a 42062A thru 4Z065A, 42612 and 42613 ‘Read carefully before attempting to azcamble, install. operate or maintain the procict described. Protect yourself and others hy abserving all {afety formation. Faure to comply with Instructions could result in personal injury andor property damage! Retain instructions for future Dayton’ Gearmotors << Description Dayton gearmotors are parallel shaft TENV units used for applications requiting continuous duty and high ‘output torque. Housings are Constructed of high strength die cast dlloy material. Gearhousing and cover dre doweled and precision machined with rabbeted joints to provide becurate gear alignment. Gearing consists of wide faced helical high-speed input stage for smooth, {ult operation. Gears and pinions are heat treated for maximum durability Under rated torque. Oil impregnated bronze bearing: support alloy tee! ‘gear pins. Output shaft is supported by Removable ‘an anificton high strength needle bearing for high overhung load Blea capacities. | ee Motors are equipped with shielded bal ae a + bearings | 8 ax) Figure 1— Dimensions or rs Rating Z ro Ca eae Over WP ir i f eee et en Ce cs capacity” Rotation AZD62A 115 A wo 87 4 038 (036 50lbs. Reversible 5% azne3a 115 A 1s 50 2 051 2 046 50 Reversible 6% AzD6AA 115 A 25 30 S401 43 0.47 50 Reversible 5% AZ065A 115 A ws 20 % 059 79082 50 Reversible 5% azz 115 A WS 18 tae 1000 50 Reversible 5% 4z613 115 A 512A 59128082 50 Reversible 5% Max. Ambient 40° C Service Factor 1.0, (*) Input motor HP when operated at SOHz is 5/6 of rated 60Hz HP. Performance data shown above is based upon using 2 SMED —- 370VAC oil-filled capacitor Dayton brand stock no. 6X653 for 50/60Hz operation. Capacitor not included. Must be purchased separately. ZDayton installation Instructions and Parts Manual Dayton Gearmotors 42062A thru 4Z065A, 42612 and 42613 General Safety Information 1. Installation and wiring of the ‘enclosed unit must be in accordance with al local electrical and safety codes. The National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA) must also be followed 2. Motor must be securely and ade- quately grounded. This can be accom- plished by using a separate ground ‘wire connected to the bare metal of ‘the motor frame or other suitable means. Refer to NEC Article 250 (grounding) for additional information. 3. Always disconnect power source before working on or near a motor or its connected load. Ifthe power rect point is out of sight, lock itn the open position and tag to prevent unexpected resumption of power. 4. Caution should be exercised when ‘touching the exterior of an operating motor — it may be hot enough to be painful or cause serious injury. With modern motors this is normal when ‘the motor is running at its rated ‘torque and voltage 5. Always check power source to be sure voltage and frequency matches. requirements of the motor. 6. When cleaning electrical or electronic ‘equipment, always use 2 nonflamma- bie cleaning agent that will not attack the finish or insulation. 7. All moving parts should be guarded. 8, Protect the power cable from coming in contact with sherp objects and moving parts. installation AWARNING| formvolers holding or overhouling application (Guch at 9 hoist or a conveyor) 9 sep2- ‘ate magnetic brake or other locking device should be used. Do not depend ‘on gear friction to hold the load. 1. Gearmotor should be located in a clean dry area. If installation is out- doors, make certain the unit is pro- ‘tected from the weather. ‘Do not install in an AWARNING] 20700 et phere! 2. Mount gearmotor to 2 rigid surface, preferably metallic, using #1032 bolts screwed into four tapped holes on face of gearmotor. Yew Red y ‘cw Rotation SMD, 370V ‘To reverse rotation Motor run Inerenange red capacitor ‘and black leads Figure 2— Wiring Diagram ‘wiRING 3.2, All wiring and electrical connec tions must comply with the NEC. and local electrical codes in effect. In particular refer to Article 430 (Motors, Motor Gireuits and Controllers) of the NEC. ». For proper motor connections, refer to the connection diagram located on the nameplate. (Make sure power source matches, requirements of motor) Whenever possible, the motor should be powered from a sepa- rate branch circuit of adequate capacity to keep voltage drop to a minimum during starting and run- ning. For longer runs, increase wire size in accordance with the wire selection guide which follows. WIRING SELECTION GUIDE rn 0 25fe 50H 100f 150ft 2004 (7) Never use smaller than #14 AWG for permanent installations. Select~ motor starter heaters on the basis of a motor service factor of 1.0. 