Mayr EAS-Compact 49 Series Quick start guide

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 1 of 22 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
Page 2: - Safety and Guideline Signs
- Safety Regulations
Page 3: - Clutch Illustrations (Variants)
Page 4: - Parts List
Page 5: - General Technical Data
Page 6: - Technical Data Type 494._ _ _._
Page 7: - Technical Data Type 496._ _ _._
Page 8: - Design
- Scope of Delivery / State of Delivery
- Function
Page 9: - Output Elements Installation
Page 10: - Cup Spring Layering
- Mounting the Clutch onto the Shaft
- De-installation of the Cone Bushings and Shrink Disks
Page 11: - Shaft Installation via Key Connection
- Joining Both Clutch Components Type 494._ _ _._
- Joining Both Clutch Components Type 496._ _ _._
Page 12: - Permitted Shaft Misalignments
- Clutch Alignment
Page 13: - Torque Adjustment
- Changing the Torque
Page 14: - Limit Switch Installation
Page 15: - Clutch Dimensioning for ROBA®-DS Mounted Couplings
Page 16: - Clutch Dimensioning for ROBA®-ES Mounted Couplings
Page 17: - Clutch Dimensioning for ROBA®-ES Mounted Couplings
Page 18: - Maintenance and Maintenance Intervals
- Disposal
Page 19: - Malfunctions / Breakdowns Type 490._ _ _._
Page 20: - Malfunctions / Breakdowns Type 494._ _ _._
Page 21: - Malfunctions / Breakdowns Type 494._ _ _._
Page 22: - Malfunctions / Breakdowns Type 496._ _ _._
Attachment: Adjustment Diagram

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 2 of 22 www.mayr.com, E-Mail: [e-mail]
Safety and Guideline Signs
CAUTION
Danger of injury to personnel and damage to
machines.
Please Observe!
Guidelines on important points.
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 initial operation of the product until you have ensured that all applicable EU directives and 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 impacts or foreign body impact.
Replace self-locking hexagon nuts when they become ineffective after frequent loosening and tightening (for ROBA®-
DS connection).
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 specialist personnel are allowed to work on the components. They must be
familiar with the dimensioning, transport, installation, initial operation, maintenance and disposal according to
the relevant standards and regulations.
Please read the Installation and Operational Instructions carefully prior to 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®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 3 of 22 www.mayr.com, E-Mail: [e-mail]
Type 494._1_._ Type 490._1_.0
Type 494._0_._
Type 494._2_._
Type 490._2_.0
Type 496._1_._
Type 496._2_._
Fig. 1
Dim. “b”
Dim. “a”
Stroke 2.5 mm
Dim. “b”
Dim. “a”
Stroke 2.5 mm

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 4 of 22 www.mayr.com, E-Mail: [e-mail]
Parts List
(Only use mayr ®original parts)
Parts for Type 490.-:
Additional parts for Type 494.-:
Item
Name
Item
Name
1
Hub
29
Connection flange
2
Pressure flange
30
Cap screw
3
Thrust washer
31
Elastomeric element 3)
4
Adjusting nut
32.1
Shrink disk hub
5
Thrust ring
32.2
Clamping hub
6
Deep groove ball bearing
32.3
Key hub
7
Locking ring
33
Cap screw
8
Steel ball
34
Cap screw
9
Cup spring
36
Set screw
10
Type tag
38
Shrink disk
11
Cone bushing
12
Hexagon head screw
Additional parts for Type 496.-:
13
Set screw1)
Item
Name
14
Set screw
17
Connection flange
15
Hexagon nut
18
Cap screw 1)
16
Limit switch 2)
19.1
Shrink disk hub
35
Adjustment table
19.2
Key hub
20
Shrink disk
21
Hexagon head screw
22
Disk pack
23
Collar bushing
24
Connection plate
25
Hexagon head screw
26
Hexagon nut
27
Washer
28
Hexagon head screw
37
Set screw
1) Secure the set screws Item 13 and cap screws Item 18 with Loctite 243
2) The limit switch Item 16 is not part of the standard scope of delivery
3) Elastomeric element colours (hardness): red (98 Sh A), yellow (92 Sh A), green (64 Sh D)

