BUDDYBOX®
Bevel BUDDYBOX® 4 Series
Bevel BUDDYBOX® 5 Series
Helical BUDDYBOX®
Application Product : BUDDYBOX® with Torque Limiter<Note>
This product should be handled by only those who have been trained for the work.
Please read this manual carefully before use.
Deliver this manual to the customer who will actually use the product.
This maintenance manual should be kept by the user for future reference.

Maintenance Manual No.CM2020E-5

ii

Introduction: Safety Precautions- Carefully read this maintenance manual and all accompanying documents before use (installation, operation, maintenance,
inspection, etc.). Use the product after throughly understanding the machine, information about safety, and all precautions forcorrect operation.
After reading, retain this manual for future reference.
- Pay close attention to the "DANGER" and "CAUTION" warnings regarding safety and proper use.

DANGER

Improper handling may result in physical damage, serious personal injury and/or death.

CAUTION

Improper handling may result in physical damage and/or personal injury.

Matters described in

CAUTION

may lead to serious danger depending on the situation.

Be sure to observe important matters described herein.

DANGER- Transport, installation, plumbing, wiring, operation, maintenance, and inspections should be performed by trained
technicians; otherwise, electric shock, injury, fire, or damage to the equipment may result.
- In the case of maintenance with disassembly, please contact the nearest authorized maintenance shop.
- When using the equipment in conjunction with explosion proof motor , a technician with understanding about the
principle and mechanism of explosion proof motor (such as explosion-proof structures, construction of electrical facility,
and relating laws) should conduct the transport, installation, plumbing, wiring, operation, maintenance and inspection of
the equipment; otherwise, explosion, ignition, electric shock, personal injury, fire or damage to the equipment may result.
- When the unit is to be used in a system for human transport, a protecting device for human safety should be installed toprevent accidents resulting in personal injury, death, or damage to the equipment due to running out of control or falling.
- When the unit is to be used for an elevator or lifter, install a safety protecting device on the elevator side to prevent falling;otherwise, personal injury, death, or damage to the equipment may result.

CAUTION- Please install loss prevention device such as oil pan to the machine which is vulnerable to oil especially (machine for foodprocessing and machine for clean room, and so on) in case oil or grease leaks; otherwise, the product may fail because of oilleakage.

1

CommonIntroduction:
How to Refer to the Maintenance Manual, Table of Contents
This maintenance manual is common for “gearmotors”, “reducers”, and “the application products: BUDDYBOX Reducer with Torque
Limiter”.
The symbols shown below appear in the upper right or left corner of each page to indicate the classification. Please read theapplicable pages.
On Common pages, regarding only specific specification, symbols are applied to indicate the contents about it.

Specifications

Mark

Common to
All Specifications

Gearmotor
Without Brake

Reducer

Application ProductWith Brake

Application
Product

CommonContents
CommonIntroduction: Safety Precautions………………………………………………………………………………………… 1
Introduction: How to Refer to the Maintenance Manual, Table of Contents………………………………………… 2
1. Receiving Inspection…………………………………………………………………………………………………… 3
2. Storage………………………………………………………………………………………………………………… 8
3. Transport……………………………………………………………………………………………………………… 9
4. Installation……………………………………………………………………………………………………………… 10
5. Coupling with Other Machines ……………………………………………………………………………………… 12
6. Wiring…………………………………………………………………………………………………………………… 21
7. Operation……………………………………………………………………………………………………………… 39
8. Daily Inspection and Maintenance…………………………………………………………………………………… 41
9. Troubleshooting……………………………………………………………………………………………………… 80
10. Construction Drawings……………………………………………………………………………………………… 82

Application Product: BUDDYBOX Reducer with Torque Limiter
11. Wiring………………………………………………………………………………………………………………… 88
12. Adjusting Preset Torque……………………………………………………………………………………………… 90
13. Daily Inspection and Maintenance………………………………………………………………………………… 91
14. Torque Indicator……………………………………………………………………………………………………… 93
15. Construction Drawings ……………………………………………………………………………………………… 94

Common16. Warranty……………………………………………………………………………………………………………… 97

2

1. Receiving Inspection Common
CAUTION- Unpack the unit after verifying that it is positioned correct side up; otherwise, injury may result.
- Verify that the unit received is the one you ordered. Installing the wrong unit may result in personal injury or equipment
damage.
- Do not remove the nameplate.

Verify the items listed below upon receiving the product. If a nonconformity or problem is found, contact our nearest agent,
distributor, or sales office.
[1] Does the information on the nameplate conform to what you ordered?
[2] Was any part broken during transport?
[3] Are all bolts and nuts tightened firmly?

1-1 Reading the Nameplates
There are two main types of nameplates: type 1 and type 2. Representative examples are shown below. Please observe them by type.
When contacting us, please provide [1]. Gearmotor or reducer nomenclature, [2]. Reduction ratio, and [3]. Serial number.

(1) For Gearmotor- Motor capacity- Motor characteristics- Motor nomenclature (See P7)[1] Gearmotor-B rake type fornomenclature (See P5)[2] Reduction ratio- Service factor- Input capacity, speed- Allowable output torque

MODEL
R AT I OSERVICE FACTORINPUTOUTPUT TORQUES E R I A L NO.

motor with brake(See P7)
kW

N •m- Motor frame size

r/min

-B
 rake torque formotor with brake[3] Serial number[3] Serial number- Brake current value for motor with brake(Gear Unit Nameplate)(Motor Unit Nameplate)Figure 1-1 Gearmotor Nameplate(2) For Reducer(See P5)[2] Reduction ratio- Service factor- Input capacity, speed

INDUCTION MOTOR

R

[1] R
 educer nomenclature
MODEL
R AT I OSERVICE FACTORINPUTOUTPUT TORQUES E R I A L NO.

kW

N •m

r/min

kW
VOLTS
Hz
M.AMP
r/min
B.AMP

P

φ TYPE

BRG.
JISC4004

SERIAL NO.

- Allowable output torqueJAPAN[3] Serial number
Figure 1-2 Reducer Nameplate

3

FRAME
M/B INS.CLASSRATING
B.TORQUE

ER243WW

N・mCommon

1. Receiving Inspection(3) For the One with Torque Limiter Application(motor unit nameplate is the same as in figure 1-1.)
Product■ Gear Unit Nameplate
Confirm that the preset torque value marked in the gear unit nameplate and the preset torque value marked on the adjustment
indicator plate (see P90) are the same as the required specification.
[1] G earmotor nomenclature(See P5)MODEL
R AT I OINPUTOUTPUT TORQUE
PRE-SET TORQUESERIAL NO.

[2] Reduction ratio- Input capacity, speed- Allowable output torque- Torque setpointwith TORQUE LIMITER

kW- Service factor

SERVICE FACTOR
N・m

r/min
N・m
N・m

JAPAN

[3] Serial number

Figure 1-3 Torque Limiter Nameplate (Gear Unit Nameplate)■ Alarm Torque Nameplate
For 2-point alarm configuration (double safety specification), an alarm torque nameplate is attached near the nameplate in figure 1-3.

ALARM TORQUE- Alarm torqueN •mFigure 1-4 Torque Limiter Nameplate (Alarm Torque Nameplate)

1-2 Checking Lubrication Method
Refer to “8-2 Confirmation of Lubrication Method” (P42) to confirm the lubrication method.
Oil lubricated machines are shipped without oil. Before operating, make certain to feed the recommended lubricating oil.
(See P43–49)

4

1. Receiving Inspection Common
1-3 Gearmotor, Reducer Nomenclature
Symbol meanings are shown below. Please confirm that the nomenclature matches your order.

L H Y M

3

4A105

EP Y1

B

46

With or Without
Brake
Without
Blank
Brake
B With Brake

Frame Size
See P6, Table 1-1
through 1-3

Mounting Location
SymbolSee P6, Table 1-4
through 1-6

Special Specification
Blank Standard Specification
S
Special Specification

Nominal Ratio

Output Shaft Direction
H Horizontal
Vertical (Hollow Shaft)V
Vertical Downward (Solid Shaft)
W Vertical Upward (Solid Shaft)Shaft TypeBlank Metric (Standard)
Taper Grip
M
MetricModel Symbol
L Bevel BUDDYBOXE Helical BUDDYBOXBlank Note
EP
AV

Mounting Style
Hollow Shaft, Shaft Mount
Y
Hollow Shaft, Flange Mount
U Solid Shaft, Case Mount
F Solid Shaft, Flange Mount
H Solid Shaft, Foot Mount

AP

SuffixWith 3-Phase
With High-Efficiency,
ES
Motor
3-Phase Motor
With PremiumEfficiency,
TL With Torque Limiter
3-Phase Motor
With AF Motor for Various
Motor Flange CodeInverter
CodeWith PremiumEfficiency, 3-Phase
Motor for Inverter

Note: Only for gearmotor

Output Shaft Direction
Blank None (Hollow Shaft)

Type of Input
Gearmotor

Reducer
Gearmotor(Motor Directly Connected)
Reducer(Reducer Type)With Motor Flange(Connected by Input Hollow Shaft)With Motor Flange(With Adapter, Connected By
Coupling)

M
Blank
XM

X

JM

J

L

One Side
Shaft from the casesurface closer to themotor center lineR

One Side
Shaft from the casesurface farther fromthe motor center line

T

Both Sides

Input Capacity Symbol (Gearmotor)
4
P

Capacity
Symbol
kW
(HP)

01

02

03

05

08

1

1H

2

3

4

5

8

0.1 0.2 0.25 0.4 0.55 0.75 1.1(1/8) (1/4) (1/3) (1/2) (3/4) (1) (1.5)

1.5
(2)

2.2
(3)

3.0
(4)

3.7
(5)

5.5 7.5 11
15 18.5 22
30
37
45
55
(7.5) (10) (15) (15) (25) (30) (40) (50) (60) (75)

5

10

15

20

25

30

40

50

60

75

Common

1. Receiving Inspection

Table 1-1 Bevel BUDDYBOX 4 Series Frame Sizes
Bevel 1 Stage + CYCLO 1 Stage or Planetary Gear 1 Stage Reduction
4A100
4B120
4C140
4D160
4E170
4F180
4A105
4B125
4C145
4D165
4E175
4F185
4A110
4B140
4C160
4D170
4E180
4F190
4A115
4B145
4C165
4D175
4E185
4F195
4A120
4B160
4C170
4D180
4E190
4A125
4B165
4C175
4D185
4E195
4A140
4A145

4A10DA
4A12DA
4A12DB

Bevel 1 Stage + CYCLO 2 Stage Reduction
4B12DA 4C14DA 4D16DA 4E17DA
4B12DB 4C14DB 4D16DB 4E17DB
4B14DA 4C14DC 4D17DA 4E17DC
4B14DB 4C16DA 4D17DB 4E18DA
4C16DB 4D17DC 4E18DB
4D18DA 4E19DA
4D18DB 4E19DB

4F18DA
4F18DB
4F19DA
4F19DB

Table 1-2 Bevel BUDDYBOX 5 Series Frame Sizes
Bevel 1 Stage + CYCLO 1 Stage or Planetary Gear 1 Stage Reduction
5Z100
5A110
5B120
5C140
5Z105
5A115
5B125
5C145
5Z110
5A120
5B140
5C160
5Z115
5A125
5B145
5C165
5Z120
5A140
5B160
5C170
5Z125
5A145
5B165
5C175

5Z10DA
5Z12DA
5Z12DB

Bevel 1 Stage + CYCLO 2 Stage Reduction
5A12DA
5B12DA
5C14DA
5A12DB
5B12DB
5C14DB
5B14DA
5C14DC
5B14DB
5C16DA
5C16DB

Table 1-3 Helical BUDDYBOX Frame Sizes
Helical 1 Stage + CYCLO 1 Stage or Planetary Gear 1 Stage Reduction
Z6090
A6100
B6120
C6140
D6160
E6170
Z6095
A6105
B6125
C6145
D6165
E6175

Z609DA

Table 1-4 Bevel BUDDYBOX 4 Series Mounting Location Symbols
First Digit
Y
F
G
K
W
V

Mounting Style
Shaft Mount, Case
Mount
Flange Mount
Foot Mount

Second Digit

Mounting Posture

1
2
3
4
5
6

Each Direction

Table 1-5 Bevel BUDDYBOX 5 Series Mounting Location Symbols
First Digit
Mounting Style
Second Digit Mounting PostureY
Shaft Mount
1
G
Flange Mount
2
3
Each Direction
4
5
6
Table 1-6 Helical BUDDYBOX Mounting Location Symbols
First Digit
Mounting Style
Second Digit Mounting PostureY
Shaft Mount
1
F
Flange Mount
2
3
Each Direction
45
6
Note: For details of mounting location symbols, refer to the catalog.

6

Helical 1 Stage + CYCLO 2 Stage Reduction
A610DA B612DA C614DA D616DA
B612DB C614DB D616DB
D616DCE617DA
E617DBE617DC1. Receiving Inspection

Common1-4 Motor Nomenclature
Symbol meanings are shown below. Please confirm that the nomenclature matches your order.
When using another manufacturer’s motor (motors made by other manufacturers are attached depending on motor specifications),
follow the operation manual for that motor.

