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Dayton® Electric ChainHoists

Operating Instructions and Parts Manual

3YB72 thru 3YB99 and 3YE10 thru 3YE15 and 4ZY54 thru 4ZY65

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and othersby observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for futurereference.

Form 5S4877

DescriptionDayton electric chain hoists are rugged, portable hoists that provide quick, preciselifting. The hoists are constructed of tough, but lightweight, die cast aluminumalloy housings. An oil bath transmission, equipped with heat-treated, alloy steelgears and an overload limiting clutch, provides smooth and reliable operation.

With a pushbutton station that fits comfortably in one hand, the operator cansafely control the hoist while the other hand is free to guide the load. Theelectrical controls, which are readily accessed under the electrical cover, utilizequick-connect terminals for easy voltage conversions and a 24V control circuit foradded safety.

Other features that ensure the safe operation of Dayton electric chain hoistsinclude a magnetic disc brake that delivers sure stopping and secure holding of the load. Adjustable upper and lower limit switches regulate the load travel. For additional safety, a chain stop is attached to the slack end of the load chain.

Dayton electric chain hoists are designed and tested in accordance with theAmerican Society of Mechanical Engineers Code B30.16, “Safety Standard forOverhead Hoists.” Hoists are built in compliance with CSA, file number LR 44484.Made in U.S.A.

Table of ContentsSECTION PAGEDescription ..............................................1Warnings .................................................2Specifications ..........................................3 General Information...............................4General Safety Information ...................5Installation ..............................................5Operation ................................................6Troubleshooting Chart ...........................7Maintenance ...........................................9Maintenance Check List .......................16Repair Parts List.....................................18Warranty ...............................................34

Printed in U.S.A.029671105/402/VCPVP

AdjustableLimit Switches

24V PushbuttonControl Station

Heat-TreatedSmooth-RunningSteel Gears

Strain Cable inControl Cord

ElectricalConnections Allat One End forEasy Changes

MagneticDisc Brake

Overload Limiting ClutchLatch-Type Hook

NEMA Hoist-DutyInduction Motor

Aluminum Housing

Jam-ResistantChain Guide

Latch-Type Hook

EnclosedLoad Block

High QualitySteel Chain

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Figure 2 — Electric Hoist Construction

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ChainStop

Figure 1 - Electric Chain Hoist

Dayton Operating Instructions and Parts Manual

Dayton Electric Chain Hoists®

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WarningsEach Dayton Electric Chain Hoist is builtin accordance with the specificationscontained herein and applicablesections of the *American Society ofMechanical Engineers Code B30.16“Overhead Hoists,” the NationalElectrical Code (ANSI/NFPA 70) and theOccupational Safety and Health Act.Since OSHA states the NationalElectrical Code applies to all electrichoists, installers are required to providecurrent overload protection andgrounding in keeping with the code.Check each installation for compliancewith the application, operation andmaintenance sections of thesearticles.*Copies of this standard can beobtained from ASME OrderDepartment, 22 Law Drive, Box 2300,Fairfield, NJ 07007-2300, U.S.A.

Improper operationof a hoist can create a

potentially hazardous situation which, if notavoided, could result in death or seriousinjury. To avoid such a potentially hazardoussituation, the operator must observe thefollowing precautions:

1. DO NOT operate a damaged,malfunctioning or unusuallyperforming hoist.

2. DO NOT operate the hoist until youhave thoroughly read andunderstood this OperatingInstructions and Parts Manual.

3. DO NOT operate a hoist which hasbeen modified.

4. DO NOT lift more than rated loadfor the hoist.

5. DO NOT use hoist with twisted,kinked, damaged, or worn loadchain.

6. DO NOT use the hoist to lift,support, or transport people.

7. DO NOT lift loads over people.8. DO NOT operate a hoist unless all

persons are and remain clear of thesupported load.

9. DO NOT operate unless load iscentered under hoist.

10. DO NOT attempt to lengthen the loadchain or repair damaged load chain.

11. Protect the hoist’s load chain fromweld splatter or other damagingcontaminants.

12. DO NOT operate hoist when it isrestricted from forming a straightline from hook to hook in thedirection of loading.

13. DO NOT use load chain as a sling, orwrap load chain around load.

14. DO NOT apply the load to the tip ofthe hook or to the hook latch.

15. DO NOT apply the load unless load chain is properly seated in the loadsheave(s).

16. DO NOT apply load if bearingprevents equal loading on all loadsupporting chains.

17. DO NOT operate beyond the limitsof the load chain travel.

18. DO NOT leave load supported bythe hoist unattended unless specificprecautions have been taken.

19. DO NOT allow the load chain orhook to be used as an electrical orwelding ground.

20. DO NOT allow the load chain orhook to be touched by a livewelding electrode.

21. DO NOT remove or obscure thewarnings on the hoist.

22. DO NOT operate a hoist on whichthe safety placards or decals aremissing or illegible.

23. DO NOT operate a hoist unless ithas been securely attached to asuitable support.

24. DO NOT operate a hoist unless loadslings or other approved singleattachments are properly sized andseated in the hook saddle.

25. Take up slack carefully - make sureload is balanced and load holdingaction is secure before continuing.

26. Shut down a hoist that malfunctionsor performs unusually and reportsuch malfunction.

27. Make sure hoist limit devicesfunction properly.

28. Warn personnel of an approaching load.

29. Maintain a firm footing or beotherwise secured when operatingthe hoist.

30. Check brake function by tensioningthe hoist prior to each lift operation.

31. Use hook latches. Latches are toretain slings, chains, etc. under slackconditions only.

32. Make sure the hook latches areclosed and not supporting any partsof the load.

33. Make sure the load is free to moveand will clear all obstructions.

34. Avoid swinging the load or hook.35. Make sure hook travel is in the same

direction as shown on the controls.36. Inspect the hoist regularly, replace

damaged or worn parts, and keepappropriate records of maintenance.

37. Use Grainger parts when repairingthe unit.

38. Lubricate load chain per instructionsin this manual.

39. DO NOT use the hoist’s overloadlimiting clutch to measure load.

40. DO NOT use the hoist’s limitswitches as routine operating stops.They are emergency devices only.

41. DO NOT allow your attention to bediverted from operating the hoist.

42. DO NOT allow the hoist to besubjected to sharp contact withother hoists, structures, or objectsthrough misuse.

43. DO NOT adjust or repair the hoistunless qualified to perform suchadjustments or repairs.

3YB72 thru 3YB99 and 3YE10 thru 3YE15

Models 3YB72 thru 3YB91 and 3YB96 thru 3YB99, 3YE10


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Specifications for 1-Speed Models

Power Amps @ Chain Control Min. Dist.Supply Motor Low Lift Cord Lift Between Housing Dimensions

Model Req. HP Voltage * Length Length Speed Hooks W D L

1/4 Ton — 500 lb. Capacity (227 kg)3YB72 115/230V 1/2 7.6 10 ft 6 ft 16 FPM 18" 811/16" 811/16" 241/8"

1 Phase3YB96 115/230V 1/2 7.6 15 11 16 18 811/16 811/16 241/8

1 Phase3YB97 115/230V 1/2 7.6 20 16 16 18 811/16 811/16 241/8

1 Phase3YB98 115/230V 1/2 7.6 10 6 32 18 811/16 811/16 241/8

1 Phase3YB99 115/230V 1/2 7.6 15 11 32 18 811/16 811/16 241/8

1 Phase3YE10 115/230V 1/2 7.6 20 16 32 18 811/16 811/16 241/8

1 Phase

1/2 Ton — 1000 lb. Capacity (454 kg)3YB78 115/230V 1/2 7.6 10 6 16 18” 811/16” 811/16” 241/8”