4, Motor should be grounded by 9 separate conductor connected to ‘the bare metal of the motor frame. The ground conductor should run to a good electrical ‘ground such as a grounded con- Suit or water system. IMPORTANT: Use of a motor run capack led) is necessary forthe unit to,run at rated speed and torque. See Performance Table for recommended capacitor size and Dayton Part No. See Wiring Diagram for proper location within cieutt Operation [APPLICATION OF LOAD GEARMOTOR NOTE: To determine output torque ‘capacity for operating conditions other than @ normal 8 hour day and shock free operation, multiply the rated out- put torque Gee Specifications & Performance) by the applicable load factor listed below. Shock loads should be avoided. LOAD FACTOR CHART rey ron Load. _mittent uniform 1.0. Mod.Shock 10 9 g um axial load capacity is OVERHUNG LOAD When connecting a load to the gear- motor output shaft, care should be ‘taken to avoid excessive tension when ether belt or chains with chain sprock-Dayton Installation Instructions and Parts Manual Models 4Z062A thru 4Z065A, 42612 and 42613 ets are used. When a sprocket is mount- ed on the gear reducer output shaft, care must be taken to avoid excess tension on the belt or chain, maximum ‘overhung load should not exceed 50 pounds at 12 inch from seal end of housing seal boss. If unitis directly cou- ped to the load, carefully check align- ‘ment and coupling runout to avoid overloading of motor and/or bearings, ‘OVERHUNG LOAD CALCULATIONS Ful loc torque Tangential force in cof speed reducerx2_= pound on center Pitch da of sprocket of output shaft of, pully or pinion in inches speed reducer ‘Multiply tangential force (arrived at from above formula) by the correct per- taining factor below to determine actu- al overhung load in "Pounds" on center of output shaft. DRIVE FactoRS Chain Gprocket) = 1.0 Pinion (gear) = 1.25 Vibelt (pulley) = 1.5 Fiat belt (pulley Locate the centerline ofthe sprocket gear or pulley a5 close tothe output Shaft ol seal as practical to minimize overhung load and increase bearing Ite the centerline of the sprocket, puliey or gears located more than 12" way from the cil seal, consut Dayton Electric Mfg. Co. Engineering Department to help determine the overhung load. On direct drive applica- tions, carefully check shaft and coupling alignment as materi being mounted. Shim motor face as required. Do not depend on a flexible coupling to com- pensate for misalignment ‘To optimize motor staring torave capability, some backlash or clearance inthe coupling, drive system or oad is desirable. Avord “preloading” the gear- motors gear train Maintenance TA CAUTION | Make certain that [A CAUTION | tye power sunny i lsconnected before attempting fo ser- vice or remove any components. Ifthe power termination location i inaccess- bie, lock it in the open position and tag to prevent unexpected resumption of power LUBRICATION This unit has been lubricated for Ife at the factory and periodic relubrication should not be required under normal conditions, regardless of mounting position. DISASSEMBLY Refer to Figure 6. 1. Remove two motor mounting screws (Ref. NOr'5) from the reat of the moter. 2.Remove motor stator (Ref. No. 1) and ‘endbell (Ref. No. 2) from the gear reducer. 3. Carefully disassemble rotor and shaft ‘assembly (Ref. No, 2) from the gear reducer by gently rocking assembly back and forth until bearing comes out of reducer. Do not hit or strike A CAUTION | Pee ee ‘age to the bearing raceways will result. Refer to Figures 3, 4, and 5 4. Remove two round head screws (Ref. No. 5) and two flat head screws (Ref. No. 6). Pry adaptor (Ref. No. 2) rom ‘gearbox, being careful not to dam- age the gasket (Ref. No. 3). Gasket ‘an be reused if not damaged; how- ever, it must be replaced if the gasket is damaged. 