H

T

C

Type of Sheath
T Totally
Enclosed
Mounting Style
H FootBlank Flange

Rotor Symbol
C Normal Box
K Special Box

F
B
E

E

X

Explosion Proof, Protection TypeA Increased Safety (Indoor)
B Increased Safety (Outdoor)
C Flameproof (Indoor)
CX Flameproof (Outdoor)
X No Explosion Proof (Outdoor)
Blank No Explosion Proof (Indoor)

Cooling TypeWith Fan (Self Ventilation)
With Fan (Fan Motor
Ventilation)
Fanless (Self Ventilation)

Support for Standards andRegulations
P Premium-Efficiency Motor
E High-Efficiency Motor(IEC Standard)
Blank Motor Other Than Above

Drive Power Source
V Inverter Drive (motor for Inverter)
Blank Commercial Power Source Drive
Other Specification
A UL, NEMA, CSA Specification (230, 240, 460, 480V)
C UL, NEMA, CSA Specification (575V)
Blank Motor Other Than Above

1-5 Brake Type
Table 1-7 shows the relationship between standard brake type, motor type, and capacity range.
Table 1-7 Brake Type
Motor Capacity (kW)Brake Type

FB-01A1
FB-02A1
FB-05A1
FB-1D
FB-1E
FB-1HE
FB-2E
FB-3E
FB-4E
FB-5E
FB-8E
FB-10E
FB-15E
FB-20
FB-30
ESB-250(Horizontal Type)
ESB-250-2(Vertical Type)

3-Phase Motor

Premium-Efficiency,
3-Phase Motor

AF Motor for Inverter

4P
0.1
0.2 0.25
0.4
0.55
-

4P
0.75
1.1
1.5
2.2
3.0
3.7
5.5
7.5
11
15
18.5 22 30

4P
0.1
0.2
0.4
-

Premium-Efficiency,
3-Phase Motor for
Inverter
4P
0.75
1.5
2.2
3.7
5.5
7.5
11
15
18.5 22 30

-

37 45

30 37

37 45

Note: Depending on the specification, brake type may differ from the types shown in Table 1-7. Check the nameplate.

7High-Efficiency,
3-Phase Motor
4P
0.2
0.4
-

Common

2. Storage

If this product is not for immediate use, note the following points when storing it.

2-1 Storage Location
Store the product in a clean and dry indoor.
Do not store the product outdoors. Store it in a location that is free of moisture, dust, extreme temperature changes, corrosive
gases, etc.

2-2 Storage Time- The storage time should be within the rust prevention time shown below.
- Standard rust prevention specifications
External rust prevention 	Rust prevention oil is applied when shipping from the factory. Check the rust conditions to see
if any rust is forming on the machined surface every six months after shipment. Reapply the rustprevention oil or any other rust prevention process if necessary.
Internal rust prevention
Lubrication
Rust prevention time
Storage conditions

Grease Lubricated Machines

Oil Lubricated Machines

One yearSix months

Store the product in a general factory or warehouse in an environment freeof moisture, dust, extreme temperature changes, corrosive gases, etc.

- If the product is for export, or if the storage time is longer than one year (grease lubricated) or six months (oil lubricated) adherence
to special rust prevention specifications is required. Please consult with us.
- If the storage time is longer than one year, run the product for a few minutes under no load once every two to three months. Measure(see P22) and check the insulation resistance of the motor at that time.

2-3 Using after Storage- Oil seals are affected by temperature, ultraviolet light and other ambient conditions and can easily degrade. After long storage
periods, inspect it before operation, and replace any degraded seals with new seals.
- If the storage period is 2 years or longer, replace the oil seals and the grease before starting operation.
- At startup, check that there are no unusual noises, vibrations, temperature rises, or other symptoms. For models with brakes, checkthat brakes work properly.
If any abnormalities are found, immediately contact the nearest authorized maintenance shop.

8

3. Transport Common
DANGER- Do not step under a unit suspended by a crane or other lifting mechanism for transport; otherwise, injury or death may
result.

CAUTION- Be careful not to drop the unit.
When a hanging bolt or hole is provided, make sure to use it. After mounting a unit on a machine, do not hoist the entire
machine by using the hanging bolt or hole; otherwise, personal injury or damage to the equipment and/or lifting device
may result due to falling of the machine or failure of hanging metal fitting.
- Before hoisting, refer to the nameplate, crate, outline drawing, catalog, etc. for the weight of the unit. Never hoist a unit thatexceeds the load capacity of the crane or other mechanism being used to lift it; otherwise, personal injury or damage to theequipment and/or lifting device may result.
- When the products are lifted, use suitable lifting parts, and confirm that eye bolts and nuts are not loose.
- Before mounting, moving, or transporting the machine, make sure to remove the lubricating oil for the machine
lubricated by oil.
Moving machine with lubricating oil in may cause oil to discharge from the air vent, etc.

9Common

4. Installation
DANGER- Do not use a standard unit in an explosive atmosphere. Under such conditions, an explosion proof motor should be used;otherwise, explosion, ignition, electric shock, personal injury, fire or damage to the equipment may result.
- In the case of an explosion proof motor , use a motor that has specifications that are appropriate for a dangerous location(a location where gas or volatile vapor is present); otherwise explosion, ignition, electric shock, injury, fire, or equipment
damage may result.
- For flameproof motor driven by an inverter , install an inverter in a place free from explosive gas since the inverter itself is not
explosion proof; otherwise, explosion, ignition, electric shock, personal injury, fire or damage to the equipment may result.

CAUTION- Do not use the products for purposes other than those shown on the nameplate or in the manufacturing specifications;otherwise, electric shock, personal injury, or damage to the equipment may result.
- Do not place flammable objects around the gearmotor; otherwise, fire may result.
- Do not place any object that may hinder ventilation around the gearmotor or reducer. Insufficient ventilation can cause
excessive heat that may result in burns or fire.
- Do not step on or hang from the gearmotor or reducer; otherwise injury may result.
- Do not touch the shaft end of the gearmotor or reducer, inside keyways, or the edge of the motor cooling fan withbare hands; otherwise, injury may result.
- Please install loss prevention device such as oil pan to the machine which is vulnerable to oil especially (machine for food processing,machine for clean room, and so on) in case oil or grease leaks; otherwise, the product may fail because of oil leakage.
- Before mounting, moving, or transporting the machine, make sure to remove the lubricating oil. Moving machine withlubricating oil in may cause oil to discharge from the air vent, etc.

4-1 Installation Location
Ambient temperature:−10 to +40℃

Ambient humidity:

85%RH or less with no condensation

Altitude: 		Maximum 1,000m

Atmosphere: 		

No corrosive or volatile gases, no steam			Dust-free, well-ventilated area.

Installation location:

Indoor type: Indoors (area with minimal dust, no contact with water)			Outdoor type: Indoors or outdoors (place where are got wet with common rainwater but no direct heavy windand rain)			

Vibration: Maximum 1G- Mounting in conditions other than the above requires adherence to optional specifications. Please consult with us.
- Products built according to special specifications, such as explosion proofing, can be used in the specified mounting environments.
However, concerning the connector to the machine used, implement measures based on the mounting environment.
- Mount in a location that enables smooth operation, such as inspection and maintenance.
- Mount on a sufficiently rigid base.

4-2 Mounting Angle
Install the product so that the output shaft becomes horizontal or vertical.
(Depends on nomenclature. See P5. Please consult with us for inclined mounting).
For machines built for specified mounting angle, only use the specified mounting angle.
Do not remove the motor’s eye-bolt. When it is removed, insert a bolt or other appropriate material into the screw hole to prevent
water or other substances from entering the motor through the screw hole.

104. Installation Common
4-3 Mounting Bolts- Use mounting bolts with the strength class 8.8 (JIS B 1051) or more.
- For Bevel BUDDYBOX 4 Series, if radial load or axial load is applied to the output shaft, use mounting bolts with JIS strength class 10.9
or more.
(The flange lock bolts and foot plate lock bolts are in JIS strength class 10.9 or more.)- For Bevel BUDDYBOX 4 Series with solid shaft, foot mount type with frame sizes 4A and 4B, it is recommended to use hexagon socket
head bolts.

4-4 Keyless Shaft Motor Assembly Points (Connected by High Speed Hollow Shaft for Servo Motors)[1] R emove oil, dirt, and other contaminants from the motor shaft and inside of the input shaft. (The inner surface of the input shaft istreated with rust prevention oil before shipping.)[2] P osition the reducer on a base so that the input shaft is on top.
[3] A lign the input shaft with the notch of the clamp ring.
[4] R emove the adapter plate cap and insert a hexagonal wrench through the setting hole into the hexagon socket head bolt of theclamp ring. Next, insert the motor shaft into the input shaft.
[5] When assembling the motor and reducer, make sure that the centers of both shafts are aligned. Do not force the assembly if the
shafts are slanted or misaligned.
[6] F asten the motor and adapter plate by using the motor mounting bolt. Tighten them after confirming that the motor spigot issecurely inserted into the adapter plate spigot. If the bolt is tightened when the spigot is not inserted, one side is fasten and it will
result in damage to the internal bearing and other components.
[7] Tighten the clamp ring hexagon socket head bolt to the torque shown in Table 4-1.
[8] A
 fter operating at low speed, increase the tightening torque as shown in Table 4-1.
[9] Attach the adapter plate cap that had been removed.
Table 4-1 Tightening Torque for the Clamp Ring Hexagon Socket Head Bolt
Bolt Size

M4

M5

M6

M8

M10

M12

Tightening Torque (N·m)

4.3

5.5

9.6

23

46

79

Motor

Clamp ringCap

Input shaft

Figure 4-1 Assembly Diagram

4-5 Keyed Shaft Motor Assembly Points (Connected by High Speed Hollow Shaft for Servo Motoror General Flange Motor)[1] R emove oil, dirt, and other contaminants from the motor shaft and inside of the input shaft. (The inner surface of the input shaft istreated with rust prevention oil before shipping.)[2] A lign the motor shaft key with the keyway of the hole in the input shaft. (Keyway dimensions conform to JIS B 1301-1996 (ISO) “Keysand Their Corresponding Keyways: Parallel keys (Normal Type)”).
[3] Coat the motor shaft with molybdenum disulfide grease to prevent fretting.
[4] D epending on the motor combination, a spacer for preventing the key from falling out may be shipped separately. Before assembly,
insert the spacer deep into the hole in the input shaft. Operation with uninserted spacer could result in the key falling out anddamaging the shaft.
[5] When assembling the motor and reducer, make sure that the centers of both shafts are aligned. Do not force the assembly if the
shafts are slanted, misaligned, or if the key is partially engaged.
[6] F asten the motor and adapter plate (internal cover) using the motor mounting bolt. Tighten after confirming that the motor spigot
is securely inserted into the adapter plate (internal cover) spigot. If the bolt is tightened when the spigot is not inserted, one side isfasten. It will result in damage to the internal bearing and other components.

11

Common

5. Coupling with Other Machines
CAUTION- Confirm the rotation direction before coupling the unit with the driven machine. Incorrect rotation direction may
cause personal injury or damage to the equipment.
- When operating the product alone (uncoupled), remove the key that is temporarily attached to the output shaft; otherwise
the key could fly off, and injury may result.
- Attach the cover to the rotating parts to avoid someone touching them; otherwise, injury may result.
- When coupling the product with another machine, check that the centering, the belt tension and parallelism of
the pulleys are within the specified limits. When the unit is directly coupled with another machine, check that thedirect coupling accuracy is within the specified limits. When a belt is used for coupling the unit with another machine, checkthe belt tension. Correctly tighten bolts on the pulley and coupling before operation; otherwise there is a risk of injury due
to scattering the broken pieces or of damage to the products.

5-1 Checking Rotational Directions and Locations of Oil Fill and Oil Drain Ports(1) For Gearmotor- P12–13 shows the rotational directions of output shaft and locations of oil fill and oil drain ports when wiring is performed as on
P24–37.
- When wiring is performed as shown on P24–37, the motor shaft rotates to the right as seen from the anti-load side.
- To make reverse rotation, reverse R and T on P24 and P26–33.

(2) For Reducer- When the input shaft rotates to the right, arrows on P12–13 show the rotational directions of output shaft.
Confirm those directions when checking the oil fill and oil drain ports locations.
Bevel BUDDYBOX 4 Series
LH□M−□−□1
Top

LH□M−□−□2Top

View fromA

View fromA

Reduction
ratio
19-305

A

BottomReduction
ratio
11-18
364-10658

LH□M−□−□3
TopA

BottomLV□M−□−□5Top
A

Bevel Gear 1 Stage + Cyclo 2 Stage type (Reduction ratio 364-10658)*

Top

Reduction
ratio
19-305A

Reduction
ratio
11-18
364-10658

BottomView fromA
Reduction
ratio
364-10658

A

BottomLH□M−□−□4Top

View fromA

A

View fromA

Reduction
ratio
19-305

Reduction
ratio
19-305

Reduction
ratio
11-18
364-10658

Reduction
ratio
364-10658

BottomLV□M−□−□6Top

View fromA

View fromA

Reduction
ratio
19-305

Reduction
ratio
19-305

Reduction
ratio
11-18
364-10658

Reduction
ratio
11-18
364-10658

BottomOutput shaft rotation direction seen from “A”

A

BottomOil filler port

Oil gauge

Oil drain port

Figure 5-1 Rotational Directions of Output Shaft and Locations of Oil Fill and Oil Drain Ports (Example: Hollow Shaft, Shaft Mount)* Bevel Gear 1 Stage + Cyclo 2 Stage type of LH□M-□-□2 (reduction ration 364-10658) applies different lubrication depending on the
manufacture date and specification. See "8. Daily Inspection and Maintenance" for detail.