1 Phase3YB84 115/230V 1/2 7.6 15 11 16 18 811/16 811/16 241/8

1 Phase3YB85 115/230V 1/2 7.6 20 16 16 18 811/16 811/16 241/8

1 Phase3YB90 115/230V 1 14.0 10 6 32 18 811/16 811/16 241/8

1 Phase3YB73 230/460V 1/2 2.0 10 6 16 18 811/16 811/16 241/8

3 Phase3YB74 230/460V 1/2 2.0 15 11 16 18 811/16 811/16 241/8

3 Phase3YB75 230/460V 1/2 2.0 20 16 16 18 811/16 811/16 241/8

3 Phase

1 Ton — 2000 lb. Capacity (907 kg)3YB79 115/230V 1 14.0 10 6 16 18” 811/16 “ 811/16” 241/8”

1 Phase3YB91 115/230V 1 14.0 15 11 16 18 811/16 811/16 241/8

1 Phase3YB83 115/230V 1 14.0 20 16 16 18 811/16 811/16 241/8

1 Phase3YB80 230/460V 1 3.2 10 6 16 18 811/16 811/16 241/8

3 Phase3YB86 230/460V 1 3.2 15 11 16 18 811/16 811/16 241/8

3 Phase3YB76 230/460V 1 3.2 20 16 16 18 811/16 811/16 241/8

3 Phase

2 Ton — 4000 lb. Capacity (1814 kg)3YB81 115/230V 1 14.0 10 6 8 193/4” 811/16” 811/16” 241/8”

1 Phase3YB87 115/230V 1 14.0 15 11 8 193/4 811/16 811/16 241/8

1 Phase3YB88 115/230V 1 14.0 20 16 8 193/4 811/16 811/16 241/8

1 Phase3YB82 230/460V 1 3.2 10 6 8 193/4 811/16 811/16 241/8

3 Phase3YB89 230/460V 1 3.2 15 11 8 193/4 811/16 811/16 241/8

3 Phase3YB77 230/460V 1 3.2 20 16 8 193/4 811/16 811/16 241/8

3 Phase(*FULL LOAD MOTOR AMPS) Amperage at high voltage is 1/2 that of the low voltage. At full load, it is not unusual for thehoist to draw in excess of the motor amperage listed. The 1 hp, 115/230V models must have a dedicated power circuit rated forat least 20A, 125V when they are wired for 115V. It is recommended to use 230V on the 115/230V models when it is available.




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Power Motor Amps * Chain Control Lift Min. Dist.Supply HP Lift Cord Speed Between Housing Dimensions

Model Req. (fast/slow) (fast/slow) Length Length (fast/slow) Hooks W D L

1/2 Ton — 1000 lb. Capacity (454 kg)3YB92 460V .5/.17 .88/1.05 10 ft 6 ft 16/5.3 FPM 18" 811/16" 811/16" 25"

3 Phase3YB93 460V .5/.17 .88/1.05 15 11 16/5.3 18 811/16 811/16 25

3 Phase3YE11 460V .5/.17 .88/1.05 20 16 16/5.3 18 811/16 83/8 25

3 Phase

1 Ton — 2000 lb. Capacity (907 kg)3YB95 460V 1/.33 1.6/1.9 10 6 16/5.3 18” 811/16” 811/16 " 251”

3 Phase3YB94 460V 1/.33 1.6/1.9 15 11 16/5.3 18 811/16 811/16 25

3 Phase3YE12 460V 1/.33 1.6/1.9 20 16 16/5.3 18 811/16 811/16 25

3 Phase

2 Ton — 4000 lb. Capacity (1814 kg)3YE13 460V 1/.33 1.6/1.9 10 6 8/2.7 193/4” 811/16” 811/16” 25”

3 Phase3YE14 460V 1/.33 1.6/1.9 15 11 8/2.7 193/4 811/16 811/16 25

3 Phase3YE15 460V 1/.33 1.6/1.9 20 16 8/2.7 193/4 811/16 811/16 25

3 Phase

(*)FULL LOAD MOTOR AMPS

General Information This hoist is intended for generalindustrial use for lifting andtransporting freely suspended materialloads within its rated capacity. Prior toinstallation and operation, we cautionthe user to review his application forabnormal environmental or handlingconditions and to observe theapplicable recommendations as follows:

ADVERSE ENVIRONMENTAL CONDITIONSDo not use the hoist in areas containingflammable vapors, liquids, gases or any

combustible dusts or fibers. Refer toArticle 500 of the National ElectricalCode. Do not use this hoist in highlycorrosive, abrasive or wetenvironments. Do not use this hoist inapplications involving extendedexposure to ambient temperaturesbelow -10°F or above 130°F.

LIFTING OF HAZARDOUS LOADSThis hoist is not recommended for usein lifting or transporting hazardousloads or materials which could causewidespread damage if dropped. Thelifting of loads which could explode orcreate chemical or radioactive

contamination if dropped requires fail-safe redundant supporting deviceswhich are not incorporated into thishoist.

LIFTING OF GUIDED LOADSThis hoist is not recommended for usein the lifting of guided loads, includingdumbwaiters and elevators. Suchapplications require additionalprotective devices which are notincorporated into this hoist. Refer toyour State and local regulationsgoverning the requirements forelevator and dumbwaiter installations.

Specifications for 2-Speed Models (Single Voltage Motor Only)

Models 3YB72 thru 3YB99 and 3YE10 thru 3YE15


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General Safety Information1. Follow all local electrical and safety

codes, as well as the NationalElectrical Code (NEC) and theOccupational Safety and Health Act(OSHA) in the United States.

2. Hoist must be securely andadequately grounded. Hoist powercable is provided with an additionallead (green) for groundingpurposes.

Always disconnectpower source before

working on or near a hoist or its connectedload. If the power disconnect point is out-of-sight, lock it in the open position and tag toprevent unexpected application of power.

3. Be careful when touching theexterior of an operating motor; itmay be hot enough to be painful orcause injury. With modern motorsthis condition is normal if operatedat rated load and voltage (modernmotors are built to operate athigher temperatures).

4. Protect the power cable and controlcable from coming in contact withsharp objects.

5. Do not kink power cable and controlcable and never allow the cable tocome in contact with oil, grease, hotsurfaces, or chemicals.

6. Make certain that the power sourceconforms to the requirements ofyour equipment.

7. Inspect the unit daily beforeoperating hoist.

8. Cluttered areas and benches inviteaccidents.

9. The operator should not engage inany practice which will divert hisattention while operating the hoist.

10. Before using the hoist, the operatorshould be certain that all personnelare clear.

11. Do not operate hoist with loads

exceeding its rated capacity.

12. Supporting frames or beams used asa hoist hanger must have a greaterload capacity than the hoist.

13. Do not attempt to operate hoistbeyond normal maximum lift range.

14. Align hoist for a straight line pull.Avoid side pull or end pull.

15. Do not operate hoist with twisted ordamaged chain.

16. Do not operate a damaged ormalfunctioning hoist until necessaryadjustments or repairs have beenmade.

17. Do not use hoist to lift people or tocarry loads over people.

18. Do not leave a load suspended inthe air unattended.

19. Always remove load before makingrepairs.

20. Do not remove or obscure capacityor warning decals.

Installation1. Before installing the hoist, check the

following:

a. Make sure all supporting structuresand attaching devices are strongenough to hold your intendedloads. If in doubt, consult aqualified structural engineer.

b. Provide proper branch circuitprotection for the hoist asrecommended in the NationalElectrical Code.

c. Power supply should be plus orminus 10% of the voltage specifiedon the motor nameplate. It iscritical to use adequately sizedpower cables, especially with 1-phase hoists (See Power SupplyPrecautions, page 15). Be sure dualvoltage hoists are connected orwired to correspond with your power supply (See Figures 11A,

11B, and 11C).

d. The installation area must providesafe operating conditions for theoperator, including sufficient roomfor the operator and otherpersonnel to stand clear of the loadat all times.

e. For installations where the slackchain hanging from the unit maybe objectionable or hazardous, theuse of a chain container isrecommended. See INSTALLATIONOF CHAIN CONTAINER ASSEMBLY.

2. Before operating the hoist, be sure toobserve the following:

a. ALWAYS DISCONNECT HOIST FROMPOWER SUPPLY before removingelectrical cover or when makingany electrical connection in thehoist or pushbutton station.

b. The ground wire (green colored) ofthe power cable should always beconnected to a suitable ground bymeans of a screw or clamp. Analligator clip does not make a safeground connection.

c. When installing a three-phasehoist, make only temporaryconnections at the power source.Push the “UP” button and observethe direction of the load block. If itraises, the phasing is correct andpermanent connections may bemade at the power source. If theload block lowers when the “UP”button is pushed, release thebutton immediately since the limitswitches will not operate to protectthe hoist from over-travel. Reverseany two wires (except the greenground wire) at the power sourceto correct the load hook direction(phasing). Do not changeconnections in the hoist orpushbutton assembly.

d. Make sure load chain is not twistedas it travels into the hoist.

Installation (Continued)e. Operate hoist in a hanging position

only. Hoist should be permitted toalign itself for a straight line pull.Do not attempt to pull aroundcorners.

f. Read ASME-B30.16 Safety Code forHoists.

3. Lubricate the chain if necessary, (SeeLUBRICATION, page 12).

4. Before placing the hoist in operation,check the limit switch settings. Forboth the upper and lower limits oftravel, operate the hoist until theload hook nears the requiredstopping point and inch into thatpoint. If either setting is incorrect,adjust according to LIMIT SWITCHADJUSTMENT, page 11.

