Mayr EAS-Compact Quick start guide

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 1of 21 Germany 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 Regulations
- Safety and Guideline Signs
Page 3: - EAS®-Compact®overload, Type 490. _ _ 4.2
- Clutch Illustrations
- Parts List
Page 4: - EAS®-Compact®overload lastic backlash-free, Type 494. _ _ 4. _ Size 4
- Clutch Illustrations
- Parts List
Page 5: - EAS®-Compact®overload lastic, Type 494. _ _ 4.2 Size 5
- Clutch Illustrations
- Parts List
Page 6: - EAS®-Compact®overload torsionally rigid, Type 496. _ _ 4.2
- Clutch Illustrations
- Parts List
Page 7: - Technical Data
Page 8: - Technical Data
Page 9: - Design
- State of Delivery
- Function
- Re-engagement
- General Installation Guidelines
Page 10: - Installation of the Output Elements
Page 11: - Cup Spring Layering
- Mounting onto the Shaft
- De-installation
Page 12: - Shaft Installation via Key Connection
- Joining Both Clutch Parts EAS®-Compact®Type 494._ _4._ Size 4
- Joining Both Clutch Parts EAS®-Compact®Type 494._ _4.2 Size 5
- Joining Both Clutch Parts EAS®-Compact®Type 496._ _4.2
Page 13: - Permitted Shaft Misalignments Types 494._ _4._ and 496._ _4.2
- Coupling Alignment Types 494._ _4._ and 496._ _4.2
Page 14: - Torque Adjustment
Page 15: - Adjustment Tables
- Limit Switch
Page 16: - Maintenance and Maintenance Intervals
- Disposal
- Malfunctions / Breakdowns Type 490._ _4.2
Page 17: - Malfunctions / Breakdowns Type 494._ _4._ Size 4
Page 18: - Malfunctions / Breakdowns Type 494._ _4._ Size 4
Page 19: - Malfunctions / Breakdowns Type 494._ _4.2 Size 5
Page 20: - Malfunctions / Breakdowns Type 494._ _4.2 Size 5
Page 21: - Malfunctions / Breakdowns Type 496._ _4.2

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 2of 21 Germany E-Mail: [e-mail]
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 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 or foreign body impact.
The clutch 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!
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).

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 3of 21 Germany E-Mail: [e-mail]
EAS®-Compact®overload, Type 490. _ _ 4.2
Type 490. _ 24.2 Design with Keyway
Fig. 1
Parts List (Only use mayr® original parts) Type 490. _ 14.2 Design with Cone Bushing
Item
Name
1
Hub
2
Pressure flange
3
Thrust washer
4
Thrust ring FRSH
5
Thrust ring
6
Steel ball
7
Adjusting nut
7.1
Set screw
7.2
Set screw
7.3
Hexagon nut
8
Deep groove ball bearing
9
Locking ring
10
Steel ball
11
Cup spring
12
Locking ring
13
Cone bushing
14
Hexagon head screw
15
Adjustment table
16
Type tag
17
Limit switch
The limit switch Item 17 is not included in the
standard delivery.
Fig. 2
2113 5
67
112
4
15/16
M8 - 3x120°
8
9
7.2
7.3
7.1
13
14
Facing direction
Stroke
Please Observe!
Remove the screws
after re-engagement,
otherwise no
overload function!
Maximum
screw-in depth
in pressure flange
Thread in pressure flange
Dimension "a"

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 4of 21 Germany E-Mail: [e-mail]
3
4
3
4
3
4
3
4
EAS®-Compact®overload lastic backlash-free, Type 494. _ _ 4. Size 4
Type 494. _ 04. Type 494. _ 14.
Lastic-side: Clamping hub Lastic-side: Clamping ring
EAS®-side: Cone bushing EAS®-side: Cone bushing
Fig. 3 Fig. 4
Type 494. _ 24.
Parts List Lastic-side: Keyway
(Only use mayr® original parts) EAS®-side: Keyway
Item
Name
1
Hub
2
Pressure flange
3
Thrust washer
4
Thrust ring FRSH
5
Thrust ring
6
Steel ball
7
Adjusting nut
7.1
Set screw
7.2
Set screw
7.3
Hexagon nut
8
Deep groove ball bearing
9
Locking ring
10
Steel ball
11
Cup spring
12
Locking ring
13
Cone bushing
14
Hexagon head screw
15
Adjustment table
16
Type tag
17
Limit switch
Item
Name
18
Cap screw
23
Clamping ring hub
19
Flange
24
Clamping ring
20
Elastomeric element
25
Cap screw
21
Clamping hub
26
Key hub
22
Cap screw
27
Set screw
The limit switch Item 17 is not included in the
standard delivery.
Fig. 5
2
11
34
71
12
15/16
8
19
7.2
7.3
7.1
5
14
13
20
2122 189
E2023
25
24 1819
2
11
34
71
12
15/16
89
7.3
7.2
7.1
52026
1918