12

5. Coupling with Other Machines Common
Bevel BUDDYBOX 5 Series
LH□M−□−□1

LH□M−□−□2

Top

Top

View
from A
Reduction
ratio
19〜305A

Top

Reduction
ratio
19〜305A

Reduction
ratio
11〜18
364〜4365

BottomLH□M−□−□3
Viewfrom AA

Reduction
ratio
11〜18
364〜4365

BottomLH□M−□−□4

BottomLV□M−□−□5

Top

Top

View
from AA

Reduction
ratio
19〜305

Reduction
ratio
19〜305

Reduction
ratio
364〜4365

Reduction
ratio
11〜18
364〜4365

Bottom

BottomOutput shaft rotation direction seen from “A”

Oil filler port

Oil gauge

Reduction
ratio
19〜305

Reduction
ratio
11〜18
364〜4365

LV□M−□−□6Top

View
from AA

View
from A

View
from A
Reduction
ratio
19〜305

A

BottomReduction
ratio
11〜18
364〜4365

Oil drain port

Figure 5-2 Rotational Directions of Output Shaft and Locations of Oil Fill and Oil Drain Ports (Example: Hollow Shaft, Shaft Mount)

Helical BUDDYBOX
EH□M−□−□1

EH□M−□−□2

Top

Top
B

View from A

A

View from B

BottomB

View from A

A

Reduction
ratio
21〜305

Reduction
ratio
21〜305

Reduction
ratio
11〜18
364〜4365

Reduction
ratio
11〜18
364〜4365

View from B

BottomEH□M−□−□3

EH□M−□−□4

Top

Top

B

View from A

View from A

AAB

BottomView from B

Reduction
ratio
11〜18
364〜4365

Reduction
ratio
11〜18
364〜4365

BottomEV□M−□−□5TopA

View from A

View from A

Reduction
ratio
21〜305

Reduction
ratio
21〜305

Reduction
ratio
364〜4365

Reduction
ratio
364〜4365

BottomOutput shaft rotation direction seen from “A”

View from B

EV□M−□−□6

Top

A

Reduction
ratio
21〜305

Reduction
ratio
21〜305

BottomOil filler port

Oil gauge

Oil drain port

Figure 5-3 Rotational Directions of Output Shaft and Locations of Oil Fill and Oil Drain Ports (Example: Hollow Shaft, Shaft Mount)

13

Common

5. Coupling with Other Machines

5-2 Mounting Connector- When mounting Connector, do not apply impact or excessive axial load to the shaft. The bearing could be damaged, or the collar
could come off.
- Shrinkage fit is recommend.

(1) When Using a Coupling
The alignment accuracy (A, B, X) in figure 5-4 should be no more than that shown in Table 5-1.
Table 5-1 Alignment Precision for Flexible Coupling
B

A
X

X

Allowable Dimensional
Error for A

0.1mm ormanufacturer-specified
value

Allowable Dimensional
Error for B

0.1mm ormanufacturer-specified
value

Dimension for X

manufacturer-specified
value

Figure 5-4(2) When Using Chains, Sprockets, or Gears- When using a chain, attach it so that the chain tension angle is perpendicular to the shaft.
- Refer to the chain catalog or other reference for chain tension.
- The pitch circle diameter of the sprocket and gear shall be more than three times of the shaft diameter.
- The load point of the sprocket or gear should be nearer to the product than to center of the shaft. (See Figure 5-5)(3) When Using a V Belt
- Over-tightening the V belt will damage the shaft and bearing. Refer to the V belt catalog or other reference for V belt tension.
- The parallelism, eccentricity β between the two pulleys should be within 20´. (See figure 5-6)
- When using multiple V belts, use the same V belts having the same circumferential length.

Connected
equipmentβThis product
Shaft

β

Figure 5-5

Figure 5-6

145. Coupling with Other Machines Common
5-3 Hollow Shaft, Torque Arm Mount/Flange Mount(1) Length of the Driven Shaft
When mounting the driven shaft to the hollow shaft, ensure that the insertion length is "recommended length of the driven shaft" or longer.
For details, refer to the catalog or consult with us.

(2) Mounting on the Driven Shaft[1] A pply molybdenum disulfide grease to the surface of the driven shaft and the inner diameter of the hollow shaft, and then insert thisproduct to the driven shaft.

Mountingthetorque1 shaft with a wooden hammer before insertion. At this time, do not[2] When the fitting part is hard, lightly
hit the end
faceof thearmhollow
hit the casing or oil seal. Also, if the fitting part is particularly hard, using the jigs shown in Figure 5-7 will help smoother insertion.

abⓐ Retaining ringcⓑ Spacerⓒ Thrust bearing

d

ⓓ Nut

e

ⓔ Head-cut bolt

Figure 5-7 Mounting Jigs
The hollow shaft is made with JIS H8 tolerance. The recommended tolerances for the driven shaft are as follows.
- When a uniform load is applied with no impact ...... JIS h6 or js6- When an impact load is applied or a radial load is large ...... JIS js6 or k6- Retaining ring (snap ring) size ...... JIS B 2804 retaining C-ring(3) Fixing to the Driven Shaft
When using the torque arm for rotation prevention, be sure to fix the product to the driven shaft.
Spacer

Setscrew

Stopper ring

Machine side

Bearing unit

Fixing with a spacer(No step on the driven shaft)

Fixing with a stepped shaft

Fixing with a setscrew and stopper ring
(No step on the driven shaft)

Figure 5-8 Example of Fixing Method that Prevents the Product from Moving to the Machine Side
Retaining ringSpacer

Setscrew

Stopper ring

Machine side

End plate

Fixing with a spacer and retaining ring

Fixing with an end plate

Fixing with a setscrew and stopper ring

Figure 5-9 Example of Fixing Method that Prevents the Product from Moving to the Anti-machine Side
Note: 1
 . Jigs and parts for mounting and fixing need to be prepared by the customer.
2. For recommended dimensions, refer to the catalog.

15

Common

5. Coupling with Other Machines(4) Mounting the Torque Arm (Optional)[1] Attach the torque arm to the driven machine side of the casing.
[2] P rovide a degree of freedom to the rotation stopper part of the torque arm (see Figure 5-11) to prevent excessive force from being
applied between the casing and the driven shaft. (The customer needs to prepare the rotation stopper part.)[3] Do not fix the torque arm using a rotation stopper bolt, etc.
[4] A ttach disc springs (see Figure 5-12) as shock absorbers between the torque arm and the mounting bolt (or spacer) to relieve theimpact.
[5] U se a bolt with the strength class 10.9 (JIS B 1051) or more.
[6] When mounting the torque arm, be sure to take a looseness prevention measure for the bolt.
(Use of a spring washer or U-nut, applying adhesive that prevents loosening of screws, etc.)

Attachment type torque arm (optional)

Banjo type torque arm (optional)

Figure 5-10 Usage Example of Torque Arm

Rotation stopper
part of torque arm
Rotation stopper
part of torque arm

The customer needs toprepare thepart.

Figure 5-11 Example of Rotation Stopper (Attachment Type Torque Arm)

(5) Mounting the Disc Springs (Optional)[1] The optional disc spring is equivalent to DIN 2093.
[2] Use a bolt with the strength class 10.9 (JIS B 1051).
[3] E nsure that there is no gap in the assembly parts (indicated as “A” in Figure 5-12).
A gap in the assembly parts may damage the torque arm mounting part due to impact.
[4] M ake sure that the disc springs are not crushed.
If the nut is tightened until the disc springs are crushed during assembly, the disc springs will lose buffer actions, which may cause an
excessive force to the mounting part of the reducer and the driven machine.
Be careful not to crush the disc springs when tightening with a double nut.
A[5] A pply lubricant such as grease to the contact surfaces and overlapping surfaces of thedisc springs in order to reduce abrasion of the disc springs.

Disc springsA[6] Take looseness prevention measures for the bolt, such as applying adhesive forlooseness prevention and use of a U-nut.
[7] I f a gap is formed in the assembly part due to initial deflection of disc springs, retighten
the nut to eliminate the gap. At this time, be careful not to crush the disc springs.

Figure 5-12 Disc Springs

165. Coupling with Other Machines Common(6) Mounting the Flange[1] Mount this product to the driven machine.
[2] Assemble the driven shaft to the hollow shaft.
[3] Assemble the driven shaft to the bearing unit and fix the bearing unit after checking there is no shaft runout.
Note: B e careful when mounting so that unnecessary force is not applied to the driven shaft and hollow shaft by the casing's being
wrenched; otherwise, an excessive force may be applied to this product and the bearing unit, resulting in damage to the internal
parts.
Bearing unitThis
product
Poor concentricity of driven shaft
and mounting spigot

Good example

Poor squareness of driven shaft centerand mounting flange surface

Bad example

Figure 5-13 Example of Flange Mounting

Mounting the torque arm 2(7) Removing from the Driven Shaft
Ensure that unnecessary force is not applied between the casing and the hollow shaft. Using the jigs shown in Figure 5-14 will help
smoother removal.

iⓕ Spacerⓖ Finished boltⓗ DischAfg

View from A

Figure 5-14 Removal Jigs
Note: 1
 . Jigs and parts for removal need to be prepared by the customer.
2. For recommended dimensions, refer to the catalog.

17ⓘ Retaining ring

Common

5. Coupling with Other Machines

5-4 Hollow Shaft, Shrink Disc Mount(1) Mounting the Shrink Disc (Optional)
The shrink disc that comes with the product is shipped with grease applied to the surface where a boss is tightened, so it can be assembled without any additional work.
[1] The insertion objects stuffed between both plates as buffer materials during transport can be removed by loosening all bolts.
[2]	When the shrink disc that has been used is removed and reused, at first disassemble and clean it, and apply seizure-preventive agent(such as molybdenum disulfide grease) to the sliding cone, tightening bolts, and the surface that makes contact with the bolt heads.
[3] Completely degrease the holes of the boss and the shaft that makes contact with it.
[4] Slide the shrink disc onto the hollow shaft. Do not tighten the tightening bolts until the driven shaft enters the hollow shaft.
[5] Slide the driven shaft or the product, and insert the driven shaft to the hollow shaft.
[6] When tightening the bolts, ensure that the surfaces of both plates are parallel to each other.
[7] After confirming the shrink disc is correctly set, start tightening the bolts using a wrench with a short haft.
	
Tighten the bolts evenly in the clockwise direction (not diagonally) while keeping the both plates parallel. At this time, it isrecommended to tighten each bolt by 90 degrees at one time.
[8] 	Next, using the torque wrench set for the tightening torque indicated in Table 5-2, tighten each bolt in the clockwise direction by
90 degrees at first. As the tightening torque is being approached (about 80% of the tightening torque), tighten each bolt by
30 degree until the tightening torque is reached.
	Even if it is confirmed that all bolts have been tightened with the tightening torque at first assembly, the tightening torque ofthe bolt tightened first may be dropped because the load applied per bolt is dispersed as bolts are tightened, and the total load
applied to the bolt first tightened may reduce. Because of this, additionally tighten the bolts in the clockwise direction with thetightening torque.
	However, this operation shall be up to 3 laps. Confirm that there is no looseness during this operation. Check the operation of thetorque wrench with one-time click.
[9] 	Confirm that all bolts have been tightened with the tightening torque shown in Table 5-2, and that the level between the sliding
cone and the plate is uniform in the whole circumference.
[10] Finally, ensure that the both plates are parallel.
Note: A fter the shrink disc is mounted in the above order, operate the product. Since the contact part of the hollow shaft and the driven
shaft is not lubricated, scratches easily occur if it is rotated with the shrink disc not correctly mounted.
Table 5-2 Tightening Bolts
Frame Size
5Z10□, 5Z11□, 5Z12□
4A10□, 4A11□, 4A12□, 4A14□
5A11□, 5A12□, 5A14□
4B12□, 4B14□, 4B16□
5B12□, 5B14□, 5B16□
4C14□, 4C16□, 4C17□
5C14□, 5C16□, 5C17□
4D16□, 4D17□, 4D18□
4E17□, 4E18□, 4E19□
4F18□, 4F19□

Quantity
8

Size
M6×25

Strength Class (JIS B 1051) Tightening Torque (N·m)
10.9
12

10

M6×25

10.9

12

7

M8×30

12.9

35

12

M8×35

12.9

35

12
10
8

M10×45
M12×45
M16×55

12.9
12.9
10.9

69
120
250

Note: The symbol □ in frame size can be “0”, “5”, “DA”, “DB” or “DC” .

(2) Removing the Shrink Disc[1] U
 sing a normal wrench, loosen each bolt in the clockwisePlatedirection by 90 degrees evenly, preventing concentration ofTightening boltload to a few bolts.

Sliding cone[2] C ontinue to loosen bolts until the shrink disc moves on the

Hollow shaft(Output shaft of the reducer)

hollow shaft. At this time, do not place a part of your body inthe bolt shaft direction.