INSTALLATION OF CHAIN CONTAINERASSEMBLY (OPTIONAL ACCESSORY)Refer to Figure 3.

1. Remove retaining clip andattachment pin and let the slackchain hang free.

2. Run load hook down to its lowestposition. Place the slack end of chainin chain container. Do not remove thechain stop.

3. Place chain container flush againsthousing with chain stripper betweentop lugs. Insert long attachment pinand replace retaining clip.

4. Feed the remainder of chain intocontainer by operating hoist in the“UP” direction to the top limit. Thiswill permit the chain to pile freelyand prevent the chain from kinking,which may occur if the chain is placedin the container by hand.

Do not allow load tocome in contact with

the chain container. If this situation exists,reset the “UP” limit switch (See LIMITSWITCH ADJUSTMENT, page 11) so that thehook block stops below the chain container.

OperationOVERLOAD LIMITING PROTECTION

This hoist is equipped with a factory-calibrated overload limiting clutch thatwill permit the lifting of loads within itsrated capacity, but will prevent thelifting of damaging overloads while thehoist is being operated. If the loadbeing lifted exceeds the liftingcapability of the overload clutch, thehoist motor will continue to run,causing overheating of both the clutchand hoist motor. This condition should

be avoided by immediately releasingthe “UP” button and reducing the loadto within the rated capacity of thehoist. See GEARING, page 13, foradditional instructions on this device.

The overloadlimiting clutch is an

emergency protective device and should notbe used to measure the maximum load to belifted, or to sense the overload imposed by aconstrained load. While the overloadlimiting clutch will protect the hoist fromdamaging overloads, it will not ensure thata load is within the rated capacity of thehoist.

SAFE OPERATIONThis hoist is designed for safe operationwithin the limits of its rated capacity. Itis controlled with the 2-button station.Two-speed hoist models have 2-stepbuttons. The “UP” or “DOWN” buttonis pressed to the first step for the slowspeed and pressed all the way down forthe fast speed. There are many safetyfeatures to protect the operator frominjury due to failure of the hoist. Hereare some points which should beobserved to maintain safe operation.

1. Do not overload the hoist.

2. Do not make extreme side pulls withthe hoist.




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Figure 3 — Installing Chain Container Assembly

Recommended For Use With:Stock Hoist Chain Lift Shpg. Dimensions in InchesNo. Capacity in Feet Wt. W L H

1/4 & 1/2-Ton 10-15-20-25 3 Lbs. 67/8" 61/2" 101/2"1 10-15-202 10

4BB28 1 25 5 61/2 61/2 201/4

2 154BB47 2 20-25 15 71/2 71/2 20

NOTE: The Chain Containers listed above are available to keep surplus chain awayfrom work area. Container is suspended from bottom of hoist, and is constructedof liner low-density polyethylene.

AttachmentPin

RetainerClip

Optional Chain Container

Included with hoist.


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Operation (Continued)3. Operate the hoist only in a hanging

position with adequate support.

4. Do not “sling” the load hook andchain around the load. Use anapproved sling.

5. Be sure there are no twists in theload chain as it travels into the hoisthousing. This condition should beconstantly checked on double chainhoists because it is possible for theload block to be “capsized” orturned over one or more times.

6. Before raising a load, always checkto see that it is held securely in thehook or sling chains, etc. Raise theload only until the load chain is tautand then double check the riggingbefore continuing to raise the load.

7. Do not stand beneath a load! Do notmove a load in such a manner as toendanger personnel.

8. Don’t lower into areas wherevisibility is obscured unless someoneelse is guiding the operation.

9. Use common sense at all times whenoperating a hoist.

10. Do not operate if direction of hooktravel is not the same as indicatedon button being pushed.

11. Do not operate unless hook travellimit devices function. Test withoutload each shift.

12. Do not operate when hoist is notcentered over load.

13. Do not operate if chain is not seatedproperly in sprockets or sheavegrooves.

14. Do not operate damaged ormalfunctioning hoist.

Do not use hoist tolift, support or

otherwise transport people.

Troubleshooting ChartSymptom Possible Cause(s) Corrective Action

Hook fails to stop at end 1. Limit switch not operating 1. Check adjustment (see LIMIT SWITCH ADJUSTMENT,of travel page 11). Check connections against wiring

diagram. Tighten loose connections or replace2. Brass limit switch nuts not 2. Check for stripped threads or bent nut guide

moving on shaft3. Hoist reversing contactor 3. Remove electrical cover and check reversing

malfunctioning contactor

Hoist does not respond 1. Power failure in supply lines 1. Check circuit breakers, switches and connectionsto pushbutton in power supply lines

2. Wrong voltage or frequency 2. Check voltage and frequency of power supplyagainst the rating on the nameplate of the motor

3. Improper connections in hoist 3. Check all connections at line connectors and onor pushbutton terminal block. Check terminal block on dual-

voltage hoists for proper voltage connections4. Brake does not release 4. Check connections to the solenoid coil. Check for

open or short circuit. Check for proper adjustment(see BRAKE ADJUSTMENT, page 11)

5. Faulty hoist reversing contactor 5. Check coils for open or short circuit. Check all connections in control circuit. Check for burned contacts. Replace as needed





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Troubleshooting Chart (Continued)Symptom Possible Cause(s) Corrective Action

Hook does not stop promptly 1. Hoist overloaded 1. Reduce load to within rated capacity of hoist2. Brake not holding 2. Check brake adjustment (see BRAKE ADJUSTMENT,

page 11). It may be necessary to replace discs

Hook moves in wrong 1. Three phase reversal 1. Reverse any two wires (except the green grounddirection wire) at the power source (see Installation 2c, page 5)

2. Improper connections 2. Check all connections against wiring diagram

Hook raises but will 1. “DOWN” circuit open 1. Check circuit for loose connections. Check “DOWN”not lower limit switch for malfunction

2. Broken conductor in push- 2. Check each conductor in the cable. If one is broken,button cable replace entire cable

3. Faulty hoist reversing 3. Check coils for open or short circuit. Check all con-contactor nections in control circuit. Check for burned

contacts. Replace as needed

Hook lowers but will 1. Hoist overloaded. Overload 1. Reduce load to within rated capacitynot raise clutch slipping

2. Low voltage 2. Ensure that the voltage at the reversing contactor is within ±10% of the nominal voltage while lifting a load

3. “UP” circuit open 3. Check circuit for loose connections. Check “UP”limit switch for malfunction

4. Broken conductor in push- 4. Check each conductor in the cable. If one is broken,button cable replace entire cable

5. Faulty hoist reversing contactor 5. Check coils for open or short circuit, check all con-nections in control circuit. Check for burnedcontacts. Replace as needed

6. Faulty capacitor (single phase 6. Check starting capacitor on motor. Replace ifhoist only) necessary

Lack of proper lifting 1. Hoist overloaded. Overload 1. Reduce load to within rated capacity of hoistspeed clutch slipping

2. Brake dragging 2. Check for proper brake adjustment or other defects3. Low voltage 3. Ensure that the voltage at the reversing contactor

is within ±10% of the nominal voltage while lifting a load

Motor brake noise or 1. Brake needs adjustment 1. See BRAKE ADJUSTMENT, page 11 chatter (while starting hoist) 2. Low voltage 2. Ensure that the voltage at the reversing contactor

is within ±10% of the nominal voltage while lifting a load

Motor brake “buzz” 1. Brake needs adjustment 1. See BRAKE ADJUSTMENT, page 11(anytime hoist is running) 2. Broken shading coil on 2. Replace shading coil or complete brake frame

brake frame assembly

In all instances, remove load and disconnect hoist from power source.


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MaintenanceINSPECTIONSA planned inspection routine should beestablished for this hoist based uponfrequency of use, severity of use, andenvironmental conditions. (ReferenceASME Standard B30.16). Someinspections should be made frequently(daily to monthly) and othersperiodically (monthly to yearly). It isstrongly recommended that anInspection and Maintenance Check Listand an Inspector’s Report, similar tothose shown in Figures 12A and 12B, beused and filed for reference. Allinspections should be performed oroverseen by a designated inspector.Special inspections should be madefollowing any significant repairs or anyoperating occurrence leading one tosuspect that the hoist’s capability mayhave been impaired.

LOWERING WITHOUT POWERIf the power fails with a loadsuspended, the hoist will automaticallystop. In an emergency the load can belowered without power as follows:1. DISCONNECT HOIST FROM POWER

SUPPLY AND REMOVE ELECTRICALCOVER.

