MONARCH MANUAL 2012 - AT Ferrell

INTRODUCTION

Your Monarch Model 8450 Can Crusher has been designed and manufactured under rigid
standards and Monarch Specialty Systems, Inc., has great interest in having your unit
provide the ultimate in performance and maximum service life.

This manual provides information for installation, operation and service of the unit.

READ THIS MANUAL AND TOTALLY FAMILIARIZE YOURSELF WITH ITS
CONTENTS BEFORE YOU ATTEMPT TO INSTALL OR PUT THE UNIT IN
OPERATION.

Should a question or problem develop, contact the dealer from whom the unit was
purchased. In the event your dealer is unable to supply the service you require, contact
Monarch Specialty Systems, Inc.

SAFETY PRECAUTIONS

Monarch Specialty Systems, Inc. has made every effort to provide you with safe
equipment, however, the following safety precautions must be observed:

(1) Always disconnect the power supply (PULL THE PLUG) before
attempting to remove a can jam, remove the top cover or, clean the unit.

(2) Be certain the electrical outlet used for the power supply is fully
grounded or, attach a separate ground wire to the frame of the crusher to
a proper grounding source according to national and local electrical
codes.

(3) Never place hands or fingers in the can inlet chamber or, the crushed
can discharge opening while the electric power is connected.

(4) Instruct all personnel fully on the operation of the machine and these
safety precautions.

(5) NEVER LET CHILDREN OPERATE THE MACHINE.

ASSEMBLY

Remove the crusher body from the carton and lay it top down on a blanket or
clean cardboard to protect the finish from scratches or damage. Bolt the (4)
support legs to the body with the 5/16 x 3/4" cap screw, flat washers and lock
washers supplied with the unit. A ratchet wrench, 8” extension and ½” socket
are ideal tools for the assembly. Before fully tightening the bolts, be certain
the outer edges of the support legs and the crusher housing are aligned.
(Oversize holes in the support legs permit movement for alignment) With the
support legs bolted in place, set the crusher upright being certain to lift the
crusher and setting it down on all (4) legs equally.

LOCATING THE CRUSHER

Ideally, locate the crusher under or near the bar so the crusher is easily
accessible when empty beverage cans are removed from the bar or tables to
permit immediate crushing of the containers.

INSTALLATION

The crusher is equipped with a 3-prong grounding type attachment plug that
provides for grounding of the unit when plugged into a fully grounded outlet.
IF A FULLY GROUNDED OUTLET PLUG IS NOT AVAILABLE, USE AN
ADAPTER AND ATTACH A GROUNDED WIRE TO THE TAB ON THE
ADAPTER AND GROUND TO A PROPER GROUNDING SOURCE OR,
ATTACH A GROUND WIRE TO THE FRAME OF THE CRUSHER TO A
PROPER GROUNDING SOURCE.

WARNING! NEVER CUT OR REMOVE THE ROUND GROUNDING
PRONG FROM THE ATTACHMENT PLUG.

If an electrical extension cord is used in addition to the cord length provided
on the unit, be certain the wire size is at least #16 and length does not
exceed 10’.
FOR UNITS WITHOUT SUPPORT LEGS it will be necessary to provide an
opening for the crushed can discharge and also for air circulation on a table
or counter. When the unit is located, bolt the crusher to the support surface
by drilling holes to correspond with the holes normally used to attach the
support legs on the bottom corners of the crusher frame. 5/16”-18 (course
thread) nuts are welded to the inside frame and it is necessary to use only
cap screws for attachment.

OPERATION

THE CONTROL PANEL in the recessed area on the front of the unit contains
an On-Off Rocker Switch, Power “On” Monitor Light and a circuit breaker for
electrical overload on the motor. With electrical supply attached to the 115
volt outlet, turn the Rocker Switch “On” and the Monitor Light will come on to
indicate the unit is in a “Ready” Mode
PLACE A CONTAINER, preferably plastic, under the left front of the unit to
receive the crushed cans. CAUTION! Be certain the container DOES NOT
EXCEED 14 INCHES IN HEIGHT. Taller containers can block the crushed
can discharge, when full, and cause the crusher to jam.
PLACE (2) CANS in the inclined ramp in the top cover to initially “Load” the
unit. Note that these cans are not crushed until additional cans are put into
the unit and (2) cans will always remain in the area directly below the inlet
opening.
ADD ADDITIONAL CANS in the same manner and as they strike the actuator
projecting in the can inlet opening, the unit begins to operate and will
continue to operate until the last can enters the chamber and it returns to the
“Ready” Mode.
LEAVE THE ROCKER SWITCH “ON” DURING NORMAL BUSINESS
HOURS and turn it “Off” during periods when it will not be attended.