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 5of 21 Germany E-Mail: [e-mail]
EAS®-Compact®overload lastic, Type 494. _ _ 4.2 Size 5
Type 494. _ 24.2
Lastic-side: Keyway
EAS®-side: Keyway
Type 494. _ 14.2
Lastic-side: Keyway
EAS®-side: Cone bushing
Parts List
(Only use mayr® original parts)
Item
Name
1
Hub
2
Pressure flange
3
Thrust washer
4
Thrust ring FRSH
5
Thrust ring
6
Steel ball
7
Adjusting nut
7.1
Set screw
7.2
Set screw
7.3
Hexagon nut
8
Deep groove ball bearing
9
Locking ring
Item
Name
10
Steel ball
18
Cap screw
11
Cup spring
19
Flange
12
Locking ring
28
Cap screw
13
Cone bushing
29
Cap screw
14
Hexagon head screw
30
Cam ring
15
Adjustment table
31
Flexible intermediate ring
(elastomeric element)
16
Type tag
32
Hub
17
Limit switch
33
Set screw
The limit switch Item 17 is not included in the standard delivery.
Fig. 6
Fig. 7
283129
3233
18 19
Z
30
2
11
34
71
12
15/16
89
7.3
7.1
5
7.2
14
13

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 6of 21 Germany E-Mail: [e-mail]
EAS®-Compact®overload torsionally rigid, Type 496. _ _ 4.2
Parts List
(Only use mayr® original parts)
Item
Name
1
Hub
2
Pressure flange
3
Thrust washer
4
Thrust ring FRSH
5
Thrust ring
6
Steel ball
7
Adjusting nut
7.1
Set screw
7.2
Set screw
7.3
Hexagon nut
8
Deep groove ball bearing
9
Locking ring
10
Steel ball
11
Cup spring
12
Locking ring
13
Cone bushing
14
Hexagon head screw
15
Adjustment table
16
Type tag
17
Limit switch
18
Cap screw
19
Flange
34
Clamping ring
35
Hexagon head screw
36
Clamping ring hub
37
Disk pack
38
Connection plate
39
Key hub
40
Set screw
Not shown:
41
Hexagon head screw
42
Hexagon nut
43
Washer
44
Hexagon head screw
The limit switch Item 17 is
not included in the standard
delivery.
Type 496. _ 14.2
Lastic-side: Clamping ring hub
EAS®-side: Cone bushing
Type 496. _ 24.2
Lastic-side: Keyway
EAS®-side: Keyway
Fig. 8
Fig.9
2
2
11
11
3
3
4
4
7
7
1
1
12
12
15/16
15/16
8
8
9
9
7.2
7.2
7.3
7.3
7.1
7.1
5
5
36
40
34
18
18
19
19
13
14
38
38
37
37
41/42/43/44
41/42/43/44

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 7of 21 Germany E-Mail: [e-mail]
Technical Data
Table 1
Limit torques for overload MG
Thrust washer
stroke
(Fig. 1; Item 3)
on overload
[mm]
Bore from - to
Size
Type
490.5_4.2
[Nm]
Type
490.6_4.2
[Nm]
Type
490.7_4.2
[Nm]
Type
490.8_4.2
[Nm]
Max.
speed
[rpm]
Type
490._14.2
[mm]
Type
490._24.2
[mm]
4
120 –300
240 –600
480 –1200
600 –1500
3500
5,5
40 –65
40 –65
5
240 –600
480 –1200
960 –2400
1200 –3000
3000
6,5
45 –85
45 –80
Table 2
Size
Thread in the
pressure flange
(Fig. 1)
Max. screw-in depth
in the
pressure flange (2)
(Fig. 1)
[mm]
Thread "M" in the
adjusting nut (7)
(Fig. 1)
Screw
tightening
torque
Item 14
[Nm]
Max. permitted
axial
forces
[N]
radial
forces
[N]
transverse
force
torques 1)
[Nm]
4
8 x M10
20
3 x M8
25
5000
7500
50
5
8 x M12
20
3 x M8
71
7700
11500
70
1) Torques, which put strain on the deep groove ball bearings due to the non-centric axial forces having an effect on the pressure flange.
Table 3
Size
Flexible, backlash-free shaft coupling Type 494._ _ 4. 

