Mayr EAS 400 04.7 Series User manual

Installation and Operational Instructions for
EAS®-element clutch
Sizes 6 –14 (B.4.3.EN)
11/02/2013 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 1 of 11 www.mayr.com, E-Mail: [e-mail]
Please read these Operational Instructions carefully and follow them accordingly!
Ignoring these Instructions may lead to malfunctions or to clutch failure, resulting in damage to other parts.
Contents:
Page 1: - Contents
- Safety and Guideline Signs
- Safety Regulations
Page 2: - Clutch Illustrations
Page 3: - Parts List
- Table 1: Technical Data and
Screw Tightening Torques
Page 4: - Design
- Function
- Scope of Delivery / State of Delivery
- General Installation Guidelines
- Mounting onto the Shaft
Page 5: - Overload Element Pre-tensioning
Page 6: - Flange Design Type 400._04.0
- Joining the Clutch Components on the
Flange Design Type 400._04.0
Page 7: - Design with Short Bearing-Supported Hub
Type 400._04.5
- Design with Cardan Shaft Connection
Type 400._04.7
- EAS®Positive-Locking Design
Type 435._04.5
Page 8: - Torque Adjustment
Page 9: - Re-engagement
- Table 2: Calculation Factor k
Page 10: - Permitted Shaft Misalignments
- Table 3: Maximum Permitted
Shaft Misalignments
- Clutch Alignment
Page 11: - Maintenance and Maintenance Intervals
- Disposal
Safety and Guideline Signs
CAUTION
Danger of injury to personnel and
damage to machines.
Please Observe!
Guidelines on important points.
According to German notation, decimal points
in this document are represented with a
comma (e.g. 0,5 instead of 0.5).
Safety Regulations
These Installation and Operational Instructions (I + O) are part of the clutch delivery.
Please keep them handy and near to the clutch at all times.
It is forbidden to start use of the product until you have ensured that all applicable EU directives, directives for the machine
or system into which the product has been installed have been fulfilled.
At the time these Installation and Operational Instructions go to print, the EAS®-clutches accord with the known technical
specifications and are operationally safe at the time of delivery.
Without a conformity evaluation, this product is not suitable for use in areas where there is a high danger of explosion. This
statement is based on the ATEX directive.
CAUTION
If the EAS®-clutches are modified.
If the relevant standards for safety and / or installation conditions are ignored.
User-implemented Protective Measures
Cover all moving parts to protect against seizure, dust or foreign body impact.
The clutches may not be put into operation without a limit switch unless mayr® has been contacted and has agreed
otherwise.
To prevent injury or damage, only professionals and specialists should work on the devices, following the
relevant standards and directives. Please read the Installation and Operational Instructions carefully before
installation and initial operation of the device.
These Safety Regulations are user hints only and may not be complete!

Installation and Operational Instructions for
EAS®-element clutch
Sizes 6 –14 (B.4.3.EN)
11/02/2013 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 2 of 11 www.mayr.com, E-Mail: [e-mail]
Fig. 1
18
17
26 27
20
25
19
24 23 22 21
16
11/12
15
9
29
7
14
134 5/6
28 8
2
3
1
10
Type 400._04.5 Type 400._04.0
Type 435._04.5
Type 400._04.7