CAUTION! CANS SHOULD BE EMPTY OF ANY LIQUID BEFORE PLACED
IN UNIT. BADLY DE-FORMED CANS CAN CAUSE THE UNIT
TO “JAM”. “POP” THE CANS BACK TO A REASONABLY
ROUND SHAPE BEFORE PLACING THEM INTO THE UNIT TO
PREVENT PROBLEMS.

THE CIRCUIT BREAKER in the panel will trip when an electrical
overload condition exists on the motor of the crusher. When tripped, the
center white portion with the numeral “5” will extend out about ¼”. If a tripped
condition exists, let the unit cool for approximately 10 minutes and then push
the white button in and resume operation. NOTE! The button will not stay in if
the breaker has not cooled sufficiently. In this case wait another 5 minutes
and attempt to reset again. If the unit is put in operation and the breaker trips
again, see the Trouble Shooting Section.

MAINTENANCE

THE RECEIVING RAMP AND THE TOP COVER SHOULD BE CLEANED
DAILY to remove beverage residue. The sticky residue will retard cans from
moving down the ramp easily. Use a damp towel or sponge with a mild
detergent, if necessary, to remove the residue.
CAUTION! Do not use abrasive type cleaners on any of the painted surfaces
or decals. ALWAYS UNPLUG THE POWER WHEN CLEANING. CANS
EQUIPPED WITH STA-TABS will many times have their tabs “POP” off
during the crushing process and some will accumulate on top of the ram body
where the (2) cans are retained in the unit. If allowed to accumulate in
numbers, the built in holding feature will be lost and (2) cans may enter the
crushing chamber simultaneously and will likely cause a “JAM”. To remove a
Tab Accumulation, UNPLUG THE ELECTRICAL POWER CORD and remove
the (2) cans in the lower chamber. With a longer flat object pull the tabs into
the can receiving area so they can be removed by hand.

THE MOTOR is equipped with pre-lubricated bearings and will not require
lubrication. If the gear reduction housing on the motor should require re-
lubrication, use AMOCO type “L-industrial 30” grease or it’s equivalent.
THE RAM BODY AND CONNECTING LINK TO THE MOTOR are equipped
with pre-lubricated materials and do not require lubrication.

CAN JAMS IN THE CRUSHING CHAMBER may be indicated in (2) ways:
(1)The unit continues to operate, but cans are not feeding into
receiving chamber.
(2)Motor Overload Circuit Breaker trips repeatedly when re-set.

Badly deformed cans may get turned in such a manner that they will not roll
over the ½” ledge at the front edge of the ram body and drop into the
crushing chamber. This ledge is a holding feature for the waiting cans and,
normally operating, a can rolls over the ledge on the return stroke of the ram.
DO NOT FORCE THE CAN OVER THE LEDGE BY APPLYING PRESSURE
ON THE OTHER CANS IN THE CHAMBER; IT WILL LIKELY ENTER THE
CRUSHING CHAMBER IN A MANNER THAT WILL CAUSE A MORE
DIFFICULT JAM TO REMOVE. Follow instructions in next paragraph to
properly remove.
If (2) or more cans have entered the crushing chamber a jam will result to
stop total operation of the unit by tripping the motor overload circuit breaker.
TO REMOVE EITHER TYPE JAM, UNPLUG THE ELECTRICAL POWER
CORD and the (2) screws on each side retaining the top cover. Remove the
top cover and check the can holding area through the large slot on top and
the slots on either side to determine where the jam is located.

If there is a badly deformed can on the ram, use a screwdriver to push it back
to the receiving chamber and remove it by hand.
If cans are wedged between the ram and crushing head, reverse the motor to
remove the pressure on the wedged cans and use a screwdriver to release
them to drop out the discharge chute.
Grasping the crank on the motor shaft and turning can reverse the motor.
(Since this is a gear reduction motor, the shaft will turn hard)

Most jams can be removed without removing the can ramp assembly.
Should it be necessary to remove the can ramp, remove the (6) 8-32 Hex
Nuts and Washers and lift the assembly upward. If the (2) wires are removed
from the Micro Switch on the assembly, be certain to replace them in their
original places.
If the unit is to be test run prior to replacement of the top cover, it will be
necessary to hold down the white button on the safety switch at the top edge
of the rear panel.

CAUTION! EXERCISE EVERY SAFETY MEASURE WHEN
OPERATING THE UNIT WITH THE TOP COVER
REMOVED. KEEP ALL HANDS OUTSIDE THE HOUSING.

REMEMBER! CAN JAMS CAN BE VIRTUALLY ELIMINATED BY NOT
PUTTING BADLY DEFORMED CANS INTO THE UNIT OR
USING A CONTAINER FOR THE CRUSHED CANS THAT
BLOCKS THE DISCHARGE OPENING WHEN THE
CONTAINER IS FULL.

