P-2096
Dairy Capping Headsets
Service & Installation Instructions
An Altra Industrial Motion Company
Magnetic Clutch Rebuild Procedure
Remove two set screws using a 3mm (YTL1-
0015) or 1/8” (YTL1-0009) hex wrench.
Remove the third set screw in the slot on the
backside of the housing using a 2.5mm (YTL1-
0014) or 3/32” (YTL1-0007) hex wrench.
Figure 1
Remove three button head Torx screws using
3mm (T-15) Torx security bit (YTL1-0002).
Place clutch shaft hex into vice. Remove the top
nut using a FIX-0004.
Figure 2
Figure 3
Figure 4
2 Warner Electric • 800-825-9050 P-2096-WE
Separate shaft, housing, spacer, magnet stack,
and nut.
Separate magnet stack and clean all magnets
– replace as required. Use an alcohol based
cleaning solvent to clean the black driver magnets.
Do not use anything abrasive when wiping the
black driver magnets. Use Scotch Brite deburr
wheel to polish the hysteresis magnets.
Figure 5
Press out old bearing using FIX-0001 and an arbor
press.
Figure 6
Figure 7
Warner Electric • 800-825-9050 P-2096-WE 3
Turn housing over. Press new bearing in housing
using FIX-0001 and an arbor press.
Install magnet plate into housing. Line up any three
holes and insert screws.
Figure 8
Tighten the three button head Torx screws with a
3mm (T-15) Torx wrench (YTL1-0002).
Apply food grade grease to stack of black magnets.
Figure 9
Figure 10
Figure 11
4 Warner Electric • 800-825-9050 P-2096-WE
Apply food grade grease to black magnet inside
of housing.
Stack remaining parts, except housing,
according to engineer drawing.
Figure 12
Place housing down around parts that were
stacked in previous step. Install clamp nut on
shaft thread.
Place clutch back into vice and, using a FIX0004 to hold the clutch in place, tighten clamp
nut to 508.4 Ncm (45 ft-lbs).
Figure 13
Figure 14
Figure 15
Warner Electric • 800-825-9050 P-2096-WE 5
Reinstall set screw on the side of the clutch.
Reinstall two larger 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.
Figure 16
Set clutch to 5 and using a digital torque wrench
and a socket check to make sure the torque is
smooth and reaching the specified maximum
torque. If torque is not smooth or is very high,
disassemble clutch to look for mechanical rubbing
or parts assembled incorrectly. Check the epoxy
over the magnet screws for signs of rubbing,
carefully trim the epoxy down to specification.
Set torque to desired setting using a face spanner
wrench (YTL2-0002) and tighten set screws.
Figure 17
Figure 18
Figure 19
6 Warner Electric • 800-825-9050 P-2096-WE
Setting Application Torque
1. Determine initial clutch setting from torque
chart below.
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.
Tighten set screws to 8-10 lb-in. Over
tightening is not necessary and will strip the
screws or possibly damage the housing body.
Do not use the set screw in the slot on the
backside of the housing for torque adjustment.
3. For optimum results, check setting with a
torque wrench and FIX-0007 or FIX-0010.
Application
Torque Setting
Application Torque Setting Charts
Clutch Set-
ting
Application Torque - Standard
Magnet
lb-in NCm
0.00 2.0 22.6
0.50 2.2 24.8
1.00 3.4 38.4
1.50 5.7 64.4
2.00 8.4 94.9
2.50 11.6 131.0
3.00 15.1 170.6
3.50 18.9 213.5
4.00 22.3 251.9
4.50 24.8 280.2
5.00 26.0 293.7
Figure 1
Warner Electric • 800-825-9050 P-2096-WE 7
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.
8 Warner Electric • 800-825-9050 P-2096-WE
• 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.
Warner Electric • 800-825-9050 P-2096-WE 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 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-2096-WE 3/14 Printed in USA
An Altra Industrial Motion Company
www.altramotion.com
Loading...