Installation and Operational Instructions for
EAS®-element clutch
Sizes 6 –14 (B.4.3.EN)
11/02/2013 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 3 of 11 www.mayr.com, E-Mail: [e-mail]
Parts List (Only use mayr® original parts)
Item
Name
Item
Name
1
Hub
10
Cap screw
2
Overload element
11
Pressure flange 1) (Type 400.604.5)
2.1
Screw-on bushing
12
Pressure flange 1) (Type 435.604.5)
2.2.1
Bolt
13
O-ring
2.2.2
Steel ball
14
Deep groove ball bearing
2.3.1
Adjusting nut
15
Angular ball bearing
2.3.2
Set screw (Sizes 6 11)
16
Bearing cover
2.4
Thrust washer
17
O-ring
2.5
Control segment
18
Cap screw
2.6
Supporting washer
19
Flange (cardan shaft connection)
2.7
Cup spring
20
Cap screw
2.8
Hexagon nut
21
Cam ring
2.9
Set screw (Sizes 12 - 14)
22
Cap screw
3
Cap screw
23
Flexible intermediate ring
4
Thrust piece
24
Flange hub
5
Cap screw
25
Claw ring
6
Spring ring
26
Cap screw
7
Shim rings
27
Locking ring
8
Bearing flange
28
Eyebolt
9
O-ring
29
Type tag
1) The pressure flange (11) and the pressure flange (12) differ in the pitch and pitch circle of the tapped hole.
If the EAS®-clutch is to be retrofitted with a flexible coupling (Items 21-27), the pressure flange (11) must be replaced
by the pressure flange (12).
Table 1: Technical Data and Screw Tightening Torques
Screw tightening torques [Nm]
Size
Air gap
a1
[mm]
Dimension
p
[mm]
Bolt-
pre-tension
[mm]
Max.
radial
forces
[kN]
Max.
axial
forces
[kN]
Item 3
Item 5
Item 10
Item 18
Item 20
Item 22
Item 26
6
2
8,0
0,5 +0,2
30
21
9
9
13
13
72
100
100
7
2
8,0
0,5 +0,2
45
31,5
9
9
25
25
174
100
100
8
2
8,0
0,5 +0,2
60
42
9
9
45
45
340
160
160
9
2
10,5
0,6 +0,2
90
63
19
9
120
120
580
240
240
10
2
10,5
0,6 +0,2
120
84
19
9
110
110
580
240
240
11
2
10,5
0,6 +0,2
180
126
19
9
110
110
- - -
490
490
12
3
15,5
0,6 +0,2
240
168
76
46
160
160
- - -
- - -
- - -
13
3
15,5
0,6 +0,2
360
252
76
46
330
330
- - -
- - -
- - -
14
3
15,5
0,6 +0,2
480
336
76
46
330
330
- - -
- - -
- - -

Installation and Operational Instructions for
EAS®-element clutch
Sizes 6 –14 (B.4.3.EN)
11/02/2013 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 4 of 11 www.mayr.com, E-Mail: [e-mail]
Design
The EAS®-element clutches are designed as mechanically
disengaging overload clutches with overload elements (2)
according to the ball-detent principle.
Function
The EAS®-clutch protects the drive line from excessively high,
unpermitted torque impacts which can occur due to unintentional
blockages.
After overload has taken place, the transmitting mechanism is
completely disconnected. Only the bearing friction continues to
have an effect.
This means that no re-engagement impacts or metallic sliding
movements occur on the clutch torque transmission geometries
when using this clutch variant.
When in operation, the set torque is transmitted from the hub (1)
(input) via the pressure flange (11) or the flange hub (24)
(flexible coupling) onto the output.
If the set limit torque is exceeded (overload), the clutch
disengages.
On disengagement, the bolts (2.2.1) in the overload elements (2)
perform an axial movement (stroke);
a contactless limit switch provided customer-side can be used
here for recognition of overload.
The bolts (2.2.1) remain disengaged. Input and output are
separated residual torque-free.
After-acting masses can run free.
CAUTION
After overload occurrence, the clutch has no
load-holding function.
The run-out time after disengagement must be
max. 10 minutes.
In order to prepare the clutch for renewed operation, the
bolts (2.2.1) must be re-engaged manually (see section Re-
engagement).
Scope of Delivery / State of Delivery
The EAS®-clutch is manufacturer-assembled ready for
installation.
The torque is set manufacturer-side according to the
customer's request (please compare the torque stipulated in
the order with the torque imprinted/engraved in the
identification).
Otherwise, the clutch must be adjusted to the required
torque by using the Adjustment Diagram (attachment) (see
section Torque Adjustment).
Please check the scope of delivery according to the Parts List as
well as the state of delivery immediately after receiving the
goods.
mayr®will take no responsibility for belated complaints.
Please report transport damage immediately to the deliverer.
Please report incomplete delivery and obvious defects
immediately to the manufacturer.
General Installation Guidelines
The bore tolerances in the hub (1) and in the flange hub (24) are
produced to tolerance quality H7. The surface roughness depth
in the bores is produced to Ra 1,6 µm.
Please secure screws with Loctite 243 (medium hard).
Please observe the screw tightening torques
acc. Table 1!
CAUTION
Before initial operation of the clutch, please
remove the eyebolt (28) (installation aid).
Mounting onto the Shaft
Mount the EAS®-element clutch using a suitable mounting device
onto the drive shaft and secure it axially (e.g. using a washer
and a screw, screwed into the shaft threaded centre hole).