THE OPERATION OF THE UNIT IS CONTROLLED BY (2) MICRO SNAP
ACTION SWITCHES operating through a relay to form an electrical interlock.
The upper switch attached to the can ramp has an actuator extending into the
can receiving chamber to start the unit when a can is inserted. With the unit
shut off by the main On-Off Switch, a click should be heard after the actuator
is moved inward approximately 1/8”, manually, the click is the action of the
switch making contact. If no click is heard, the unit will not start and the
switch will need to be checked for adjustment.

To adjust, UNPLUG THE ELECTRICAL POWER CORD and remove the (2)
screws on each side of the top cover and remove the cover. Manually bend
the arm of the switch to obtain a click when the actuator is moved inward
about 1/8”. Be conservative on the amount of bending done before a test. In
all probability only a small amount of adjustment will be necessary.

The lower Micro Switch stops the unit on the return stroke of the ram by
breaking the inter-lock. (As long as there is a can in the receiving chamber,
the upper Micro Switch keeps the unit running.) If the lower Micro Switch
does not open; the unit will continue to run even though no can is in the
receiving chamber.
To adjust, UNPLUG THE ELECTRICAL POWER CORD and remove the top
cover. With the ram in a forward stroke and not making contact with the arm
of the switch, move the switch arm manually and bend arm until a click is
heard when the arm is about 1/8” away from it’s resting point on the ram
housing.

NOTE! WHEN THE UNIT OPERATES CONTINUOUSLY ALWAYS
CHECK THE OPERATION AND ADJUSTMENT OF BOTH
MICRO SWITCHES.

TROUBLE SHOOTING

PROBLEM POSSIBLE CAUSE
1. Unit won’t Start
Rocker Switch Not “On”.
2. Motor Overload Breaker Motor Overload Breaker Tripped.
Keeps Tripping. Unit not connected to “Live” Outlet.
Upper Micro Switch is out of
3. Unit Runs All the time when Adjustment or is defective.
Rocker Switch is “On”
Can Jam In Crushing Chamber.
4. Frequent Can Jams Motor Defective.
Overload breaker defective.
In-adequate electric power supply.

Lower Micro Switch Not breaking
Circuit or, defective.
Upper Micro Switch stuck in closed
position.

Badly deformed cans.
Sta-Tabs built up on top of Ram body.
Container for crushed cans too high,
Blocking discharge.

LIMITED WARRANTY

MONARCH SPECIALTY SYSTEMS, INC. warrants products of their manufacture to be free from
defects in material and workmanship for a period of 12 months after purchase by the end-user.
During this warranty period, MONARCH SPECIALTY SYSTEMS, INC.’S obligation under this
warranty shall be limited to the repair or replacement, at MONARCH SPECIALTY SYSTEMS,
INC’S option, of such product which may prove defective, provided that the product is returned,
transportation costs prepaid, to MONARCH SPECIALTY SYSTEMS, INC. Ossian Indiana; and in
no event shall MONARCH SPECIALTY SYSTEMS, INC. be liable for consequential or special
damages or for transportation, or other expenses which shall arise in connection with such product.
This warranty covers only defects in material or workmanship in normal use and does not cover
damages resulting from accident, negligence, misuse, lack of responsible care, alteration, or other
unreasonable use. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED. MONARCH SPECIALTY SYSTEMS, INC. MAKES NO
WARRANTIES EXPRESS, OR IMPLIED, AS TO MERCHANTABILITY OR THE PRODUCT OR
AS TO THE FITNESS OF THE PRODUCT FOR ANY PARTICULAR PURPOSE, AND
MONARCH SPECIALTY SYSTEMS, INC. SHALL NOT BE LIABLE FOR ANY LOSS OR
DAMAGE, DIRECTLY OR INDIRECTLY, ARISING FROM THE USE OF SUCH PRODUCT OR
FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. MONARCH SPECIALTY SYSTEMS,
INC. reserves the right to make changes in products manufactured and/or sold by them at any time
without incurring any obligation to make the same or similar changes on products previously
manufactured and/ or sold by them. No other representations or warranties have been made by
MONARCH SPECIALTY SYSTEMS, INC. or relied upon by the purchaser. No waiver, alteration,
or modification of the foregoing warranties shall be valid unless made in writing and signed by an
executive officer of MONARCH SPECIALTY SYSTEMS, INC.

SERVICE OR WARRANTY CONSIDERATION
If service or warranty considerations are required, contact the dealer from whom the unit
was purchased. In the event local service cannot be obtained or, questions remain,
contact:

MONARCH SPECIALTY SYSTEMS, INC.
1440 South Adams Street
Bluffton, Indiana 46714
260-824-5213

Always contact Monarch Specialty Systems, Inc. before returning any item for Warranty
Consideration. Monarch Specialty Systems, Inc will authorize all necessary returns in
writing.



REPLACEMENT PARTS
8450 CAN CRUSHER

ITEM PART NO. DESCRIPTION QTY.

