Warner Electric TG-2000 User Manual
Residential, TG-2000, and
Commercial MagStop
P-1177
819-0457
Installation & Operation
®
Clutch/Brake
Contents
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
®
MagStop
Mounting Requirements. . . . . . . . . . . . . . . . . 6-7
Anti-Rotation Examples . . . . . . . . . . . . . . . . 8-14
Troubleshooting Checklist . . . . . . . . . . . . . 15-16
Electrical Evaluation . . . . . . . . . . . . . . . . . . . . 17
Components . . . . . . . . . . . . . . . . . . 5
This guide applies to Warner Electric MagStop
®
clutches and clutch/brakes used on power
quipment.
e
Residential, TG-2000, and Commercial MagStops
are available in a range of torque capacities. The
®
MagStop
name comes from the permanent
magnet brake (magnetic stopping) rather than
conventional spring activated mechanical brakes.
In addition to these general procedures, any
applicable OEM general and safety procedures
must also be followed.
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.
Warner Electric • 800-825-9050 P-1177 • 819-0457
2
MagStop®Bearing Mounted Electric Clutch and Clutch/Brake Assemblies and Operation
Components: (See Figure 1 on page 5.)
1. Rotor Assembly
Generally, the input of the clutch. Includes
a keyed hub which mates with the keyway in
the crank shaft. The rotor transmits the torque
from the crankshaft (driving shaft) to the
armature assembly (output).
2. Armature Assembly
Generally, the output of the clutch. Consists of
a disk, springs and pulley (or output flange).
With power applied the armature transmits
torque from the rotor to the driven load. Power
from the armature disk is transmitted to the
pulley or flange by means of the leaf springs.
3. Field Assembly
The clutch “power” source contains the coil
which generates magnetic attractive force.
4. Brake Poles
The two permanent magnets and plates
affixed to the field shell provide the brake
torque when the clutch is disengaged.
Brake poles are not present if the assembly
is a clutch only.
Optional Washer
A single .250 inch (6.35 mm) minimum thick steel
washer must be used between the clutch and the
crank shaft retaining bolt if the D-drive spacer is
not used.
A washer less than .250 inch
(6.35 mm) thick will deform and allow the
clamping load to be lost, resulting in damage
to the clutch and/or the crankshaft and
possible personal injury due to clutch
separating from the shaft. Multiple thinner
washers are not acceptable.
5. D-drive Spacer
A hub that is inserted into either armature
or field bearing (see Figure 2). The head
has flats that can be held with a wrench to
prevent rotation of the crankshaft when
tightening the mounting bolt (see Figure 5).
This hub also takes the place of the standard
retaining washer.
6. Anti-rotation Slot
Anti-rotation Slot (used with OEM’s
anti-rotation device) prevents MagStop from
rotation with crankshaft. If the field is bolted
rigidly or if its axial movement is restricted
the bearing in the field assembly will be
improperly loaded and may fail. Use OEM
supplied anti-rotation.
Warner Electric • 800-825-9050 P-1177 • 819-0457
3
MagStop® Components
Wash er
Diameter
Must Not
Exceed OD
of Bearing
Inner Race.
Optional
Wash er
.250 Inch
(6.35 mm)
Minimum
Wash er
Thickness.
Coil
One piece
Field Assembly
D-drive
Spacer
Armature
Assembly
F
ield
Bearing
Armature
Bearing
Brake Pole s
Rotor
A
ssembly
Armature Leaf
Springs
2
Anti-
Rotation
Slot
Top View
One Piece Field Assembly with
Integral Anti-Rotation Slots
Field
A
ssembly
Support bearing
inner race
D-drive Spacer
Press
Support bearing outer race
D-drive Spacer
Press
Figure 1
D-drive Spacer Removal/Installation
D-drive Spacer removal
D-drive spacer may be installed on either end of clutch by OEM.
D-drive spacer must be removed or installed using an arbor press or equivalent.
On installation, opposite bearing INNER race must be supported or bearing damage may occur.
On removal, adjacent bearing OUTER race must be supported or bearing damage may occur.
Figure 2
D-drive Spacer installation
Warner Electric • 800-825-9050 P-1177 • 819-0457
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REQUIREMENTS
for a Successful Clutch
Application/Installation
Critical Requirements
The two most important requirements for a
successful clutch application or installation
are:
1. Antirotation device must allow both axial
and radial free-play!
Failure to allow this free-play will result
in field bearing failure. The greater the
restriction the faster the bearing will
fail!
2. Mounting bolt torque to be
minimum of:
• 3/8 -24 UNF use Grade 8 bolt torqued
to 40-45 lb.-ft.
(Grade 5 bolt is unacceptable)
• 7/16-20 UNF Grade 5 or 8 bolt torqued
to 50-55 lb.-ft.
(Grade 5 or 8 bolt is
acceptable)
• M 10 X 1.50 Class 10.9 torqued to
55-60 N-m
Note: All values are for dry (unlubricated)
plated bolts, please consult fastener
manufacturer if any type of locking element
(thread lock compound, patch etc.) is to
be used.
Failure to adhere to these requirements
will result in the failure of the clutch!
Warner Electric • 800-825-9050 P-1177 • 819-0457
5
S
haft
S
houlder
G
round
D
rive
Pulley
Shaft end and
D-drive
spacer must
not touch
D
-drive Spacer
E
ngine Shaft
Failure to torque bolt
to requirements will
degrade clamping and
can allow the clutch to
separate from the
shaft, causing risk of
personal injury.
Thread size Torque ft.lb. Torque N-m
3/8-24" UNF 40-45 ft.lb. 54-61 N-m
7
/16-20" UNF 50-55 ft.lb. 67-75 N-m
M 10 X 1.50 40-45 ft.lb. 54-61 N-m
Ground drive pulley or spacer
must be chamfered to clear this
radius on the engine shaft
shoulder.
Shaft
G
round Drive Spacer
(
or spacer if no ground
r
ound
drive used)
Always bottom the clutch against a
flat surface; never against radius.
N
ote:
Must have faces parallel to each other
(within .003") and be perpendicular
t
o the bore.
Note: All values are for dry (unlubricated) plated bolts,
please consult fastener manufacturer if any type of locking
e
lement (thread lock compound, patch etc.) is to be used.
Grade Class
Grade 8
G
rade 5 or 8
Grade 10.9
Anti-rotation Slots
Mounting
Figure 3
Typical Engine Installation with Ground Drive Pulley
Anti-Rotation
Figure 4
See Anti-Roatation Examples on pages 8-14
or if its axial movement is restricted, the
If the field is bolted rigidly
bearing in the field assembly will be
Warner Electric • 800-825-9050 P-1177 • 819-0457
6
improperly loaded and may fail. Use only
factory installed anti-rotation device.
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