Installation and Operational Instructions for
EAS®-element clutch
Sizes 6 –14 (B.4.3.EN)
11/02/2013 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 5 of 11 www.mayr.com, E-Mail: [e-mail]
Overload Element (2) Pre-tensioning:
In order to guarantee problem-free function of
the EAS®-element clutch, a defined bolt pre-
tension (acc. Table 1) is necessary.
This bolt pre-tensioning has already been
adjusted manufacturer-side with the exception
of Type 400._04.0.
The overload element (2) and the thrust piece (4) must
align exactly with each other (Fig. 3).
1
(Fig. 3 / air gap between the hub (1) and the pressure
flange (11/12) or the customer flange, on engaged
elements).
Determine the pre-tensioning using difference dimension
Dimension "v" is the
distance from the bolt end (2.2.1) to the facing side of the
screw-on bushing (2.1).
Pre-tension the element by placing shim rings (7) under
the thrust piece (2).
For de-installation of the thrust piece (4), please see Fig.
4.
Procedural Method:
1. De-install the overload element (2).
2. Move the bolts (Item 2.2.1) up against the control
segments (2.5) by applying axial force onto the ball (2.2.2),
e.g. by tapping them with a plastic hammer.
3. Using the inspection dimension "p" (see Table 1 and Fig.
2), the axial contact of the bolt (2.2.1) can be checked.
4. 
de-installed overload element (2).
5. Mount the thrust piece (4) and the overload element (2)
into the adaptor bores.
6. 
compare it to the noted value. The difference dimension
equals the bolt pre-tension.
7. In order to correct the pre-tension, both the overload
element (2) and the thrust piece (4) must be de-installed
again.
8. Now the required pre-tension acc. Table 1 can be set by
adding or removing shim rings (7) under the thrust piece
(4).
9. After correct pre-tension adjustment, apply a screw-
securing product, e.g. Loctite 243, to the cap screws
(Items 3 and 5).
Fig. 2
Fig. 3
Fig. 4
pv2.2.22.12.2.1
Dial gauge
11/121
2.2.1
2.1
2.2.2 45/6
a1 v
7
6 5 4 7 11/12
Extraction tool
Extraction thread

Installation and Operational Instructions for
EAS®-element clutch
Sizes 6 –14 (B.4.3.EN)
11/02/2013 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 6 of 11 www.mayr.com, E-Mail: [e-mail]
Flange Design Type 400._04.0 (Fig. 5).
The flange design consists of Items 1 7, 28 and 29 (see Parts
List and Fig. 1). The thrust pieces (4) are installed in the output
element (Fig. 5) or a flange, and greased. For greasing, please
use NLGI Class 1,5 grease with a basic oil viscosity of 460
mm2/s at 40 °C, e.g. Mobilith SHC460.
The input and the output elements must be supported on their
bearings axially and radially backlash-free.
Please observe the axial forces occurring in operation!
Fig. 5
Joining the Clutch Components on the
Flange Design Type 400._04.0
(Input and Output Figs. 1, 5 and 6)
The bolt (2.2.1) in the overload element (2) must be
engaged.
The bolts (2.2.1) in the overload element (Item 2 / input)
and the thrust piece (Item 4 / output) must align
(max. position deviation 0,1 mm).
The air gap “a1” acc. Table 1 and Fig. 6 must be kept to!
Mark the position.
Please make sure that the defined bolt pre-
tension in the overload elements (2)
acc. Table 1 is kept to.
Fig. 6
Markings for
re-engagement
Engaged
Shim rings (7) for
bolt pre-tension
Air gap a1