Hub bore from - to
Screw tightening torques
Clamping hub
Item 21
[mm]
Clamping ring hub
Item 23
[mm]
Key hub
Item 26
[mm]
Item 18
[Nm]
Item 22
[Nm]
Item 25
[Nm]
4
45 –80
45 –75
38 –80
80
200
120
Table 4
Size
Flexible, backlash-free shaft coupling Type 494._ _ 4. 

Nominal and maximum torques
Max. permitted shaft misalignments
Yellow elastomeric
element
Red elastomeric element
Axial
Ka
[mm]
Yellow elastomeric
element
Red elastomeric
element
TKN
[Nm]
TK max.
[Nm]
TKN
[Nm]
TK max.
[Nm]
Radial
Kr
[mm]
Angular
Kw
[°]
Radial
Kr
[mm]
Angular
Kw
[°]
4
900
1800
1040
2080
±2,6
0,25
1,0
0,18
0,9
Table 5
Size
Elastomeric element (Item 20) of the flexible, backlash-free shaft coupling Type 494._ _ 4. 

Elastomeric element hardness
[Shore]
Colour
Permitted temperature range
Continuous temperature
Max. temperature, for a short
period of time
4
92 Sh A
yellow
-40 to +90 °C
-50 to +120 °C
98 Sh A
red
-30 to +90 °C
-40 to +120 °C

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 8of 21 Germany E-Mail: [e-mail]
Technical Data
Table 6
Size
Flexible shaft coupling Type 494._ _ 4.2
Hub bore from - to
Screw tightening torques
Item 32
[mm]
Item 18
[Nm]
Item 28
[Nm]
Item 29
[Nm]
5
60 –100
143
143
122
Table 7
Size
Flexible shaft coupling Type 494._ _ 4.2
Nominal and maximum torques
Max. permitted shaft misalignments
Type 494. 


_ 4.2
Elastomeric element
Pb 72 Sh A
Type 494.8 _ 4.2
Elastomeric element
Pb 82 Sh A
Axial
Ka
[mm]
Radial
Kr
[mm]
Angular
Kw
[°]
TKN
[Nm]
TK max.
[Nm]
TKN
[Nm]
TK max.
[Nm]
5
2400
4800
3700
8650
± 2
0,3
0,07
Table 8
Size
Torsionally rigid shaft misalignment compensation coupling Type 496._ _ 4.2
Hub bore from - to
Screw tightening torques
Item 36
[mm]
Item 39
[mm]
Item 18
[Nm]
Item 35
[Nm]
Items 41/44
[Nm]
4
55 –90
35 –70
87
25
35
5
50 –85
45 –90
110
35
120
Table 9
Size
Torsionally rigid shaft misalignment compensation coupling Type 496._ _ 4.2
Nominal and maximum torques
Max. permitted shaft misalignments
TKN
[Nm]
TK max.
[Nm]
Axial 2)
Ka
[mm]
Radial 3)
Kr
[mm]
Angular 4)
Kw
[°]
4
1600
2400
± 1,5
0,30
0,7
5
3500
5250
± 1,2
0,25
0,5
2) The values refer to couplings with 2 disk packs. Only permitted as static or virtually static value.
2) The values refer to couplings with 2 disk packs and a connection plate.
4) The values refer to 1 disk pack.