5.\With gearhousing disassembled, {gears can now be removed. f the ‘output shaft and gear assembly (Ref. No. 7) has to be removed or an out- pout shaft seal (Ref. No. 4) replaced, ‘cover the output shaft with 1" wraps Of paper or thin plastic to guide lip, of seal onto shaft to prevent cutting ‘the seal on the flat. Remove shaft burrs. 6.00 seals can be removed by prying out with a screwdriver, Clean the eav- ity and press new seal squarely in place, ip edge inward towards (gearcase cavity until seal bottoms. REASSEMBLY 1. Afterall the gears have been replaced in the proper locations refill the gearcase with Lubriplate #930- ‘AA Lubriplate #630-AA; Shell ‘alvania-2 or Dow Corning #44 ‘About 4 02. (by weight) will be required. Do not mix lubricants. Clean gearbox completely and replace with new lubricant. 2. install new gasket. if required, and reinstall adapter to housing with four (two round head and two fiat head) Screws, tightening uniformly all four 3. Replace rotor and shaft assembly ‘onto gearhousing assembly being ‘areful not to damage rotor pinion, first stage gear (Ref. No. 10) or bear- ing, Carefully twist rotor shaft while inserting to ensure engagement and gently push bearing into seat. 4. Replace motor onto gear reducer and tighten two screws firmly. [A CAUTION | 2°"! overtighten. A CAUTION vert off when too much torque is applied. 5. Start and stop motor. Gearing should ‘tum freely without binding. CLEANING Properly selected and installed electric motors are capable of operating for long periods of time with minimal care However, periodically ciean motors especially in ard around vent openings by vacuuming. This improves heat trans- fer and motor cooling. At the some ime, check that al electrical connec- ma‘Dayton installation instructions and Parts Manual 42062A thru 42065A, 42612 and 42613 Dayton Gearmotors Troubleshooting Chart Unit fails to operate 1, Blown fuse or open circuit breaker 1. Replace fuse or reset circuit breaker 2. No power 2. Contact power company _ 3. Defective motor 3, Replace motor or repair 4, Defective manual or magnetic 4, Repair or replace switch ‘control switch 5. Defective capacitor 5, Replace Unit operational but no output Defective gears Check and replace if necessary Intermittent rotation of output ‘Damaged intermediate gear Replace gear and if possible avoid shaft assembly possibly caused by shock load shock load Excessive nie 1. Bearings worn 7. Replace 2. Belt too tight 2. Adjust tension 3, Overhung load exceeds rating 3. Correct load and/or replace bearing and causes bearing wear > Limited Warranty ‘Dayton One-Year Linited Warranty Deyton gearmotor, Modes 70524 tr AZOSSA, 42612 and 42613, are waranted by Dayton Elec Mf. Co {Bapan\ the olga! wer apart oclacs fr workrnstshi or ates under normal use for one yor afer date Of purse Ary part which det tniled tbe defect in matepal or workransip and retumed to an authorized service cation ex Dayton desea sinping css prepaid, il be as ‘Pe excuse remedy pared or teeced of Dyers spbon For lnited warranty Gaim proceaures see PROMPT DISPOSITION below Ts lirited war fant ges purses ech ga hts whi vary om ate Sate Gntation of Ubi. To the extent alewable uncer ppt av, Dayton bit for consequential ard incidents cbmopes is expres cies. Diya hasty ea ents sited to an shar enced the putas re al. waranty DisdlmerDoyton bos made gant efor to urate and esibe the produc ths terete accel; howeve sch lusatins and dessiplon are torino pps of ant tesson, and ao ot eapres or mph waranty that the produc are merchantable o” Hf» pares Purpose, or tat te proouces ui pecesarlyconforh tothe iharatons of desptons. ‘Except es provided below, no waranty oratfrmaton ofc expend or Implic, ether than sated inthe “UMMITED WARRANTY" above made or suthorze by Dayton. roduc Sulabiy. Many states and locales have codes and regulations governing sles construction instalation andor ue of product for certain ‘vt whch yey Fane righting ree avon ama fase ets edu cme go Hana gua ‘a comolonce and