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 5 of 22 www.mayr.com, E-Mail: [e-mail]
General Technical Data
Table 1
Limit torque for overload MG
Size
Type 49_.5_ _._
[Nm]
Type 49_.6_ _._
[Nm]
Type 49_.7_ _._
[Nm]
Type 49_.8_5._1)
[Nm]
Max.
Speed
[rpm]
4
120 –300
240 –600
480 –1200
600 –1500
800
1) Only available in synchronous design, max. speed = 250 rpm.
Table 2
Thrust washer (Fig. 1; Item 3) stroke
on overload
[mm]
Bore from –to
Size
Hub (1) with cone bushing (11)
Ø d
[mm]
Hub (1) with keyway
Ø dp
[mm]
4
2.5
40 –65
40 –65
Table 3
Type 49_.5_ _._
Type 49_.6_ _._
Size
Maximum
torque
MG
[Nm]
Inspection
dimension “a”
(Fig. 1)
at approx.
70 % MG
[mm]
Dimension “b”
(Fig. 1)
[mm]
Maximum
torque
MG
[Nm]
Inspection
dimension “a”
(Fig. 1)
at approx.
70 % MG
[mm]
Dimension “b”
(Fig. 1)
[mm]
4
300
4.4
20
600
4.7
18
Type 49_.7_ _._
Type 49_.8_5._
Size
Maximum
torque
MG
[Nm]
Inspection
dimension “a”
(Fig. 1)
at approx.
70 % MG
[mm]
Dimension “b”
(Fig. 1)
[mm]
Maximum
torque
MG
[Nm]
Inspection
dimension “a”
(Fig. 1)
at approx.
70 % MG
[mm]
Dimension “b”
(Fig. 1)
[mm]
4
1200
4.8
14
1500
5.2
12
Table 4
Size
Max. permitted bearing loads
Axial forces
[N]
Radial forces [N]
Transverse force torques 2)
[Nm]
Permitted
ambient temperature
1-bearing design
2-bearing design
4
5000
5000
7500
50
-20 °C to +80 °C
2) Torques, which put strain on the deep groove ball bearing due to the non-centric axial forces having an effect on the pressure flange.
Table 5
Size
Screw tightening torques 3) [Nm]
Item 12
Item 18
Item 21
Item 25
Item 28
Item 30
Item 33
Item 34
4
25
75
25
35
35
75
200
100
3) Secure Item 18 with Loctite 243.

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 6 of 22 www.mayr.com, E-Mail: [e-mail]
Technical Data Type 494._ _ _._
Table 6
Bore lastic-side from –to
Size
Respective
ROBA®-ES
Size
Clamping hub (32.2)
Type 494._0_._
[mm]
Shrink disk hub (32.1)
Type 494._1_._
[mm]
Key hub (32.3)
Type 494._2_._
[mm]
4
65
45 –80
45 –75
38 –80
Table 7
Nominal and maximum torques, flexible backlash-free shaft coupling, TKN and TK max.
Type 494._ _ _.3
(yellow elastomeric element 92 Sh A)
Type 494._ _ _.4
(red elastomeric element 98 Sh A)
Type 494._ _ _.6
(green elastomeric element 64 Sh D)
Size
TKN
[Nm]
TK max.
[Nm]
TKN
[Nm]
TK max.
[Nm]
TKN
[Nm]
TK max.
[Nm]
4
900
1800
1040
2080
1250
2500
Table 8
Transmittable torques TR[Nm] on clamping hubs frictional locking (Item 32.2 / Type 494._0_._)
- dependent on bore - suitable for tolerance constellation F7/k6
Size
Ø 45
Ø 48
Ø 50
Ø 52
Ø 55
Ø 58
Ø 60
Ø 62
Ø 65
Ø 68
Ø 70
Ø 72
Ø 75
Ø 78
Ø 80
4
545
590
630
662
710
764
800
840
900
954
990
1032
1095
1158
1200
Table 9
Transmittable torques TR[Nm] on shrink disk hubs frictional locking (Item 32.1 / Type 494._1_._)
- dependent on bore - suitable for tolerance constellation H7/k6
Size
Ø 45
Ø 48
Ø 50
Ø 52
Ø 55
Ø 58
Ø 60
Ø 62
Ø 65
Ø 68
Ø 70
Ø 72
Ø 75
4
1195
1425
1595
1680
1945
2210
2395
2575
2855
3140
3330
3525
3825
Table 10
Shaft misalignments flexible coupling Type 494.
Dim.
“E”
(Fig. 7)
[mm]
Locking set screw (36)
for hub (Item 32.3 / Fig. 1)
Axial ΔK a
Radial ΔK r
Angular ΔK w
Size
[mm]
92 Sh A
[mm]
98 Sh A
[mm]
64 Sh D
[mm]
92 Sh A
[°]
98 Sh A
[°]
64 Sh D
[°]
Thread
Tightening
torque
[Nm]
4
2.6
0.25
0.18
0.13
1.0
0.9
0.8
35
M10
20