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
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Design
The EAS®-Compact®overload clutch is designed as a
mechanical disengaging overload clutch according to the ball
detent principle.
State of Delivery
The clutch is manufacturer-assembled and set to the torque
stipulated in the order.
Unless the customer requests a particular torque setting, the
clutch will be pre-set to approx. 70 % of the maximum torque.
The adjusting nut (7) is marked with dimension "a" (70% of the
maximum torque, see Figs. 1 and 18).
Please check state of delivery!
Function
The 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 backlash-free
onto the output from the motor shaft via the EAS®-Compact®
overload clutch (pressure flange (2)). If the set limit torque
(overload) is exceeded, the clutch disengages. The input and the
output are separated residual torque-free.
An installed limit switch registers the disengagement movement
and switches off the drive.
After-acting masses can run free.
CAUTION
The clutch has no load-holding function after
overload occurrence!
Re-engagement
Re-engagement must only take place when the
device is not running or at low differential
speeds (< 10 rpm).
EAS®-Compact®overload clutch re-engagement is carried out by
applying axial pressure to the thrust washer (3).
For this, the following procedures are possible:
By evenly screwing three screws M8 (not included in
delivery) into the adjusting nut (7).
CAUTION
After re-engagement has taken place, the three
hexagon head screws must be removed
immediately, as they could stop the clutch
functioning (blockage).
By using two screwdrivers, applied opposite each other
and supported by the cup springs (11), see Fig. 10.
By using an engagement mechanism.
The engagement procedure can also be automated using
pneumatic or hydraulic cylinders.
On all variants, it may be necessary to turn between the clutch
input and output sides slightly.
Fig. 10
General Installation Guidelines
As a standard, the bores in the hubs (1, 23, 26, 32, 36, 39) are
produced with H7 tolerances, the bores in the clamping hubs
(21) with F7 tolerances.
The surface roughness depth in the bores is produced with
Ra = 1,6 µm.
113
Re-engagement
direction

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 10 of 21 Germany E-Mail: [e-mail]
Installation of the Output Elements (Fig. 11)
The output element is centred on the deep groove ball bearing
(8) (tolerance H7/h5) and screwed together with the pressure
flange (2).
Please observe the maximum screw-in depth in
the pressure flange (2) (Fig. 1, page 3 and
Table 2, page 7).
If the resulting radial force from the output element is anywhere
near the centre of the ball bearing (8) and under the max.
permitted radial load acc. Table 2, an additional bearing for the
output element is not necessary.
No appreciable axial forces (see Table 2) should be
transferred from the output element onto the clutch
pressure flange (2).
On very small diameters, the output element is screwed together
with the clutch pressure flange (2) via a customer-side
intermediate flange.
Ball bearings, needle bearings or bearing bushings are suitable
as bearings for the output element, depending on the installation
situation and the installation space.
In order to prevent the output element (pressure flange (2))
from moving axially in the direction of the thrust washer (3)
during overload, please make sure that the bearing of the
output element is designed as a location bearing (Fig. 11).
Fig. 11
Please observe the connection dimensions "a"
and "e" for the output elements (Fig. 11 and
Table 10).
Table 10
Size
Connection dimensions
a
e
4
12 +0,1
130 h5
5
13 +0,1
160 h5
a
2
8 3 14
113
e
Tapped extracting hole

