Residential, TG-2000, and Commercial MagStop® Clutch/Brake
Contents
1. 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 pos sible personal injury due to clutch separating from the shaft Multiple thinner washers are not acceptable 819 0457 MagStop Components One Piece Field Assembly with Integral Anti Rotation Slots Brake Poles One piece Field Assembly Armature Leaf Ani Springs Slot Coil it D drive Optional Field Spacer Washer Bearing F 7 A dilr 250 Inch 6 35 mm r Minimum Rotor Nak nn KURDENE Washer Assembly Thickness Washer Diameter Must Not Armature Exceed OD Bearing of Bearing Inner Race Field Assembly i Armature Top View Assembly from Pulley Figure 1 D drive Spacer Removal Installation Support bearing outer race inner race D drive Spacer D drive Spacer removal D drive Spacer installation Figure 2 D drive spacer may be installed on either end of clutch by OEM ACAUTION 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 Warner Electric 800 825 9050 819 0457 5 REQUIREMENTS for a Successful Clutch Ap2. Replace spindle e Repair leak Replace with new MagStop unit 819 0457 15 Troubleshooting Checklist Continued D Symptom Noisy clutch Vibration Problem Possible Causes Solution Failed bearing e Loose mounting bolt not torqued properly e Replace see Mounting Figure 3 page 7 e Field assembly movement restricted e Confirm proper Anti rotation see Anti rotation Figure 4 page 7 Adapter plate rattles against e Some noise is normal lf noise is excessive repair or replace anti rotation pin anti rotation device Follow OEM s Specifications See Anti rotation Figure 4 page 7 Clutch loose on shaft e Loose mounting bolt not torqued properly Tighten mounting bolt to specification See Mounting Figure 3 page 7 e Mounting bolt too long and bottoms Use correct length bolt see in engine shaft before clamping clutch Mounting page 7 Figure 3 e Mounting washer too thin and deforms e See Figure 1 and Warning on page 5 when bolt is tightened e Shaft bottoms on D drive e Use proper spacer see Mounting page 7 Clutch not mounted square e Ground Drive Spacer mounting shoulder e Replace not squared See Mounting Figure 3 e Clutch integral key hitting end of keyway Space clutch away from radius in shaft in engine shaft keyway e Incorrect or no chamfer on ground e Increase chamfer on ground drive spacer drive spacer See Caution Figure 3 page 7 Broken Spring e Loose mounting e Replace clutch PAVANI
3. Grade 10 9 40 45 ft lb 54 61 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 AWARNING Failure to torque bolt ACAUTION to requirements will Always bottom the clutch against a degrade clamping and flat surface never against radius can allow the clutch to separate from the shaft causing risk of personal injury Shaft Shoulder Ground Drive Pulley Figure 3 Typical Engine Installation with Ground Drive Pulley Anti Rotation __ Aanti rotation Slots Figure 4 See Anti Roatation Examples on pages 8 14 ACAUTION 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 only factory installed anti rotation device Warner Electric 800 825 9050 819 0457 7 Anti Rotation Example Attached To Frame Do Not Orient So That Do Not Bottom In Slot Bracket Will Bind In Slot Incorrect Correct 030 Min Loose Fit 060 Min Worst Case Stackup Must Not Allow Bottoming In Slot 8 Warner Electric e 800 825 9050 819 0457 Make Sure That This Area Does Not Contact Field Shell Anti Rotation Example 125 Min Do Not Orient So That Do Not Bottom In Slot Bracket Will Bind In Slot Correct 030 Min Loose Fi
4. Residential TG 2000 and Commercial MagStop Clutch Brake Lp Installation amp Operation 819 0457 Warner Electric 2 Warner Electric e 800 825 9050 819 0457 Contents TEMINY g lt 2ya in Qub he n da dn 4 MagStop Components 005 5 Mounting Requirements 6 7 Anti Rotation Examples 8 14 Troubleshooting Checklist 15 16 Electrical Evaluation sia eedkeed oe ees 17 Warner Electric 800 825 9050 This guide applies to Warner Electric MagStop clutches and clutch brakes used on power equipment Residential TG 2000 and Commercial MagStops are available in a range of torque capacities The MagStop name comes from the permanent magnet brake magnetic stop ping rather than conventional spring activated mechanical brakes In addition to these general procedures any applicable OEM general and safety procedures must also be followed PNM ee Failure to follow these instructions may result in product damage equipment damage and serious or fatal injury to personnel 819 0457 3 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
5. assembly output 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 trans mitted to the pulley or flange by means of the leaf springs Field Assembly The clutch power source contains the coil which generates magnetic attractive force 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 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 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 4 Warner Electric 800 825 9050 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