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 7 of 22 www.mayr.com, E-Mail: [e-mail]
Technical Data Type 496._ _ _._
Table 11
Bore, torsionally rigid side, from –to
Nominal torque TKN and peak torque TKS
for torsionally rigid backlash-free shaft coupling
Size
Respective
ROBA®-DS
Size
Shrink disk hub
Key hub
Type 496._ _ _._
Type 496._1_._
[mm]
Type 496._2_._
[mm]
TKN
[Nm]
TKS
[Nm]
4
100
55 –90
35 –70
1600
2400
Table 12
Transmittable torques [Nm] on shrink disk hubs frictional locking (Type 496._1_._)
- dependent on bore - suitable for tolerance constellation H7/g6
Size
Ø 55
Ø 60
Ø 65
Ø 70
Ø 75
Ø 80
Ø 85
Ø 90
4
2074
2366
2658
2943
3213
3458
3666
3828
Table 13
Size
Max. permitted shaft misalignments
for torsionally rigid coupling Type 496._ _ _._
Locking set screw (37)
for hub (Item 19.2 / Fig. 1)
Axial ΔK a 1)
[mm]
Radial ΔK r
[mm]
Angular ΔK w
[°]
Thread
Tightening torque
[Nm]
4
1.5
0.3
1.4
M10
14
1) Only permitted as a static or virtually static value.

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 8 of 22 www.mayr.com, E-Mail: [e-mail]
Design
The EAS®-compact®clutch is a mechanical overload clutch
according to the ball-detent principle.
Scope of Delivery / State of Delivery
The 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).
Unless the customer requests a particular torque setting
when ordering, the clutch will be pre-set to approx. 70 % of
the maximum torque.
On Type 496._ _ _._, the misalignment-flexible part
(ROBA®-DS) must be separated for customer-side
installation from the overload clutch (EAS®-compact®) by
loosening the cap screws (18). In the as-delivered condition,
the cap screws (18) and the set screws (13) are not secured
with Loctite 243.
Before initial operation of the clutch, please
secure the set screws (13) and cap screws (18)
(only on Type 496._ _ _._) with Loctite 243.
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.
Function
The clutch protects the drive line from excessively high,
unpermitted torque impacts which can occur due to unintentional
blockages.
Function in normal operation
The EAS®-compact®clutch transfers the torque from a drive
shaft onto an output element which can be mounted onto the
clutch ball bearing-supported pressure flange (2).
The torque transmission takes place backlash-free for the entire
lifetime of the clutch.
The clutch Types 494. und 496. connect two shafts and
compensate for shaft misalignment.
Function in case of overload
If the set limit torque is exceeded (overload), the clutch
disengages, the thrust washer (3) carries out an axial hub
movement, a customer-side mounted limit switch (16) senses
this stroke movement and emits a signal to switch off the drive.
The residual torque is approx. 5 to max. 15 % of the set torque.
This means that the EAS®-compact®clutch is not load holding.
Once the overload is removed, the clutch becomes automatically
ready for operation again on reaching an engagement position.
Re-engagement:
The ratchetting division on the EAS®-compact®ratchetting clutch
Type 49_._ _0._ is 15°
The ratchetting division on the EAS®-compact®synchronous
clutch Type 49_._ _5._ is 360°

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 9 of 22 www.mayr.com, E-Mail: [e-mail]
Output Elements Installation
The output element is centred on a deep groove ball bearing (6)
(tolerance H7/h5) and bolted together with the pressure flange
(2).
Please observe the maximum permitted screw-
in depth in the pressure flange (2) as well as
the connection dimensions "a" and "e" for the
output elements, see Figs. 3 or 4 and Table 14.
If the resulting radial force from the output element is anywhere
near the centre of the ball bearing (6) and under the max.
permitted radial load acc. Table 4, an additional bearing for the
output element is not necessary.
No appreciable axial forces (see Table 4) should be
transferred from the output element onto the clutch
pressure flange (2).
The EAS®-compact®with a long protruding hub (Type
490._ _ _.1 / Fig. 2) is recommended for extremely wide output
elements, or for elements with small diameters.
On very small diameters, the output element is screwed together
with the clutch pressure flange (2) via a customer-side
intermediate flange.
In case of increased radial forces, a 2-bearing design (Type
490._ _ _.2 / Fig. 2) should be used.
Example:
Type 490.71_.1 Type 490.71_.2
Fig. 2
Ball bearings, needle bearings or bearing bushings are suitable
as bearings for the output element, depending on the installation
situation and the installation space.
Please ensure that the output element bearing is designed
as a fixed bearing (Fig. 4).
Fig. 3
Fig. 4
Table 14
Size
Thread in the pressure flange (Fig. 3)
with required screw quality
and tightening torque for the customer-side
screw connection
Max. screw-in depth [mm]
in the pressure flange (Fig. 3)
Connection dimensions [mm]
(Fig. 4)
a +0.1
e H7
h5
4
8 x 45° / M10 or 6 x 60° / M10
12.9
75 Nm
15
12
130
Max. screw-in depth
in the pressure flange
Thread
in pressure flange
Tapped extracting hole