Completely degrease the innerdiameter of the hollow shaft andthe outer diameter of the driven
shaft[3] I f the both plates are not parallel, do not remove the bolts;
otherwise, the both plates may jump out of the sliding
cone, resulting in injury. Therefore, loosen all bolts slightly,
and insert a wedge between the both plates to make them

Driven shaft(Driven machine shaft)parallel.
Figure 5-15 Shrink Disc Structure18

5. Coupling with Other Machines Common
5-5 Hollow Shaft, Taper Grip Mount(1) Mounting the Taper Grip (Optional)■ Preparation of the machine shaft to be mounted[1] Ensure that the shaft has no rust, bumps or dips (especially convexity).
[2] The recommended tolerance for the shaft is h8.
[3] Wipe off dust and oil attached on the shaft with cloth, alcohol solvent, etc.
Especially, wipe off oil and grease completely.
■ Setting the taper grip
[1] Apply oil lightly to the screw part of the taper grip.
[2] Place the thrust collar on the screw part of the taper grip.
Insert the taper grip into the hollow shaft while rotating the taper grip in the clockwise direction.
Insert the taper grip in rotation until the flange makes contact with the thrust collar. (Figure 5-16)[3] N ext, rotate the taper grip in the anticlockwise direction, and align the counterbore hole of the thrust collar and the screw hole of thetaper grip.
At this time, the distance between the thrust collar and the taper grip flange should be about 1mm. (Figure 5-17)
Next, tighten all set bolts to the taper grip.
The tightening force should be in the degree in which the bolt lightly makes contact with the counterbore hole of the thrust collar(force with which a screw is tightened directly with hand).

Taper GripFlange
Thrust collar

Hub

1mm

Taper Grip

This productFigure 5-16 Mounting the Taper Grip

Figure 5-17 Gap between Taper Grip Flange and Thrust collar■ Setting to the machine shaft[1]	Place the hollow hole of the taper grip on the machine shaft, and insert it to the1predetermined position (minimum length of thread engagement).
		If it is difficult to insert, slightly loosen the tightening bolt. Do not hit it with a hammer, etc.

6

3

4

5

[2] Tighten the screws of the taper grip.
		 When tightening the bolts, be sure to use a torque wrench.
		 The predetermined tightening torque for bolts is shown in Table 5-3, and Table 5-4 on P20.
		First, tighten all bolts in the order shown in Figure 5-18 (1 → 2 → 3 → 4 → 5 → 6) with2

about one-third of the predetermined tightening torque.
		Next, tighten all bolts in the same way with about two-third of the predeterminedtightening torque.
		 Then, tighten all bolts in the same way with the predetermined tightening torque.

Figure 5-18 B olt Tightening Order
1→2→3→4→5→6

		 Finally, repeat tightening all bolts several times in the same way with the same predetermined tightening torque.
		 This is all for the mounting procedure.
		 (Use bolts with the strength class 12.9 (JIS B 1051) or more.)

19

Common

5. Coupling with Other Machines■ Retightening after operation[1] I n 20 to 30 hours after operation, check the tightening torque. If the bolts are loose, retighten them with the predeterminedtightening torque.
[2] Check the tightening torque periodically every six month.
Table 5-3 Tightening Bolts (Bevel BUDDYBOX)
Frame Size

QuantitySize

Tightening Torque (N·m)

4A10□, 4A11□, 4A12□, 4A14□

6

M12×1575

4B12□, 4B14□, 4B16□

6

M12×15140

4C14□, 4C16□, 4C17□

6

M16×20250

4D16□, 4D17□, 4D18□

6

M16×20300

4E17□, 4E18□, 4E19□

8

M16×20300

QuantitySize

Tightening Torque (N·m)

Z609□

6

M10×15

31

A610□

6

M12×15

51

B612□

6

M12×15

51

C614□

6

M16×20

128

D616□

6

M16×20

200

E617□

8

M16×20200

Table 5-4 Tightening Bolts (Helical BUDDYBOX)
Frame Size

Note: The symbol □ in frame size can be "0”, "5”, “DA”, “DB” or “DC” .

(2) Removing the Taper Grip
[1] Loosen the tightening bolts slowly in order until they are separated from the counterbore hole of the thrust collar.
[2] Next, hit the flange of the taper grip lightly with a wooden hammer.
In this way, the reducer is free from the machine shaft.
[3] Next, tighten the two tightening bolts lightly with hand.
This is necessary to prevent the taper grip from being locked when the reducer is removed from the shaft.
In this state, remove the reducer from the machine shaft.
When it is difficult to remove, use the taper grip flange with a puller for removal.
Note : 1. Never use oil or grease containing antifriction agent; otherwise, the predetermined transmission torque cannot be obtained.
2. B
 e sure to use a torque wrench to tighten the bolts with the predetermined torque in the order as described in this manual;
otherwise, the predetermined transmission torque may not be obtained, or the bolts may be loosened.
3. D
 o not tighten the bolts with more than the predetermined tightening torque; otherwise, the bolts or the taper grip may bedamaged.
4. For safety, retighten the bolts periodically.

20

6. Wiring

CommonWhen using another manufacturer’s motor (There are some models made by other manufacturers.), follow the operation manual forthat motor.
This manual shows wiring for motors with Japanese standard specifications. Please consult with us for motors with overseas
specifications.

DANGER- Do not handle the unit when cables are energized. Be sure to turn off the power when working on the unit; otherwise,electric shock may result.
- Connect a power cable to the unit according to the diagram shown inside the terminal box or in the maintenancemanual; otherwise, electric shock or fire may result.
- Do not forcibly bend, pull, clamp or push the power cable and lead wires; otherwise, electric shock or fire may result.
- Correctly ground the grounding bolt; otherwise, electric shock may result.
- For explosion proof motor , the lead-in condition shall conform to the facility’s regulations, electrical codes, and explosion
proofing standard, as well as the maintenance manual; otherwise, electric shock, personal injury, explosion, fire, or damage
to the equipment may result.

CAUTION- When wiring, follow the domestic laws and standards; otherwise, burning, electric shock, injury, or fire may result.
- The motor is not equipped with a protection device. However, it is compulsory to install an over current protecting device
according to the laws and standards. It is recommended to install other protective devices (earth leakage breaker,etc.), in addition to an over current protecting device in order to prevent burning, electric shock, injury, and fire.
- Never touch the terminals when measuring insulation resistance; otherwise, electric shock may result.
- When using a star-delta starter , use an electromagnetic switch on the primary side (3-contact point type); otherwise, fire
may result.
- PWM inverters that use IGBT generate high-voltage surges at the motor terminals, which may degrade the insulation on
the motor windings. Especially when the motor is in the 400V class with the long cable, a surge voltage over 1300V occurs.
Therefore, in this case, install an LCR filter, output AC reactor, etc. between the inverter and motor to inhibit the surge
voltage.
- When using a motor with brake , do not energize the brake coil when the motor is stopped; otherwise, coil burnout may
result. Also, mistaken wiring could damage the rectifier.
- When using an explosion proof motor driven by an inverter , use one inverter for one motor. Use the approved inverter forthe motor.
- When measuring the insulation resistance of an explosion proof motor , confirm that there is no gas or explosive vapor in
the vicinity; otherwise, explosion or ignition may result.
- If ambient temperature exceeds 60℃ , place the rectifier in a location where the temperature is 60℃ or less. In this case,always protect the entire rectifier with a cover. However, ambient temperature conditions for standard units with andwithout brakes must be −10 to 40℃ . (Manufacture with special specification is required for operation in an environment
where ambient temperature exceeds 40℃.)- Long cables cause large voltage drops. Select cables with appropriate diameter so that the voltage drop will be no greaterthan 2%.
- After wiring outdoor types and explosion proof types , check that mouting bolts for terminal box are not loose, andcorrectly attach the terminal box cover.

21

6. Wiring
6-1 Removing and Attaching the Resin Terminal Box Cover
3-phase motor 4P: 0.1–0.4kW, high-efficiency, 3-phase motor 4P: 0.2kW, AF motor for inverter: 0.1–0.2kW(1) Removal
As shown in figure 6-1, to remove the cover, grab the sides of the terminal box, and pull it toward you.

(2) Attachment
Push the terminal box cover from above the terminal box case until it snaps shut.

Figure 6-1

6-2 Measuring Insulation Resistance
When measuring insulation resistance, always disconnect the control board and measure the motor alone.
Measure insulation resistance before wiring. Insulation resistance (R) is changed by a number of factors, including motor output,
voltage, type of insulation, winding temperature, moisture, degree of fouling, hours used, and amount of time test voltage is applied.
However, normally, it must be above the values in Table 6-1.
Table 6-1 Values for Insulation ResistanceMotor Voltage
Low-voltage motors of
no more than 600V

Ohmmeter Voltage

Insulation Resistance (R)

500V

Minimum 1MΩ

Reference: JEC -2100 provides the following equation.

R≧

R≧

Rated Voltage (V)Rated output power (kW) + 1,000
Rated Voltage (V) + (RPM/3)
Rated output power (kW) + 2,000(MΩ)＋ 0.5(MΩ)

Low insulation resistance is a sign that there is an insulation failure. Do not apply power. Consult the nearest maintenance shop.

6-3 Coordination of System Protection- Use a wiring breaker for short circuit proofing.
- Use an over current protecting device which operates when the currents exceed the rated current on the nameplate.
- For Increased safety motor , use an over current protecting device which operates in the locked rotor current on the nameplate
within the allowable locking time.

6-4 Connecting the Power Cable
Connect the power cable and motor lead wire by joining pressure connection
terminals as shown in figure 6-2.

Power cable
Insulation tape
Motor lead wire

Figure6-2
11
Figure22

6. Wiring
6-5 Motor Wiring
This page shows the page numbers for motor wiring diagrams.
Table 6-2 Without Brake
Motor Type

3-Phase
Motor

PremiumEfficiency
3-PhaseMotor
AF Motor for
Inverter

Number ofPoles

Standard

4P
4/8P

Increased safety,
explosion proof

4P

Flameproof

4P

Standard

4P

Increased safety,
explosion proof

4P

Standard

4P

Flameproof

4P

Premium-Efficiency,
3-Phase Motor for Inverter
High-Efficiency, 3-Phase Motor

4P
4P

Capacity (kW)

Number of
Lead Wires

0.1–0.55
All
0.1–7.5
11–55
0.1–2230–37
0.75–3.7
5.5–550.75–3.7
5.5–22
0.1–0.4
30–45
0.2–1522
30–37
0.75–3.7
5.5–55
0.2–0.4

3
6
3
6
3
6
3
6
3
6
3
11
3
6
11
3
6
3

Capacity (kW)Brake Type0.1
0.2 0.25
0.4
0.55
0.75
1.1
1.5
2.2
3.0
3.7
5.5
7.5
11
15
18.5 22 30

FB-01A1
FB-02A1
FB-05A1
FB-1D
FB-1E
FB-1HE
FB-2E
FB-3E
FB-4E
FB-5E
FB-8E
FB-10E
FB-15E
FB-20
FB-30
ESB-250
ESB-250-2
FB-02A1
FB-05A1
FB-1D
ESB-250
ESB-250-2
FB-1E
FB-2E
FB-3E
FB-5E
FB-8E
FB-10E
FB-15E
FB-20
FB-30
ESB-250
ESB-250-2
FB-05A1
FB-1D

Page
Direct Input from
Commercial
Inverter Drive
Power Source
P24
P25
P24
P24

-

P24

-

P24

P25

P24

-

-

P25

-

P25

-

P25

P24

P25

Table 6-3 With Brake
Motor Type

3-Phase Motor

Premium-Efficiency,
3-Phase Motor

Number of
Poles
4P

4P

37 45

AF Motor for Inverter

4P

0.1
0.2
0.4
30 37

Premium-Efficiency,
3-Phase Motor for Inverter

4P

0.75
1.5
2.2
3.7
5.5
7.5
11
15
18.5 22 30
37 45

High-Efficiency, 3-Phase Motor

4P

0.2
0.4

One-Direction
Rotation

Page
Plugging
Rotation

5

P26

P30

P34

5

P26

P30

P34

P27

P31

P28

P32

P29

P33

-

-

Number of
Lead Wires

8

5

Inverter Drive

P35

P36
P34

13

P37

5

P34

-

-

P35

8
P36
5

P26

P30

P34

Note : 1. Brake type may differ depending on specification. Check the nameplate.
2. For motors with standard Japanese domestic specifications. Please consult with us for motors with overseas specifications.

23

6. Wiring
In this section, motor wiring, standard specification for terminals, and symbols of lead wires are shown.

■ Without Brake

3-Phase Power Source

3-Phase Motor
Premium-Efficiency, 3-Phase Motor
High-Efficiency, 3-Phase Motor
3 Lead Wires

RS

6 Lead Wires (Direct On-Line Starting)

T

R

S

T

MC

MC
Control Panel

Control Panel

OLR

OLR

V

Motor

Motor

U

W

U1

Motor

V2

V1

W1

W2

U2

Motor

6 Lead Wires (R

S−ΔStarting)

T

MC
OLR

4/8P Two Speed, Single Wound Rotor (Constant Torque)

MCM
At start
MCΔ
WiringMC
Δ wiring
MCM
MCΔ
when
acceleration is MC
completed

ON
OFF
ON
ON
ON
OFF

R

MCΔ

MCM

V2

W2

U2

OLRL

OLRH

1U

1V

Motor

MC: Electromagnetic contactor
OLR: Over current protection device or thermal relay

1W 2U
Motor

2V

2W

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.