1 2A1119 Top Cover Assy. 1

2 2A1131 Can Inlet Chute Assy. 1

3 2A1129 Bottom Panel 1

4 2A1121 Base Support Assy. 1

5 2A1118 Housing Assy. 1

6 2A1130 Front Panel 1

7 2A1120 Support Leg Assy. 4

8 2A1128 Micro Switch Assy. 1

9 4A346 Pushbutton Switch 1

10 4A347 Circuit Breaker 1

11 4A173 Light - Amber 1

12 4A192 Rocker Switch 1

13 4A349 Grommet 1

14 2A1137 Power Cord Assy. 1

15 9A549 Decal 1

16 9A547 Decal 3

17 9A546 Decal 1

18 9A545 Decal 1

19 9A548 Decal 2

20 3A250 Gear Motor 1

21 2A1166 Crank Assy. 1

22 2A1167 Spacer 1

23 2A1135 Spacer 1

24 10A244 Connector Link (w/Bushing & Brg.) 1

25 2A1124 Ram Assy. (w/Wear Plates) 1

26 2A1123 Wear Plate 6

27 4A10G3 Micro Switch 1

28 2A1132 Crusher Body Assy. 1

29 2B1127 Can Stop Assy. 1

30 4A344 Relay 1

30A 4A343 Relay Assembly ** 1

** Relay Assembly will be needed on Serial # 1210767 and before

31 4A334G1 Cable Clamp 3

32 7A35 Bushing 1

33 9A555 Spring 1

34 9A32 Shaft Collar 1

35 8A760G1 Shoulder Bolt 1

36 7A36 Needle Bearing 1

37 7A37 Bearing Inner Race 1

38 2A1180 Bottom Support * 1

39 2A1181 Top Support * 2

* Shipped on Production Units on Serial #287190 and After.



Instruction Sheet: Replace Relay 4A345 W/Relay 4A344

Read this entire procedure and inventory parts before starting. 

1. Remove replacement parts/assembly from KOP and inventory: 
a. Assembly 4A343 consisting of: 
i. Relay 4A344 (1ea) 
ii. Bracket #4A342 
 
b. 1 wiring diagram consisting of: 
1. (page 1): “Wiring Diagram, 115V Power Supply, Can crusher 8450 (PN2A1137) 
2. (page 2): “Wiring Diagram, 115V Power Supply, Can Crusher 8450 (PN4A343) 

2. Unplug the Can Crusher 8450  
 

3. Remove top of unit  
a. 4ea Screws 

4. Remove can guide assembly & set to the side 
a. 6ea nut, lock washer and washer 
b. 2ea wire leads (#s 7 & 9) 
i. Be sure to mark leads if they are not already marked 

5. Disassemble and remove old control relay (4A345) 
a. Observe location of old control relay (4A345).  
b. As you remove wire leads, make sure that each is marked in accordance with the KOP wiring diagram, (page 1). 
If not so marked, use masking tape and indelible marker, tagging each wire as it is removed). 

6. Remove ground wire screw and its lock washer. 
7. Install new relay assembly bracket, using ground wire screw hole for one end, and furthest hole from ground wire hole in 

the group of three screw holes aligned where old relay was mounted.  
a. Be sure to look closely at the relay and identify the terminal labels (printed on the side of the relay by the 
manufacturer) before mounting it where you cannot see the diagram. 
b. Put the ground wire back on the same location, with the lock washer between screw head and the wire loop 
terminal end.  

8. Using wire diagram (page 2), reinstall the wire leads on the proper relay terminals.  
a. Cut 10 inches of the terminal end on the black wire off of the power cord lead, strip approximately ¼” of 
insulation, and attach the incoming leads to the screw terminal (black) connectors on the new relay assembly 
as shown on page two of your wiring diagrams at the lower right corner of the page. 
b. Cut the white wire off the power cord.  Make it the same length on the power cord to, put this wire in the 
bottom of the white terminal block with wire #12. 
i. Make sure not to remove more wire than is absolutely necessary when you cut off the terminal ends. 
 

9. Attach the terminal ends of each wire to the new relay as shown on wiring diagram (page 2). 
 

10.  Now on the wire number 5 and 12. 
 

11. On the terminal 5 & 12 cut back 4  inches from wire 12 only.  (this is off the terminal that goes on the old relay) 
a.  And strip approximately 1/4" of insulation for screw terminal attachment. 
b.  Be careful not to cut more wire from the common lead than is absolutely necessary. 
c.  Put the #12 wire going to the motor on the bottom of the (white) terminal block with the white wire from power cord. 
d.  The other end of #12 goes into the top of the (white) terminal block. 
 

12. Attach motor common (white) wire to screw terminal with lead #12/#5 jumper.  
a. It may be necessary to cut the terminal end off of the motor common wire, and strip approximately ¼” of 
insulation to allow for screw terminal attachment. 
b. Be careful not to cut more wire from the common lead than is absolutely necessary to remove the terminal.  