2. Refer to Figure 8. Open disc brakemanually by using two screwdriverblades, one on each side of the brakeat a point close to the brake springposts. Apply pressure to theunderside of the armature plate(points “X”) to close the solenoid andrelease the brake.

Do not allow screw-driver blades to touch

rotating friction disc “C”.

Do not allow theload to descend

rapidly. This causes the motor to race andserious damage may result.

3. Use several quick releases instead ofholding brake open continuously. Donot exceed normal lowering speed.

HOOKSRefer to Figure 4.1. Inspect hooks once daily for cracking,

extreme wear or spreading. Replacehooks showing any of these signs. Ifthe throat openings are spread widerthan the maximum permissible 15%increase listed here, the hooks havebeen overstressed and must bereplaced. Any hook that is bent ortwisted more than 10 degrees fromthe plane of an unbent hook mustalso be replaced.

2. The hook latches should be inspectedto ensure that they close the hookthroat opening in a secure mannerwhen a load is applied. Inspect thehook shank and nut for any strippingof the threads or other damage. Thehook nut should be fully restrainedby the retaining pin.

3. In addition to above, load hooksshould be inspected for cracks by themagnetic particle, dye penetrant orother suitable crack testing inspectionmethod. This should be done at leastonce a year.

1/4, 1/2 & 1 Ton 111/32" 17/32"2 Ton 111/32" 111/32"(*) Maximum permissible throatopening of hook.

CHAINChain is to be kept clean and lubricated.(See LUBRICATION, page 12). Visuallycheck chain every time hoist is used.Hoist must not be operated when chainis twisted or kinked. An importantphase of hoist maintenance is chaininspection. Check individual links andcheck for chain elongation.

1. Check the chain for overall wear orstretch by selecting an unworn,unstretched length of chain (at theslack end for example). Let the chainhang vertically with a light load(about 20 pounds) on the chain topull it taut. Use a large caliper tomeasure the outside length of aconvenient number of links (about 12inches). Measure the same number oflinks in a used section of chain andcalculate the percentage increase inlength of the worn chain.

2. If the length of the worn chain ismore than 11/2% longer than theunused chain (0.015" per inch ofchain measured), then the chainshould be replaced. If the chain isworn less than 11/2%, check it atseveral more places along its length.If any section is worn more than11/2%, the chain should be replaced.

The chain used onthis hoist has very

carefully controlled dimensions and hasbeen heat treated. Do not attempt tosubstitute other manufacturer’s chain.

“X” Dimension*Hoist Top Bottom

Capacity Hook Hook

Figure 4 — Hook Inspection Figure 5 — Limit Switch Assembly

SpringGuidePlate

Silver Nut(Down)

Gold Nut(Up)

X


Maintenance (Continued)

CHAIN REPLACEMENT WITH CHAIN IN HOIST.

CHAIN REPLACEMENT WITH NO CHAIN IN HOIST.




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Figure 6 — Chain Replacement Diagram

and attached chain through the chainstripper). Be sure that the welds of thenew chain will face outward from the load sheave. The end links must beoriented for attachment to the slack end attachment pin and the chainanchor (double -chained only) withoutany twist in the chain.

7. With the electrical cover off, connect the hoist to the power supply. Be surethat the green ground wire is properly grounded (see installation, page 5)

8. Carefully jog the “UP” button and runthe joined pieces of chain into the hoist until about 15” of the new chain comes out the other side.

9. DISCONNECT HOIST FROM POWER SUPPLY.

10. Remove the “C” link and the oldchain. Remove the chain stop by prying off its retaining ring with a flathead screwdriver. If attached, remove the old chain from the chain stripper by removing the retainer clip and attachment pin.

11. Attach the chain stop to the slack end of the new chain by capturingthe 12th link with the two stophalves positioned with their tapered ends pointing towardsthe hoists. Slide the sleeve overthe halves and attach theretaining ring. If you are not usinga chain container, attach the slack endof the new chain to the chain stripper using the attachment pin and retaining clip. DO NOT allow twists in the chain.

12. Adjust the lower limit switch (See ADJUSTING LOWER LIMIT, page 11).

13. Attach the bottom block on singlechained hoists using a new load blockscrew(See Figure 26). On double- chained hoists, feed the chain throughthe load block (welds of theupstanding links will be in towards the sheave) and fasten the end of

Refer to Figure 61. Run hook up to its to limit.2. DISCONNECT HOIST FROM POWER

SUPPLY and remove the electricalcover.

3. Using a screwdriver, pry the springguide plate out of the slots in the limit switch nuts (See Figure 5). Turnthe slotted nut nearest you, the goldnut, back to about the center of thethreaded screw. Do not disconnect the wires from the switches.

4. Remove the load block assembly from old chain. On double -chainedhoists it is necessary to remove the chain stripper to detach the chainfrom the chain anchor and pull it through the load block assembly. The chain should also be pulled outof the chain stripper.

5. Make a “C” link by grinding through the end link on the loadend of the old chain.

6. Use the “C” link to attach the newchain to the load end of the old chain. (on double - chained hoistsit is necessary to pass the “C” link

a new chain anchor pin (See Figure 26) and reassemble the chain stripper. Be sure there are no twists in the chain.

14. Adjust the upper limit switch (SeeADJUSTING UPPER LIMIT, page 11).

Refer to Figures 6 and 71. DISCONNECT HOIST FROM

POWER SUPPLY and move hoist to a work table. Do not remove the electrical cover.

2. Detach the chain stripper from the bottom of the hoist.

3. Following the instructions in the section on GEARING, disassemble the transmission assembly.

4. Remove the output shaft through the transmission, allowing the load sheave and chain guide to be removed from the bottom of the hoist. Be care not to lose the spacer that is between the load sheave and the bearing on the motor end. NOTE: Inspect chain guides and load sheave for wear, replace as needed.

5. Lay the new chain over the load sheave. Allow about 15” of chain below the hoist on the slack end.(See Figure 6) Be sure the welds of the upstanding links are out away from the load sheave and the proper orientation is observed for attachment of the slack end. Also be sure the load hook assembly (if already attached to the chain) is toward the center of the hoist or to your right looking from the transmission end.

6. Reinstall the chain guide in the housing. Grease the splined bore of the load sheave, then position the load sheave and spacer in the housing.

Double-ChainOnly


®

11

ENGLISH

Maintenance (Continued)7. Reassemble the output shaft and

transmission.8. Pass the new chain through the

opening in the chain stripper.9. Follow steps 11 through 14 in the

previous section, CHAINREPLACEMENT WITH CHAIN INHOIST, to complete the chainreplacement procedure.

LIMIT SWITCH ADJUSTMENTRefer to Figure 5.IMPORTANT: Before placing hoist inoperation, check the limit switch ad-justment. Limit switches are provided toprotect the hoist against damage result-ing from overtravel or to allow settingthe hook travel within the factory-setlimits of travel. For easy identificationand association with the proper direc-tion of travel, the upper and lower limitswitch adjusting nuts are color-codedgold and silver respectively. Each limitnut has 10 slots for fine adjustment,and the increment of adjustment is suchthat one slot is equivalent to approxi-mately one link of chain travel.Movement of the limit switch nutstoward or away from each otherincreases or decreases the hook travelrespectively. Care should be exercisedwhen adjusting either limit of travel.

ADJUSTING UPPER LIMIT (GOLD NUT)1. Suspend the hoist. For single chain

models raise the load block untilthere is a minimum clearance of 2"from the hoist housing and the top ofthe block. Double chain models require a minimum clearance of 1" from the chain support to the top ofthe load block.

2. DISCONNECT HOIST FROM POWERSUPPLY and remove the electricalcover.

3. With a screwdriver, pry the springguide plate out of the slots in thelimit switch nuts.

4. Turn the slotted gold nut toward itslimit switch until the switch “clicks”then turn two slots farther. Release

the spring guide plate and be sure itslips back into the slots in both limitswitch nuts. Do not disturb the silverslotted nut if it has been set previously.

ADJUSTING LOWER LIMIT (SILVER NUT)1. Suspend the hoist. Carefully lower the

load block to a point where the slack-end loop of the chain hangs down 6"or more from the hoist housing (orthe limit desired in any particular ap-plication allowing the minimum 6").There should be a minimum clearanceof 11/2" between the chain stop andbottom of hoist.

2. DISCONNECT HOIST FROM POWERSUPPLY and remove the electricalcover.

3. With a screwdriver, pry the springguide plate out of the slots in thelimit switch nuts.

4. Turn the slotted silver nut toward itslimit switch until the switch “clicks,”then turn two slots farther. Releasethe spring guide plate and be sure itslips back in the slots in both limitswitch nuts. Do not disturb the goldslotted nut if it has been setpreviously.

