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.GB)
18/02/2008 GC/TK/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 1 of 10 Germany eMail: [e-mail]
Please read the 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
- Manufacturer’s Declaration
- Safety Regulations
Page 2: - Clutch Illustrations
Page 3: - Parts List
- Technical Data
- Table 1: Torques, Speeds, Thrust Washer Stroke,
Min. and Max. Bores
- Table 2: Max. Torques /
Inspection Dimension "a", Dimension "b"
- Table 3: Threaded Holes and Max. Screw-in
Depths into Pressure Flange (2),
Screw Tightening Torques
Page 4: - Table 4: Max. Axial and Radial Forces and Max.
Radial Force Torques,
Torsionally Rigid Shaft Compensation
Coupling Type 496._ _ _.0: Min. and
Max. Bores, Nominal and Impact Torque
- Table 5: Flexible Backlash-free Shaft Coupling
Type 494._ _ _.4: Min. and Max.
Bores, Nominal Torque
- Safety and Guideline Signs
- Design
- State of Delivery
- Function
Page 5: - General Installation Guidelines
- Output Element Installation
- Mounting the Device onto the Shaft
- De-installation
- Shaft Installation via Key Connection
Page 6: - Cup Spring Layering
- Joining the Clutch Parts
- Permitted Shaft Misalignments
Page 7: - Coupling Alignment Types 496. and 494.
- Limit Switch Installation
- Torque Adjustment
Page 8: - Torque Adjustments
- Maintenance
- Disposal
- Malfunctions / Breakdowns
Page 9: - Malfunctions / Breakdowns
Page 10: - Malfunctions / Breakdowns
Attachment: Adjustment Diagram
Manufacturer’s Declaration
This product is intended for installation in a machine or system, based on the machine directive 98/37/EC.
It is forbidden to start use of the product until the machine or system into which it should be built is operating in accordance with the EC
directives.
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.
Danger!
This warning applies if:
 the EAS®-Compact®clutches are modified.
 the relevant standards for safety and / or installation conditions are ignored.
User-implemented Protective Measures
 Cover 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 consulted and has agreed
otherwise.
To prevent injury or damage, only professionals and suitably qualified personnel should work on the devices,
following the relevant standards and directives. Please read the Installation and Operational Instructions
carefully before installing and operating the device.
These Safety Regulations are user hints only and may not be complete!
Please Observe:
Without a conformity inspection, this product is not suitable for areas where there is a high danger of explosion. This statement is based on
the directive 94/9 EC (ATEX directive).
Please Observe!
According to German notation, decimal points in this document are represented with a comma (e.g. 0,5 instead of 0.5).

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.GB)
18/02/2008 GC/TK/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 2 of 10 Germany eMail: [e-mail]
Fig. 1
7 6
3
5
4
14
12
11
1
15
13
10/35
27
23
21
20
19.1
26
26
19.2
22
25
24
26
28
18
17
31 3029
32.1
34
33
32.2
32.3
5
4
14
13
10/35
15
7
6
3
1
Type 494._1_.4
Type 490._1_.0
Type 490._2_.0
Type 494._0_.4
Type 494._2_.4
Type 496._1_.0
Type 496._2_.0
Stroke 2,5 mm
Maximum screw in depth
in pressure flange
Threaded hole in pressure flange
Dimension “a”
Dimension “b”
Stroke 2,5 mm
Maximum screw in depth
in pressure flange
Threaded hole in pressure flange
Dimension “a”
Dim. “b”

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.GB)
18/02/2008 GC/TK/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 3 of 10 Germany eMail: [e-mail]
Parts List (Only use mayr®original parts)
Parts for Type 490.- Additional Parts for Type 496.- Additional Parts for Type 494.-
1 Hub EAS®17 Connection flange 29 Connection flange
2 Pressure flange 18 Cap screw 30 Cap screw
3 Thrust washer 19.1 Shrink disk hub 31 Elastomeric element
4 Adjusting nut 19.2 Hub with keyway 32.1 Shrink disk hub
5 Thrust ring 20 Shrink disk 32.2 Clamping hub
6 Deep groove ball bearing 21 Hexagon head screw 32.3 Hub with keyway
7 Locking ring 22 Disk pack 33 Cap screw
8 Steel ball 23 Collar bushing 34 Cap screw
9 Cup spring 24 Connection plate
10 Type tag 25 Hexagon head screw
11 Cone bushing 26 Hexagon nut
12 Hexagon head screw 27 Washer
13 Set screw 28 Hexagon head screw
14 Set screw
15 Hexagon nut
16 Limit switch
35 Adjusting Table
Please Observe!