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 10 of 22 www.mayr.com, E-Mail: [e-mail]
Cup Spring Layering (Fig. 5)
Correct cup spring layering is a prerequisite for problem-free
clutch function and torque adjustment.
Torque range “medium”:
one cup spring (Type 49_.5_ _._)
Torque range “high”:
two cup springs (Type 49_.6_ _._)
Torque range “very high”:
four cup springs (Type 49_.7_ _._)
Torque range “maximum”:
five cup springs (Type 49_.8_ _._)
1x layered 2x layered
Type 49_.5_ _._ Type 49_.6_ _._
4x layered 5x layered
Type 49_.7_ _._ Type 49_.8_5._
Fig. 5
Mounting onto the Shaft
EAS®-compact®clutches Size 4 include
cone bushings, shrink disks, clamping hubs or keyways as part of
the standard delivery.
During installation of cone bushings or shrink disks, please
observe the following:
Recommended shaft tolerance
for cone bushings: h6
for clamping hubs: see Table 8
for shrink disk hubs: see Tables 9 and 12
Shaft surface: finely turned or ground
(Ra = 0.8 µm).
Shaft material: yield point at least 400 N/mm2,
e.g. C45 +QT, 42CrMoS4 +QT.
Degrease or remove conserving layers on the shafts and
bores before installing the clutch.
Greasy or oily bores or shafts do not transmit the torques
defined in the catalogue.
Mount the clutch or clutch hubs onto both shaft ends using a
suitable device and bring it / them into the correct position.
Tighten the tensioning screws (12) of the cone bushing (11) in
2 steps cross-wise and then in 3 to max. 6 tightening
sequences evenly using a torque wrench to the torque stated
in Table 5.
Type 494.-:
Tighten the tensioning screws (34) in the shrink disks (38)
stepwise (in 3 to max. 6 tightening sequences) and cross-
wise evenly using a torque wrench to the torque stated in
Table 5.
Type 496.-:
Tighten the tensioning screws (21) in the shrink disks (20)
using a torque wrench evenly and one after the other in max.
6 sequences to the torque stated in Table 5.
The transmittable torques of the shaft-hub connection are
dependent on the bore diameter and the quality of the drive
shafts used. Please observe the respective transmission
Tables 8, 9 and 12.
The clutch or clutch hub carries out an axial
movement in the direction of the cone bushing
(11) when tightening the cone bushing (11).
Because of this effect, please ensure that on
the EAS®-compact®clutch with disk pack (Type
496._ _ _._), first the cone bushing (11) is
completely tightened, then the other (disk pack)
side.
De-installation
of the Cone Bushings and Shrink Disks
In the cone bushings and the shrink disks, there are tapped
extracting holes next to the tensioning screws.
1) Loosen all tensioning screws by several thread turns.
2) Screw out the tensioning screws located next to the tapped
extracting holes and screw them into the tapped extracting
holes up to their limits.
Then tighten these screws until the tensioning connection
loosens.

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 11 of 22 www.mayr.com, E-Mail: [e-mail]
Shaft Installation via Key Connection
On the EAS®-compact®with a keyway, the clutch must be axially
secured both EAS®-side and lastic-side after mounting onto the
shaft, e.g.:
for Type 490.
with a press cover and a screw, screwed into the shaft
threaded centre hole
for Types 494. and 496.
on the EAS®-side with a press cover and a screw, screwed
into the shaft threaded center hole and on the lastic-side with
a locking set screw:
locking set screw (36) for hub (32.3), see Fig. 1 on page 3
and Table 10 on page 6,
locking set screw (37) for hub (19.2), see Fig. 1 on page
3, Fig. 6 on page 11 and Table 13 on page 7.
Joining Both Clutch Components (1/32)
for Type 494._ _ _._ (Figs. 1 and 7)
The flexible elastomeric element (31) is pre-tensioned between
the metallic claws by joining the components (32.1, 32.2 or 32.3)
with the connection flange (29). To do this, an axial installation
force is required.
The force required can be reduced by lightly greasing the
elastomeric element.
Use PU-compatible lubricants (e. g. Vaseline or
a multi-purpose grease based on mineral oil,
NLGI Class 2, with a basic oil viscosity of
approx. 200 mm2/s).
No unpermittedly high axial pressure should be
placed on the elastomeric element (31) in
completely assembled condition.
Keep to distance dimension “E” acc. Fig. 7
and Table 10!
Fig. 7
Joining Both Clutch Components
Type 496._ _ _._ (Fig. 1)
Join the misalignment-flexible part and the overload clutch and
screw together with cap screws (18) to the tightening torque
75 Nm.
The cap screws (18) must be protected using a screw-
securing product, e.g. Loctite 243.
Fig. 6
Dimension “E” = 35 mm