CHECK BOTH UPPER ANDLOWER LIMITS1. Connect the hoist to the power

supply. Be sure the green groundwire is properly grounded (SeeInstallation 2-b, page 5).

2. Check load hook direction (SeeInstallation 2-c, page 5).

3. Carefully raise load block to upperlimit and observe if it stopsautomatically at desired level. Do notallow load block to run into hoisthousing — this will damage the hoist.Maintain a minimum clearance of 2"from the hoist housing and the top ofthe load block on single-chainedmodels and 1" from the chainsupport to the top of the load blockon double-chained models.

4. Carefully lower load block to lowerlimit and observe if it stopsautomatically at the desired level. Do

not allow slack-end loop of chain tobecome taut against hoist housing.This will damage the hoist. Thereshould be a minimum clearance of11/2" between the chain stop and thebottom of the hoist.

5. If upper and lower limits operatesatisfactorily, hoist is ready for use. Ifthey are not as desired, repeatadjustment.

If the wires runningto the limit switches

are ever disconnected for any purpose, besure to replace wires in accordance with thecorrect wiring diagram (See Figures 11A, 11B,and 11C).

BRAKE ADJUSTMENTRefer to Figure 8.Properly adjusted, this brake willrelease promptly when energized. It iscapable of both smoothly stopping andsecurely holding the rated capacity ofthe hoist. If the hoist develops eitherundesirable over-travel after thepushbutton is released (this condition ismost noticeable in the loweringdirection) or hesitates to lift the loadpromptly when the pushbutton isdepressed (this condition is mostnoticeable in the hoisting direction),the brake should be adjusted as follows.

Figure 8 — Brake Assembly

Gap

F

G

X

B

E

AX

D

H

C


Maintenance (Continued)1. DISCONNECT HOIST FROM POWER


2. With reference to Figure 8, the gapbetween the brake armature “A” andthe field “B” should be checked. Thecorrect gap is 0.015". Adjustmentshould not be necessary until gapreaches 0.040".

3. Adjust gap by adjusting the 3locknuts “F” and checking with afeeler gauge to be sure gap is thesame on both ends of the solenoid.

Be sure the bottomof the armature does

not bear against the splined adapter “H”. Asadjustments are made, the built-in clearancewill be reduced. When this clearance is goneREPLACE BRAKE DISCS. Minimum allowabledisc thickness is .162".4. Adjustment is now complete and the

brake properly set. Replace theelectrical cover, reconnect the powersupply, and check hoist brake action.

CONTROLLERBoth the pushbutton and the reversingcontactor are mechanically interlockedto prevent shorting the circuit andcausing serious damage.As part of maintenance, always checkfor proper closure of contact points aswell as for burned contacts. Ifreplacement is necessary, see Figures 21,22, 24, and 25 for repair parts.

WIRINGRefer to Figures 11A, 11B and 11C.Single-phase units (115/230V) areshipped wired for 115V and the 1-speed, three phase units (230/460V)are wired for 460V. Two-Speed hoistsare designed for 460V only. Conversionof 1-speed hoists to either the higher orlower voltage can be done simply andquickly as follows:1. DISCONNECT HOIST FROM POWER


2. Each dual-voltage hoist has aterminal block for theinterconnection of the electrical

components of the hoist. To convertvoltage, reconnect the leads to theterminal block according to thewiring diagram located inside theelectrical cover. Do not move anywires or make any changes to theelectrical circuit except at theterminal block.

3. After converting voltage, recheckphasing and limit switch operation(See Installation 2-c & 4, pages 5 & 6).

IMPORTANT: Always refer to the wiringdiagram located on the inside of theelectrical cover when performingelectrical repairs. Make sure allterminals are securely fastened andcheck for damaged insulation.LUBRICATIONRefer to Figure 13.Proper lubrication is necessary for along and relatively trouble-free hoistoperation. Refer to the following andthe RECOMMENDED LUBRICATIONSCHEDULE for lubrication points, typeof lubricant, and frequency oflubrication.LOAD CHAIN. Clean the load chain withacid-free solvent and coat with SAE 90gear oil. Wipe excess oil to preventdripping. Never apply grease to thechain.GEARING. The gear case of this hoist isfilled at assembly with approximately 11/2 pints of SAE 90 EP gear oil. Checkoil level by removing the oil level checkplug from the side of the hoist. Withthe hoist hanging level, gear oil shouldbe even with the hole.BEARINGS. All bearings except hookand idler sheave bearings are lubricatedat the factory and should not requireadditional lubrication. Noisy or wornbearings should be replaced.LIMIT SWITCH SHAFT. Remove any dirtaccumulation and spray with a generalpurpose lubricant.HOOK BEARING. Apply a few drops ofSAE 30 gear or motor oil around theedge of the bearing.IDLER SHEAVE BEARING (BUSHING). Dis-assemble load block and apply a lightcoat of NLGI #2 grease, or equivalent,

inside of bearing.HOIST REPAIRS1. For major repairs or when the hoist is

to be sectioned in the suspensionarea, it will be necessary to move thehoist to a workbench or table.

2. For repairs which can be done byremoving the electrical cover only,the hoist need not be moved.Lowering the hoist to a convenientworking level is desirable.

NOTE: If you do not have anexperienced mechanic to do your repairwork, we recommend that you sendyour hoist to an approved servicestation for repairs. Use authorizedrepair parts only.

Remove load anddisconnect hoist from

power supply before starting to do anyrepairs or to take any sections apart.

The following repair instructions willhelp you in understanding repairprocedures, when related to the RepairParts List starting on page 18. For claritythese are broken down into areas.

ELECTRICAL PARTS AND BRAKERefer to Figures 11A, 11B and 11C.1. Remove the electrical cover. The

control panel, brake assembly, andlimit switch assembly are locatedunder the cover. The contactor andterminal block are accessible withoutfurther disassembly. It will benecessary to remove the electricalpanel to replace the transformer,solenoid, limit switches, or brakeparts.

2. Remove the electrical panel byremoving the three stand-off screws,(See Figures 21 and 22). Remove thetransformer bolted to the back of thepanel plate if it requires replacement.

3. With the electrical panel taken off,the limit switch and brake areexposed. Figure 9 shows this areawith the panel removed.




ENGLISH

12


®

13

ENGLISH

Maintenance (Continued)4. Refer to Figure 23 to disassemble

the brake. See BRAKE ADJUSTMENTto properly set the brake.

5. Refer to Figure 20 to disassemble thelimit switch. See LIMIT SWITCHADJUSTMENT to properly set theupper and lower limits of travel.

6. Refer to Figures 24 and 25 for repairson the pushbutton station. Also referto the wiring diagram inside theelectrical cover for wiring instructions.

MOTOR

Refer to Figures 16, 17, and 18.The hoist motor is located on theopposite end to that of the electricalparts, but the two are tied togetherwith electrical leads running throughthe housing.

1. If it is necessary to replace or repairthe motor, DISCONNECT THE HOISTFROM THE POWER SUPPLY andremove the electrical cover.

2. Remove the cable clamp from theelectrical panel and all the terminalsleading from the motor to theelectrical section (See Figures 21 and 22).

3. Remove the four motor mountingbolts attaching the motor to thehousing. It will come loose at themotor coupling.

4. Inspect the motor coupling, motorshaft and all the bearings. Replace asnecessary.

5. Install new or repaired motoraccording to the wiring diagramlocated inside the electrical cover.

GEARING

Refer to Figures 10, 15 and 19.As disassembly is extensive for gearing,disconnect the hoist and move it to aworkbench.1. Remove the electrical cover.2. Remove the electrical panel.3. Remove the brake assembly and the

limit switch assembly.4. Drain the oil from the gearbox.5. Remove the four screws that attach

the gear box cover to the gear housingand remove the gear box cover. Thelimit switch drive shaft will come alongwith the cover.

6. Inspect gears for broken or severelyworn teeth and inspect all bearings.Replace as necessary. The overloadslip clutch is factory calibrated andmust not be disassembled orreadjusted.

Do not disassembleor readjust the clutch,

or interchange it with a clutch assembly fromanother hoist. Doing so will void thewarranty and may create an unsafecondition. If replacement is needed due towear or loss of adjust-ment, always use anew clutch assembly.

7. Reassemble in reverse order of disassembly, making sure that the gasket is in place and in good condition. Coat the gasket with Permatex® or other gasket cement.

Extreme care should be taken to avoid damage to oil seals.