 Limit switch Item 16 is not included in standard delivery
 Secure the set screws Item13 und cap screw Item18 with Loctite 243
Technical Data
Table 1:
Limit torques 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]
Thrust washer
stroke on overload
(Item 3)
[mm]
Bore
(Item 1)
Type 490._ _ _._
from – to
[mm]
4 120 – 300 240 – 600 480 – 1200 600 – 1500 800 2,5 40 – 65
1) Only available in synchronous design, max. speed = 250 rpm.
Table 2:
Type 490.5_ _._ Type 490.6_ _._
Size
Maximum
torque
MG
[Nm]
Inspection
dimension "a"
(Fig. 1)
at c. 70 % MG
[mm]
Dimension "b"
(Fig. 1)
[mm]
Maximum
torque
MG
[Nm]
Inspection
dimension "a"
(Fig. 1)
at c. 70 % MG
[mm]
Dimension "b"
(Fig. 1)
[mm]
4 300 4,4 20 600 4,7 18,0
Type 490.7_ _._ Type 490.8_ 5._
Size
Maximum
torque
MG
[Nm]
Inspection
dimension "a"
(Fig. 1)
at c. 70 % MG
[mm]
Dimension "b"
(Fig. 1)
[mm]
Maximum
torque
MG
[Nm]
Inspection
dimension "a"
(Fig. 1)
at c. 70 % MG
[mm]
Dimension "b"
(Fig. 1)
[mm]
4 1200 4,8 14 1500 5,2 12
Table 3:
Screw tightening torques
Size
Threaded hole in
pressure flange
(Item 2)
Max. screw-in depth
in pressure flange
(Item 2)
[mm] Item 12
[Nm]
Item 18
[Nm]
Item 21
[Nm]
Item 25
[Nm] Item 28 [Nm] Item 30 [Nm]
Item 33
[Nm] Item 34 [Nm]
4 8 x 45°/ M10 2)
or
6 x 60°/ M10 2) 15 25 80 25 35 35 80 200 90
2) For clutch operation in the max. torque range, screws quality class 12.9 must be used to secure the input element.

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.GB)
18/02/2008 GC/TK/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 4 of 10 Germany eMail: [e-mail]
Table 4:
Max. permitted Torsionally rigid shaft compensation coupling Type 496._ _ _.0
Bore hub
Size
Axial forces
[N]
Radial forces
[N]
Radial force
torques3)
[Nm]
Item 19.1
from – to
[mm]
Item 19.2
from – to
[mm]
Nominal torque
TKN
[Nm]
Impact torque
TKS
[Nm]
4 5000 5000 50 55 – 90 35 – 70 1600 2400
3) Torques, which place a load on the deep groove ball bearing due to unequal axial forces on the pressure flange.
Table 5:
Flexible backlash-free shaft coupling Type 494._ _ _.4
Bore hub Nominal torque
Size
Item 32.1
from – to
[mm]
Item 32.2
from – to
[mm]
Item 32.3
from – to
[mm] TKN [Nm] TKN max. [Nm]
4 45 – 75 45 – 80 38 – 80 1040 2080
Safety and Guideline Signs
Danger!
Danger of injury to personnel and damage
to machines.
Please Observe!
Guidelines on important points.
Design
The EAS®-Compact®clutch is designed as a mechanical overload
clutch, based on the ball-detent-principle.
State of Delivery
The EAS®-Compact®clutch is manufacturer-assembled, including
the clamping devices, for backlash-free shaft installation.