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 11 of 21 Germany E-Mail: [e-mail]
Cup Spring Layering (Fig. 12)
Correct cup spring layering is a prerequisite for problem-free
clutch function and torque adjustment.
For the lower torque range, one cup spring
(Type 49_.5_ 4._),
for the medium torque range, two cup springs
(Type 49_.6_ 4._),
for the high torque range, four cup springs
(Type 49_.7_ 4._)
and for the maximum torque range
five cup springs (Type 49_.8_ 4._) are installed.
1x layered 2x layered
Type 49_.5_4._ Type 49_.6_4._
4x layered 5x layered
Type 49_.7_4._ Type 49_.8_4._
Fig. 12
Mounting onto the Shaft
EAS®-Compact®clutches include cone bushings or keyways as
part of the standard delivery.
Please observe the following when mounting cone
bushings:
Shaft tolerances from h8 to k6 are permitted.
Shaft surface: finely turned or ground
(Ra = 0,8 µm)
Shaft material: yield point at least 400 N/mm2,
e.g. St 60, St 70, C 45, C 60.
Degrease or remove preservation 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 (Item 14) 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 2.
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 in the valid and applicable product catalogue.
The clutch or the clutch hub carries out an axial
movement in the direction of the cone bushing
(13) when tightening the cone bushing (13).
De-installation
In the cone bushing (13), tapped extracting holes are located
next to the tensioning screws (14).
1) Loosen all tensioning screws (14).
2) Screw out the tensioning screws (14) 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®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 12 of 21 Germany E-Mail: [e-mail]
Shaft Installation via Key Connection
On the EAS®-Compact®with keyway, the clutch must be secured
axially after mounting onto the shaft, e.g. using a press cover
and a screw, screwed into the shaft threaded centre hole (EAS®-
side) and/or a set screw (adjusting screw, lastic-side, see Figs.
5, 6, 9 and 11).
Joining Both Clutch Parts on
EAS®-Compact®Type 494._ _4._ Size 4
(Figs. 3 to 5)
The flexible elastomeric element (20) is pre-tensioned between
the metal claws by joining components 21/23/26 with component
19. For this, an axial installation force is required.
The amount of force required can be reduced by lightly greasing
the elastomeric element.
Use PU-compatible lubricants (e.g.
Mobilgrease HP 222)!
Do not place unpermittedly high axial pressure
onto the elastomeric element (20) in fully
installed state.
Please observe the distance dimension
"E" = 35 mm, see Fig. 3!
Fig. 13
Joining Both Clutch Parts on
EAS®-Compact®Type 494._ _4.2 Size 5
(Figs. 6 and 7)
The flexible intermediate ring (31) is pre-tensioned between the
metal claws by joining component 32 with component 19. For
this, an axial installation force is required.
The amount of force required can be reduced by lightly greasing
the intermediate ring (31).
Use PU-compatible lubricants (e.g.
Mobilgrease HP 222)!
Do not place unpermittedly high axial pressure
onto the intermediate ring (31) in fully installed
state.
Please observe the distance dimension
"Z" = 4 mm, see Fig. 6!
Joining Both Clutch Parts on
EAS®-Compact®Type 496._ _4.2
(Figs. 8 and 9)
Join the misalignment-flexible part and the overload clutch and
screw them together using cap screws (Item 18) to the tightening
torque stated in Table 8.
Screw securement, e.g. Loctite 243, must be provided for
the cap screws (Item 18).
The clutch or the clutch hub carries out an axial
movement in the direction of the cone bushing
(13) when tightening the cone bushing (Item
13, Fig. 8).
Due to this effect, for the EAS®-Compact®
clutch with disk pack (Type 496._ _4.2) please
observe that the cone bushing (13) must be
completely tightened first and then the other
(disk pack) side.
E1
26 20
27

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 13 of 21 Germany E-Mail: [e-mail]
Permitted Shaft Misalignments on
Types 494._ _4._ and 496._ _4._
EAS®-Compact®clutches Types 494._ _ 4._ and
496._ _ 4._ compensate for radial, axial and angular shaft
misalignments (Figs. 15 - 17).
However, the permitted shaft misalignments indicated in Tables
4, 7 and 9 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. 13. The sum total of the actual misalignments in percent
of the maximum value must not exceed 100 % (see Example
below).
The misalignment values stated in Tables 4, 7 and 9 refer to
clutch operation at nominal torque, an ambient temperature of
+30 °C and a operating speed of 1500 rpm. If the clutch is
operating in other or more extreme operating conditions, please
contact the manufacturers.
Example: Type 496. _ _ 4. 2, Size 4:
Axial displacement occurrence Ka = 0,6 mm equals 40 % of the
permitted maximum value m Ka max = 1,5 mm.
Angular misalignment in the disk pack Kw = 0,21°
equals 30 % of the permitted maximum value Kw max = 0,7°.
=> Permitted radial misalignment Kr = 30 % of the maximum
valueKr max = 0,3 mm => Kr = 0,09 mm
Coupling Alignment on
Types 494._ _4._ and 496._ _4._
Exact alignment of the coupling reduces the load on the shaft
bearings and increases the coupling lifetime substantially.
We recommend alignment of the coupling using a dial gauge or
special laser on drives operating at very high speeds.
However, in most of the applications, coupling alignment using a
straight edge in two levels vertical to each other is sufficient.
Fig. 14
Type 494._ _4._ (Size 4)
Axial Radial Angular
displacement misalignment misalignment
Fig. 15
Type 494._ _4.2 (Size 5)
Difference dimension ΔKw= ΔKw1 - ΔKw2
Please measure ΔKw1 and ΔKw2 vertically and horizontally
offset by 180 °
Axial Radial Angular
displacement misalignment misalignment
Fig. 16
Type 496._ _4.2 (Size 5)
Axial Radial Angular
displacement misalignment misalignment
Fig. 17
20
30%
25%
75%
0%
50%
20
40%
40
30%
60
60
80
80
100
100
ΔKw[%]
Angular misalignment
ΔK [%] Axial displacement
a
ΔK [%] Radial misalignment
r
ΔKa
ΔKr ΔKw
ΔKw1
ΔKw2
ΔKw
ΔKa
ΔKr
ΔKa
Δ
K
w
2
x
Δ
K
w
ΔKr