canfot be repose or hon the product italed or wed. Before purchase od se Of 3 product. please review the protct ‘Spotcaton, and nuonal ae oc codes and equation: and be sre tate produc alin, and use wl comply with em. Certain aspects of cshtners ara no appable to corsure prods #0) sme sates dona alow the extsion or iitation of incidental or cose ‘Suantat darrages she store atin x excsion ay nt spy t you: (8) obo Some Sates ao nat ale a taton on how fog an imped war. ‘glass corsage te above lntatn ay nt spe yo: ana (by adn tepid of ths ited werrnty any imped warrenty of Inoed merchant or Fens or prter purpose appheabe fo Consumer produits purchase By Consumers ay tbe excused o other ae cece. ramet Dtposton Dayton wil make 2 god fet effort for prompt correction or oter aunt with respect t any product which proves to be Gere win tited waranty Foray produc Seleved tbe defective within iitca worry fs write oral ser fam wh the product mas Durcased Dealer lore addon artons unable fo reve stacy ure 0 Oajan ot sees belonging dates name, sores date, Sd numberof Sealers inv ond describing the nature oF te defec Tie and rk of as past buyer on delivery to common car Hf prodect was ‘mages in var you fle cam wi caret ‘Manufactured for Dayton Electric Mfg. Co.. 5959 W. Howard St, Niles, linols 60714 U.S.A.‘Dayton Installation instructions and Parts Manual 4Z065A, 42612 and 42613 For Replacement Parts, call 1-800-323-0620 eae pre ning oman “Seal number it ay) “Part descriptions and number as shown in pars fst Adres pars corespondence te: ans Company of America, 1657 Shermer Road ‘Northorook, f. 60062-5362 Figure 3 — Gearbox Replacement Pars tlustration for Models 2065A, 42612 and 42613 Replacement Parts List 1 Gearhousing assembly ys-10132-01 ys10132-01 ust0132.01 1 2 Adaptor assembly AT-10131-01 AT10131-01 ATI0131-01 1 32 Gasket 11097 11097 1097 1 4 Ollseat 1019 J-1019 J1019 1 5 #10-32 x 3/4" Rd. hd. machine screw * * * 2 © 10-32 x 7/8" Flat hd. machine screw + = * 2 7 Output sft. assembly (final stage) 50P-4500-103-1 ES0P-4300-125-2ES0P.4100-154-1 1 8 Gear & pin assembly (third stage) - - - 1 9 Gear & pin assembiy (second stage) S - = 1 10 Gear & pin assembly (first stage) ESGP-4511-1 ESGP-4614-80 ESGP-4615-80 1 11 Washer wes W228 W218 1 (*) Standard hardware item available locally. aaDayton insallavon instructions and Parts Manual 42062A and 4Z063A For Replacement Parts, call 1-800-323-0620 Pease proud fotowing information: ‘Model aumber ‘Set number fay) “Fan desenpto7g 3d sumer as shown in pats st “Aatess pats correspondence to: Pants Company of America 165) Shermer Roac ‘Nortbreok 69052-5362 Figure 4 — Gearbox Replacement Parts Ilustration for Models 42062A and 420638 Replacement Parts List 1 Gearhousing assembly Us-10133.01 us10133-01 1 2 Adaptor assembly AT-10131-04 ‘AT10386-01 1 3 Gasket L-1097 1.1097 1 4 Ollseal 1019 41019 1 5 #1032 x 1%" Rd, hd. machine screw ‘ a 2 © #10-32 x Mh" Flat hd. machine screw = > 2 7 Output sft. assembly (Final stage) E50P-£500-15-1 50P.4300.28-1 1 8 Gear & pin.assembly (third stage) ESGP-8715-1 ESGP-5213-2 1 9 Gear & pin assembly (second stage) ESGP-5218-1 E5GP.4723-1 1 10. Gear & pin assembly first stage) ESGP-4818-1 ESGP-3823-1 1 11 Washer W089 ‘w-3089 1 (*) Standard hardware item available locally.Dayton installation Instructions and Parts Manual 420648 For Replacement Parts, call 1-800-323-0620 Please provide folowing information: “Model number “Sera number ¢f any) “Fant desenpions an number as oun in pans ist Adres pars conespondence Parts Company of America 1657 Shermer Road NNonhbrook, 60062-5362 Figure 5 — Gearbox Replacement Parts Mlustration for Model 4Z064A Replacement Parts List no ieee 1. Geathousing assembly 1us-10132.02 1 2 Adaptor assembiy ‘At-10131-02 1 3 Gasket 11097 1 4 Oilseal 34019 1 5 #1032 3/4" Ra hd. machine screw ¥ 2 6 #1032 114" Flat hd. machine screw . 2 7 Output sft. assembly (final stage) 50P-4300-56-1 1 8 Gear & pin assembly third stage) = i © Gear & pin assembly Gecond stage) SGP 52134 7 10 Gear & pin assembly (first stage) F5GP-4623-1 1 11 Washer w.3088 1 12. Retaining ring H-1705-2 1 (*) Standard hardware item available locally a