Unless the customer requests a particular torque setting, the
EAS-Compactclutch will be pre-set to c. 70 % of the respective
maximum torque and calibrated.
The set screws (Item 13) are not secured with Loctite 243 on a
calibrated clutch.
On Type 496._ _ _.0, the misalignment flexible part (ROBA®-DS)
must be separated for customer-side installation from the
overload clutch by loosening the cap screws (Item 18).
On delivery, the cap screws (Item 18) and the set screws
(Item 13) are not secured with Loctite 243.
Please Observe!
Before initial operation of the clutch, please
secure the set screws (Item 13) and cap
screws (Item 18, only on Type 496._ _ _.0)
with Loctite 243.
Please check state of delivery!
Function
The clutch protects the drive line from unpermitted, excessively
high torque peaks, which can be caused by unforeseeable
blockages.
When in operation, the EAS-Compactclutch transmits the set
torque backlash-free from the hub (Item 1) via the pressure flange
(Item 2) to the customer-side output element.
If the set limit torque is exceeded (overload), the clutch
disengages, the thrust washer (Item 3) performs an axial stroke
movement, a customer-side mounted limit switch (Item 16)
senses this stroke movement and emits a signal to switch off the
drive.
The residual torque totals c. 5 to max. 15 % of the set torque.
The EAS®-Compact®clutch is therefore not load holding.
After the removal of the overload, the clutch is automatically ready
for operation. It moves independently into an engaged position.
Re-engagement:
The ratchetting division of the EAS®-Compactratchetting clutch
Type 49_._ _0._ is 15°.
The ratchetting division of 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.GB)
18/02/2008 GC/TK/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 5 of 10 Germany eMail: [e-mail]
General Installation Guidelines
The bores in the hubs Item 1, Item 19.1, Item 19.2, and Item 32.3
have an H7 tolerance. The bores in the hub Item 32.1 have an H7
tolerance and in hub Item 32.2 an F7 tolerance.
The surface roughness depth in the bores are produced to
Ra = 1,6 µm.
Output Element Installation (Fig. 2)
The output elements are centred on the deep groove ball bearing
(Item 6) (tolerance H7/h5) and screwed together with the pressure
flange (Item 2).
If the resulting radial force from the output element lies anywhere
near the centre of the ball bearing, an additional output bearing
for the output element will not be necessary.
No appreciable axial forces are to be transmitted from the
output element onto the clutch pressure flange (Item 2).
For extremely wide output elements or for elements with a small
diameter, we recommend the EAS-Compactwith a long
projecting hub (Type 49_._ _ _.1).
For very small diameters, the output element is screwed to the
clutch pressure flange via a customer-side intermediate flange.
Ball bearings, needle bearings or bearing bushings are suitable
bearings for the output element, depending on the installation
situation and the installation space available.
Please ensure that the output element bearing is implemented as
a location bearing (Fig. 2).
Fig. 2
Mounting the Device onto the Shaft
EAS®-Compact®clutches Size 4 are sent as a standard delivery
which includes manufacturer-assembled cone bushings or shrink
disks, or keyways.
Please observe the following guidelines during the
installation of the cone bushings and shrink disks:
 The shafts must be solid shafts without a keyway.
Shaft tolerance up to diameter 38 h6, over diameter 38 h8 or
k6.
 Surface of the shafts:
finely polished or ground (Ra = 0,8 µm).
 Shaft material: the yield point must be at least 350 N/mm2,
e.g. St 60, St 70, C 45, C 60.
 Before the clutch or the clutch hubs are installed, the shafts
and the bores must be de-greased or the conserving layers
must be removed.
Greasy or oily bores or shafts do not transmit the torque
TRstated on order.
 Mount the clutch or clutch hubs onto both shaft ends using a
suitable mounting device and bring them into the correct
position.
 Tighten the clamping screws evenly (Items 12, 21 and 34)
using a torque wrench crosswise and stepwise (in 3 to max. 6
tightening revolutions) to the torque shown in Table 3.