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 14 of 21 Germany E-Mail: [e-mail]
Torque Adjustment
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 to approx. 70 % of the
maximum torque. The adjusting nut (7) is marked with dimension
"a" (70% of the maximum torque, see Fig. 18).
Adjustment takes place via dimension "a" by turning the set
screws (Item 7.2, Fig. 18).
The adjusting nut (7) remains turned in flush position with the
hub (1).
The installed cup springs (11) are operated in the negative range
of the characteristic curve (see Fig. 19); this means that a
stronger pre-tensioning of the cup springs results in a decrease
of the spring force.
Turning the set screws (7.2) clockwise causes
a reduction in torque (Fig. 19, dimension "a -"
acc. Adjustment Table (Item 15) and Fig. 20).
Turning it anti-clockwise causes the torque to
increase (Fig. 19, dimension "a +" acc.
Adjustment Table (Item 15) and Fig. 20).
You should be facing the adjusting nut (7) as
shown in Fig. 18.
Changing the Torque
The torque is changed exclusively via the set
screws (7.2) and not via the adjusting nut (7).
a) Loosen all hexagon nuts (6 pieces, Item 7.3).
b) For dimension "a", see the Adjustment Table (Item 15, Fig.
20) (The Adjustment Table (15) is glued onto the outer
diameter of the adjusting nut (7), see Fig. 18).
c) Adjust all set screws (6 pieces, Item 7.2) evenly to the
required dimension "a" using a hexagon socket wrench,
wrench opening 6.
d) Counter (secure) the set screws (6 pieces, Item 7.2) again
with hexagon nuts (7.3).
Adjusting the adjusting nut (7) or distorting the
cup springs (11) out of the cup spring
characteristic curve (see Fig. 19) stops the
clutch functioning.
The inspection dimension "a" (markings on
adjusting nut) 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" (acc. markings on the adjusting nut and the
Adjustment Table).
Fig. 18
The adjusting nut (Item 7) is marked with
dimension "a" (70% of the maximum torque).
The adjusting nut (7) is turned in flush position
with the hub (1).
Fig. 19
Dimension "a"
Facing direction
7
7.3
7.2
11 15
1
a –
a +
Move to
operational range
Force F
Graph of
spring characteristic
curve
Operational
range Spring path S

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 15 of 21 Germany E-Mail: [e-mail]
Adjustment Tables (Item 15)
Größe / Size 4
Tellerfeder
M-Bereich
"a" [mm]
FRSH
Cup springs
Torque range
100 %
90 %
80 %
70 %
60 %
50 %
40 %
49-.5-4._
49-.6-4._
49-.7-4._
49-.8-4._
1x1 /
1x2 //
1x4 ////
1x5 /////
120-300 Nm
240-600 Nm
480-1200 Nm
600-1500 Nm
a + 1,0
a + 0,6
a + 0,3
a
a –0,2
a –0,5
a –0,8
Größe / Size 5
Tellerfeder
M-Bereich
"a" [mm]
FRSH
Cup springs
Torque range
100 %
90 %
80 %
70 %
60 %
50 %
40 %
49-.5-4.2
49-.6-4.2
49-.7-4.2
49-.8-4.2
1x1 /
1x2 //
1x4 ////
1x5 /////
240-600 Nm
480-1200 Nm
960-2400 Nm
1200-3000 Nm
a + 1,5
a + 0,9
a + 0,4
a
a –0,4
a –0,8
a –1,2
Fig. 20
Limit Switch (Item 17; Figs. 1 and 21)
In order to limit run-out times after overload has taken place, a
limit switch must be mounted onto the overload clutch.
The contactless limit switch is to be mounted onto the switching
edge of the clutch (Fig. 21) so that no signal changes are caused
during normal operation on the limit switch by the usual clutch
run-out errors.
In case of overload, the thrust washer (3) carries out a stroke
(see Table 1, page 7) in the direction of the adjusting nut (7)
(Fig. 1), which is used to change the signal on the limit switch.
The signal change should take place at the latest after an axial
thrust washer (3) stroke of 0,5 mm. At the same time, please
maintain a radial minimum distance of 0,5 mm in order to prevent
start-up of the contactless limit switch.
Limit Switch Installation
Adjust the switch distances for the contactless and mechanical
limit switch acc. Fig. 21. The distance of the thrust washer (3) to
the switching point can be easily adjusted using a hexagon head
screw, wrench opening 7.
Contactless limit switch (attachment example)
Fig. 21
3
0,5
SW7
a
a

