Gearhead Maintenance ManualT he gearhead and motor should be handled, installed and maintained by trained technicians. Carefully read this manual and allaccompanying documents before use.
A copy of this manual should be sent to the actual user of the gear unit.
This manual should be maintained by the user.

1. Safety and other precautions

CAUTIONGeneral
. The gearhead and motor should be operated only under the specification indicated In name plate and catalogue; otherwise, electric shock, injury or damage to system
may occur.
. Keep hands and all foreign objects from the internal moving part of the gear unit and motor; otherwise, electric shock, injury, fire or damage to system may occur.
. Damaged units should be taken off-line; otherwise, injury or fire may occur.
. Do not remove nameplate.
. Any modifications or alterations of any kind, to the unit, will void the warranty and all subsequent claims.
Transport. Exercise ample care not to drop the unit and fall during transport.
Installation
. Do not place any inflammables around the gearhead and motor; otherwise, fire may result.
. Do not place any objects that will hinder ventilation around motor; otherwise, cooling effect is reduced, and may lead to a possible fire hazard and a burn due to excessive
heat built-up.
. Do not touch the key way at the shaft end or on the inside of the dear unit and motor; otherwise, injury may result.
. When the unit is used in food processing applications vulnerable to oil contamination, install an oil pan or other such device to deal with oil leak which rarely happen.
Otherwise, oil leakage may damage products.
Coupling with other machines. Install appropriate guard devices around rotation parts; otherwise, injury may result.
. Confirm the direction of rotation before coupling the unit with its driven machine. Difference in the direction of rotation may cause injury or damage to the system.
Wiring. Do not touch lead wire when measuring the insulation resistance. Electric shock may result.

DANGER
Wiring. Connect a power cable to the motor according to the connection diagram or maintenance manual; otherwise, electric shock or fire may result. (For motors without
terminal box, exercise insulation in the connecting part.). Do not forcibly curve, pull or clamp the power cable and lead wires; otherwise, electric shock may result.
. Correctly ground the grounding bolt; otherwise, electric shock may result.
. Use power source stated in the nameplate; otherwise, motor may burn or fire.
Operation. Never approach or touch any rotating parts (shaft, etc.) during operation; otherwise, loose clothing caught in these rotation parts may result in severe injury to humans.
. When the power supply is interrupted, be sure to turn off the power switch. Unexpected resumption of power may cause injury or damage to the equipment.
Daily inspection and maintenance. Never approach or touch any rotating parts (shaft, etc.) during maintenance; otherwise, loose clothing caught in these rotating parts may result in severe injury to humans.
Inspection upon delivery. Verify that the unit received is relevant to the order. When a different product is installed, injury or damage to the system may result.

2. Inspection upon delivery. Gearhead and motor with same model number and same heat treatment symbols can be combined.
Please refer to Fig. 1 as an example.
{Motor}Fig.1 Combination example ofmotor & gearhead{Gearhead}

1) A8 M 25 DG8KModel No.

2) A9{Motor}

M{Gearhead}

60

A

HG9B

K H

Model No.

:Reduction ratio

Heat treatment symbol

3. Allowable maximum torque. Allowable maximum torque is maximum torque during motor operation. It is limited by rated motor torque, temperature rise, andstrength of gearhead combined. This torque depends on reduction ratio. Please refer to catalogue for details.

4. Rotating direction. There are two rotating directions for output shaft of gearhead, same direction as motor and counter-direction, determined by reduction
ratio. Refer to (table 1).
. Direction of intermediate gearhead (1/10) is the same as a single unit.

Table 1. Rotating direction of gearhead output shaft
Model
G6 D
G7 K
G8 K
G9A K
G9B KH

Ratio

3

3.6

56

7.5

910 12.5 15182025: Reduction ratio

5. Operation life & service factor (SF) of gearhead. Apply each service factor corresponding to the load type(Refer to Table 2).
. The operating life of gearhead with service factor 1.0 would be 5,000hrs.

30364050607590 100 120 150 180 200: Same direction as motor: Reverse-direction

Table 2. Service factor & load type
Load type
Example of load
Service factor
Uniform load
Continuous running
1.0
Moderate shock Frequent start/stop running
1.5
Heavy shock Frequent cw/ccw running
2.0

6. Radial load & axial load
. Radial load can be obtained by following formula.
Pr=Pℓ Cf S.F./R
Where
Pr: Radial load [N]Pℓ : Actual transmitted torque on output shaft [N·m]Cf : Coupling factor (Refer to Table 3)
SF : Service factor (Refer to Table 2)
R : Radius of gear or pulley [m]. When gearhead is used with load exceeding the allowablevalue (Table 4), bearing's short-term damage, bend of output
shaft, and fatigue damage by repeating loads may result.
. Make sure not to exceed allowable radial and axial load on theshaft when coupling gear, which generates axial load at theoutput shaft of the gearhead.
Gearhead

