Warner Electric ZRC User Manual
P-2018
ZRC/ARC
ZRC Clutch / ARC Top Load
Service & Installation Instructions
An Altra Industrial Motion Company
ARC Installation Procedure
Wrench ats
Customer
Supplied Chuck
Figure 1
Install chuck (not supplied). Use appropriate openend wrench (YTL4-0005, YTL4-0008, YTL4-0010)
depending on headset model to hold headset
output. See Figure 1.
Spanner
Holes
Apply Anti-seize
Figure 4
Apply anti-seize compound to spindle shaft. Install
headset on spindle. Turn onto threaded spindle until
headset is fully seated on spindle. See Figure 4.
Jam Nuts
Figure 2
Set the top-load assembly using provided spring
setting chart. Lock the jam nuts using O.D. spanner
wrenches with 1/4” pins (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.
Spanner Holes
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-2018 • ZRC/ARC
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-2018 • ZRC/ARC 3
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 injector needle, apply lubricant into
the grease port.
- Recommended grease: No. 2 Food Grade Grease
Grease Port
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 6.0 67.8
0.50 3.50 39.5 7.0 79.1
1.00 5.00 56.5 8.0 90.4
1.50 8.50 96.0 11.5 129.9
2.00 10.50 118.6 14.0 158.2
2.50 13.50 152.5 16.0 180.8
3.00 16.00 180.7 21.0 237.3
3.50 17.50 197.7 23.5 265.5
4.00 18.50 209.0 25.5 288.1
4.50 19.00 214.6 28.0 316.4
5.00 19.50 220.3 29.5 333.3
Torque-Low
Inertia
Magnet
Application
Torque (Ncm)
Standard
Magnet
- See rebuild instructions for detailed information on
disassembly and assembly of Warner 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-2018 • ZRC/ARC
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-2018 • ZRC/ARC 5
Figure 13
Continued on page 6.
Tool Kit Component Parts Cont.
Figure 14
Figure 15
FIX-0019 – Clutch nut removal
xture for some ZRC style units.
Not included in tool kits. May be
ordered on an as-needed basis.
FIX-0005 – Upper assembly nut
removal xture for ARC style
unit.
FIX-0007 – Torque checking
xture 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,
YTL4-0007 – Open end
wrenches used to install
and remove chucks on
several ARC & ZRC models.
YTL2-0002 – Face
Spanner Wrench for
adjusting end cap and
setting static torque on
ARC & ZRC units.
Figure 16
Figure 17
FIX-0010 – Torque checking
xture 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-2018 • ZRC/ARC
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