24

Motor

W1

MCH1

ON
OFF
OFF
OFF
ON
ON

Control Panel

V1

MCL

MCL
MCH1
MCH2
MCL
MCH1
MCH2

MCH2

Motor

U1

T

Control PanelMCS

When at low
speed
(8P)
When athigh speed(4P)6. Wiring■ Without Brake

Inverter Drive

3-Phase Motor
Premium-Efficiency, 3-Phase Motor
AF Motor for Inverter
Premium-Efficiency, 3-Phase Motor for Inverter
High-Efficiency, 3-Phase Motor
3 Lead Wires

RS

6 Lead Wires

T

R

S

T

MCB

W

U

V

W

U

U1

Motor

V2

S

T

V

W

V1

W1

W2

U2

Inverter

Motor

V

R

Motor

T

Control PanelU

S

Inverter

Control Panel

R

MCB

Motor

11 Lead Wires
AF Motor for Inverter With Axial Fan
Indoor 200V Class Outdoor 200V Class, 400V Class
Flameproof TypeR

S

Indoor 400V Class
R

T

S

T
MCB1

MCB1

U1
V2

V1
W2
Motor

W1

T1

T2

U2
Thermostat

R

MCB2
F

U

S

T

V

W

V1

W1

W2

U2

InverterF

U

V
Axial fan

W

U1
V2

Motor

MCB : Miniature circuit breakerTr: Transformer capacity 250–600VA, Secondary voltage 200–220V
F: Fuse 3–5A

T1

T2

Motor

W

T
W

Control Panel

V
Axial fanS

V

Inverter

Motor

U

U

Control Panel

R

MCB2

400V class
Tr
200V class

Thermostat

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- When using inverter for 400V class 3-phase motor/high-efficiency 3-phase motor, the motor must be insulated.
In the case of motor with axial fan (totally enclosed, fan motor ventilation type) , note the following items.
- Also connect a power source to the axial fan.
- For an indoor 400V class ( except flameproof type ), the axial fan power source voltage will be 200V class. For the motor with special
specifications, specifications may differ from the above.
- Connect the fan so that it rotates in the same direction as that shown on the nameplate for direction of rotation.
(Normally, the air from the fan will blow in a direction from the anti-load side to the load side.)- When the motor is shut down for a long period, also shut down the axial fan motor.
- Wire the mounted thermostat.
Operating function: Normally closed (break contact)- Thermostat specification: 	Terminal symbols: T1, T2 or P1, P2
Operating temperature: 135℃ (for thermal class 155 (F)) Maximum current: DC 24V, 18A; AC 230V, 13A25

6. Wiring■ With Brake

3-Phase Power Source

Operates Rotating in One Direction.

3-Phase Motor
Premium-Efficiency, 3-Phase Motor
High-Efficiency, 3-Phase Motor
FB-01A1 – FB-05A1

FB-1D, FB-1E – FB-5E
5 Lead Wires

R

S

T

R

T

OLR

Motor

U

V

1

W

Motor
R

S

2

4

M N

Rectifier

Brake

Motor

Normal Braking Circuit

OLR

Control PanelMC

Control Panel

MC

S

U

1

W

Motor

T

R
MC

V

S

2

3

4

M N

Rectifier

Brake

T
MC

OLR

VR

Control Panel

OLR

Motor

U

V

W

Motor

4

M N

Rectifier

1

2

Brake

MC : Electromagnetic contactor
OLR : Over current protection device or thermal relay
VR : Varistor (for protecting contact points, rectifier, etc.)

Motor

Quick Braking CircuitControl Panel

VR

U

V

W

Motor

1

4

M N

Rectifier

2

3

Brake

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- The interval time between the current stop and brake action is different between normal and quick braking circuits.
Table 7-2 on P40 shows action delay time. Choose the circuit that matches work requirements.
- Use a quick braking circuit to improve hoisting equipment and stopping precision.
- Use a quick braking circuit when a phase-advancing capacitor is mounted.
- For information on electromagnetic contactors and varistors for quick braking circuits, see Table 6-4 on P38.
- For quick braking circuits, interlock brake circuit's electromagnetic contractor with the motor's electromagnetic contractor.

26

6. Wiring■ With Brake

3-Phase Power Source

Operates Rotating in One Direction.

Premium-Efficiency, 3-Phase Motor
FB-8E – FB-15E
8 Lead Wires
Direct On-Line Starting−Δ Starting
MCM
MCΔ
MC
Δ wiring
MCM
MCΔ
when
acceleration MC
is completed
At start
Wiring

R S T
R

S

T

MC

OLR

V2

V1

W1

1 2 3 4

M N

W2

U2

Rectifier

Brake

MCΔ

MCM

MC

Motor

1

U1 V1 W1 V2 W2 U2

Motor

2 3 4
RectifierT

Quick Braking CircuitControl Panel Motor

MC

VR

OLR

V1

W1

1 2 3 4

M N

V2

W2

U2

Rectifier

Brake

Motor

OLR

MC

U1 V1 W1 V2 W2 U2Motor

MC : Electromagnetic contactor
OLR : Over current protection device or thermal relay
VR : Varistor (for protecting contact points, rectifier, etc.)

VR

MCΔ

MCM

1

2 3 4
Rectifier

M N
Brake

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- The interval time between the current stop and brake action is different between normal and quick braking circuits.
Table 7-2 on P40 shows action delay time. Choose the circuit that matches work requirements.
- Use a quick braking circuit to improve hoisting equipment and stopping precision.
- Use a quick braking circuit when a phase-advancing capacitor is mounted.
- For information on electromagnetic contactors and varistors for quick braking circuits, see Table 6-4 on P38.
- For quick braking circuits, interlock brake circuit's electromagnetic contractor with the motor's electromagnetic contractor.

27

Motor

U1

ON
OFF
ON
ON
ON
OFF

Control Panel

S

MCM
MCΔ
MC
Δ wiring
MCM
MCΔ
when
acceleration MC
is completed
At start
Wiring

R S T
R

M N
Brake

Motor

U1

OLR

Control Panel

Control Panel Motor

Normal Braking Circuit

MC

ON
OFF
ON
ON
ON
OFF

6. Wiring

FB-20, FB-30
8 Lead Wires
Direct On-Line StartingR

S−Δ Starting

T
MC

OLR

OLR

MCM

MCΔ

Motor

V1

W1

1 2 3 4 5 6

M N

V2

W2

U2

Rectifier

Brake

MC

U1 V1 W1 V2 W2 U2Motor

MC : Electromagnetic contactor
OLR : Over current protection device or thermal relay

MC

Motor

U1

ON
OFF
ON
ON
ON
OFF

Control Panel

Control PanelMC

Quick Braking Circuit

MCM
MCΔ
MC
Δ wiring
MCM
MCΔ
when
acceleration MC
is completed
At start
Wiring

R S T

Motor

1 2 3 4 5 6Rectifier

M N

Brake

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- Use with a quick braking circuit. For information on electromagnetic contactors for quick braking circuits, see Table 6-4 on P38.
- For quick braking circuits, interlock brake circuit's electromagnetic contractor with the motor's electromagnetic contractor.
- The motor is shipped with a short circuit plate connected between terminals 5 and 6. Remove the short circuit plate when wiring.

28

6. Wiring■ With Brake

3-Phase Power Source

Operates Rotating in One Direction.

Premium-Efficiency, 3-Phase Motor
ESB-250, ESB-250-2
8 Lead Wires
Direct On-Line StartingR

S−Δ Starting

T
MC

MC

1 2 3 4 5 6Rectifier

V1

W1

V2

W2

U2

Brake

R

S

MC

MC

1 2 3 4 5 6RectifierT

U1 V1 W1 V2 W2 U2

4 3

Motor

Brake

MC

MC
OLR

OLR
Tr
400V class

F

MCM

MCΔ

Control Panel

200V class

Rectifier
V1

W1

4

3

V2

W2

U2

Brake

Tr
400V classMotor: Electromagnetic contactor: Over current protection device or thermal relay: Transformer capacity 250–600VA, secondary voltage 200–220V: Fuse 3–5A

F
200V
class

1 2 3 4 5 6RectifierU1 V1 W1 V2 W2 U2

4 3

Motor

Brake

Motor

U1

MC

Control Panel

1 2 3 4 5 6

ON
OFF
ON
ON
ON
OFF

MC

Motor

Quick Braking Circuit 400V Class

MCM
MCΔ
MC
Δ wiring
MCM
MCΔ
when
acceleration MC
is completed
At start
Wiring

R S T

Motor

3

MCΔ

Motor

U1

4

MCM

ON
OFF
ON
ON
ON
OFF

Control Panel

Control Panel

Quick Braking Circuit 200V Class

OLR

OLR

Motor

MC
OLR
Tr
F

MCM
MCΔ
MC
Δ wiring
MCM
MCΔ
when
acceleration MC
is completed
At start
WiringR S T

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- Use with a quick braking circuit. For information on electromagnetic contactors for quick braking circuits, see Table 6-4 on P38.
- For quick braking circuits, interlock brake circuit's electromagnetic contractor with the motor's electromagnetic contractor.
- Rectifiers are external to the main unit. Rectifiers are made for indoor use. Install in an area where they will not contact with water, etc.
- The brake unit is for 200V class. For 400V class power sources, prepare a 400V/200V transformer.

29

6. Wiring■ With Brake

3-Phase Motor

Plugging Operation

3-Phase Motor
Premium-Efficiency, 3-Phase Motor
High-Efficiency, 3-Phase Motor
FB-01A1 – FB-05A1

FB-1D, FB-1E – FB-5E
5 Lead Wires

R

S

R

T

OLR

T

Normalrotation

ReverserotationControl Panel

ReverserotationControl Panel

OLR

U

V

1

W

Motor
R

S

4

M N

Rectifier

2

Brake

Motor

Motor

Normal Braking Circuit

Normalrotation

S

U

V

1

W

Motor
R

T

S

4

M N

Rectifier

2

3

Brake

T

MC
VR

OLR

Reverse MC
rotation

Normalrotation

VR

OLR

V

W

Motor

4

M N

Rectifier

1

2

Brake

Electromagnetic contactor for normal and reverse rotation
MC : Electromagnetic contactor
OLR : Over current protection device or thermal relay
VR : Varistor (for protecting contact points, rectifier, etc.)

Motor

Motor

U

U

V

W

Motor

4

M N

Rectifier

Brake

1

2

3

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- The interval time between the current stop and brake action is different between normal and quick braking circuits.
Table 7-2 on P40 shows action delay time. Choose the circuit that matches work requirements.
- Use a quick braking circuit to improve hoisting equipment and stopping precision.
- Use a quick braking circuit when a phase-advancing capacitor is mounted.
- For information on electromagnetic contactors and varistors for quick braking circuits, see Table 6-4 on P38.
- For plugging operations using a quick braiking circuit, interlock brake circuit's electromagnetic contactor with the motor's
electromagnetic contactor.

30

Control Panel

ReverserotationControl Panel

Quick Braking Circuit

Normalrotation6. Wiring■ With Brake

3-Phase Motor

Plugging Operation

Premium-Efficiency, 3-Phase Motor
FB-8E – FB-15E
8 Lead Wires
Direct On-Line Starting−Δ Starting
MCM
MCΔ
MC
Δ wiring
MCM
MCΔ
when
acceleration MC
is completed

R S T
T

OLR

MC Δ

MC M

Motor

V1

W1

V2

W2

U2

Rectifier

Brake

1

U1 V1 W1 V2 W2 U2

Motor

Motor

2 3 4
Rectifier

MCM
MCΔ
MC
Δ wiring
MCM
MCΔ
when
acceleration MC
is completed

R S T
T

VR

MC Δ MC

MC M

Motor

V2

V1
W2

W1

1 2 3 4

M N

U2

RectifierBrake
U1 V1 W1 V2 W2 U2

Motor

Electromagnetic contactor for normal and reverse rotation
MC : Electromagnetic contactor
OLR : Over current protection device or thermal relay
VR : Varistor (for protecting contact points, rectifier, etc.)

Motor

1

2 3 4
Rectifier

M N
Brake

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- The interval time between the current stop and brake action is different between normal and quick braking circuits.
Table 7-2 on P40 shows action delay time. Choose the circuit that matches work requirements.
- Use a quick braking circuit to improve hoisting equipment and stopping precision.
- Use a quick braking circuit when a phase-advancing capacitor is mounted.
- For information on electromagnetic contactors and varistors for quick braking circuits, see Table 6-4 on P38.
- For plugging operations using a quick braiking circuit, interlock brake circuit's electromagnetic contactor with the motor's
electromagnetic contactor.

31

Motor

U1

MC

VR

Control Panel

Control Panel

OLR

ON
OFF
ON
ON
ON
OFF

OLR

Y

Reverse rotation

Quick Braking Circuit

Normal rotationMC

At start
WiringReverse rotation

S

Normal rotation

R

M N
Brake

Motor

U1

M N

Y

MC
1 2 3 4

ON
OFF
ON
ON
ON
OFF

Control Panel

Control Panel

Reverse rotation

Normal rotation

Normal Braking Circuit

OLR

Reverse rotation

S

Normal rotationR

At start
Wiring

6. Wiring■ With Brake

3-Phase Motor

Plugging Operation

Premium-Efficiency, 3-Phase Motor
FB-20, FB-30
8 Lead Wires
Direct On-Line Starting
S

MCM
MCΔ
MC
Δ wiring
MCM
MCΔ
when
acceleration MC
is completed
At start
WiringR S T

TReverse rotation

OLR

Normal rotation
OLR

Motor

MC Δ

MC M

MC
V1

W1

V2

W2

U2

Rectifier

M N

Brake
U1 V1 W1 V2 W2 U2

Motor

Electromagnetic contactor for normal and reverse rotation
MC : Electromagnetic contactor
OLR : Over current protection device or thermal relay

Motor

MC

1 2 3 4 5 6Rectifier

M N

Brake

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- Use with a quick braking circuit. For information on electromagnetic contactors for quick braking circuits, see Table 6-4 on P38.
- The motor is shipped with a short circuit plate connected between terminals 5 and 6. Remove the short circuit plate when wiring.
- For plugging operations, interlock brake circuit's electromagnetic contractor with the motor's electromagnetic contractor.

