. Place the AT clutch onto its shaft, making
sure it is properly positioned over the shaft
key. If the clutch is to be mounted vertically,
it must be mounted with the armature fins
down, or improper operation will result.
Note: The Warner Electric special furnished
key must be used with ATC-25-7/8" bore
units.
7. Tighten the hub setscrews into the shaft to
the appropriate torque for your size unit:
4. If used, install the Warner Electric conduit box
or conduit box/CBC-100 control combination in
accordance with instructions furnished with the
conduit box.
5. The Warner Electric patented Autogap™
automatically adjusts the proper operating gap
between the armature and friction face for the
life of these components. The proper gap is
approximately .050". If the armature and
friction face have moved during shipment,
reset the Autogap by pushing the friction face
against the armature. Release. The Armature
will spring back about .050" and the proper
gap is set.
Size Torque
25 80 in.-lbs.
55 160 in.-lbs.
115 275 in.-lbs.
205 275 in.-lbs.
305 620 in.-lbs.
Assure proper alignment of driving and driven
sheave, pulley or sprocket before tightening
the set screws.
Warner Electric • 800-825-9050 P-217-1 • 819-0372
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8. Install the field restraining arm.
Note: The field must retain a degree of
movement freedom to compensate for
bearing and shaft alignment tolerances.
9. Attach the wires to the DC power source,
using wire nuts or other approved
connecting devices. Either wire can be
connected to the + or - of the voltage
source. If a CBC-100 or other Warner
Electric control is used as the power source,
follow the connection diagram supplied with
the control. Assure that the voltage rating of
the clutch is the same as the output rating
of the power source.
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 AT clutch is now ready to run.
Note: Depending on application break in
period may be longer due to load and rpm,
and require more cycles.
10. Your AT 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
with an audible "click."
11. Install the drive belt or chain.
12. Run the clutch under its operating load.
13. Your AT clutch may not achieve its full
Warner Electric • 800-825-9050 P-217-1 • 819-0372
5
AT Clutch Troubleshooting Guide
If performance problems are present after carefully following the instructions in this manual, use the
following checklist.
Symptom Check
Problem Possible Cause
Clutch Rotor will not move or engage when • Coil Resistance
power is applied to the coil Coil may be open. See Chart 1.
• Power Supply
Assure proper DC voltage is being delivered to the clutch.
• Airgap
If greater than .050'' around entire periphery, reset Autogap.
• Autogap
Assure that clutch rotor is free to move on hub spline and releases
approximately .050'' when pressure is removed.
Vibration • Runout
Assure that shaft on which the clutch is mounted doesn’t have
excessive runout.
• Shaft Engagement
Assure adequate shaft length and diameter engagement in the hub.
Excessive Start or Stop Times • Power Supply
Assure proper DC voltage is being delivered to the clutch.
• Adequate Burnishing
Unit must be run and cycled a few times to achieve full rated torque.
• Friction Surfaces
Replacement may be required.
• Friction Surfaces
Installation of replacement friction material or armature segments
may be incorrect and not allow full contact.
Approx. Coil Approx. Coil
Clutch/Brake Size Coil Voltage Resistance (Ohms) Coil Voltage Resistance
25 6 1.4 24V 20.2
90 290
55 6 1.2 24V 19.6
90 230
115 6 1.0 24V 16.5
90 180
205 6 1.02 24V 13.2
90 169
305 6 1.05 24V 14.4
90 183
Chart 1
Warner Electric • 800-825-9050 P-217-1 • 819-0372
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Dimensions
Clearance
for 1/4" bolts
O
T
Optional
Restraining Strap
G
N
H
.750
(19.05)
S
R
Optional
Conduit
Box
F
.875
(22.22)
Wire Protector
included with
Clutch
Key and Retaining Ring
included with Clutch
1.544
See
Detail
View
A
C
M
L
K
P
B
D
J
E
Q
W
U
V
90°
1/4-20 UNC thru.
(2) Jackscrew Holes
on X dia.
Detail View
Bore-to-size Requirements
Bore-to-size data
drawing for pulley,
sheaves, and
sprockets. See Boreto-size data below.