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 12 of 22 www.mayr.com, E-Mail: [e-mail]
Permitted Shaft Misalignments
The EAS®-compact®clutches Types 494._ _ _._ (lastic backlash-
free) and 496._ _ _._ (torsionally rigid backlash-free) compensate
for radial, axial and angular shaft misalignments (Fig. 8) without
losing their backlash-free function.
However, the Type-specific permitted shaft misalignments
indicated in Tables 10 and 13 must not simultaneously reach their
maximum value.
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. 9.
The sum total of the actual misalignments in percent of the
maximum value must not exceed 100 %.
The permitted misalignment values given in Tables 10 and 13
refer to clutch operation at nominal torque, an ambient
temperature of +30 °C and an operating speed of 1500 rpm. If the
clutch is operated in other or more extreme operating conditions,
please observe the dimensioning guidelines stated in the
individual shaft coupling catalogues or contact the manufacturer.
Type 494._ _ _._ (lastic backlash-free)
Axial Radial Angular
displacement misalignment misalignment
Type 496._ _ _._ (torsionally rigid backlash-free)
Axial Radial Angular
displacement misalignment misalignment
Fig. 8
Example (Type 496._ _ _._):
Axial displacement occurrence ΔKa= 0.6 mm equals 40 %
of the permitted maximum value ΔKa= 1.5 mm.
Angular misalignment occurrence ΔKw= 0.42° equals 30 % of the
permitted maximum value ΔKw= 1.4°.
=> permitted radial misalignment ΔKr= 30 % of the maximum
value ΔKr= 0.3 mm => ΔKr= 0.09 mm
Fig. 9
Clutch Alignment
Exact alignment of the clutch increases the clutch service lifetime
and reduces the load on the shaft bearings.
In most of the applications, clutch alignment using a straight edge
in two levels vertical to each other is sufficient.
However, we recommend alignment of the clutch (of the shaft
ends) using a dial gauge or laser measurement devices on drives
operating at very high speeds.
Δ Kw[%]
Angular misalignment
Δ Ka[%] Axial displacement
Δ Kr[%] Radial misalignment

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 13 of 22 www.mayr.com, E-Mail: [e-mail]
Torque Adjustment
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 3
gives good results.
On very high load alternations, high accelerations and irregular
operation, please set the adjustment factor higher.
Adjustment is carried out via dimension “a” by turning the set
screws (14) (Fig. 11).
The installed cup springs (9) are operated in the negative range
of the characteristic curve (see Fig. 10); this means that a
stronger pre-tensioning of the cup spring results in a decrease of
the spring force.
The torque is set manufacturer-side according to the customer's
request. If no particular torque adjustment is requested customer-
side, the clutch will always be pre-set and marked (calibrated)
manufacturer-side to approx. 70 % of the maximum torque.
Turning the set screws (14) clockwise causes a
reduction in torque. Turning them anti-
clockwise causes an increase in torque. You
should be facing the adjusting nut (4) as shown
in Fig. 11.
Even if the customer does not intend to change
the pre-set torque, the hexagon head screw
(13) must still be screwed out customer-side,
painted with Loctite 243 and screwed back in
again.
Fig. 10
Changing the Torque (Fig. 11)
The torque is changed exclusively via the set
screws (14) and not via the adjusting nut (4).
Loosen all hexagon nuts (15) (6 pieces).
Adjust all set screws (14) (6 pieces) evenly to the required
dimension “a” using a hexagon socket wrench.
Find dimension “a” in the Adjustment Table (35) (Fig. 12)
(the Adjustment Table (35) is glued to the thrust washer (3),
see also Fig. 12).
Counter (secure) set screws (14) (6 pieces) again using
hexagon nuts (15).
Adjusting the adjusting nut (4) or distorting the
cup spring (9) outside of the cup spring
characteristic curve (see Fig. 10) stops the clutch
functioning.
The inspection dimension “a” (see Table 3) can
show deviations due to construction tolerances or to clutch
wear. After de-installing the clutch
(e.g. due to cup spring replacement or changes to the cup
spring layering), the clutch must be re-adjusted and calibrated
using dimension “a” and dimension “b” (see Adjustment Table
(35) Fig. 12, Table 3 and Fig. 11).
Fig. 11
Fig. 12 (Adjustment Table (35))
Move to operating
range
Graph of spring
characteristic
curve
Operating
range
Spring path S
Force F
Dim. “a”
Dim. “b”
Facing direction

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 14 of 22 www.mayr.com, E-Mail: [e-mail]
Limit Switch Installation
The switching direction arrow on the housing lid of the mechanical
limit switch faces in the direction of the adjusting nut (4) or in the
thrust washer (3) stroke direction, Fig. 1. Adjust the switch
distances for the contactless and mechanical limit switch acc. Fig.
13 or Fig. 14. The distance of the thrust washer (3) to the
switching point can be adjusted using a hexagon head screw,
wrench opening 7 (Figs. 13 and 14).
Fig. 13: contactless limit switch
Fig. 14: mechanical limit switch
Switching
direction