13. Double‐check all connections, and then reassemble the can crusher, using the reverse of steps 3‐5.  
14. Once reassembled, plug in unit and test. If all connections have been correctly made, your Can Crusher 8450 should be 

back in service for many years of additional use.  



Dayton Single- E
Phase and Three- N
Phase Fractional G
AC Gearmotors L
I
S
H

Gearmotor Installation,
Maintenance and
Warranty Information

IMPORTANT: This manual only furnishes general installation and maintenance
information. Refer to the enclosed Product Specific Information Manual fur-
nished seperately for additional information.

Form 8S707

Read the Gearmotor Installation and Maintenance Information Manual

included with this product before installing or performing mainte-

nance. Read this document carefully before attempting to disassem-

ble, reassemble, operate or maintain the product described.

E Protect yourself and others by observing all safety information.

N Failure to comply with instructions could result in personal injury

G and / or property damage! Retain instructions for future references.

L Initial Inspection and Handling
I
S s After opening carton, look for concealed damage. If concealed damage

is found, immediately file claim with carrier.
H s Check the nameplate to verify that data conforms to specifications of

gearmotor ordered.

Storage

s Gearmotor should be stored in a clean, dry location.

General Safety Information

High voltage and moving parts around gearmotor,
and gearmotor driven equipment can cause seri-
ous or fatal injuries. Always disconnect power source before working
on a gearmotor or its connected load. Installation must conform to all
OSHA requirements, the National Electrical Code (NEC) in the United
States and all local codes.

Do not use this gearmotor in a location where fire
or explosion hazards may exist as defined by
Article 500 , Hazardous Locations, of the National Electric Code (NEC)
in the United States.

Gearmotor must not be used in any combustible atmosphere or near
any combustible material.

Gearmotors not equipped with a thermal protector are not suitable
for installation in remote, unattended applications. Overload or
locked shaft condition could result in winding burnout and/or fire and
electrical shock.

When an installation involves a holding or over-
hauling application (such as a hoist or conveyer),
a separate brake or other locking device should be used. Do not
depend on gear friction to hold the load.

Load movement may occur in the event of a gear failure. Gear failures
can be a result of loads that produce shock or exceed the rated out-
put torque specified. Over time gear wear could affect the strength of
the gears leading to gear failure.

Do not use automatic reset devices (such as an auto reset protector)
where unexpected gearmotor starting could be hazardous to person-
nel or equipment.

Installation, maintenance, troubleshooting, or service to be per-
formed by only qualified personnel.

ELECTRICAL SAFETY

Disconnect power before installing or servicing.

Make certain that the power source conforms to the requirements of the
gearmotor.
Gearmotor must be securely and adequately grounded by wiring with a
grounded metallic conduit, or other grounding method approved by the NEC
and local codes. Refer to NEC Article 250 (Grounding) for additional information.

2

Insulate all connections carefully to prevent grounding or short circuits. E
Reinstall all conduit and terminal box covers. Do not force connections into N
the conduit box. G
Always discharge capacitor when working on gearmotor. L
I
MECHANICAL SAFETY S
Remove the output shaft key before running the gearmotor without a H
connected load.

Guard all moving parts.

Be careful when touching the exterior surface of an operating gearmotor!
Gearmotor surface may be hot enough to be painful or cause injury. This
condition is normal for most gearmotors when operated at rated load and
voltage.

Do not permit the load to exceed the gearmotor torque rating.

Do not exceed gearmotor’s overhung load and/or axial load ratings.

Do not modify gearmotor unless otherwise specified by instructions.

When making repairs only use Dayton authorized replacement parts.

THERMAL PROTECTION
Use thermally protected gearmotors or a motor starter incorporating thermal
overload protection wherever required by safety regulations; including (NEC),
local codes or Underwriters Laboratory (UL) Standards; or where overloading,
jamming or other abnormal operating conditions may occur. Under low tem-
perature conditions, manual reset protectors may reset automatically, causing
gearmotor to start unexpectedly.

Installation

Do not install or operate this gearmotor in an
explosive atmosphere.

LOCATION
Open, Dripproof Gearmotor - Clean dry locations with access to an adequate
supply of cooling air.
Totally Enclosed Gearmotors - Harsher environments where damp and dirty
conditions may exist. Totally enclosed gearmotors are not water-proof.
Temperature around the gearmotor should not exceed 104°F(40°C). Minimum
temperature must be considered in the application of the gearmotor.
Temperatures less than 0°F (-18°C) may result in reduced output or no-start.
If installation is outdoors, make certain that the gearmotor is protected from
the environment.