8. Check all wire terminals to be surethat they are properly seated and inaccordance with the correct wiringdiagram. Before placing the hoistback into service, check the brakeadjustment and limit switch settings.

SUSPENSION

(See below)Periodic inspections of the topsuspensions can be made withoutdisassembly. For more extensiveinspections the top hook mayberemoved as follows:1. Disconnect the hoist and remove it to

workbench.2. Remove the top hook retaining

screw. 3. Remove the top hook retainer.4. Remove the top hook.

Care should be taken during reassemblyto have the hook in proper orientation.Refer below for proper orientation.

Figure 9 - Electrical Panel Removed

Figure 10 - Assembled Gearing

Single Chain

Double Chain

The transmission must be disassembled inorder to inspect load sheave and chainguide.(see CHAIN REPLACEMENT WITHNO CHAIN IN HOIST, page 10). Refer toFigure 19 and 2. When reassembled,recheck the limit switch settings.See LIMIT SWITH ADJUCTMENT, page 11.


Figure 11 - Suspension



3YB72 thru 3YB91 and 3YB96 thru 3YB99, 3YE10and 4ZY54 thru 4ZY65

ENGLISH

14

Figure 11A — Wiring Diagram for 1-Speed, 1-Phase Models 3YB72, 3YB78, 3YB79, 3YB81, 3YB83, 3YB84, 3YB85, 3YB87, 3YB88, 3YB90, 3YB91, 3YB96 thru 3YB99 & 3YE10 thru 3YE15. For Hoists with VFD(Variable Frequency Drive)control units refer to Multi-Vector VCP Manual included with Hoist.

Figure 11B — Wiring Diagram for 1-Speed, 3-Phase Models 3YB73 thru 3YB77, 3YB80, 3YB82, 3YB86 & 3YB89. For Hoists with VFD(Variable Frequency Drive) control units refer to Multi-Vector VCP Manual included with Hoist.


Models 3YB92 thru 3YB95 and 3YE11 thru 3YE15 and 4ZY54 thru 4ZY65


®

15

ENGLISH

Figure 11C — Wiring Diagram for 2-Speed, 3-Phase Models 3YB92 thru 3YB95 & 3YE11 thru 3YE15. For Hoists with VFD(Variable Frequency Drive) control units refer to Multi-Vector VCP Manual included with Hoist.


M a x i m u m C o n d u c t o r L e n g t h i n F e e tHP Voltage 14 AWG 12 AWG 10 AWG 8 AWG

(1-Phase)

Power Supply Precautions with 1-Phase HoistsElectric hoists require a sufficient power supply. It is especially important with single-phase voltage to ensure that theconductors running to the hoist from the power source are adequate in size to handle the power requirements of the hoist.Inadequate power cables and branch circuits will cause low voltage, high amperage, damage to the hoist, and potentialfire hazards. Such problems can be minimized by using 230V power on 115/230V hoists. The following are recommendationsfor the conductor gage size depending on the length, horsepower, and voltage.

1 115V 0 30 50 75230V 120 190 310 490

1/2 115V 40 60 100 150230V 200 330 520 810




ENGLISH

16

INSPECTION AND MAINTENANCE CHECK LISTELECTRIC POWERED OVERHEAD CHAIN HOIST

Type of Hoist ___________________________________________________________ Capacity (Tons)________________________________________________________

Location _______________________________________________________________ Original Installation Date ______________________________________________

Manufacturer___________________________________________________________ Manufacturer’s Serial No. ______________________________________________

Item Frequency of Inspection Possible Deficiencies OK Action

Frequent PeriodicRequired

Daily Monthly 1-12 Mo.

Operating Controls * * * Any deficiency causing improper operation

Limit Switches * * * 1. Any deficiency causing improper operation2. Pitting or deterioration

Brake Mechanism * * * 1. Slippage or excessive drift2. Glazing, contamination or excessive wear

Hooks* * * Excessive throat opening 15% bent or twisted more than 10

degrees, damaged hook latch, wear, chemical damage,worn hook bearing. Cracks (use dye penetrant, magnetic orother suitable detection method)

Suspension Lug (if used)* * * Cracks, excessive wear or other damage which may impair

the strength of the lug. Cracks (use dye penetrant,magnetic particle or other suitable detection method)

Chain * * * Inadequate lubrication, excessive wear or stretch, cracked,damaged or twisted links, corrosion or foreign substance

Hook and Suspension * Cracks, bending, stripped threadsLug Connections

Pins, Bearings, Bushings * Excessive wear, corrosion, cracks, distortionShafts, Couplings

Nuts, Bolts, Rivets * Looseness, stripped and damaged threads, corrosion

Sheaves * Distortion, cracks, and excessive wear. Build-up of foreign substances

Housings, Load Block * Cracks, distortion. Excessive wear, internal build-up offoreign substances

Wiring and Terminals * Fraying, defective insulation

Contact Block, Hoist Reversing Contactor, other Electrical * Loose connections, burned or pitted contactsApparatus

Supporting Structure and Trolley Damage or wear which restricts ability to support (if used) * imposed loads

Nameplates, Decals, * Missing, damaged or illegibleWarning Labels

NOTE: Refer to Maintenance and Inspection Sections of the Hoist-Maintenance Manual for further details.

FREQUENCY OF INSPECTIONFrequent — Indicates items requiring inspection daily to monthly. Daily inspections may be performed by the operator if properly designated.Periodic — Indicates items requiring inspection monthly to yearly. Inspections to be performed by or under the direction of a properly designated period. The

exact period of inspection will depend on frequency and type of usage. Determination of this period will be based on the user’s experience. It isrecommended that the user begin with a monthly inspection and extend the periods to quarterly, semi-annually or annually based on user’s monthlyexperience.

Figure 12A — Recommended Inspection and Maintenance Check List

NOTE: This inspection and maintenance check list is in accordance with our interpretation of the requirements of the SafetyStandard for Overhead Hoists ASME B30.16. It is, however, the ultimate responsibility of the employer/user to interpret andadhere to the applicable requirements of this safety standard.



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17

ENGLISH

INSPECTOR’S REPORTITEM REMARKS (LIST DEFICIENCIES AND RECOMMENDED ACTION)

Inspector’s DateSignature Inspected Approved by Date

Figure 12B — Recommended Inspector’s Report

NOTE: All bearings except hook and idler sheave bearings are prelubricated and sealed.

(*) This lubrication schedule is based on a hoist operating in normal environment conditions. Hoists operating in adverse atmospherescontaining excessive heat, corrosive fumes or vapors, abrasive dust, etc., should be lubricated more frequently.

Figure 13 — Recommended Lubrication Schedule


RECOMMENDED LUBRICATION SCHEDULE*DAYTON ELECTRIC POWERED CHAIN HOIST

PAGE AND COMPONENT TYPE OF LUBRICANT TYPE OF SERVICE ANDREFERENCE NO. FREQUENCY OF LUBRICATION

HEAVY NORMAL INFREQUENT

Pages 32 & 33 Load Chain SAE 90 gear oil Daily Weekly MonthlyRef. No. 18

Pages 22 & 23 Gearing Stock No. 4F979 or At periodic inspection (see Figure 12A)SAE 90 extreme pressure (EP) gear oil

Page 24 Limit Switch Shaft Dayton Dem-Kote No. 5X628 multi- Monthly Yearly YearlyRef. No. 9 purpose oil or general purpose spray

Pages 32 & 33Ref. No. 38 & 50 Load Hook Bearing SAE 30 gear or motor oil Weekly Monthly Yearly

Stock No. 4ZF46Pages 32 & 33 Idler Sheave Bearing NLGI #2 multipurpose lithium At periodic inspection (see Figure 12A)Ref. No. 44 (Bushing) Assembly base bearing grease


Repair Parts List for Basic Hoist

1 Motor — 1(See Figures 16 & 17)

2 Cover screw H2976P 73 Trim cover JM37 14 Transmission housing JM3533 15 Transmission case gasket JM560 16 Transmission cover JM34 17 Electrical cover gasket JM563 18 Electrical cover JM36 19 Hook Retainer Screw H2709P 1

10 Top hook assembly,rigid(std.) 3M405A01S 1

11 Latch kit assembly 4X1305 112 Hook retainer JM285 113 Dayton decal JL677-1 214 1/4 ton Capacity decal JM675K-02 1

1/2 ton Capacity decal JM675K-05 11 ton Capacity decal JM675K-10 12 ton Capacity decal JM675K-20 1

▲▲ †Nylon cover for 1/4 ton 08771W 1†Nylon cover for 1/2 ton 08772W 1†Nylon cover for 1 ton 08773W 1†Nylon cover for 2 ton 08774W 1

Chain container 08348W 1

For Repair Parts, call 1-800-323-062024 hours a day - 365 days a year Please provide following information:

-Model number-Serial number (if any)-Part description and number as shownin parts listAddress parts correspondence to:Grainger Parts P.O. Box 30741657 Shermer RoadNorthbrook, IL 60065-3074 U.S.A.