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 15 of 22 www.mayr.com, E-Mail: [e-mail]
Clutch Dimensioning for
ROBA®-DS Mounted Couplings
Definition of terms:
TKN [Nm] Coupling nominal torque
TKS [Nm] Coupling peak torque
TB[Nm] Operating torque
TS[Nm] Operating peak torque
P [kW] Drive machine nominal power
fB[-] Service factor according to Table 15
ft[-] Temperature factor according to Fig. 15
n [rpm] Drive machine nominal speed
Table 15
Service Factor fB
Work Machine
Load Class
I
II
III
Drive machine
Electromotor,
turbine,
hydraulic motor
1.1
1.4
1.9
Piston machine with more
than 3 cylinders
1.4
1.7
2.2
Piston machine with up to
3 cylinders
1.7
2.0
2.5
If the operating torque is known, the coupling nominal torque
must be higher than the maximum occurring operating torque
TKN > TB(TKN acc. Table 11). Please also observe the height and
type of start-up impacts or sporadic load impacts.
As individual events, these may not exceed the stated clutch peak
torque TKS > TS(TKS acc. Table 11). The max. number of impact
occurrences over the entire coupling lifetime must not exceed
pulsating 1 x 10e5 or alternating 1 x 10e4 .
Fig. 15
Table 16
Classification of Work Machines
into Load Classes
Construction machinery
- Concrete blenders
- Chain conveyors
- Chain carriages
- Crushers
II
III
III
III
Chemical industry
- Mixers (thick fluids)
- Mixers (thin fluids)
- Centrifuges
- Blenders
II
I
II
II
Fans / vents
II
Generators / convertors
- Frequency converters
- Generators
I
II
Foodstuffs machines
- Kneading machines
- Mills
- Packaging machines
II
III
II
Paper machines
III
Compressors
II
Conveyor systems
- Conveyor belts
- Sloping elevators
- Goods elevators
- Passenger elevators
II
III
II
II
Wood / plastic processing
- Planing machines
- Reciprocating saws
- Extruders
- Blenders
II
III
II
II
Crane systems
II
Metal processing
- Punching / pressing
- Machine tools
III
II
Pumps
- Centrifugal pump (thin fluids)
- Centrifugal pump (thick fluids)
- Pistons / plunger pumps
I
II
III
Textile machines
II
Washing machines
II
TKN ≥ 9550 × P × fBft
n
Temperature [°C]
Temperature factor ft[-]

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 16 of 22 www.mayr.com, E-Mail: [e-mail]
Clutch Dimensioning for ROBA®-ES Mounted Couplings
1. Approximate calculation of the coupling torque:
1.1. TN from the nominal power
TN= 9550 x PAN/LN
n
1.2. Dynamic torques TSand TW(5.1 and 5.2):
Drive-side excitation: Load-side excitation:
Peak torque: TS = TAS x JL
JA+ JLx SAPeak torque: TS= TLS x JA JA+ JLx SL
Alternating torque: TW= TAW x JL
JA+ JLx VRAlternating torque: TW= TLW x JA JA+ JLx VR
2. Comparison of torques occurring in the coupling with the permitted torques
The coupling must be dimensioned so that the loads occurring do not exceed the permitted values in any operating condition.
2.1. Load due to nominal torque
TKN ≥ TNx Sδ
2.2. Load due to torque impacts (5.3)
TK max ≥ TSx SZx Sδ+ TNx Sδ
2.3. Load due to resonance passing through (5.4)
TK max ≥ TSx SZx Sδx VR+ TNx Sδ
2.4. Load due to constantly alternating torque –cycle operation (5.5 and 5.6)
Permitted alternating torque on coupling:
TKW = 0.25 x TKN (for aluminum hubs)
TKW = 0.35 x TKN (for steel hubs)
TKW ≥ TWx Sδx Sf
3. Inspection of permitted misalignments
ΔKa≥ ΔWax Sδ
ΔKr≥ ΔWrx Sδx Sn
ΔKw≥ ΔWwx Sδx Sn
If more than one kind of misalignment occurs at the same time, please observe Fig. 9 (page 12).
4. Frictional locking inspection on hub connection
TR> Tmax : Tmax is the maximum torque occurring in the coupling.
For values for TR: see Tables 8 and 9 on page 6.
5. Explanations
5.1. The torque determination on the coupling is applicable if the shaft coupling in the system is the torsionally softest element,
and therefore the system can be considered as a double-mass oscillator. If this is not the case, the calculation of the torque on
the coupling requires a more detailed calculation procedure.
5.2. The impact factors SA/ SLdescribe the impact progression. A rectangular progression of the peak torque is the heaviest impact
(SA/SL= 2.0). A flat sinus progression of the peak torque is a light impact (SA/SL= 1.2).
5.3. TS , the peak torque in the coupling, is the maximum torque on the coupling during the impact
minus the system torque having an effect on the coupling during normal operation.
TS= Tmax, impact - TN
5.4. If a drive is operated supercritically, meaning that the operating speed n lies above the resonance speed nR , then resonance
passing through causes particular loads.
If the resonance passes through quickly below the operating speed, only a few resonance peaks occur. The alternating torque
in resonance can therefore be compared to the maximum torque on the coupling (see also 5.6).
5.5. Sftakes the frequency dependency of lifetime into account. The frequency dependency is first taken into account above 5 Hz.
5.6. On appreciable vibration excitation, the resonance must be moved out of the operating range by selecting a suitable torsional
spring rigidity of the coupling.