De-installation
In the cone bushings or shrink disks, extraction holes (see also
Fig. 2) can be found next to the clamping screws (Items 12, 21
and 34).
1) Loosen all clamping screws by several thread turns.
2) Screw out the clamping screws next to the extraction holes,
and screw them up to their limits into the extraction holes.
3) Tighten the clamping screws (Items 12, 21 and 34) evenly
stepwise. In this way, the cone bushing or the shrink disk is
loosened from the hub.
4) Screw out the clamping screws from the extraction holes.
Shaft Installation via Key Connection
For the EAS®-Compact®with keyway, the clutch must be
stabilised axially after it has been fitted onto the shaft. This can,
for example, be done using a press cover and a screw, which are
screwed into the shaft centring thread (EAS®-side) and / or a set
screw (lastic-side, see Fig. 3).
Fig. 3
16
2
1
6
11
3
12
T
a
p
p
e
d
e
x
t
r
a
c
t
i
n
g
h
o
l
e

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.GB)
18/02/2008 GC/TK/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 6 of 10 Germany eMail: [e-mail]
∆
K
a
∆
K
w
2
x
∆
K
w
∆
K
r
Cup Spring Layering (Fig. 4)
The correct cup spring layering is a prerequisite for problem-free
clutch function and torque adjustment.
For the different torque ranges (see Adjustment Table, Item 35)
one cup spring for Type 49_.5_ _._, two cup springs for Type
49_.6_ _._, four cup springs for Type 49_.7_ _._ and five cup
springs for Type 49_.8_ 5._ are installed (Fig. 4).
The maximum torque range (Type 49_.8_ 5._) can only be
delivered in synchronous clutch design.
Single layer Double layer
Type 49_.5 _ _._ Type 49_.6 _ _._
4 layer 5 layer
Type 49_.7 _ _._ Type 49_.8 _ 5._
Fig. 4
Joining the Coupling Parts on Type 494._ _ _.4
(Figs. 1 and 5)
The flexible elastomeric element (31) is pre-tensioned between
the metallic jaws by joining the hub (32.1, 32.2 or 32.3) with the
connection flange (29). To do this, axial force must be used.
The force required can be reduced by lightly greasing the
elastomeric element (31). Please Observe! Use PU-compatible
lubricants (e. g. Mobilgrease HP 222)!
Please Observe!
After joining the coupling parts, no axial pressure must be placed
on the elastomeric element (31).
Keep to the distance dimension "E" = 35 mm acc. Fig. 5!
Fig. 5
Joining the Coupling Parts on Type 496._ _ _.0
(Fig. 1)
Join the misalignment-flexible part and the overload clutch and
screw them together using the cap screws (Item 18) to a
tightening torque of 80 Nm.
The cap screws (Item 18) must be covered with a thread
locking solution, e.g. Loctite 243.
Permitted Shaft Misalignments
EAS®-Compact®clutches Type 496._ _ _.0 and Type
494._ _ _.4 compensate for radial, axial and angular shaft
misalignment (Figs. 6/7), without losing their resistance to
backlash.
However, the permitted shaft misalignments shown in Tables 6
and 7 may not simultaneously reach their maximum value. If more
than one kind of misalignment takes place simultaneously, they
influence each other. Therefore, each permitted alignment value
(see Fig. 8, page 7) is dependent on another. The sum total of the
actual misalignments in percent of the maximum value must not
exceed 100 % (example page 7).
The permitted shaft misalignments shown in Tables 6 and 7 refer
to clutch operation at nominal torque, an ambient temperature of
+30 °C and an operating speed of 1500 rpm. In other or more
extreme clutch conditions, please observe the design guidelines
in the individual clutch catalogues, or contact the manufacturers.