POWER SOURCE
Voltage, frequency and phase of the power supply must correspond to that
shown on the gearmotor nameplate. Low voltage can reduce performance
and cause overheating.
A 208 volt system requires a gearmotor rated at 200 or 208 volts.
On three-phase power, voltage on all three lines should be balanced within
1%. Unbalanced voltages cause motor overheating, noise, and poor perfor-
mance.

MOTOR CONTROL DEVICES
Power supply lines must have short circuit protection for the gearmotor and
controller.
Any switching device used to control gearmotor must have a horsepower rat-
ing equal to or greater than the motor.

3

Do not use an electronic adjustable speed control device with this
gearmotor.

Use of a suitable motor starting device is advisable and usually required

by local electrical codes.
E When a motor starter is used, follow the control manufacturer’s recom-
N mendations on heater selection or setting. If an existing controller is to
G be used with a replacement gearmotor, new heaters may be required.

L Do not use an inverter with this gearmotor. Motors incorporated
I on three-phase gearmotors are not rated for inverter-duty service.

S GEARMOTOR MOUNTING
Mount gearmotor to a rigid surface, preferably metallic, using high-qua-
H

lity bolts of the largest possible diameter that will fit mounting holes. Gear-

motor must be securely fastened to mounting surface.

COUPLING GEARMOTOR TO LOAD

s For operating conditions, other than a normal 8 hour day and shock-free
operation, multiply the rated output torque of the gearmotor by the
applicable load factor listed in the LOAD FACTOR TABLE. Shock loads
must be avoided.

LOAD FACTOR TABLE

Nature Inter- Operating Time Continuous
of Load mittent Normal 24 hrs.
8-hr. day
Uniform 1.0 0.9
Mod. Shock 1.0 1.0 0.8
0.9

s Direct-coupled installations require a careful check of shaft and coupling
alignment. Shim gearmotor mounting as necessary. Do not depend on a
flexible coupling to compensate for misalignment.

s Avoid excessive side load (e.g. over tightened chain or belt). Overhung load
must not exceed unit’s OVERHUNG LOAD rating (listed in catalog) at the
mid-span point on output shaft.

DETAILED OVERHUNG LOAD CALCULATIONS
Sideward (radial) force on an output shaft is called overhung load. Driving a
load through a sprocket, pulley, or gear which is mounted on the output shaft
causes overhung load on the shaft. Too much overhung load can break the
shaft or cause the bearings to fail prematurely. Locate the center line of the
sprocket, pulley, or gear as close to the oil seal as practical to minimize over-
hung load and increase bearing life.

Calculate the amount of overhung load in your installation as follows:

Overhung = (2) x (T) x (D) x (L)
Load (lbs.) (P)

The terms of the above formula are defined as follows:
(T)=Full load torque of gearbox, in in/lbs, from specifications and performance

(D)=Drive factor from following chart, accounting for type of drive

(P)=Pitch diameter, in inches, of drive being mounted on gearbox output shaft

(L)=Leverage factor from following chart, accounting for position of drive
along length of gearbox output shaft.

4

DRIVE FACTORS

Type Factor

Sprocket . . . . . . . . . . . . . . . . . . . . . . . . .1.00 E
Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . .1.50 N
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25 G
Flat belt pulley . . . . . . . . . . . . . . . . . . . .2.50 L
I
LEVERAGE FACTORS S
H
Coupling Location Factor

End of shaft extension . . . . . . . . . . . . .1.20
Center of shaft extension . . . . . . . . . . .1.00
Next to shaft extension shoulder . . . . .0.80

After calculating the amount of overhung load expected in your installation,
compare it to the overhung load rating (limit) listed in catalog. If the expect-
ed amount of overhung load is higher than the specified limit, you must
change a component or the location of a component in your installation to
bring the overhung load within the limit. To increase the operating life of the
gearbox bearings, design your installation to reduce overhung load as much
as possible.

CONNECTING POWER TO GEARMOTOR
To connect gearmotor for proper voltage and rotation, refer to the
connection diagram on the nameplate or inside the terminal/conduit box.

TABLE A – MINIMUM WIRE SIZES FOR SINGLE-PHASE GEARMOTORS

Motor 25 Feet 50 Feet 100 Feet 150 Feet 200 Feet
HP 115V 230V 115V 230V 115V 230V 115V 230V 115V 230V

1/15 14 14 14 14 12 14 10 14 10 14
1/12 14 14 14 14 12 14 10 14 10 14
1/8 14 14 14 14 12 14 10 14
1/6 14 14 12 14 10 14 8 14
1/4 14 14 10 14 6 14 6 12
1/3 14 14 10 14 8 14 6 12 4 10
1/2 12 14 8 14 6 12 4 10
3/4 10 14 8 14 6 12 4 10 38
1 10 14 6 12 4 10 28 16
6 12 4 10 28 16

TABLE B – MINIMUM WIRE SIZES FOR THREE-PHASE GEARMOTORS

Motor 25 to 50 Feet 100 Feet 150 to 200 Feet
HP 230V 460V 230V 460V 230V 460V

up to 14 14 14 14 14 14
1/3 14 14 14 14 12 14
1/2 14 14 14 14 10 14
3/4 14 14 12 14 10 14
1

NOTE:
s Above wire sizes based on approximate 5% voltage drop during starting;

copper conductors. For aluminum wire, increase two wire size steps mini-
mum. See NEC Article 310 for ampacities of aluminum conductors.