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 17 of 22 www.mayr.com, E-Mail: [e-mail]
Service Factors for Coupling Dimensioning
VR= Resonance factor
nR= Resonance speed
nR= 30
π CT dyn. JA + JL JA x JL[rpm]
fR= Resonance frequency
fR= 1
2π CT dyn. JA + JL JA x JL[1/s]
Sn= Speed factor
Sf= Frequency factor
F in Hz
≤ 5
> 5
Sf
1
f
5
f shows the load alternation per second (Hz = 1/s)
Sz= Start-up factor/impact frequency
S/h
0 –100
101 –200
201 –400
401 –800
801 –1000
Sz
1
1.2
1.4
1.6
1.8
Sδ= Safety factor for temperature
T
-30 °C / +30 °C
+60 °C
+90 °C
Sδ
1
1.5
2
SAor SL= Impact factor
Impacts
SAor SL
Light impacts
1.2
Medium impacts
1.6
Heavy impacts
2.0
Terms
PAN/LN [kW] Drive-side/load-side power
TR[Nm] Transmittable torque (frictional locking,
Tables 8, 9 and 12)
TAS/AW [Nm] Excitational torque, drive end
TLS/LW [Nm] Excitational torque, load side
TN[Nm] System torque
TW[Nm] System alternating torque
TS[Nm] Peak torque
Tmax [Nm] Maximum torque in the coupling
TKN [Nm] Permitted nominal torque
TKmax [Nm] Permitted maximum torque
TKW [Nm] Permitted permanent alternating torque
JA[kgm2] Mass moment of inertia, drive end
JL[kgm2] Mass moment of inertia, load side
ΔKa[mm] Permitted axial displacement
∆Kr[mm] Permitted radial misalignment
∆Kw[°] Permitted angular misalignment
∆Wa[mm] Axial shaft misalignment
∆Wr[mm] Radial shaft misalignment
∆Ww[°] Angular shaft misalignment
cT[Nm/rad] Torsional spring rigidity
n [rpm] Nominal speed
nR[rpm] Resonance speed
SA/L [ - ] Impact factor, drive end/load side
Sn[ - ] Speed factor
SZ[ - ] Start-up factor/impact frequency
Sδ[ - ] Temperature factor
Sf[ - ] Frequency factor
VR[ - ] Resonance factor
f [1/s] = [Hz] Load factor
fR[Hz] Resonance frequency
blue: elastomeric element 80 Sh A
green: elastomeric element 64 Sh D
red: elastomeric element 98 Sh A
yellow: elastomeric element 92 Sh A

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 18 of 22 www.mayr.com, E-Mail: [e-mail]
Maintenance and Maintenance Intervals
The following maintenance and inspection intervals are to be
maintained:
1.) Before initial operation:
Visual inspection. Inspection of the installation
parameters (misalignment and tightening torques (see
Table 5)) and the clutch running behaviour
2.) After 5 to 10 operating hours:
Check the tightening torques produced
3.) After 1000 h, at the latest after 3 months:
Visual inspection
Inspection of the screw tightening torques
The specified tightening torques (see Table 5) must be
maintained.
Inspection of torsional backlash and elastomer wear
(Type 494._ _ _._)
Inspection of the misalignment and the clutch running
behavior
4.) If no irregularities or wear are found during the maintenance
and inspection interval defined in point 3.), further inspection
intervals can, with unchanged operating parameters, take
place after 2000 operating hours, after 100
disengagements or after maximum 12 months. The
following work must be carried out:
Visual inspection
Functional inspection
Inspection of the shaft-hub connection
Inspection of the screw tightening torques
The specified tightening torques (see Table 5) must be
maintained.
Inspection of the set torque
Clutch release inspection
Inspection of the bearing or bearing pre-tension
Inspection of torsional backlash and elastomer wear
(Type 494._ _ _._)
Inspection of the misalignment and the clutch running
behavior
We recommend that this maintenance work is carried out
at the site of manufacture:
Re-greasing of the transmission geometries, balls,
recesses and sealing elements.
5.) Replacement of the elastomeric element (Type 494._ _ _._)
after 5 years.
Clutch re-greasing must only be carried out at the place of
manufacture or 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 maintenance intervals.
Elastomer wear limit (Type 494._ _ _._):
Elastomeric elements are parts subject to wear,
which change their characteristics depending
on the ambient conditions and loads.
The maximum operating time for the elastomer
is 5 years.
No abraded particles are allowed on the elastomeric element
(31).
The gap between two claws must be filled with the elastomer, with
no room for backlash.
You should not be able to insert a feeler gauge with a thickness
of 0.1 mm (Fig. 15).
Fig. 15
If wear or damages are detected on the clutch in general, the
affected components must be replaced immediately and the
cause of the malfunction must be determined.
Causes of malfunctions could be:
a) Excessive misalignment
b) Excessive load (load alternations, start-up impacts, overload)
c) Ambient influences
Wear or damage on the shaft coupling manifest themselves as:
a) Noise development
b) Troubled running behavior, vibration occurrences
c) Formation of cracks on the components
d) Warming
e) Loosening of the components
f) Buckling of the disk packs (Type 496._ _ _._)
g) Friction tracks
Should any irregularities occur, the system
must be stopped independently of imminent
maintenance and inspection intervals, and the
cause of the malfunction must be determined
using the Malfunctions / Breakdowns Table.
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.
Steel components:
Steel scrap (Code No. 160117)
All aluminum components:
Non-ferrous metals (Code No. 160118)
Seals, O-rings, V-seals, elastomers:
Plastic (Code No. 160119)
Feeler gauge
0.1 mm
Elastomeric
element
Item 31
Item 29
Items 32.1/2/3