ENGLISH

18


3

10

7

2

9

1

4

6

13

12

5

Ref. PartNo. Description No. Qty.


(▲▲ ) Not Shown (†)Optional

2

14

8

11

Figure 15- Basic Hoist

NOTE: SEE FIGURE 11 FORCORRECT HOOK ORIENTATION

For Repair Parts, call 1-800-323-062024 hours a day - 365 days a year

Please provide following information:-Model number-Serial number (if any)-Part description and number as shownin parts listAddress parts correspondence to:Grainger Parts P.O. Box 30741657 Shermer RoadNorthbrook, IL 60065-3074 U.S.A.


19

2

6

7

3

8

1

9

54

Figure 16- 1-Single-Phase Motor

Repair Parts List for 1-Speed, Single PhaseRef.No. DescriptioPart No Qty.

1 1-speed motor, complete 1/2 hp Motor 1 hp Motor 1115/230V, 60 Hz 861JM12 861JM14

2 Stator assembly † † 13 Rotor assembly † † 14 End shield 35EP3100D15 35EP3100D15 15 Rear bearing 500K3 500K3 16 Front bearing 732012C 732012C 17 Shim washer JL4301-01 JL4301-01 18 Thru bolt HA3100A56 HA3100A56 49 #10 Spring lockwasher H4082P H4082P 4

(†) Not available as an individual part. Complete motor must be purchased.

Ref.No. Description Part No. 1/2 H.P. Qty.

‡

(‡) Refer to the motor nameplate for part numbervoltage, full load amperage, horsepower, and other motor information.

ENGLISH

®

3YB72, 3YB78, 3YB79, 3YB81, 3YB83, 3YB84, 3YB85, 3YB87, 3YB88, 3YB90, 3YB91, 3YB96 thru 3YB99 & 3YE10

Repair Parts List for 1-Speed, 3-Phase Motor

1 1-speed motor, complete 1/2 hp Motor 1 hp Motor 1230/460V, 60 Hz 863JM2 863JM4





Dayton Operating Instructions and Parts Manual 3YB73 thru 3YB77, 3YB80, 3YB82, 3YB86 and 3YB89

ENGLISH

20

2

6

7

3

8

1

9

54

‡


Ref.No Description Part No. Qty.

Figure 16- 1-Speed, Three-Phase Motor

Repair Parts List for 2-Speed, 3-Phase Motor

1 1-speed motor, complete 1/2 hp Motor 1 hp Motor 1460V, 60 Hz 873JM6 873JM8




Dayton Operating Instructions and Parts Manual 3YB92 thru 3YB95 and 3YE11 thru 3YE15

21

Ref.No Description Part No. Qty.

Figure 18 - 2-Speed, 3-Phase Motor

2

6

7

3

8

1

9

54


‡


ENGLISH





22

11

1

4

2

12

9

3

10

8

7

2124

2221

*18

23

26

29

5

*16*18

*1915

11

31

16

*20

13

11

14

14

16

17

6

Figure 19 - Gearbox

24

**33

2527

28 12

(**) NOTE: Orient output gear (33) with long boss towards transmission cover.

(*) NOTE: This stage of gearing is not required on 32 FPM models.

®

32

30

ENGLISH

34

34

Repair Parts List


23

Repair Parts List for Gearbox

1 Sheave housing JM3533 1

2 Transmission gasket JM560 1

3 Transmission cover JM34 1(includes oil seals)

4 Spring washer 360J1 1

5 O-ring H5605 1

6 Pressure relief fitting SK1912-21W 1

7 Chain Guide JM273 1

8 Oil plug- Drain H6297 1

9 Oil plug- Fill H6296 1

10 Oil plug- Level H6295 1

11 Oil seal 561K2 3

12 Screw,HWH Self-threading H2693P 5

13 Motor coupling JM107 1

14 Bearing 500K33 2

15 Input pinion for 8 & 16 fpm JL400B 1Input pinion for 32 fpm JL400-1 1

16 Retaining ring H5501 3

17 Brake adapter JL142 1

18 Bearing for 8 & 16 fpm 500K34 2

19 High speed pinion for 8 & 16 fpm JL426 1

20 Intermediate pinion for

1/4 & 1/2 ton, 16 fpm JL402A 11 & 2 ton JL403A 1

21 Bearing 500K39 2

22 Output pinion JL401 1

23 Overload clutch assembly for

1/4 ton, 16 fpm 591JG25 1

1/4 ton, 32 fpm 591JG22 1

1/2 ton, 16 fpm 591JG16 1

1/2 ton, 32 fpm 591JG21 1

1 & 2 ton 591JG17 1


25 Bearing 500K28 1

26 Bearing P003255 1

27 Spacer-Load sheave JM127 1

28 Load sheave- 9/32” chain JF16-3 1

29 Load sheave shaft JM132 1

30 Stub shaft- limit switch drive JM140 1

31 Oil seal 011612800 1


33 Output gear JL421 1

34 Dowel pin H5382 2

▲▲ Gear oil H7642 11/2pt

Ref. PartNo Description No. Qty.


(▲▲ ) Not shown.

ENGLISH



ENGLISH




24

10

12

9

11

14

7

3

2

4

15

13

1

1 Transmission cover JM34 1

2 Limit switch assembly 918JG4 1

(includes items 4-12)

3 Limit switch bracket assembly 918JG3 1

(includes items 4-8)

4 Switch 815J1 2

5 6-32UNC X 1" Screw H1402P 4

6 6-32UNC Elastic locknut H3944 4

7 Limit switch bracket JF900-3 1

(includes item 8)

8 Bushing JF531-4 1

9 Limit switch shaft JF117-3S 1

10 Limit switch nut (silver) SK6000-63Z 1

11 Limit switch nut (gold) SK6000-63W 1


13 Insulator JF754 1

14 Spring JF343-3 1

15 10-24UNC X 1/2" Screw H2970 2

Figure 20 - Limit Switch Assembly

6

5

6

4

5

8

Repair Parts List for Limit Switch AssemblyRef. PartNo. Description No. Qty.


®

3YB72 thru 3YB91 and 3YB96 thru 3YB99, 3YE10




25

Figure 21 - Electrical Parts for 1-Speed Models

1 Transmission cover JM34 12 Panel plate 257JM200 13 Reversing contactor for

1 hp, 115/230V 24791 11 hp, 230/460V 25943 11/2 hp Only 28860 1

4 Transformer forPri.: 115/230V, Sec.: 24V 821J412 1Pri.: 230/460V, Sec.: 24V 821J432 1

5 Terminal block for115/230V 909J10 2115/230V,230/460V 909J10 8

6 Terminal block for115/230V 909J14 4

7 End plate for115/230V 909J15 1230/460V 909J12 1

8 End clamp 909J13 39 Marking strip 909J11 1

10 15 ft Power cord assembly for115/230V, 1/2 (3 cond.) 951JL1 1115/230V, 1 hp (3 cond.) 952JL1 1230/460V (4 cond.) 953JL1 1

11 PB & cable assembly(See Figure 24) — 1

12 Panel standoff spacer 200J4 313 1/4" Internal-tooth lockwasher H4134 314 1/4-20UNC X 4" Screw H1027P 315 8-32UNC X 5/16" Screw H2751 216 #8 External-tooth lockwasher H4158 217 1/4" Flatwasher H4002P 118 10-24UNC X 1/2" Screw H2970 119 Can mounting bracket JM811 220 SINPAC® Starting Switch 839J3 121 Capacitor

1 Hp motor JL810-4 11/2 Hp motor JL810-7 1



Repair Parts List for Electrical Parts, 1-Speed Models

1

12

12

13

14

3

2

7

198

14

13

4

9

8

8

6

5

16

15 16

10

1117

18

18

2021

ENGLISH

1

15

8

4

10

9

10

9

15

3

6

14

12

8

7

11

2

12

1413

5

ENGLISH


2 Panel plate 257JM200 1

3 Reversing contactor for

1 hp 25943 1

1/2 hp 28860 1

4 Speed control relay for

1 hp 28885 1

1/2 hp 28878 1

5 Transformer 821J432 1

Pri.: 230/460V, Sec.: 24V

6 15 ft Power cord assembly 953JL1 1

7 PB & cable assembly

(See Figure 25) — 1

8 Panel standoff spacer 200J4 3

9 1/4" Internal-tooth lockwasher H4134 3

10 1/4-20UNC X 4" Screw H1027P 3

11 8-32UNC X 5/16" Screw H2751 2

12 #8 External-tooth lockwasher H4158 2

13 1/4" Flatwasher H4002P 1

14 10-24UNC X 1/2" Screw H2970 1

15 End clamp 909J13 2

16 Multi-Vector VCP (Hoist with VCP Only)

Refer to Manual included with Hoist for operation

instructions.)