Determine direction of rotation before con-
necting driven equipment to prevent damage.

5

If the gearmotor is exposed to excessive moisture (e.g., flooded,
submerged, sprayed), have the gearmotor serviced by a qualified

motor repair shop before operating.

E Operating Gearmotor

N Connect gearmotor to load and run briefly. Check for unusual noises and
G vibration (see Troubleshooting). Check gearmotor current; it should not
L exceed nameplate value.
I Visually re-inspect the installation. Make sure that the guards and all
other protective devices are securely in place. All covers and gaskets must
S be re-installed to minimize the entry of dirt and moisture.
H
During continual operation, the surface temperature of the gearmotor

may become hot. For most gearmotors when operated at rated load and

voltage, this condition is usually normal. To verify if condition is normal, check

gearmotor current and voltage; they should be close to the ratings specified

on the nameplate.

Gearmotors are not designed for instantaneous reversing. The gearmotor
must come to a complete stop before reversing rotation.

Recommended Maintenance

Remove dirt accumulations in and around gearmotor, specifically around
motor vent openings, by vacuuming. Dirt accumulations can cause motor
heating and a fire hazard. Enclosed motors can be cleaned with an air jet;
wear eye protection.

Periodically inspect the installation. Check for dirt accumulations; unusual
noises or vibration; overheating; worn or loose couplings, sheaves and belts or
sprockets and chain; high motor current; poor wiring or overheated connec-
tions; voltage; loose mounting bolts or guards; and worn motor starter con-
tacts.

Exercise caution with solvents; some solvents may attack motor insulation,
finish or bearing lubricants; some are highly flammable. If solvents are used,
make sure area is well vented.

Dayton gearmotor bearings (ball and/or sleeve) are pre-lubricated at the
factory and do not require relubrication.

Ordering Replacement Parts

Use only Dayton authorized replacement parts
when repairing gearmotor.

IMPORTANT: For replacement parts information, refer to the enclosed
Product Specific Information Manual furnished seperately.

Order Replacement Parts By Calling Toll Free 1-800-323-0620
24 hours a day - 365 days a year

Please provide following information: Address parts correspondence to:
s Model Number Grainger Parts Operations
s Serial Number (if any) P.O. Box 3074
s Part Number as 1657 Shermer Road

shown in Product and Specific Northbrook, IL 60065-3074 U.S.A.

Information Manual.

Troubleshooting

This chart suggests common answers to gearmotor problems. The information
is not all-inclusive and does not necessarily apply in all cases. When unusual
operating conditions, repetitive failures, or other problems occur, obtain tech-
nical assistance.

6

Troubleshooting

Symptom Possible Cause(s) Corrective Action

Unit fails to operate 1. No power 1. Consult local E
power company N
2. Blown fuse or open G
circuit breaker 2. Replace fuse L
or reset I
circuit breaker S
Check for H
grounded
motor winding

3. Voltage too low at 3. Consult local power
motor terminals due company. Check for
to line drop poor connections.
Increase wire size
(refer to Minimum
Wire Size Tables A
or B)

4. Improper line 4. Check connections
connections against diagram
supplied with unit

5. Defective motor 5. Repair or replace

6. Defective control 6. Repair or replace
switch or starter

7. Overload, motor starter 7. Check and reset
tripped overload relay in
starter. Check heater
rating against gear
motor nameplate
current rating

8. Gearmotor may be 8. Reduce load or
overloaded increase gearmotor
size. Check load
and alignment of
coupling

Unit stalls during 1. Overload 1. Determine cause of
operation overload. Reduce
load or increase
gearmotor size

2. Low voltage 2. Verify that name-
plate voltage is
maintained

Unit operational but 1. Defective gear(s) 1. Check and replace
no output if necessary

2. Gear loose on shaft 2. Check and replace
if necessary

7

Symptom Possible Cause(s) Corrective Action
Unit operational
but no output 3. Loose coupling, 3. Check and tighten
sheave or sprocket if necessary
E (Continued)
N 4. Sheared key on 4. Replace key and
G output shaft inspect keyway for
L damage
I Intermittent
S rotation of Damaged intermediate Replace and, if
H output shaft gear caused by shock possible, avoid
load shock load
Excessive noise
1. Bearing worn or 1. Replace
Unit overheats while damaged
running under load
2. Belt or chain too tight 2. Adjust tension