Installation and Operational Instructions for
EAS®-element clutch
Sizes 6 –14 (B.4.3.EN)
11/02/2013 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 7 of 11 www.mayr.com, E-Mail: [e-mail]
Design with Short Bearing-Supported Hub
Type 400._04.5 (Figs. 1 and 7)
The design Type 400._04.5 consists of Items 1 to 11,
13 to 18, 28 and 29, see Parts List and Fig. 1.
The output element can be mounted directly onto the bearing-
supported output-side pressure flange (11) of the clutch. Please
find the maximum permitted forces on the flange connection in
radial and axial direction in Table 1.
Fig. 7
Design with Cardan Shaft Connection
Type 400._04.7 (Figs. 1 and 8)
The design Type 400._04.7 consists of the Items 1 to 11,
13 to 20, 28 and 29, see Parts List and Fig. 1.
The cardan shaft can be screwed to the flange (19) without an
additional bearing, and then screwed to the pressure flange (11).
The cardan shaft additional forces are absorbed by the clutch
bearing (see Table 1).
Fig. 8
EAS®Positive-Locking Design
Type 435._04.5 (Figs. 1, 9 and 12)
The EAS®-element clutch, combined with a positive-locking,
flexible coupling component, consists of Items 1 to 10,
12 to 18 and 21 to 29, see Parts List and Fig. 1.
The flexible coupling component (Items 21 27) is in simple
plug-in coupling form and compensates for axial, radial and
angular shaft misalignments, whereby the total sum of
misalignments must not exceed 100 %.
When installing the clutch, the EAS®-clutch component and the
flexible component are mounted onto the shafts (input and
output) and secured axially. After this, both clutch/coupling
components can be jo
Table 3, Page 10).
Fig. 9

Installation and Operational Instructions for
EAS®-element clutch
Sizes 6 –14 (B.4.3.EN)
11/02/2013 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 8 of 11 www.mayr.com, E-Mail: [e-mail]
Torque Adjustment (Fig. 10)
Set the limit torque MG for overload on the clutch by changing the
cup spring pre-tension on each overload element (2) according
to the Adjustment Diagram.
On the clutch Sizes 6 11, the adjusting nut (2.3.1) is adjusted
by turning it in the overload element (2) using a face wrench. On
Sizes 12 14, adjustment takes place via 4 set screws (2.9).
During torque adjustment, please ensure that
all overload elements (2) on the clutch are
evenly adjusted!
Torque Adjustment:
1. Determine the limit torque MGfor overload.
2. 
included in clutch delivery.
This dimension is equal to the required limit torque MG.
3. Loosen the set screws (2.3.2) on Sizes 6 11 or the
hexagon nuts (2.8) on the Sizes 12 14.
4. Set all overload elements (2) by turning the adjusting nut

found in the Adjustment Diagram (Fig. 10).
5. Tighten the set screws (2.3.2) again in the adjusting nuts
(2.3.1) or counter the set screws (2.9) with the hexagon nuts
(2.8).
In order to guarantee low-wear clutch operation,
it is essential that the clutch torque is set to a
sufficiently high service factor (overload torque
to operating torque). Our experience has shown
that an adjustment factor of 1,5 to 4 gives good
results. On very high load alternations, high accelerations and
irregular operation, please set the adjustment factor higher.
Sizes 6 11
Sizes 12 14
Fig. 10
a
2.6 2.5 2.4 2.7
2.3.2
2.1
2.2.1
2.2.2
2.3.1
2.8
2.9
2.3.1
a

Installation and Operational Instructions for
EAS®-element clutch
Sizes 6 –14 (B.4.3.EN)
11/02/2013 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 9 of 11 www.mayr.com, E-Mail: [e-mail]
Re-engagement (Figs. 6 and 11)
In order to make the clutch ready for operation again after
overload occurrence, the bolts (2.2.1) in the overload elements
(2) must be re-engaged.
The marking bores on the outer diameters of the hub (1) and the
pressure flange (11/12) must align with each other (Fig. 3).
Re-engagement takes place by placing axial pressure on the bolt
end of each overload element (2). Tap gently all around with a
plastic hammer, see Fig. 11, so that the bolts (2.2.1) are inserted
evenly.
The level of engagement force is dependent on the set limit
torque for overload and can be roughly calculated using the
formula below.
FE= k x MG[kN]
k = Calculation factor [1/m] acc. Table 2
MG= Set limit torque for overload [kNm].
FÜ= Engagement force per overload element [kN].
FÜ= 

n = Number of overload elements
Fig. 11
Table 2: Calculation factor k
Size
Calculation factor k [1/m]
6
1,7
7
1,4
8
1,3
9
1,0
10
0,8
11
0,6
12
0,5
13
0,4
14
0,3
FE
FÜ
FÜ

