ARC Magnetic Capping Headsets Service & Installation Instructions P-2016 ARC An Altra Industrial Motion Company
ARC Installation Procedure Wrench flats Knock-out Rod Customer Supplied Chuck Spring Spring Seat Figure 1 Install chuck (not supplied). Use appropriate openend wrench (YTL4-0009 or YTL4-0007) depending on headset model to hold headset output. See Figure 1. Figure 4 Spanner Holes Apply anti-seize compound to spindle shaft. Install spring seat and spring (not supplied) if required. See Figure 4. Jam Nuts Figure 2 Set the top-load assembly using provided spring setting chart.
Setting Top Load Spring Force Top Load Spring Force Setting Chart 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.
Setting Application Torque Recommended Maintenance Schedule 1. Determine initial clutch setting from torque chart below. 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.
Installation Tools and Fixtures FIX-0001 – Bearing installation and removal fixture for the ZRC style bearings. Figure 12 Figure 10 FIX-0002 – Bearing installation and removal fixture for the ARC style bearing. Figure 11 FIX-0003 – Use to hold the output of ARC style unit during disassembly. Earlier revision levels with a larger output dimension 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.
Tool Kit Component Parts Cont. FIX-0019 – Clutch nut removal fixture for some ZRC style units. Not included in tool kits. May be ordered on an as-needed basis. Figure 14 Figure 18 FIX-0005 – Upper assembly nut removal fixture for ARC style unit. Figure 19 Figure 15 FIX-0007 – Torque checking fixture for some ARC models. Figure 16 YTL3-0009 (Qty 2) & YTL3-0008 – Adjustable O.D. Spanner Wrenches used for adjusting top load and separating top load and clutch body.
ARC Clutch Rebuild Procedure Figure 25 Figure 22 Remove three socket head cap screws using a 9/64” 3mm hex wrench. See FIgure 25. Remove set screw between clutch and top load assembly using a 1/8” 3mm hex wrench. See Figure 22. FIX-0005 FIX-0003 Figure 26 Figure 23 Place FIX-0003 in a vice. Place clutch in the fixture and put FIX-0005 on top. Loosen nut and lift off housing. See Figure 26. Separate top load assembly from clutch using two spanner wrenches (YTL3-0009) and soft hammer.
FIX-0002 Figure 33 Figure 29 Press bearing out of housing using FIX-0002 and an arbor press. See FIgure 29. FIX-0002 To replace the magnet on end cap, break the magnet with a hammer. Remove broken magnet pieces and old screws. Install new magnet and new screws. Epoxy magnet holes with epoxy packet from rebuild kit. Make sure epoxy does not build up on surface of magnet more than .010” (0.25mm). See epoxy instructions below (Figure 34) Figure 34 Figure 30 Turn housing over.
Figure 37 Insert shaft into housing. See Figure 37. Figure 41 Apply a thin layer of grease to the adjustable end cap driver magnet. See Figure 41. Torque Index Mark Torque Settings Figure 38 Apply a thin layer of grease to the driver magnet. See Figure 38. Figure 42 With torque settings on the housing and torque index mark on end cap facing you - place housing on end cap. Use caution as magnets will attract to each other. Tap in place with soft hammer if necessary. See Figure 42.
Apply Blue Loctite Figure 44 Figure 47 Apply a small amount of blue loctite (242 threadlocker) on the inner thread of the nut; screw into place. See Figure 44. Install two ¼” (M6) set screws. See Figure 47. FIX-0005 FIX-0003 Figure 48 Apply grease to top of seal. See Figure 48. Figure 45 Using FIX-0003 and FIX-0005 to hold the clutch in place, torque to 45 ft-lbs. (508Ncm). See Figure 45. Figure 49 Torque test the unit before re-installing upper assembly and installing headset on machine.
Figure 50 Using FIX-0007 or FIX-0010 and a torque wrench, 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. If the epoxy is rubbing, carefully trim the epoxy down to specification. See Figure 50.
Figure 57 Apply a thin layer of grease the seal and bore. See Figure 57. Figure 61 Thread together the clutch and top-load assembly. See Figure 61. Figure 58 Install shaft in top load assembly. Make sure all 4 pins stay engaged during insertion. See Figure 58. Figure 62 Tighten using spanner wrenches (YTL3-0009) and a soft hammer. See Figure 62. Figure 59 Set top-load on FIX-0002 so that the shaft does not push in while compressing the spring.
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.
• 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 certified Warner Service Technician contact Melissa Bottke at 1-888-350-1891 Upgrade Kits Warner Electric Capping Headsets Benefits of upgrading your M4.5 Headsets: 1.
NOTES Warner Electric • 800-825-9050 P-2016 • ARC 15
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.