32

Motor

U1

1 2 3 4 5 6

ON
OFF
ON
ON
ON
OFF

Control Panel

Quick Braking CircuitControl Panel

Reverse rotation

Normal rotation

MC

Y

R

−Δ Starting6. Wiring■ With Brake. 3-Phase Motor. Plugging Operation
Premium-Efficiency, 3-Phase Motor
ESB-250, ESB-250-2
8 Lead Wires
Direct On-Line Starting
T

Reverse rotation

Normal rotation

MCM

OLR

MC

Rectifier

W1

4

W2

U2

Brake

3

RectifierU1 V1 W1 V2 W2 U2

4 3

Motor

Brake

Motor

Reverse rotation

Normal rotation

OLR

MCM

MCM
MCΔ
MC
Δ wiring
MCM
MCΔ
when
acceleration MC
is completed
At start
Wiring

ON
OFF
ON
ON
ON
OFF

MC

MCΔ

MC

OLR
400V classF
200V class

1 2 3 4 5 6Rectifier
W1

4

W2

U2

Brake

3

Motor

Electromagnetic contactor for normal and reverse rotation
MC : Electromagnetic contactor
OLR : Over current protection device or thermal relayTr: Transformer capacity 250–600VA, secondary voltage 200–220V
F: Fuse 3–5A

200V class

1 2 3 4 5 6RectifierU1 V1 W1 V2 W2 U2

4 3

Motor

Brake

Motor

V1

V2

Motor

U1

400V class

F

Control Panel

Tr

Tr

Control Panel

Quick Braking Circuit 400V Class

MC

R S T

Reverse rotation

T

Normal rotation

S

Motor

V1

V2

1 2 3 4 5 6

Motor

U1

Control Panel

1 2 3 4 5 6

R

ON
OFF
ON
ON
ON
OFF

MC

MCΔ

Control Panel

Quick Braking Circuit 200V Class

OLR

MC

MCM
MCΔ
MC
Δ wiring
MCM
MCΔ
when
acceleration MC
is completed
At start
WiringReverse rotation

S

Normal rotationR−Δ Starting
R S T

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- Use with a quick braking circuit. For information on electromagnetic contactors for quick braking circuits, see Table 6-4 on P38.
- Rectifiers are external to the main unit. Rectifiers are made for indoor use. Install in an area where they will not contact with water, etc.
- The brake unit is for 200V class. For 400V class power sources, prepare a 400V/200V transformer.
- For plugging operations, interlock brake circuit's electromagnetic contractor with the motor's electromagnetic contractor.

33

6. Wiring■ With Brake

Inverter Drive

3-Phase Motor
Premium-Efficiency, 3-Phase Motor
AF Motor for Inverter
Premium-Efficiency, 3-Phase Motor for Inverter
High-Efficiency, 3-Phase Motor
FB-01A1 – FB-05A1

FB-1D, FB-1E – FB-5E
5 Lead Wires

R

S

T

R

S

T

MCB

MC

W

V

W

1

Motor
R

S

4

M N

Rectifier

2

Brake

U

S

T

V

W

V

W

Inverter

MC

U

Motor

T

R

S

W

Motor

M N

Brake

1

2

VR

4

M N

RectifierBrake

MC : Electromagnetic contactor
MCB : Miniature circuit breaker
VR : Varistor (for protecting contact points, rectifier, etc.)

R
U

S

T

V

W

V

W

Inverter

U

Motor

MC

1

2

3

VR

4

M N

Rectifier

Brake

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- The motor must be insulated to inverter-drive a 400V class 3-phase motor/high-efficiency, 3-phase motor.
- The interval time between the current stop and brake action is different between normal and quick braking circuits.
Table 7-2 on P40 shows action delay time. Choose the circuit that matches work requirements.
- Use a quick braking circuit to improve hoisting equipment and stopping precision.
- Use a quick braking circuit when a phase-advancing capacitor is mounted.
- For information on electromagnetic contactors and varistors for quick braking circuits, see Table 6-4 on P38.
- Always use the inverter’s power source side for the brake power source.
- Match the opening and closing of the brake circuit’s electromagnetic contactor to the timing of the inverter control.

34

Motor

V

3

Control Panel

W

MC

Motor

U

T

V

2

MCB

Control Panel

Quick Braking Circuit

U

S

Inverter

4

Rectifier
T

MCB

R

1

Motor

V

R

Motor

U

T

Control PanelU

S

Inverter

Control Panel

Normal Braking Circuit

R

MCB

6. Wiring■ With Brake

Inverter Drive

Premium-Efficiency, 3-Phase Motor
Premium-Efficiency, 3-Phase Motor for Inverter
FB-8E – FB-15E

FB-20, FB-30
8 Lead Wires

R

S

T
MCB

T

W

V1

W1

1

4

M N

U2

Rectifier

Brake

V2

W2

MC

2

3

Motor

S

V

Inverter

U1

Control Panel

Normal Braking Circuit

R
U

Motor
R

S

T

R

S

T

MCB

T

MC

VR

U1

V1

W1

1

4

M N

V2

W2

U2

Rectifier

Brake

2

3

T

V

W

U1

V1

W1

V2

W2

U2

U

MC

1

2

3

4

5

Rectifier

6

M N

Brake

Motor

Motor

MC : Electromagnetic contactor
MCB : Miniature circuit breaker
VR : Varistor (for protecting contact points, rectifier, etc.)

S

Inverter

Motor

W

Motor

V

R

Control PanelU

S

Inverter

Control Panel

Quick Braking Circuit

R

MCB

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- The interval time between the current stop and brake action is different between normal and quick braking circuits.
Table 7-2 on P40 shows action delay time. Choose the circuit that matches work requirements.
- Use a quick braking circuit to improve hoisting equipment and stopping precision.
- Use a quick braking circuit when a phase-advancing capacitor is mounted.
- For information on electromagnetic contactors and varistors for quick braking circuits, see Table 6-4 on P38.
- Use FB-20, FB-30 with quick braking circuits.
- FB-20, FB-30 are shipped with a short circuit plate connected between terminals 5 and 6. Remove the short circuit plate when wiring.
- Always use the inverter’s power source side for the brake power source.
- Match the opening and closing of the brake circuit’s electromagnetic contactor to the timing of the inverter control.

35

6. Wiring■ With Brake

Inverter Drive

Premium-Efficiency, 3-Phase Motor
Premium-Efficiency, 3-Phase Motor for Inverter
ESB-250, ESB-250-2
8 Lead Wires
R

S

T

R
U

S

T

V

W

InverterMC
1 2 3 4 5 6Rectifier
U1

V1

W1

4

V2

W2

U2

Brake

3

Control Panel Motor

Quick Braking Circuit 200V Class

MCB

Motor
R

S

T

Tr
400V class
R
U

S

T

V

W

InverterF
200V class

Control PanelMC
1 2 3 4 5 6Rectifier

U1
V2

V1
W2

W1

4

U2

Brake

3

Motor

Quick Braking Circuit 400V Class

MCB

Motor

MC : Electromagnetic contactor
MCB : Miniature circuit breakerTr: Transformer capacity 250–600VA, secondary voltage 200–220V
F: Fuse 3–5A

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- Use with a quick braking circuit. For information on electromagnetic contactors for quick braking circuits, see Table 6-4 on P38.
- Rectifiers are external to the main unit. Rectifiers are made for indoor use. Install in an area where they will not contact with water, etc.
- The brake unit is for 200V class. For 400V class power sources, prepare a 400V/200V transformer.
- Always use the inverter’s power source side for the brake power source.
- Match the opening and closing of the brake circuit’s electromagnetic contactor to the timing of the inverter control.

36

6. Wiring■ With Brake

Inverter Drive

AF Motor for Inverter
ESB-250, ESB-250-2
13 Lead Wires
AF Motor for Inverter With Axial Fan
Quick Braking Circuit Indoor 200V Class
Outdoor 200V Class

R

S

T
MCB1

MCB2

U

S

T

V

W

InverterMC
1 2 3 4 5 6RectifierU

V

W

Axial fan

U1

V1

W1

V2

W2

U2

Motor
S

4

T2

3

Brake

Thermostat
T
MCB1

F

U

S

T

V

W

InverterMCF

1 2 3 4 5 6Rectifier

W

U1
V2

V1
W2

Motor

W1

T1

T2

U2

4

3

Brake

Thermostat

MC : Electromagnetic contactor
MCB : Miniature circuit breakerTr: Transformer capacity 250–600VA, secondary voltage 200–220V
F: Fuse 3–5A

S

T
MCB1

F

Tr
400V class

R

MCB2

U

S

T

V

W

Inverter

200V classMC
1 2 3 4 5 6RectifierU

V

Axial fan

W

U1

V1

W1

V2

W2

U2

Motor

T1

T2

4

3

Brake

Motor

V

Axial fan

Motor

U

R

Control Panel

R

MCB2

Control Panel

Quick Braking Circuit
Indoor 400V Class

400V class
Tr
200V class

Quick Braking Circuit Outdoor 400V ClassR

T1

Control Panel Motor

R

Thermostat

Customer needs to prepare.

- This diagram shows cases for motors with standard Japanese domestic specifications. Please consult with us for motors withoverseas specifications.
- For brake types, see Table 1-7 on P7.
- Use with a quick braking circuit. For information on electromagnetic contactors for quick braking circuits, see Table 6-4 on P38.
- Rectifiers are external to the main unit. Rectifiers are made for indoor use. Install in an area where they will not contact with water, etc.
- The brake unit is for 200V class. For 400V class power sources, prepare a 400V/200V transformer.
- Always use the inverter’s power source side for the brake power source.
- Match the opening and closing of the brake circuit’s electromagnetic contactor to the timing of the inverter control.
In the case of motor with axial fan (totally enclosed, fan motor ventilation type) , note the following items.
- Also connect a power source to the axial fan.
- For an indoor 400V class, the axial fan power source voltage will be 200V class.
- For special specifications, specifications may differ from the above. Check the manufacturing specifications.
- Connect the fan so that it rotates in the same direction as that shown on the nameplate for direction of rotation.
(Normally, the air from the fan will blow in a direction from the anti-load side to the load side.)- When the motor is shut down for a long period, also shut down the axial fan motor.
- Wire the mounted thermostat.
Operating function: Normally closed (break contact)- Thermostat specification: Terminal symbols: T1, T2 and P1, P2
Operating temperature: 135℃ (for thermal class 155 (F)) Maximum current: DC 24V, 18A; AC 230V, 13A

37

6. Wiring
6-6 Points to Note When Using a Quick Braking Circuit
When using brakes with quick braking circuits, take note of the following items.
- C onnect a varistor (protection element) to protect the quick braking circuit contact points from surge voltage generated by the brakeaction.
- Wire the quick braking circuit contact points to the brake power source secondary side contact points; otherwise, contact points
might not be protected.
- For information on using an alternating current electromagnetic contactor for contact points for quick braking circuits, see Table 6-4.
If multiple contact points are required, note the following issues.
- C onnect electromagnetic contactor contact points in serial. (See figure 6-3)
- Connect the varistor (VR) as close to the unit as possible. (See figure 6-3)
Table 6-4 Nomenclature for Parts Recommended When Using a Quick Braking Circuit (When Using an Alternating Current Electromagnetic
Contactor).
Recommended Contactor Nomenclature
AC
Voltage

Made by Mitsubishi Electric
Corporation

SC-05

Serial contact
points: 1(0.7A)

S-T12

Serial contact
points: 1(1.2A)

SC-05

Serial contact
points: 2(3.0A)

S-T12

Serial contact
points: 2(3.0A)

SC-05

Serial contact
points: 3(4.0A)

S-T20

Serial contact
points: 3(5.0A)

SC-5-1

Serial contact
points: 3
(10A)

S-T21

Serial contact
points: 3(10A)

Serial contact
points: 1(0.25A)
Serial contact
points: 2(0.4A)

S-T12

Serial contact
points: 2(0.5A)

S-T12

Serial contact
points: 3(2.0A)

S-T20

Serial contact
points: 3(2.0A)

Minimum
1.5A

S-T21

Serial contact
points: 3(4.0A)

Minimum
3.0A
Minimum
2.5A

FB-01A1
FB-02A1
FB-05A1
FB-1D
FB-1E
FB-1HE
FB-2E
FB-3E
FB-4E
FB-5E

200V
220V

FB-8E
FB-10E
FB-15E
FB-20
FB-30
ESB-250
ESB-250-2
FB-01A1
FB-02A1
FB-05A1
FB-1D
FB-1E
FB-1HE
FB-2E
FB-3E
FB-4E
FB-5E

400V
440V

Recommended
Contactor
Contact Point
Capacity(DC-13 class)Made by Fuji Electric FA
Components & Systems
Co., Ltd.