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 16 of 21 Germany E-Mail: [e-mail]
Maintenance and Maintenance Intervals
Maintenance work, which should be carried out after approx.
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,
pages 4 and 5) must be maintained.
Set torque inspection
Clutch release inspection
Bearing or bearing pre-tension inspection
Re-greasing of the transmission geometries, balls,
recesses and sealing elements
Clutch re-greasing must only be carried out by specially trained
personnel.
For greasing, please use NLGI Class 2 grease with a basic oil
viscosity of 220 mm2/s at 40 °C, e.g. Mobilgrease HP222.
When re-installing the clutch, please secure all screws with
Loctite 243 (medium hard).
It may be necessary to carry out inspections at shorter intervals
should the device be subjected to very dirty, dusty or extreme
ambient conditions.
We recommend that maintenance work is carried out at the
site of manufacture.
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)
All aluminium components:
Non-ferrous metals (Code No. 160118)
Seals, O-rings, V-seals, elastomers:
Plastic (Code No. 160119)
Malfunctions / Breakdowns Type 490._ _ 4.2
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
Adjustment 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
Adjustment nut has changed position
Disengagement mechanism blocked by a
foreign body
Worn clutch
Running noises on
overload occurrence
as clutch slows down
Bearing on output flange is worn or has
been previously damaged
1) Set the system out of operation
2) Inspect the clutch at the place of manufacture
Worn disengagement mechanism
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
Loosened screws
Loosened adjusting nut

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 17 of 21 Germany E-Mail: [e-mail]
Malfunctions / Breakdowns Type 494._ _ 4._ / Size 4
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 screw, broken motor attachment, warmth
expansion of system components, changes in clutch installation
dimension "E")
3) Check the coupling for wear
Worn elastomeric element, short-term
torque transmission via metal contact
1) Set the system out of operation
2) Dismantle the clutch and remove the remainders of the
elastomeric element
3) Check the coupling parts and replace if damaged
4) Insert elastomeric element, mount the clutch parts
5) Check the alignment and correct if necessary
Tensioning and clamping screws or
locking set screw for axial hub
securement 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 to the required torque or tighten the locking set
screw and secure it against self-loosening using sealing lacquer
4) Check the coupling for wear
Cam breakage
Worn elastomeric element, torque
transmission via 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 / excessive shaft
misalignment
1) Set the system out of operation
2) Replace the entire coupling
3) Check the alignment
4) Find the cause of overload
Operating parameters are not
appropriate for the coupling
performance
1) Set the system out of operation
2) Check the operating parameters and select a suitable coupling
(observe installation space)
3) Install a new coupling
4) Check the alignment
Clutch characteristic values are
exceeded due to incorrect operation
1) Set the system out of operation
2) Check the coupling dimensioning
3) Replace the entire coupling
4) Check the alignment
5) Train and advise operating personnel
Premature wear on
the elastomeric
element
Incorrect alignment
1) Set the system out of operation
2) Find / resolve the cause of incorrect alignment
(e.g. loose foundation screw, broken motor attachment, warmth
expansion of system components, changes in clutch installation
dimension "E")
3) Check the coupling for wear

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 18 of 21 Germany E-Mail: [e-mail]
Malfunctions / Breakdowns Type 494._ _ 4._ / Size 4 (continued)
Malfunction
Possible Causes
Solutions
Premature wear on
the elastomeric
element
e.g. contact with aggressive fluids / oils,
ozone influence,
too high ambient temperatures, etc,
which cause physical changes in the
elastomeric element
1) Set the system out of operation
2) Dismantle the clutch and remove the remainders of the
elastomeric element
3) Check the coupling parts and replace if damaged
4) Insert elastomeric element, mount the clutch parts
5) Check the alignment and correct if necessary
6) Make sure that further physical changes in the elastomeric
element can be excluded
The ambient or contact temperatures
permitted for the elastomeric element
are exceeded, see Table 4
1) Set the system out of operation
2) Dismantle the clutch and remove the remainders of the
elastomeric element
3) Check the coupling parts and replace if damaged
4) Insert elastomeric element, mount the clutch parts
5) Check the alignment and correct if necessary
6) Check the ambient or contact temperature and regulate them
(possibly using other elastomeric element materials)
Premature wear on
the elastomeric
element (material
liquefaction in the
elastomeric element
tooth interior)
Drive vibrations
1) Set the system out of operation
2) Dismantle the clutch and remove the remainders of the
elastomeric element
3) Check the coupling parts and replace if damaged
4) Insert elastomeric element, mount the clutch parts
5) Check the alignment and correct if necessary
6) Determine the cause of vibration (maybe the problem can be
resolved by using an elastomeric element with lower or higher
shore hardness)