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 19 of 22 www.mayr.com, E-Mail: [e-mail]
Malfunctions / Breakdowns Type 490._ _ _._
Malfunction
Possible Causes
Solutions
Premature
clutch
release
Incorrect torque adjustment
1) Set the system out of operation
2) Check the torque adjustment
3) Secure the adjusting nut
4) If the cause of malfunction cannot be found, the clutch must be
inspected at the place of manufacture
Adjusting nut has changed position
Worn clutch
Clutch does not
release
on overload
Incorrect torque adjustment
1) Set the system out of operation
2) Check whether foreign bodies influence the disengagement
mechanism function
3) Check the torque adjustment
4) Secure the adjusting nut
5) If the cause of malfunction cannot be found, the clutch must be
inspected at the place of manufacture
Adjusting nut has changed position
Worn clutch
Running noises in
normal operation
Insufficient clutch securement
1) Set the system out of operation
2) Check the clutch securement
3) Check the screw tightening torques
4) Check the torque adjustment and that the adjusting nut sits
securely
5) If the cause of malfunction cannot be found, the clutch must be
inspected at the place of manufacture
Loosened screws
Loosened adjusting nut

Installation and Operational Instructions for EAS®-compact®
Ratchetting clutch, Type 49_._ _0._ Size 4
Synchronous clutch, Type 49_._ _5._ Size 4 (B.4.14.4.EN)
17/03/2021 TK/GC/NU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 20 of 22 www.mayr.com, E-Mail: [e-mail]
Malfunctions / Breakdowns Type 494._ _ _._
Malfunction
Possible Causes
Solutions
Changes in running
noise
and / or
vibration
occurrence
Incorrect alignment
1) Set the system out of operation
2) Find / resolve the cause of incorrect alignment
(e. g. loose foundation screws, motor securement breakage, heat
expansion of system components, changes in the coupling
installation dimension “E”)
3) Check the clutch for wear
Wear on the elastomeric element,
temporary torque transmission due to
metal contact
1) Set the system out of operation
2) Dismantle the clutch and remove the remainders of the
elastomeric element
3) Check the clutch parts and replace if damaged
4) Insert a new elastomeric element, install clutch components
5) Check the alignment and correct if necessary.
Tensioning and clamping screws or
locking set screw for axial hub
securement or
Connection screws are loose
1) Set the system out of operation
2) Check the coupling alignment
3) Tighten the tensioning and clamping screws for axial hub
securement and the connection screws to the required
torque or tighten the locking set screw and secure it against self-
loosening using sealing lacquer
4) Check the clutch for wear
Cam breakage
Wear on the elastomeric element,
torque transmission due to metal
contact
1) Set the system out of operation
2) Replace the entire clutch
3) Check the alignment
Cam breakage due to high impact
energy / overload / excessively high
shaft misalignments
1) Set the system out of operation
2) Replace the entire clutch
3) Check the alignment
4) Find the cause of overload
Operating parameters are not
appropriate for the clutch performance
1) Set the system out of operation
2) Check the operating parameters and select a suitable clutch
(observe installation space)
3) Install a new clutch
4) Check the alignment
Operational mistakes due to clutch
characteristic data being exceeded
1) Set the system out of operation
2) Check clutch dimensioning
3) Replace the entire clutch
4) Check the alignment
5) Train and advise operating personnel