3. Overhung-load exceeds 3. Correct load and/or

rating and causes replace bearing

bearing wear

4. Defective gear(s) 4. Replace

5. Output shaft 5. Realign
misaligned

6. Loose sheave or 6. Tighten setscrew(s).

sprocket or misaligned Realign coupling

coupling

7. Defective motor 7. Repair or replace
winding

8. High or unbalanced 8. Check wiring
voltage connections.
Consult local power
company

9. Three-phase motor 9. Check for open
running single-phase circuit, blown fuse,
or unbalanced
voltage

1. Overloaded 1. Reduce load,
increase gearmotor
size; belts or chain
too tight

2. High or low voltage 2. Check voltage at
motor connections,
should not be more
than 10% above or
below

3. Faulty connection 3. Check and tighten if
necessary

8

Symptom Possible Cause(s) Corrective Action

Unit overheats 4. Dirt blocking ventilation 4. Clean motor
while running under openings
load (Continued)
E
5. Defective motor 5. Repair or replace N
G
6. If three-phase, 6. Check lines for L
one-phase may open phase. I
be open Check voltage S
with gearmotor H
disconnected,
one fuse may be
blown

7. If three-phase, 7. Check for faulty
unbalanced supply connections.
voltage Voltage on all
three lines
should be balanced
within1%

Unit does not come 1. Voltage too low at 1. Check for poor
connections.
up to speed or takes motor terminals Increase wire size
(refer to Minimum
too long to accelerate Wire Size Tables A &
B) If three-phase,
check for voltage
unbalance

2. Starting load too high 2. Unit may be under
size to start load.
Increase unit size.
Load contains a
bound condition.
Clear condition

3. Excessive loading; tight 3. Reduce load;
belts or chain increase unit size.
Adjust belt or chain
tension

4. Defective gearmotor 4. Repair or replace

5. Inadequate starting 5. Replace with larger
torque. High inertia unit
load

9

Limited Warranty

Dayton Two-Year Limited Warranty. Dayton® Single-Phase and Three-Phase

Fractional AC Gearmotors are warranted by Dayton Electric Mfg. Co. (Dayton) to

E the original user against defects in workmanship or materials under normal use
N for two years after date of purchase. Any part which is determined to be defective
in material or workmanship and returned to an authorized service location, as
G Dayton designates, shipping costs prepaid, will be, as the exclusive remedy,
L repaired or replaced at Dayton’s option. For limited warranty claim procedures,
I see PROMPT DISPOSITION below. This limited warranty gives purchasers specific
S legal rights which vary from jurisdiction to jurisdiction.
H
Limitation of Liability. To the extent allowable under applicable law, Dayton’s

liability for consequential and incidental damages is expressly disclaimed. Dayton’s

liability in all events is limited to and shall not exceed the purchase price paid.

Warranty Disclaimer. Dayton has made a diligent effort to provide product informa-
tion and illustrate the products in this literature accurately; however, such information
and illustrations are for the sole purpose of identification, and do not express or imply
a warranty that the products are merchantable, or fit for a particular purpose, or that
the products will necessarily conform to the illustrations or descriptions.

Except as provided below, no warranty or affirmation of fact, expressed or implied,
other than as stated in the “LIMITED WARRANTY” above is made or authorized by
Dayton.

Product Suitability. Many jurisdictions have codes and regulations governing sales,
construction, installation, and/or use of products for certain purposes, which may vary
from those in neighboring areas. While Dayton attempts to assure that its products
comply with such codes, it cannot guarantee compliance, and cannot be responsible
for how the product is installed or used. Before purchase and use of a product, review
the product applications, and all applicable national and local codes and regulations,
and be sure that the product, installation, and use will comply with them.

Certain aspects of disclaimers are not applicable to consumer products; e.g., (a) some
jurisdictions do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you; (b) also, some
jurisdictions do not allow a limitation on how long an implied warranty lasts, conse-
quentially the above limitation may not apply to you; and (c) by law, during the peri-
od of this limited warranty, any implied warranty of implied merchantability or fitness
for a particular purpose applicable to consumer products purchased by consumers,
may not be excluded or otherwise disclaimed.

Prompt Disposition. Dayton will make a good faith effort for prompt correction or
other adjustment with respect to any product which proves to be defective within lim-
ited warranty. For any product believed to be defective within limited warranty, first
write or call dealer from whom the product was purchased. Dealer will give additional
directions. If unable to resolve satisfactorily, write to Dayton at address below, giving
dealer’s name, address, date, and number of dealer’s invoice, and describing the
nature of the defect. Title and risk of loss pass to buyer on delivery to common carrier.
If product was damaged in transit to you, file claim with carrier.

Manufactured for Dayton Electric Mfg. Co., 5959 W. Howard St., Niles, Illinois
60714 U.S.A.

Printed in U.S.A. © 1996 W.W. Grainger, Inc. 8S707