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 19 of 21 Germany E-Mail: [e-mail]
Malfunctions / Breakdowns Type 494._ _ 4.2 / Size 5
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 screw, broken motor attachment,
warmth expansion of system components, changes in clutch
installation dimension "Z")
3) Check the coupling for wear
Worn elastomeric element,
short-term torque transmission via metal
contact
1) Set the system out of operation
2) Dismantle the coupling and remove the remainders of the
elastomeric element
3) Check the coupling parts and replace if damaged
4) Insert new elastomeric element, mount the coupling parts
5) Check the alignment and correct if necessary
Unbalance
1) Set the system out of operation
2) Check the balance condition of the system components and
correct if necessary
3) Check the coupling parts for wear
4) Check the alignment and correct if necessary
Loose connection screws
1) Set the system out of operation
2) Check the coupling alignment
3) Tighten 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 coupling for wear
Cam breakage
Worn elastomeric element,
torque transmission via 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 /
overloading
1) Set the system out of operation
2) Replace the entire coupling
3) Check the alignment
4) Find the cause of overload
Operating parameters are not appropriate for
the coupling performance
1) Set the system out of operation
2) Check the operating parameters and select a suitable
coupling (observe installation space)
3) Install a new coupling
4) Check the alignment
Operating errors on the system unit by
exceeding clutch characteristic data
1) Set the system out of operation
2) Check the coupling dimensioning
3) Replace the entire coupling
4) Check the alignment
5) Train and advise operating personnel

Installation and Operational Instructions for
EAS®-Compact®overload clutch, Type 49_._ _4._ Sizes 4 and 5 (B.4.14.6.GB)
25/01/2013 GC/NH/GH/SU Chr. Mayr GmbH + Co. KG Tel.: [phone]
Eichenstraße 1 Fax: [phone]
D-87665 Mauerstetten www.mayr.com
Page 20 of 21 Germany E-Mail: [e-mail]
Malfunctions / Breakdowns Type 494._ _ 4.2 / Size 5 (continued)
Malfunction
Possible Causes
Solutions
Premature wear of
the elastomeric
element
Incorrect alignment
1) Set the system out of operation
2) Find / resolve the cause of incorrect alignment
(e.g. loose foundation screw, broken motor attachment,
warmth expansion of system components, changes in
coupling installation dimension "Z")
3) Check the coupling for wear
4) Insert new elastomeric element
e.g. contact with
aggressive fluids / oils,
ozone influence,
too high ambient temperatures, etc,
which cause physical changes in the
elastomeric element
1) Set the system out of operation
2) Dismantle the coupling and remove the remainders of the
elastomeric element
3) Check the coupling parts and replace if damaged
4) Insert new elastomeric element, mount the coupling parts
5) Check the alignment and correct if necessary
6) Make sure that further physical changes in the elastomeric
element can be excluded
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 remainders of the
elastomeric element
3) Check the coupling parts and replace if damaged
4) Insert new elastomeric element, mount the coupling parts
5) Check the alignment and correct if necessary
6) Check the ambient or contact temperature and regulate
them (possibly using other elastomeric element materials)
Premature wear of
the elastomeric
element (liquefied
material in the interior
of the elastomeric
element cams)
Drive vibrations
1) Set the system out of operation
2) Dismantle the coupling and remove the remainders of the
elastomeric element
3) Check the coupling parts and replace if damaged
4) Insert new elastomeric element, mount the coupling parts
5) Check the alignment and correct if necessary
6) Determine the cause of vibration (maybe the problem can
be resolved by using an elastomeric element with lower or
higher shore hardness)