Specifications
Model Size Voltage DC Unit Inertia*-WR2(lb.ft.2) Max. RPM Weight (lbs.) Static Torque (lb.ft.) @ 1800 RPM
25 6 Clutch .048 3600 8 25 12 lb. ft.
55 6 Clutch .173 3600 18 55 20 lb. ft.
115 6 Clutch .483 3600 28 115 30 lb. ft.
24 .048 3600 8 25 12 lb. ft.
90 .048 3600 8 25 12 lb. ft.
24 .173 3600 18 55 20 lb. ft.
90 .173 3600 18 55 20 lb. ft.
24 .483 3600 28 115 30 lb. ft.
90 .483 3600 28 115 30 lb. ft.
Dynamic Torque
Warner Electric • 800-825-9050 P-217-1 • 819-0372
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inches (mm)
ABCDEFGHJK L MT
Model Dia. Max. Nom. Dia. Max. Max. Max. Max. Dia. Max. Nom. Max. Nom.
25 3.60 4.39 2.375 1.080 4.748 3.767 3.282 5.11 4.822 1.68 1.003/.991 .715/.703 .375
55 3.95 4.935 2.925 1.40 5.182 3.767 4.032 5.11 6.275 1.817 1.113/1.101 – .375
115 5.254 5.977 3.102 1.86 6.089 3.767 4.246 10.11 7.906 2.467 1.539/1.523 – .375
Max. Nom. Max.
(91.44) (111.51) (60.33) (27.43) (120.60) (95.68) (83.36) (129.79) (122.49) (42.67) (25.48/25.17) (18.16/17.86) (9.53)
(100.33) (125.35) (74.30) 35.56) (131.62) (95.682) (102.412) (129.792) (159.39) (46.152) (28.27/27.97) (9.53)
(133.452) (151.822) (78.792) (47.242) (154.662) (95.682) (107.852) (256.792) (200.812) (62.662) (39.09/38.68) (9.53)
Model Holes Thread Size Depth Circle Nom. Nom. Nom. Min. Min.
25 3 1/4-20 .500 3.00 .500 .036 3.586 .752 .279
55 4 1/4-20 .635 3.50 .500 .081 4.156 .722 .265
115 4 5/16-18 .830 4.75 .500 .237 4.927 .504 .265
No. of N Max. Bolt OPQRS
(12.7) (0.91) (91.10) (19.08 (7.09)
(12.7) (2.06) (105.56) (18.34) (6.73)
(12.7) (6.02) (125.15) (12.80) (6.73)
Bore to Size Data
inches (mm)
Model Bore Dia. Keyway Height Keyway Width Bolt Circle
25 2.502/2.500 2.601/2.591 .1905/.1855 3.00
55 3.002/3.000 3.099/3.089 .1905/.1885 3.50
115 4.002/4.000 4.127/4.117 .378/.376 4.50
UV WX
(63.55/63.50) (66.06/65.81) (4.84/4.79) (76.20)
(76.25/76.20) (78.71/78.46) (4.84/4.79) (88.90)
(101.65/101.60) (104.83/104.57) (9.60.9.55) (114.30)
Bore Size and Keyways
Size Unit Bore Key
ATC-25 .5025 12.76 1/8 Sq.
ATC-25 .7525 19.11 3/16 Sq.
ATC-55 .7505 19.06
ATC-25 .8775 22.29 3/16 Sq.
ATC-55 .8755 22.24
ATC-55 1.0025 25.46 1/4 Sq.
ATC-55 1.1275 28.64 1/4 Sq.
ATC-115 1.1255 28.59
ATC-115 1.2525 31.81 1/4 Sq.
Warner Electric • 800-825-9050 P-217-1 • 819-0372
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.5005 12.71
.6275 15.94 3/16 Sq.
.6255 15.89
1.0005 25.41
1.2505 31.76
1.3775 34.99 5/16 Sq.
1.3755 34.94
1.5025 38.16 3/8 Sq.
1.5005 38.11
Warner Electric • 800-825-9050 P-217-1 • 819-0372
9
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 Specifications
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.
Warner Electric
31 Industrial Park Road
815-389-3771
www.warnerelectric.com
P-217-1 • 819-0372 10/11 Printed in USA
• Fax: 815-389-2582
• New Hartford, CT 06057
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