Table 6:
Max. permitted shaft misalignments
for Type 496 _ _ _.0
Axial displacement ∆Ka
Only permitted as a static or virtually static value. ± 1,5 mm
Radial misalignment ∆Kr0,3 mm
Angular misalignment ∆Kw per disk pack 0,7°
Angular misalignment ∆Kw total 1,4°
Axial Radial Angular
displacement misalignment misalignment
Fig. 6 Type 496._ _ _.0
Table 7:
Max. permitted shaft misalignments
for Type 494._ _ _.4
Radial misalignment ∆Kr0,18 mm
Axial displacement ∆Ka 2,6 mm
Angular misalignment ∆Kw 0,9°
Radial Axial Angular
misalignment displacement misalignment
Fig. 7: Type 494._ _ _.4
∆
K
a
∆
K
w
L
∆
K
r
32._
31
29
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.GB)
18/02/2008 GC/TK/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 7 of 10 Germany eMail: [e-mail]
Fig. 8
Example (Type 496._ _ _.0):
Axial displacement occurrence Ka = 0,6 mm equals 40 % of the
permitted maximum value Ka = 1,5 mm.
Angular misalignment occurrence Kw = 0,42°equals 30 % of the
permitted maximum value Kw = 1,4°.
=> permitted radial misalignment Kr = 30 % of the maximum value
Kr = 0,3 mm => Kr = 0,09 mm
Coupling Alignment on Type 496._ _ _.0 and
Type 494._ _ _.4
An exact coupling alignment greatly increases the lifetime of the
clutch and reduces the load on the shaft bearings.
In particularly high speed drives, we recommend the use of an
alignment device (e.g. laser).
Normally however, it is sufficient to align the coupling using a
straight edge at two vertical levels next to each other.
Limit Switch Installation
The switching direction arrow on the mechanical limit switch
housing cover points in the direction of the adjusting nut (Item 4)
or in the stroke direction of the thrust washer (Item 3), see Fig. 1.
Please set the switch distances for the mechanical and
contactless limit switch according to Figs. 9 or 10.
The distance from the thrust washer (Item 3) to the switching
point can be finely adjusted using a hexagon head screw SW 7
(Figs. 9/10).
Fig. 9 (mechanical limit switch)
Fig. 10 (contactless limit switch)
Torque Adjustment (manufacturer-side)
The clutch is set to the torque requested on order.
The adjustment is carried via dimension “a” by turning the set
screws (Item 14, Fig. 12).
The installed cup springs (Item 9) are operated in the
negative range of the characteristic curve. This means that a
stronger pre-tension of the cup springs decreases the spring
force (Fig. 11).
Therefore, turning the set screws (Item 14) clockwise
decreases the torque. Turning them anti-clockwise increases
the torque.
(Facing the adjusting nut (Item 4) as in Fig. 12).
Guidelines!
Please Observe!
Even if the pre-set torque is not changed by the customer,
the set screws (Item 13) must still be unscrewed customer-
side, painted with Loctite 243 and screwed in again.
Construction tolerances or wear on the clutch can cause
deviations in inspection dimension "a" (Table 2, Page 3).
Fig. 11 (This diagram only serves as an example)
20
30%
25%
75%
0%
50%
20
40%
40
30%
60
60
80
80
100
100
∆
K
w
Angular misalignment
[%]
∆
K [%] Axial displacement
a
∆
m
i
s
a
l
i
g
n
m
e
n
t
K
[
%
]
R
a
d
i
a
l
r
SW7
1,5
0,5
Switching
direction
Move to
operational range
F
o
r
c
e
F
Graph of
spring characteristic
curve
Operational
range Spring path S

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.GB)
18/02/2008 GC/TK/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 8 of 10 Germany eMail: [e-mail]
Fig. 12
Torque Adjustment (Fig. 12)
Warning!
Torque adjustment is only carried out via the set
screws (Item 14) and not via the adjusting nut
(Item 4).
 Loosen all hexagon nuts (6 pieces, Item 15).
 Adjust all set screws (6 pieces, Item 14) evenly to the
required dimension “a” using a hexagon socket screw.
 See the Adjustment Table (Item 35, Fig. 12) for
dimension “a” (attached Adjustment Table (Item 35) on the
thrust washer (Item 3), also see Fig. 13).
 Counter (secure) the set screws (6 pieces, Item 14) again
using hexagon nuts (Item 15).
Guideline!
Please Observe!