Please providefollowinginformation:-Model number-Serial number (ifany)-Part descriptionand number asshownin parts listAddress partscorrespondence to:

Grainger Parts P.O. Box 30741657 Shermer RoadNorthbrook, IL60065-3074 U.S.A.

Dayton Operating Instructions and Parts Manual3YB92 thru 3YB95 and 3YE11 thru 3YE15

and 4ZY54 thru 4ZY65

26

Figure 22 - Electrical Parts for 2-Speed Models. For Hoists with VFD(Variable Frequency Drive) control units refer to Multi-Vector VCP Manual included with Hoist.

Repair Parts List for Electrical Parts, 2-Speed Models (460V)Ref. PartNo. Description No. Qty.


®

16





27

1 Disc brake assembly for1-phase 854JM1 13-phase, 1-speed 854JM2 13-phase, 2-speed 854JM3 1

2 Plate & stud assembly 859JG1 1

3 Brake Disc 581J1A 34 Brake plate JF291 2

5 Plate & armature assembly JF858 1

6 Spring 344J6 3

7 Retainer JF710 1

8 Plate & frame assembly JF857 1

9 Brake Coil for 1-phase 853JL1 1Brake Coil for 1-speed, 3-phase 853JL2 1Brake Coil for 2-speed, 460V 853JL3 1

10 Locknut H3978 3

11 Adapter JL142 1

12 Screw H2976P 3


14 Shading coil 860J1 2Shading coil adhesive H7812 1

15 Lockwasher H4134 3

Figure 23 - Brake Assembly



NOTE: Refer to the wiring diagram inside the electrical cover or Figures 11A, 11B, or 11C when connecting any wires.

Repair Parts List for Brake Assembly

13

1311

2

15

12

4

34

3

5

6

14

8

10

7

10

6

91

3

ENGLISH

15

12

12

15

12

6

7

1011

4

5

13

14

154

84

9

16

3

2

1

3YB72 thru 3YB91 and 3YB96 thru 3YB99, 3YE10

ENGLISH




28

Figure 24 - 1-Speed Pushbutton Station

®

Repair Parts List


29

1 Pushbutton station & control cable assembly for

6 ft Cable length PB2100-6 1



Special drop PB2100-S# 1

2 Pushbutton station assembly 36900R 1

3 Control cable assembly for

6 ft Cable length PBC2100-6 1



Special drop PBC2100-S# 1

4 Enclosure 36998 1

5 Gasket 36986 1

6 Contact assembly (includes items 6 & 7) 36987 1

7 Button assembly 36988 1

8 Grommet 36989 1

* Hardware kit 36939 1

(includes items 9 - 16)

▲▲ Warning tag 687K3W 1

(#) Equal to cable length.(▲▲ ) Not shown.

Repair Parts List for 1-Speed PushbuttonRef.No. Description Part No. Qty

ENGLISH

3YB72 thru 3YB91 and3YB96 thru 3YB99, 3YE10

ENGLISH



Dayton Operating Instructions and Parts Manual 3YB92 thru 3YB95 and 3YE11 thru 3YE15

30

13

Figure 25 - 2-Speed Pushbutton Station

®

12

6

7

1011

4

5

1314

15

4

84

9

16

32

1


1 Pushbutton station & control cable assembly for




Special drop PB2200- S# 1

2 Pushbutton station assembly 36800R 1

3 Control cable assembly for




Special drop PBC2200- S# 1

4 Enclosure 36998 1

5 Gasket 36986 1

6 Contact assembly (includes items 6 & 7) 36868 1

7 Button assembly 36869 1

8 Grommet 36866 1

* Hardware kit 36939 1

(includes items 9 - 16)

▲▲ Warning tag 687K3W 1

Repair Parts List


31

(#) Equal to cable length in feet.(▲▲ ) Not shown

Repair Parts List for 2-Speed PushbuttonRef.No. Description Part No. Qty

ENGLISH


ENGLISH




32

Figure 26 - Chaining Parts

2-Ton Models

1/4, 1/2 & 1-Ton Models

1

4

5

3

2

6

9

188 19

15

14

26 24

15

28

32

29

12

29

7

25

31

16

14

3023

22

24

7

21

13

17

13

20

®

10

11

27

Repair Parts List


33

Repair Parts List for Chaining Parts

1 Housing JM3533 1


3 Electrical cover JM36 1

4 Anchor pin (2-ton only) JM111 1

5 Anchor (2-ton only) JM109 1

6 Chain stripper JM254 1

7 Chain stop kit 75JG6K 1(Kits include halves, sleeve and retaining ring)

8 Load chain JL19-1 •

9 Attachment pin JM18-1 1

10 Retaining clip H5597 1

11 1/4-20UNC x 1¼" S49-77 1

Socket head cap screw

12 Bottom block assembly 1/4,1/2 & 1 ton 913JG3AS 1

13 1/4-20UNC x 1¼" S49-77 2

Socket head cap screw

14 1/4" Internal-tooth lockwasher H4134 2

15 Load block frame 30J14 2

16 Load block pin 18J8 1

17 Slotted hex nut H3986P 1

18 Bearing JF510 1

19 Latch Kit 4X1304 1

20 Bottom hook assembly with latch 3JG20S 1

for 1/4, 1/2 & 1 ton

21 Bottom block assembly for 2 ton JF914-6 1

22 3/8-24 Hex locknut H3964P 2

23 Load block screw H2403P 2

24 Load block frame JF30-1 2

25 Sheave shaft assembly JF917-1 1

26 Sheave shaft JF122-1 1

27 Sheave & bearing assembly JF916 1

28 Roll pin H5234 2

29 3/8-24 Hex locknut H3991P 1

30 Bearing JF511 1

31 Latch kit 4X1305 1

32 Bottom hook assembly with latch 3KG1W 1

for 2 ton

Ref. PartNo Description No. Qty.


(•) Repair chain is sold by the foot. For single-chained models, add 2 ft to the lift for the total amount of feet.For double-chained models, double the lift and add 3 ft.

(▲▲ ) Not shown

ENGLISH





LIMITED WARRANTYDAYTON ONE-YEAR LIMITED WARRANTY. Dayton® Electric Chain Hoists, Models covered in this manual, arewarranted by Dayton Electric Mfg. Co. (Dayton) to the original user against defects in workmanship or materialsunder normal use for one year after date of purchase. Any part which is determined to be defective in materialor workmanship and returned to an authorized service location, as Dayton designates, shipping costs prepaid,will be, as the exclusive remedy, repaired or replaced at Dayton’s option. For limited warranty claim procedures,see PROMPT DISPOSITION below. This limited warranty gives purchasers specific legal rights which vary fromjurisdiction to jurisdiction.

LIMITATION OF LIABILITY. To the extent allowable under applicable law, Dayton’s liability for consequential andincidental damages is expressly disclaimed. Dayton’s liability in all events is limited to and shall not exceed thepurchase price paid.

WARRANTY DISCLAIMER. Dayton has made a diligent effort to provide product information and illustrate theproducts in this literature accurately; however, such information and illustrations are for the sole purpose ofidentification, and do not express or imply a warranty that the products are MERCHANTABLE, or FIT FOR APARTICULAR 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 Daytonattempts to assure that its products comply with such codes, it cannot guarantee compliance, and cannot beresponsible for how the product is installed or used. Before purchase and use of a product, review the productapplications, 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 allowthe exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may notapply to you; (b) also, some jurisdictions do not allow a limitation on how long an implied warranty lasts,consequently the above limitation may not apply to you; and (c) by law, during the period of this Limited Warranty, any implied warranties 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 withrespect to any product which proves to be defective within limited warranty. For any product believed to bedefective within limited warranty, first write or call dealer from whom the product was purchased. Dealer willgive additional directions. If unable to resolve satisfactorily, write to Dayton at address below, giving dealer’sname, 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.

Manufactured for Dayton Electric Mfg. Co.Niles, Illinois 60714 U.S.A.

®

ENGLISH

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