Radial load

Table 3. Coupling factor for operating typeOperating type
Chain, sprocket
Gear
PulleyTable 4. Allowable radial & axial loads
Model
G6 D
G7 K
G8 K
G9A K

Axial load

Cf
11.25
1.5

G9B KH

Reduction ratio Max.allowable
torque [Nm]3-18
0.10-0.60
20-2500.60-2.90
3-18
0.30-1.80
20-2002.00-4.90
3-18
0.20-2.50
20-2002.90-7.80
3-18
0.40-3.90
20-2003.90-9.80
3-10
0.80-3.90
12.5-20
3.90-7.80
25-60
4.90-19.60
75-200Allowableradial load [N]
60
150
100
200
120240290360440510Allowable
axial load [N]304050100150590Note: Allowable maximum torque depends on reduction ratio.

7. Load moment of inertia
 . Load moment of inertia on motor shaft can be obtained by following formula.
JM=J/i2
Ratio 50 J: Load moment of inertia [kgm2]
JM=J/502 50 Ratio JM:Load moment of inertia on motor shaft [kgm2]

Table 5. Allowable load moment of inertia on motor shaft [10-4kgm2]. When gearhead is used with moment of inertia exceeding the allowable value(Table 5), gear's and bearing's short-term damages may result.

8. How to install motor and gearhead

ModelA6 06
A7 15
A8 25
A9 40
A9 60
A9 90

Capacity[W]615254060
901-phase
0.05
0.15
0.30
0.75
1.00
1.00

3-phase
0.30
0.75
1.00
1.00

. Install motor and gearhead, putting both contact surfaces together as in Fig. 2 while rotating them little by little. Forcing into motor shaft
and bumping into the inside of gearhead, at assembly, may cause abnormal noise by broken gear and shorten the operating life.
. Use accessory key by processing keyway on the transmission component side, when fixing power transmission components (chain,pulley, sprocket, etc.) on the gearhead shaft with keyway.
. When holding transfer fittings down to gearhead shaft,applying impacts may cause damages or shortening
operation life of gearhead. Please do not hit thegearhead shaft.

Motor capacity
6W
15, 25W
40, 60, 90W

Gearhead size
G6
G7, G8G9Screw size
M4
M5
M6

Tightening torque2N • m
2.5N • m
3N • mName
plate

9. Ambient conditions
Location
Temperature
Humidity
Elevation
AtmosphereI ndoors(Minimal dust and humidity). Consult us when mounting our equipment other than the conditions mentioned above. Special specification
will be necessary.
. Install the equipment where it is easy to carry out inspection and maintenance.
. Install
the equipment on a mount having sufficient rigidity.
-10°C-40°C
Under 85%RH with no condensation
Under 1,000m
Well ventilated location free of corrosive & explosive gases, vapors and dust.

Fig. 210. Warranty

The scope of warranty of our delivered products is limited only to what we manufactured.
Warranty (period and description)
Warranty period

Description

Exclusionfrom thewarranty

The warranty period applies only to new products and represents 18 months after the shipment or 12 months after the actual operation, whichever is shorter.
If the product failed within the warranty period, during which despite a proper mounting, connection and maintenance & administration are followed according
to the maintenance manual, and the product is properly run based on the specification on the catalog or under conditions agreed separately, we will repair orprovide an alternative product at our discretion for free of charge, except the exclusions below.
However, as far as the product is connected with customers' other devices, we will not indemnify those expenses on dismounting from/mounting on the devices, etc. and other associated construction expenses, transportation expenses and opportunity loss and operation loss the customers suffered from, and otherindirect damages.
The following items will be excluded from the warranty:
1. A breakdown resulting from defects in the installation of the product and coupling with other devices, etc.
2. A breakdown resulting from insufficient maintenance & administration and improper handling of the product, including a case that the product is not storedaccording to our defined storage manual.
3. A breakdown resulting from operation which does not fall within our specification and other operation conditions and use status we hardly can know or a
failure caused by the use of lubricant which we do not recommend.
4. A breakdown resulting from defects, special specification, etc. of device prepared and connected by customer.
5. When this product is disassembled or modified by the customer, or the parts are replaced by the customer.
6. A breakdown resulting from defects in parts supplied or specified by customers.
7. A breakdown caused by inevitable force including earthquake, fire, flood disaster, salt damage, gas damage, and lightning strike, etc.
8. Natural wear and tear, abrasion, and deterioration of such relevant consumable parts as a bearing and oil seal, etc. under normal usage.
9. A breakdown caused for reasons not attributable to each of the above item.

Specifications, dimensions, and other items are subject to change without prior notice.

Power Transmission & Controls Group
Headquarter ThinkPark Tower, 1-1 Osaki 2-chome, Shinagawa-ku, Tokyo 141-6025, Japan

No.EM0101E-4.1

EE01 Printed 2023.01