Adjusting the adjusting nut (Item 4) or distorting the cup
springs (Item 9) out of the cup spring characteristic curve
(see Fig. 11) stops the clutch functioning.
After clutch de-installation (e.g. by changes to the cup
springs or cup spring layering), the clutch must again be pre-
set and calibrated using dimension "a" and dimension "b"
(see Adjustment Table, Fig. 13, or Table 2, page 3).
Maintenance
The EAS®-Compact®clutch is mainly maintenance-free.
The only maintenance work needed is a regular inspection of
functionality and torque adjustment. => yearly.
Special maintenance work may be necessary in extreme ambient
or load conditions, or when large amounts of dirt or dust are
present. This special maintenance includes:
 a bearing inspection
 inspection of the tightening torques
 lubrication of the transmitting geometries, balls, detents and
sealing elements
In these conditions, it may be necessary to carry out inspections
at much shorter intervals.
We recommend that the maintenance inspections are carried
out at the place of manufacture.
Disposal
Electric Components (limit switch):
Products which have not been dismantled can be disposed of
under Code No.160214 (Mixed Materials) or Components under
Code No. 160216, or can be disposed of by a certified waste
disposal firm.
All steel components:
Steel scrap (Code No. 160117)
Seals, O-rings, V-seals, elastomers:
Plastics (Code No. 160119)
Fig. 13 (Adjustment Table / Item 35)
Malfunctions / Breakdowns
Malfunction Possible Causes Solutions
Incorrect torque adjustment
Adjusting nut adjustment has
changed (position)
Premature clutch
release
Worn clutch
1) Set the system out of operation
2) Check the torque adjustment
3) Secure the adjusting nut
4) If the cause of the malfunction cannot be found, the clutch must be
inspected at the place of manufacture.
Incorrect torque adjustment
Adjusting nut adjustment has
changed (position)
Clutch does not
release on overload
Worn clutch
1) Set the system out of operation
2) Check whether foreign bodies influence the disengaging
mechanism function
3) Check the torque adjustment
4) Secure the adjusting nut
5) If the cause of the malfunction cannot be found, the clutch must be
inspected at the place of manufacture.
4
14
15
35
3
9
Facing direction
Dimension “b”
Dimension “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.GB)
18/02/2008 GC/TK/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 9 of 10 Germany eMail: [e-mail]
Malfunctions / Breakdowns
Malfunction Possible Causes Solutions
Insufficient clutch securement
Loosened screws
Running noises in
normal operation
Loosened adjusting nut
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 the malfunction cannot be found, the clutch must be
inspected at the place of manufacture.
Incorrect alignment
1) Set the system out of operation
2) Find and solve the cause of incorrect alignment (e. g. loose foundation
screws, motor securement breakage, warmth expansion of system
components, changes in the coupling installations dimension "E")
3) Check the coupling for wear
Wear on the elastomeric element,
temporary torque transmission
due to metal contact
1) Set the system out of operation
2) Dismantle the coupling and remove the remains of the elastomeric
element
3) Check the coupling parts and replace them if damaged
4) Insert a new elastomeric element, install coupling parts
5) Check the alignment and correct if necessary
Loose clamping screws and
socket set screws or locking set
screw for axial hub securement
Changes in running
noises and/or
vibrations occurrence
Type 494.-
Loose connection screws
1) Set the system out of operation
2) Check the coupling alignment
3) Tighten the clamping and socket set screws for axial securement of the
hubs as well as the connection screws to the specified torque, or
tighten the locking set screw and paint it with locking solution against
self-loosening
4) Check the coupling for wear
Wear on the elastomeric element,
torque transmission due to
metal contact
1) Set the system out of operation
2) Replace the entire coupling
3) Check the alignment
Cam breakage due to high
impact energy / overload
1) Set the system out of operation
4) Replace the entire coupling
2) Check the alignment
3) Find the cause of overload
Operating parameters do not
match the coupling performance
1) Set the system out of operation
2) Check the operating parameters and select a suitable coupling (please
observe the installation space)
3) Install a new coupling
4) Check the alignment
Cam breakage
Type 494.-
Operational mistakes on the
system unit due to coupling
characteristic data being
exceeded
1) Set the system out of operation
2) Check coupling dimensioning
3) Replace the entire coupling
4) Check the alignment
5) Train operating personnel
Incorrect alignment
1) Set the system out of operation
2) Find and solve the cause of incorrect alignment
(e. g. loose foundation screws, motor securement breakage, warmth
expansion of system components, changes in the coupling installation
dimension "E")
3) Check the coupling for wear
4) Insert a new elastomeric element
Premature wear on
the elastomeric
element
Type 494.- e.g. contact with aggressive
liquids / oils, ozone influences,
excessively high ambient
temperature etc., which lead to
physical changes in the
elastomeric element
1) Set the system out of operation
2) Dismantle the coupling and remove the remains of the elastomeric
element
3) Check the coupling parts and replace them if damaged
4) Insert a new elastomeric element, install coupling components
5) Check the alignment and correct if necessary
6) Make sure that further physical changes to the elastomeric element can
be ruled out.