Installation and Operational Instructions for
EAS®-element clutch
Sizes 6 –14 (B.4.3.EN)
11/02/2013 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 10 of 11 www.mayr.com, E-Mail: [e-mail]
Permitted Shaft Misalignments (Figs. 12 and 13)
EAS®-positive locking Type 435._04 for compensation of axial,
radial and angular shaft misalignments, Fig. 12.
Please see Table 3 for the maximum permitted shaft
misalignments. If more than one kind of misalignment takes
place simultaneously, they influence each other. This means that
the permitted misalignment values are dependent on one
another, see Fig. 13.
Difference dimension ΔKw= Kw 1 - Kw 2
=> Measure dimensions ΔKw 1 and ΔKw 2
vertically and horizontally offset by 180°.
Fig. 12
Example:
EAS®-element clutch, Size 6
- Axial displacement occurrence: Ka= 0,8 mm
- Angular misalignment occurrence: Kw= 0,09 mm
- Required: Permitted radial misalignment ΔKr
a= 0,8 mm
40 % of the permitted Table value a zul. = 2,0 mm
w = 0,09 mm
30 % of the permitted Table value w zul. = 0,3 mm
The permitted radial misalignment in % is determined from Fig.
13:
ΔKr= 30 %
30 % of the permitted Table value r zul. = 0,3 mm means
that the permitted radial misalignment in this particular case is
0,09 mm.
Fig. 13
Clutch Alignment
Exact alignment of the clutch minimises the compensating forces
having an effect in the drive line, improves the running
smoothness of the clutch and reduces the load on the shaft
bearings. The clutch service lifetime and therefore also the
engagement accuracy in case of overload are also increased.
We recommend aligning the coupling using a suitable measuring
device, e.g. a laser.
Table 3:
Max. Permitted Shaft Misalignments
The misalignment values are valid for a referential speed of
1500 rpm.
Size
s
[mm]
ΔKa
[mm]
ΔKr
[mm]
ΔKw
[mm]
6
4
2
0,3
0,3
7
4
2
0,3
0,3
8
5,5
2,5
0,3
0,3
9
8
2,5
0,3
0,3
10
8
2,5
0,3
0,3
11
8
2,5
0,3
0,3
12
12
0,5
0,55
1,0
13
13
0,7
0,55
1,25
14
13
0,7
0,65
1,25
ΔKw
Kw1
Kw2
ΔKr
s ±ΔKa
w [%]
Angular misalignment
20
30%
25%
75%
0%
50%
20
40%
40
30%
60
60
80
80
100
100
a [%] Axial displacement
r [%] Radial misalignment

Installation and Operational Instructions for
EAS®-element clutch
Sizes 6 –14 (B.4.3.EN)
11/02/2013 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
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Maintenance and Maintenance Intervals
Maintenance work, which should be carried out after 2000
operating hours, after 1000 disengagements or at the latest after
1 year, includes:
Visual inspection
Functional inspection
Inspection of the shaft-hub connection
Inspection of the screw tightening torques
The specified tightening torques (see Technical Data,
page 3) must be maintained.
Inspection of the set torque
Clutch release inspection
Bearing
or bearing pre-tension inspection
Re-greasing of the contact components of the
overload elements (2) and the thrust pieces (4) as well as
the bearing.
Clutch re-greasing must only be carried out by specially trained
personnel.
For greasing, please use NLGI Class 1,5 grease with a basic oil
viscosity of 460 mm2/s at 40 °C, e.g. Mobilith SHC460.
When re-installing the clutch, please secure all screws with
Loctite 243 (medium hard).
If large amounts of dirt or dust are present or in extreme ambient
conditions, it may well be necessary to carry out inspections at
shorter intervals.
We recommend that maintenance work is carried out at the
site of manufacture.
On balanced clutches, please observe:
Maintaining the exact angular position between
the clutch components is absolutely necessary
for maintaining the balance quality.
On balanced clutches, the components are
therefore marked and are, on re-installation, to
be screwed together again in the marked
angular position to the tightening torque
according to Table 1.
Disposal
Electronic components
(Limit switch):
Products which have not been disassembled can be disposed of
under Code No. 160214 (mixed materials) or components under
Code No. 160216, or can be disposed of by a certified disposal
firm.
All steel components:
Steel scrap (Code No. 160117)
Seals, O-rings, V-seals, elastomers:
Plastic (Code No. 160119)