Brake Type

SC-05
SC-05

SC-05

Serial contact
points: 3(2.0A)FB-8E
FB-10E
FB-15E
FB-20
FB-30

-

-

Minimum
0.4A
Minimum
0.5A
Minimum
0.7A

DC
110V

Minimum
1.5A

Recommended Varistor (For Protecting Contactor Contact Points)
Maximum
Varistor
Power
Allowable
Varistor Nomenclature
VoltageRatingCircuit
Voltage
0.25W

TND07V-471KB00AAA0
TND10V-471KB00AAA0

0.4W
AC300V

470V(423–517V)

TND14V-471KB00AAA0

0.6W

TND20V-471KB00AAA0

1.0W

TND10V-821KB00AAA0

0.4W

Minimum
3.0A
Minimum
5.5A
Minimum
4.5A
Minimum
0.2A
Minimum
0.3A
Minimum
0.5A

DC
220V

TND14V-821KB00AAA0
AC510V

Minimum
1.0A

820V(738–902V)

TND20V-821KB00AAA0

0.6W

1.0W

- This
recommended contactor nomenclature is for Fuji Electric FA Components & Systems Co., Ltd. and Mitsubishi Electric Corporation
contactors. Products from other manufacturers are also allowable if they have equivalent capabilities.
- Recommended contactor contact point capacity indicates the D-13 class rated used current in the case where durability regarding
electronic opening and closing (service life) is approximately 2 million times (for FB-30, ESB-250 and ESB-250-2, approximately
1 million times) the rating of main contact point and auxiliary contact point can differ, so check by catalog and other materials.
- Of the recommended contactors, the Mitsubishi Electric Corporation S-T12 and S-T20 have one auxiliary contact point. Please be
careful in the case where the brake requires 2 and more contract points and is driven by inverter. (Other connectors in Table 6-4 have
two or more auxiliary contact points.)- This recommended varistor nomenclature is for Nippon Chemi-Con Corporation varistors. Products from other manufacturers are also
allowable if they have equivalent capabilities.
- In the FB-20, FB-30, ESB-250 and ESB-250-2, a varistor for protecting the connector contact points is built in to the rectifier.
Figure 6-3 Examples of Contact Point Connections With Quick Braking Circuits
For FB-01A1 – FB-15E

MCVR

U phase Note Brake terminal Ｎ
Rectifier terminal 2
Serial contact points: 1

For FB-20, FB-30, ESB-250 and ESB-250-2

MCVR

U phase Note

Brake terminal Ｎ

Rectifier terminal 2
Serial contact points: 2

MCVR

U phase Note

Brake terminal Ｎ

MCRectifier terminal 5 Rectifier terminal 6

Rectifier terminal 2
Serial contact points: 3

Note: For inverter drives, connect to the R phase (power source side).

38

Serial contact points: 3

7. Operation Common
DANGER‐ Do not approach or touch rotating parts (output shaft, etc.) during operation; otherwise loose clothing may became caught
in these rotating parts and cause serious injury or death.
‐ When the power supply is interrupted, be sure to turn off the power switch; otherwise, restoration of power may cause
electric shock, personal injury, or damage to the equipment.
‐ Do not operate the unit with the terminal box cover removed. Return the terminal box cover to the original position after
maintenance in order to prevent electric shock.
‐ Do not operate the machine while the brake is released by the manual brake release bolt; otherwise, falling, going out ofcontrol, or damage to the equipment may result.

CAUTION‐ Do not put fingers or foreign objects into the opening of the products; otherwise, electric shock, injury, fire, or damage tothe equipment may result.
‐ The products becomes very hot during operation. Touching the unit may result in burns.
‐ Do not loosen the oil filler plug during operation; otherwise, hot, splashing lubricant may cause burns.
‐ If any abnormality occurs during operation, stop operation immediately; otherwise, electric shock, personal injury, or fire
may result.
‐ Do not operate the unit under more than rated load; otherwise, personal injury, or damage to the equipment may result.

7-1 Items to Check Before Operation‐  Oil-lubricated models and parts are shipped without oil. Before operating, make certain to feed the recommended lubricating oil.
(See P43–49)‐ Some models require replenishment of oil at two locations (output side: bevel gear unit or helical gear part, input side: cyclo unit orplanetary gear part).
‐ Grease is encapsulated in the grease lubrication part at the time of shipment.
After installation and wiring are completed,check the following before operating.

Oil gauge center‐ Is the wiring correct?
red upper line

‐ Is the unit properly coupled with the driven
machine?

oil level‐ Are mounting bolts tightened firmly?

red or yellow underline‐ Is the direction of rotation as required?
‐ For oil-lubricated models and parts lubricatedwith oil, is the oil level at the center of the oil
gauge (Figure 7-1) when operation is stopped?

Figure 7-1 Oil Gauge

Is the oil level in the center of red upper line andred or yellow underline (figure 7-1) when it stops? (There is no problem when the oil lavel between red upper line and rede or yellow
underline.)
After confirming these items, operate without a load and gradually apply a load. Check the items shown in Table 7-1.
Note: 1. E ven if the oil level is adjusted to the center of the oil gauge at the time of lubrication, the oil level may drop when operationis stopped because the air inside of the reducer is released during operation. Therefore, be sure to check the oil level after test
operation. When the oil level is low, replenish the lubricating oil.
2. C heck the oil level some time after operation is stopped. The oil level cannot be checked during operation and immediately after
operation is stopped.

39

Common

7. Operation

7-2 Items to Check During Operation
Table 7-1 Items to Check During Operation
Does abnormal sound or vibration
generate?

‐ Is the housing deformed because the installation surface is not flat?
‐ Is insufficient rigidity of the installation base generating resonance?
‐ Is the shaft center aligned with the driven machine?
‐ Is the vibration of the driven machine transmitted to the gearmotor or reducer?

Is the surface temperature abnormallyhigh?

‐ Does the voltage rise or drop substantially?
‐ Is the ambient temperature too high?
‐ Does the current value to the gearmotor exceed the rated current shown on the
nameplate?

If any abnormalities are found, immediately stop operation and contact the nearest authorized maintenance shop.

7-3 Brake Torque and Activation Delay TimeThe table below shows standard specification brake types, their brake torque, and their relationship to brake activation delay time.
Table 7-2 Brake Torque and Activation Delay Time

Brake
Type

FB-01A1
FB-02A1
FB-05A1
FB-1D
FB-1E
FB-1HE
FB-2E
FB-3E
FB-4E
FB-5E
FB-8E
FB-10E
FB-15E
FB-20
FB-30

ESB-250(Horizontal)
ESB-250-2(Vertical)

3-Phase
Motor

Motor Capacity (kW)Premium
PremiumEfficiency, AF Motor
Efficiency,
3-Phase for Inverter 3-Phase Motor
Motor
for Inverter

Brake Activation Delay Time (s)HighNormal
Efficiency,
Brake Torque
Braking
3-Phase(Dynamic Friction
Circuit
Motor
Torque) (N•m) (Simultaneous
Turn-Off
4P
Circuit)

4P

4P

4P

4P

0.1
0.2 0.25
0.4
0.55
-

0.75
1.1
1.5
2.2
3.0
3.7
5.5
7.5
11
15
18.5
22
30

0.1
0.2
0.4
-

0.75
1.5
2.2
3.7
5.5
7.5
11
15
18.5
22
30

0.2
0.4
-

-

-

30

-

-

-

37

37

37

-

-

45

-

45

-

1.0
2.0
4.0
7.5
7.5
11
15
22
30
40
55
80
110
150
190
220
200
Horizontal
VerticalHorizontal
VerticalHorizontal
Vertical

212
195
266
244
320
292

NormalBraking
Circuit forInverter(SeparateTurn-OffCircuit)Quick
Braking
Circuit0.15–0.2

0.08–0.12

0.015–0.02

0.1–0.15
0.2–0.3
0.25–0.45
0.45–0.65
0.35–0.55
0.75–0.95
0.65–0.85
1.1–1.3
1.0–1.2
1.8–2.0
1.6–1.8-

0.03–0.07
0.1–0.15
0.15–0.25
0.25–0.35
0.15–0.25
0.4–0.5
0.3–0.4
0.4–0.5
0.3–0.4
0.6–0.7
0.5–0.6-

0.01–0.015
0.01–0.02--

0.03–0.11

-

-

0.065

0.01–0.03

0.02–0.04

0.06–0.14

Note: 1. Brake type may differ depending on the specifications. Check the nameplate.
2. B rake torque will change according to operating environment, operating conditions, the condition of the friction surface, etc. In
particular, brake torque may not be at the prescribed level for initial operation, and after a long period of inactivity. In such a case,turn the brake on and off under as light load as possible to contact the brake’s friction surfaces.
3. Brake activation delay time will change according to the brake’s wiring circuit. Select the optimum circuit for the application.

40

8. Daily Inspection and Maintenance Common
DANGER‐ Do not handle the unit when cables are energized. Be sure to turn off the power when working on the unit; otherwise,electric shock may result.
‐ Do not approach or touch any rotating parts (output shaft, etc.) during maintenance or inspection while operating the unit;
otherwise, loose clothing may become caught in these rotating parts and cause serious injury or death.
‐ For explosion proof motors , customers must not disassemble or modify; otherwise, explosion, ignition, electric shock, or
damage to the equipment may result.
‐ For explosion proof motors , the lead-in condition shall conform to the facility’s regulations, electrical codes, and explosion
proofing standard, as well as the maintenance manual. Additionally, do not open the terminal box cover while operating;otherwise, explosion, ignition, electric shock, or damage to the equipment may result.
‐ Do not operate the machine while the brake is released by the manual brake release bolt; otherwise, falling, going out ofcontrol, or damage to the equipment may result.

CAUTION‐ Do not put fingers or foreign objects into the opening of the products; otherwise, electric shock, injury, fire, or damage tothe equipment may result.
‐ The products becomes very hot during operation. Touching the unit with bare hands may result in serious burns.
‐ Do not touch the terminals when measuring insulation resistance; otherwise, electric shock may result.
‐ Do not operate the unit without a safety cover (removed during inspection); otherwise loose clothing may became caught
in these rotating parts and cause serious injury or death.
‐ When any abnormality happens, observe the condition based on maintenance manual. Do not operate the unit until thecause is detected and repaired.
‐ Change lubricant according to the maintenance manual instructions. Be sure to use lubricant that we recommend.
‐ When install, move, or transport oil lubricated model, be sure to remove lubricating oil from it. Moving machine withlubricating oil in may cause oil to discharge from the air vent, etc.
‐ Do not change lubricant during operation or immediately after stopping operation; otherwise, burns may result.
‐ Do not operate damaged gearmotors or reducers; otherwise, injury, fire, or damage to the equipment may result.
‐ We cannot assume any responsibility for damage or injury resulting from an unauthorized modification by a customer, as itis outside the scope of the warranty.
‐ Dispose of products lubricant as general industrial waste.
‐ When measuring the insulation resistance of explosion proof motors , confirm that there is no gas or explosive vapor in thevicinity in order to prevent possible explosion or ignition.
‐ Changing brake linings requires experience. Consult with the nearest authorized maintenance shop.
‐ Brake torque will change with operation environment and conditions, the condition of the friction surface, and otherfactors. In particular, brake torque may not be at the prescribed level for initial operation, and after a long period ofinactivity. In such a case turn the brake on and off under as light load as possible to contact the brake’s friction surfaces.

8-1. Daily Inspection
Make certain to carry out daily inspections in accordance with Table 8-1. Lack of inspections is a source of trouble.
Table 8-1 Daily Inspection
Inspection Item
Current value
Noise
Vibration

Surface temperature

Inspection DetailIs the current no greater than the rated value shown on the nameplate?
Are there unusual noises, or are there extreme changes in the noises?
Is there abnormally large vibration? Are there extreme changes?
Is surface temperature unusually high? Is there a sudden rise?
T emperature rises during operation will differ according to model and type. However, there is no particular
problem if fluctuation is slight even if the difference between the gear unit surface temperature and theambient temperature is approximately 60°C. 						When the surface temperature turns over 90°C, oil deteriorates earlier. So, change oil earlier.

)

Oil level
Is the oil level at the center of the oil gauge when operation is stopped?
( Oil-lubricated models and parts )Lubricant contamination
Oil, grease leaks
Mounting bolts
Air breather cap
Chain, V-belt

Is the lubricating oil contaminated?
To check oil contamination, extracting oil while the machine stops and using the oil gauge are
effective.
If the oil gauge is contaminated, promptly change it.
Are oil or grease leaking from the gear unit? Are the oil seal sliding surfaces corroded?
Are the mounting bolts loose?
Is the air breather cap loose?
Are the chain or V-belt loose?

‐ If any abnormality is discovered during the daily inspection, take measures in accordance with “9.Troubleshooting” (P80, 81). If theseactions do not solve the issue, immediately contact the nearest authorized maintenance shop.

41)

Common

8. Daily Inspection and Maintenance

8-2 Confirmation of Lubrication Method
Please look for the relevant items and make certain to do maintenance. Lack of maintenance is a source of trouble.

(1) Standard lubrication method (When driven at standard input speed)‐ Check Table 8-2 to Table 8-4 for the lubrication method for the gear unit of the model used by the customer.
‐ Table 8-5 lists the maintenance method by lubrication method.
‐ For the Bevel BUDDYBOX with Torque Limiter, specifications may differ from those shown in Table 8-2 and Table 8-3. Check the
manufacturing specifications.
Table 8-2 Bevel BUDDYBOX 4 Series
Bevel Gear 1 Stage + Cyclo or Planetary Gear 1
Stage Reduction

4A10□

4A11□

4A10DA

Frame
Size
Bevel Gear 1 Stage + Cyclo 2 Stage Reduction

OutputSide–

4A12□ 4A14□ 4B16□ 4C17□ 4D18□ 4E19□
4B12□ 4B14□ 4C16□ 4D17□ 4E18□ 4F19□
4C14□ 4D16□ 4E17□ 4F18□
4A12DA 4B14DA 4C16DA 4D17DA 4D18DA 4E19DA
4A12DB 4B14DB 4C16DB 4D17DB 4D18DB 4E19DB
4B12DA 4C14DA 4D16DA 4D17DC 4E18DA 4F19DA
4B12DB 4C14DB 4D16DB 4E17DA 4E18DB 4F19DB
4E17DB 4F18DA
4C14DC
4E17DC 4F18DB

Bevel Gear Unit

Cyclo Unit orPlanetary Gear Unit
Input Side
Cyclo Unit

Oil bath lubrication

Mounting Location
Oil bath lubrication■1, ■3, ■5, ■6
Mounting Location ■2
Cyclo or Planetary Gear 1
Oil bath lubrication
Stage Reduction
Grease lubrication
Mounting Location ■2* Long-life grease lubrication
Cyclo 2 Stage Reduction
Oil bath lubrication
Mounting Location ■4 Long-life grease lubrication
Grease lubrication*The lubrication method differs depending on the manufacture date and specification. You can identify them from the appearance. See P48.
Note: 1. The symbol □ in frame size can be “0” or “5”.
2. The symbol ■ in mounting location can be “Y”, “F”, “G”, “K”, “W” or “V”.
3. If input speed is not standard, consult with us.
4. For mounting positions ■ 5 and ■ 6, only the bearing on the upper side of the output shaft uses the grease lubrication method.