6. clutch with broken rivets or springs may separate from the shaft and cause personal injury Burnishing Procedure when installing a new MagStop Clutch Brake This procedure should be performed with the 3 Repeat these procedures 1 and 2 10 times load attached mowing deck snowblower After burnish procedure is complete to pump etc maximize deck drive train life always engage clutch at half throttle Note Do NOT add additional load e g cutting grass 1 Run engine at full throttle and engage load bringing load to full speed then disengage load 2 Let load come to a full stop then engage again 16 Warner Electric 800 825 9050 819 0457 Electrical Evaluation Step 1 How to Measure Clutch Coil resistance See Figure 5 1 Turn engine and PTO switch off 2 Disconnect clutch at clutch connector 3 Select meter setting for ohm reading 4 Connect meter leads to clutch 5 Check meter reading and refer to the chart below for correct clutch resistance reading values are 68 F If reading falls in acceptable range proceed to step 2 if not replace the clutch Meter Connector Figure 5 Resistance Measurement Table 1 Resistance Torque at 70 F Model ft lb Nom Nm ohms 5 MS 60 60 81 7 18 MS 80 80 108 3 68 TG2K 125 125 169 2 84 CMS 150 150 203 2 47 CMS 175 175 237 2 30 CMS 200 200 271 1 84 Note If bench tested with 12 volts applied armature may no
7. plication Installation Critical Requirements The two most important requirements for a successful clutch application or installation are 1 Antirotation device must allow 2 Mounting bolt torque to be both axial and radial free play minimum of e 3 8 24 UNF use Grade 8 bolt Failure to allow this free play will torqued to 40 45 Ib ft result in field bearing failure The Grade 5 bolt is unacceptable greater the restriction the faster the bearing will fail e 7 16 20 UNF Grade 5 or 8 bolt torqued to 50 55 lb ft Grade 5 or 8 bolt is acceptable e M 10 X 1 50 Class 10 9 torqued to 55 60 N m Note All values are for dry unlubri cated plated bolts please consult fastener manufacturer if any type of locking element thread lock com pound patch etc is to be used Failure to adhere to these requirements will result in the failure of the clutch 6 Warner Electric 800 825 9050 819 0457 Mounting Note Must have faces parallel to each other within 003 and be perpendicular to the bore Ground Drive Spacer or spacer if no ground drive used Ground drive pulley or spacer must be chamfered to clear this radius on the engine shaft shoulder Shaft end and D drive spacer must not touch D drive Spacer Thread size Grade Class Torque ft lb Torque N m 3 8 24 UNF Grade 8 40 45 ft lb 54 61 N m 7 16 20 UNF Grade 5 or 8 50 55 ft lb 67 75 N m M 10 X 1 50
8. t 060 Min Worst Case Stackup Must Not Allow Bottoming In Slot Warner Electric 800 825 9050 819 0457 9 Anti Rotation Example 10 Warner Electric e 800 825 9050 Make Sure That Twisted Area Does Not Contact Field Shell Beginning of Flat Do Not Orient So That een Do Not Bottom In Slot Bracket Will Bind In Slot Correct 030 Min Loose Fit 060 min Worst Case Stackup Must Not Allow Bottoming In Slot 819 0457 Anti Rotation Example 030 Min Loose Fit Screw Must Be Free To Move Warner Electric 800 825 9050 819 0457 11 Anti Rotation Example Aircraft Cable 030 Min Slack 12 Warner Electric 800 825 9050 819 0457 Anti Rotation Example 030 Min Combined Loose Fit Warner Electric 800 825 9050 819 0457 13 Anti Rotation Example 030 Min Loose Fit 060 Min Worst Case Stackup Must Not Allow Bottoming In Slot 14 Warner Electric 800 825 9050 819 0457 Troubleshooting Checklist A Symptom Clutch will not engage Problem Possible Causes Blown fuse Low coil resistance e Defective battery Faulty charging system Bad wiring or connections PTO switch Low voltage supply e Defective battery Less than 12 VDC at clutch Faulty charging system Bad wiring or connectors PTO switch Incorrect coil resistance e Damaged coil see Step 1 page 17 Inadequate current s
9. t pull away from brakepoles Rotational motion is required to engage clutch Warner Electric 800 825 9050 Step 2 Measure the supply voltage at the clutch See Figure 6 1 2 Turn engine off Connect meter leads at the clutch connector Select meter setting for voltage reading Make sure wires will not become entangled in rotating components of clutch Start engine and engage PTO switch Measure voltage across the leads at the connectors Voltage should be 12 14 volts DC If clutch still fails to operate replace clutch If voltage is not within 12 14 volt range consult EOM s service manual Connectors Ir Meter Figure 6 Voltage Measurement 819 0457 17 Warner Warner Electric LLC Manufacturing Facility 449 Gardner Street South Beloit IL 61080 802 E Short Street Columbia City IN 46725 Electric 815 389 3771 Fax 815 389 2582 260 244 6183 Fax 260 244 3928 www warnerelectric com P 1177 819 0457 5 05 Printed in USA
10. upply Broken clutch lead wire Faulty electrical system Rotor armature airgap too large Rotor armature wear End of usable life greater than 125 inch 3 18mm Solution Replace with new MagStop unit Replace e Repair or replace e Repair or replace Replace e Repair or replace e Repair or replace Replace with new MagStop unit e Repair e Measure clutch coil resistance and supply voltage at the clutch If both are correct electrical system is faulty Repair or replace Replace with new MagStop unit B Symptom Brake will not engage Problem Possible Causes Armature brake poles wore out End of usable life Contaminated friction surfaces e Engine oil leak on brake Solution e Replace with new MagStop unit Repair leak e Replace with new MagStop unit C Symptom Clutch slip Problem Possible Causes Low voltage supply e Defective battery less than 12 VDC at clutch Faulty charging system Bad wiring or connectors PTO switch Inadequate current supply e Broken clutch lead wire Faulty electrical system Overloaded clutch e Clogged deck back spindle etc Contaminated friction surfaces Engine oil leak on clutch Warner Electric 800 825 9050 Solution Replace e Repair or replace e Repair e Repair e Measure clutch coil resistance and supply voltage at the clutch If both are correct electrical system is faulty Repair or replace e Remove excess grass
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