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.GB)
18/02/2008 GC/TK/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 10 of 10 Germany eMail: [e-mail]
Malfunctions / Breakdowns
Malfunction Possible Causes Solutions
Premature wear on
the elastomeric
element
Type 494.-
The ambient or contact
temperatures permitted for the
elastomeric element are
exceeded
1) Set the system out of operation
2) Dismantle the coupling and remove the remains of the elastomeric
element
3) Check the coupling parts and replace them if damaged
4) Insert a new elastomeric element, install coupling components
5) Check the alignment and correct if necessary
6) Check the ambient or contact temperature and regulate them (if
necessary using other elastomeric element materials)
Premature wear on
the elastomeric
element
(material liquefies
inside the elastomeric
element toothing)
Type 494.-
Drive vibrations
1) Set the system out of operation
2) Dismantle the coupling and remove the remains of the elastomeric
element
3) Check the coupling parts and replace them if damaged
4) Insert a new elastomeric element, install the coupling components
5) Check the alignment and correct if necessary
6) Find the cause of vibration (if necessary by using an elastomeric
element with a lower or higher shore hardness)
Incorrect alignment,
incorrect installation
1) Set the system out of operation
2) Find and solve reason for incorrect alignment
3) Check the clutch for wear
Loose connecting screws,
minor friction corrosion under the
screw head and on the disk pack
1) Set the system out of operation
2) Check clutch parts and replace them if damaged
3) Tighten the connection screws to the stated torque
4) Check the alignment and correct if necessary
Changes in running
noise and/or vibration
occurrence
Type 496.-
Loose clamping screws or
securing set screw for axial hub
securement
1) Set the system out of operation
2) Check the clutch alignment
3) Tighten the clamping and socket set screws for axial securement of the
hubs as well as the connection screws to the specified torque, or
tighten the locking set screw and paint it with thread locking solution
against self-loosening
4) Check the clutch for wear
Disk pack breakage due to high
load impacts / overload
1) Set the system out of operation
2) Dismantle the coupling and remove the remains of the disk packs
3) Check coupling components and replace them if damaged
4) Find the cause for overload and remove it
Operating parameters do not
match the coupling performance
1) Set the system out of operation
2) Check the operating parameters and select a suitable coupling (please
observe the installation space)
3) Install a new coupling
4) Check the alignment
Disk pack breakage
Type 496.-
Operational mistakes on the
system unit
1) Set the system out of operation
2) Dismantle the coupling and remove the remains of the disk packs
3) Check coupling components and replace them if damaged
4) Train operating personnel
Disk pack or
connection screws
breakage / cracks
Type 496.-
Drive vibrations
1) Set the system out of operation
2) Dismantle the coupling and remove the remains of the disk packs
3) Check coupling components and replace them if damaged
4) Check the alignment and correct if necessary
5) Find the cause of the vibrations and remove it
Please Observe!
mayr®will take no responsibility or guarantee for replacement parts and accessories which have not been
delivered by mayr®, or for damage resulting from the use of these products.