Warner Electric 5219 Series Installation instructions
Residential, TG-2000 and
Commercial MagStop®Clutch/Brake
Installation & Operation Instructions
P-1177-WE
819-0457
This Manual covers Magstop Product Families as outlined below:
Series Reference Name Torque Range
5217 Series RMS 60 & 80 ft-lb.
5218 Series CMS 175 & 200 ft-lb.
5219 Series TG 2000 105 & 125 ft-lb.
5228 Series CMS 250 225 & 250 ft-lb.
2Warner Electric • 800-825-9050 P-1177-WE • 819-0457
Contents
Terminology............................3
MagStop® Components...................4
Mounting Requirements ................5-6
Anti-Rotation Examples ................7-13
Troubleshooting Checklist .............14-15
Electrical Evaluation.....................16
Series Reference Name Torque Range
5217 Series RMS 60 & 80 ft-lb.
5218 Series CMS 175 & 200 ft-lb.
5219 Series TG 2000 105 & 125 ft-lb.
5228 Series CMS 250 225 & 250 ft-lb.
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 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-WE • 819-0457 3
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.
Components: (See Figure 1 on page 4.)
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 ffixed
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.
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.
MagStop®Bearing Mounted Electric Clutch and Clutch/Brake Assemblies and Operation
4Warner Electric • 800-825-9050 P-1177-WE • 819-0457
Figure 1
Figure 2
MagStop® Components
D-drive Spacer Removal/Installation
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.
D-drive Spacer removal D-drive Spacer installation
Washer
Diameter
Must Not
Exceed OD
of Bearing
Inner Race.
Optional
Washer
.250 Inch
(6.35 mm)
Minimum
Washer
Thickness.
Coil
One piece
Field Assembly
D-drive
Spacer
Armature
Assembly
Field
Bearing
Armature
Bearing
Brake Poles
Rotor
Assembly
Armature Leaf
Springs
3
2
4
1
5
Anti-
Rotation
Slot
6
Top View
from Pulley
One Piece Field Assembly with
Integral Anti-Rotation Slots
Field
Assembly
Support bearing
inner race
D-drive Spacer
Press
Support bearing outer race
D-drive Spacer
Press
Warner Electric • 800-825-9050 P-1177-WE • 819-0457 5
REQUIREMENTS
for a Successful Clutch
Application/Installation
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!
Critical Requirements
The two most important requirements for a successful clutch application or installation are:
2. Mounting bolt torque to be
minimum of:
• 3/8 -24 UNF use Grade 8 bolt torqued
to 45-49 lb.-ft.
(Grade 5 bolt is unacceptable)
• 7/16-20 UNF Grade 5 or 8 bolt torqued
to 55-60 lb.-ft.
(Grade 5 or 8 bolt is
acceptable)
• M 10 X 1.50 Class 10.9 torqued to
55-65 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!
6Warner Electric • 800-825-9050 P-1177-WE • 819-0457
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.
Figure 3
Typical Engine Installation with Ground Drive Pulley
Figure 4
Shaft
Shoulder
Ground
Drive
Pulley
Shaft end and
D-drive
spacer must
not touch
D-drive Spacer
Engine 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 45-49 ft.lb. 61-66 N-m
7/16-20" UNF 55-60 ft.lb. 75-81 N-m
M 10 X 1.50 40-48 ft.lb. 55-65 N-m
Ground drive pulley or spacer
must be chamfered to clear this
radius on the engine shaft
shoulder.
Shaft
Ground Drive Spacer
(or spacer if no ground
round
drive used)
Always bottom the clutch against a
flat surface; never against radius.
Note:
Must have faces parallel to each other
(within .003") and be perpendicular
to the bore.
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.
Grade Class
Grade 8
Grade 5 or 8
Grade 10.9
Anti-rotation Slots
Mounting
Anti-Rotation
See Anti-Roatation Examples on pages 8-13
Warner Electric • 800-825-9050 P-1177-WE • 819-0457 7
Attached To Frame
Incorrect
Do Not Orient So That
Bracket Will Bind In Slot
Do Not Bottom In Slot
Correct
.030 Min.
Loose Fit
.060 Min.,
Worst Case Stackup
Must Not Allow
Bottoming In Slot
Attached To Frame
Incorrect
Do Not Orient So That
Bracket Will Bind In Slot
Do Not Bottom In Slot
Correct
.030 Min.
Loose Fit
.060 Min.,
Worst Case Stackup
Must Not Allow
Bottoming In Slot
Anti-Rotation Example
8Warner Electric • 800-825-9050 P-1177-WE • 819-0457
Incorrect
Make Sure That This
Area Does Not Contact
Field Shell
.125 Min.
Do Not Orient So That
Bracket Will Bind In Slot
Do Not Bottom In Slot
Correct
.030 Min.
Loose Fit
.060 Min.,
Worst Case Stackup
Must Not Allow
Bottoming In Slot
Incorrect
Make Sure That This
Area Does Not Contact
Field Shell
.125 Min.
Do Not Orient So That
Bracket Will Bind In Slot
Do Not Bottom In Slot
Correct
.030 Min.
Loose Fit
.060 Min.,
Worst Case Stackup
Must Not Allow
Bottoming In Slot
Anti-Rotation Example
Warner Electric • 800-825-9050 P-1177-WE • 819-0457 9
Make Sure That
Twisted Area Does
Not Contact
Field Shell
Do Not Orient So That
Bracket Will Bind In Slot
.030 Min.
Loose Fit
.060 min.,
Worst Case Stackup
Must Not Allow
Bottoming In Slot
.125 Min.
Correct
Do Not Bottom In Slot
Incorrect
Beginning of Flat
Make Sure That
Twisted Area Does
Not Contact
Field Shell
Do Not Orient So That
Bracket Will Bind In Slot
.030 Min.
Loose Fit
.060 min.,
Worst Case Stackup
Must Not Allow
Bottoming In Slot
.125 Min.
Correct
Do Not Bottom In Slot
Incorrect
Beginning of Flat
Anti-Rotation Example
10 Warner Electric • 800-825-9050 P-1177-WE • 819-0457
.030 Min.
Loose Fit
Screw Must Be
Free To Move
.030 Min.
Loose Fit
Screw Must Be
Free To Move
Anti-Rotation Example
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