Table 8-3 Bevel BUDDYBOX 5 Series
Bevel Gear 1 Stage + Cyclo or Planetary Gear 1
Stage Reduction

5Z10□

5Z11□
5A11□

5Z10DA

Frame
Size
Bevel Gear 1 Stage + Cyclo 2 Stage Reduction

OutputSide–

Bevel Gear Unit

Cyclo Unit or
Input Side Planetary Gear Unit
Cyclo Unit

Mounting Location■1, ■2, ■3, ■5, ■6
Mounting Location ■4

5Z12□
5A12□
5B12□
5Z12DA
5Z12DB
5A12DA
5A12DB
5B12DA
5B12DB

5A14□ 5B16□ 5C17□
5B14□ 5C16□
5C14□
5B14DA 5C16DA
5B14DB 5C16DB
5C14DA–
5C14DB
5C14DCOil bath lubrication
Oil bath lubrication
Long-life grease lubrication

Grease lubrication

Note: 1. The symbol □ in frame size can be “0” or “5”.
2. The symbol ■ in mounting location can be “Y” or “G”.
3. If input speed is not standard, consult with us.
4. For mounting positions ■ 5 and ■ 6, only the bearing on the upper side of the output shaft uses the grease lubrication method.

Table 8-4 Helical BUDDYBOX
Frame
Size

Helical Gear 1 Stage + Cyclo or Planetary Gear 1
Z609 □ A610 □ B612 □–––C614 □ D616 □ E617 □Stage Reduction
Z609DA A610DA B612DA C614DA D616DA E617DA
B612DB C614DB D616DB E617DB
Helical Gear 1 Stage + Cyclo 2 Stage Reduction–––
D616DC E617DC

OutputSide
Input Side

Helical Gear Unit
Cyclo Unit orPlanetary Gear Unit

Mounting Location■1, ■2, ■3, ■4

Cyclo Unit

Mounting Location ■5, ■6

Note: 1. The symbol □ in frame size can be “0” or “5”.
2. The symbol ■ in mounting location can be “Y” or “F”.
3. If input speed is not standard, consult with us.

Oil bath lubrication
Long-life greaselubrication
Long-life greaselubrication

42

Grease lubrication

Oil bath lubrication

Grease lubrication

Grease lubrication

8. Daily Inspection and Maintenance Common
Table 8-5 Maintenance Manual Pages that can be Referenced Regarding Lubrication Maintenance
Location of Information on Maintenance Technique
Oiling, Greasing at Timeof Purchase, Prior toOperation

Lubrication MethodOillubrication
Greaselubrication

Oil Bath
Long-life
greaseGreaseOil, Grease
Change, Replenish
Intervals

Recommended
Lubricating Oil, Grease

Oil Fill Quantity
Grease Supply Quantity

Oil Fill and Drain
Procedures
Grease Lubrication andDischarge Procedures

Selflubricating

Required

8-3
(1)
P43

8-3
(2)
P43

8-3
(3)
P44–46

8-3(4)
P47–49Selflubricating

Not required

8-4
(1)
P50

8-4
(2)
P50

8-4
(3)
P51

8-4
(4)
P52

8-3 Lubrication and Oil Change for Oil Lubricated Gear Units(1) Oil Change Interval
Table 8-6 Lubricating Oil Inspection and Change Intervals
Lubrication
First timeOilchange

2nd andsubsequent
times

Change IntervalTime of purchase
After 500 hours or 6 months, whichever comes first.
Every 5,000 hours, or every year, whichever comes
first.

Operating Condition−−
Indoors, etc. at 0 to 35°C
Outdoors or hot location where temperature are
not maintained between 0 and 35°C or in thecase the surface temperature of gear part is morethan 90°C, etc.,

Every 2,500 hours, or every 6 months, whichevercomes first.

‐ Oil degrades more rapidly when ambient temperature is high or changes radically, and when corrosive gases are present. In suchcases confer with the lubricating oil manufacturer.

(2) Recommended Lubricating Oil
Always use lubricating oils recommended by Sumitomo Heavy Industries as shown in Table 8-7.
Table 8-7 Recommended Lubricating Oils (Equivalent to SP Type Industrial High-Pressure Gear Oil or JIS K2219)
Ambient
Temperature
°C

COSMO

ENEOS

IDEMITSU

Shell-10 to 5

COSMO
GEAR SE
68−

DaphneSuper
Gear Oil
68

Shell Omala Shell Omala
S2 G
S2 GX
68
68

0 to 35COSMO
GEAR SE
100, 150

BONNOCTS
150

DaphneSuper
Gear Oil
100, 150

30 to 50COSMOGEAR SE
220 - 460

BONNOCTS
220 - 460

DaphneSuper
Gear Oil
220 - 460

Mobil

CALTEXbp

Mobilgear
Gulf EP
600 XP Lubricant HD
68
68

–

Energol
GR-XP
68

Shell Omala Shell Omala
Spartan EP
S2 G
S2 GX
150
100, 150
100, 150

Gulf EP
Mobilgear
600 XP Lubricant HD
100, 150
100, 150

Meropa100, 150

Energol
GR-XP
100, 150

Shell Omala Shell Omala
Spartan EP
S2 G
S2 GX
220 - 460
220 - 460
220 - 460

Gulf EP
Mobilgear
600 XP Lubricant HD
220 - 460
220 - 460

Meropa220 - 460

EnergolGR-XP
220 - 460−

Gulf

[1] When using in winter or where the ambient temperature is relatively low, use an oil with low viscosity shown in the table below.
[2] For allowable lubricating oil viscosity, see Table 8-8. Use within this required viscosity range.
Table 8-8 Allowable Oil Lubricant Viscosity
Minimum Allowable
Viscosity

For oil temperature during operation,
minimum 15mm2/S.

Viscosity that will obtain required film strength under load.

Maximum Allowable
Viscosity

Oil bath lubricatedmodelsViscosity at which BUDDYBOX can start

Maximum
4,300mm2/S[3] For a smooth startup, use oil with a pour point at least 5℃ below ambient temperature.
[4] If operating temperature changes widely, use a high viscosity index oil that meets requirements [2] and [3].
[5] If regularly operating outside the ambient temperature range of 0 to 40℃ , some parts of the mechanism may need to bechanged, or lubricating oil might need to be preheated, or cooled. Please consult with us.

43Common

8. Daily Inspection and Maintenance(3) Oil Fill Quantity‐ Table 8-9 to Table 8-11 provide approximate oil fill quantities. There are individual differences in actual quantities due to difference ineach structure. Make sure to check that the oil level is at the center of the oil gauge, because the oil quantity may be more or less thanrequirement even if the oil is replenished according to Table 8-9 to Table 8-11.
‐ For the Bevel BUDDYBOX with Torque Limiter, refer to P92.

■ Bevel BUDDYBOX 4 Series

Table 8-9 Approximate Oil Fill Quantity (L)Bevel Gear 1 Stage + Cyclo or Planetary Gear 1 Stage Reduction
Frame Size
4A10 □
4A11 □
4A12 □

Y1, F1, G1
K1, V1
1.6
1.7
1.7

Y2, F2, G2
K2, V2, W2
3.3
3.4
3.5

Y3, F3, G3
K3, V3, W3
1.6
1.7
1.7

4A14 □

1.9

4.1

1.9

4B12 □

3.3

6.6

3.3

4B14 □
4B16 □
4C14 □
4C16 □
4C17 □
4D16 □
4D17 □
4D18 □
4E17 □
4E18 □
4E19 □
4F18 □
4F19 □

3.5
3.9
5.5
6.0
6.3
10.1
10.4
10.7
14.6
14.7
15.7
20.0
20.8

7.3
7.8
11.4
12.0
12.8
20.1
20.8
21.3
29.1
29.4
30.7
39.7
40.9

3.5
3.9
5.5
6.0
6.3
10.1
10.4
10.7
14.6
14.7
15.7
20.0
20.8

Mounting Location
Y4, F4, G4, K4, W4
Output Side
Input Side
Long-life
greaselubrication
1.1
Greaselubrication
Long-life greaselubrication
1.7

2.7
4.6
6.3
7.3

Greaselubrication

Y5, F5, G5
K5, V51.4
1.4
1.5

Y6, F6, G6
K6, V6
1.8
1.9
1.9

1.7

2.1

3.3

3.2

3.5
4.0
5.3
5.7
6.1
9.7
10.0
10.3
13.1
13.2
14.2
18.5
19.3

3.4
3.9
5.9
6.3
6.7
10.4
10.8
11.1
16.1
16.2
17.2
21.4
22.2

Bevel Gear 1 Stage + Cyclo 2 Stage Reduction
Mounting Location
Y2, F2, G2, K2, V2, W2*
Y4, F4, G4, K4, W4
Frame Size Y1, F1, G1
Y3, F3, G3
Y5, F5, G5
Y6, F6, G6
Input side (Cyclo part)Oil bath
K1, V1
K5, V5
K6, V6
Grease lubricated typelubricated K3, V3, W3 Output side Input sidemodels
Output side Input side
4A10DA
1.7
3.2
1.7
1.4
1.9
1.0
1.1
4A12DA
1.7
3.4
1.7
1.5
2.0
Long-life
Long-life
greasegrease
4A12DB
1.8
3.4
1.8
1.5
2.0
lubrication
lubrication
4B12DA
3.3
6.5
3.3
3.4
3.3
4B12DB
3.4
6.6
3.4
3.4
3.3
2.0
1.7
4B14DA
3.5
7.0
3.5
3.6
3.5
4B14DB
3.6
7.0
3.6
3.6
3.5
4C14DA
5.6
11.2
5.6
5.3
5.9
4C14DB
5.6
11.2
5.6
5.4
5.9
3.5
2.7
4C14DC
5.6
11.3
5.6
5.4
6.0
4C16DA
6.0
11.8
6.0
5.8
6.4
4C16DB
6.1
11.9
6.1
5.9
6.4
4D16DA
10.1
20.0
10.1
9.8
10.5
4D16DB
10.1
20.0
10.1
9.8
10.5
4D17DA
10.2
20.0
10.2
9.8
10.6
5.0
4.6
4D17DB
10.5
20.6
10.5
10.2
10.9
4D17DC
10.7
20.7
10.7
10.3
11.0
GreaseGrease
4D18DA
10.8
21.1
10.8
10.5
11.2
lubrication
lubrication
4D18DB
11.7
21.4
11.7
11.4
12.1
4E17DA
14.6
28.8
14.6
13.1
16.1
4E17DB
14.7
28.9
14.7
13.2
16.2
4E17DC
14.8
29.0
14.8
13.3
16.3
7.3
6.3
4E18DA
14.8
29.3
14.8
13.3
16.3
4E18DB
15.7
29.6
15.7
14.2
17.2
4E19DA
17.5
31.0
17.5
16.0
19.0
4E19DB
17.7
31.0
17.7
16.2
19.2
4F18DA
20.1
39.6
20.1
18.6
21.5
4F18DB
21.0
39.9
21.0
19.5
22.4
12.0
7.3
4F19DA
22.6
41.2
22.6
21.1
24.0
4F19DB
22.8
41.2
22.8
21.3
24.2
*The lubrication method differs depending on the manufacture date and specification. You can identify them from the appearance. See P48.
Note: 1. The symbol □ in frame size can be “0” or “5”.
2. Output side: Bevel gear unit, Input side: Cyclo unit or Planetary gear unit
3. Depending on the viscosity or temperature of the lubricating oil, it takes time to replenish oil.
4. For grease replenishment amount for the grease lubrication part, refer to P51.

44

8. Daily Inspection and Maintenance Common■ Bevel BUDDYBOX 5 Series
Table 8-10 Approximate Oil Fill Quantity (L)Bevel Gear 1 Stage + Cyclo or Planetary Gear 1 Stage Reduction
Frame Size

Y1, G1

Y2, G2

Y3, G3

5Z10 □
5Z11 □
5Z12 □
5A11 □
5A12 □

0.8
0.9
0.9
1.6
1.7

1.6
1.7
1.8
3.1
3.2

0.8
0.9
0.9
1.6
1.7

5A14 □

1.9

3.6

1.9

5B12 □

2.7

5.2

2.7

5B14 □
5B16 □
5C14 □
5C16 □
5C17 □

2.9
3.3
5.4
6.1
6.5

Mounting Location
Y4, G4
Output side
Input side
0.7

0.8

1.6
5.5
6.2
10.7
11.6
12.1

2.9
3.3
5.4
6.1
6.5

3.5

Long-life
greaselubrication
Greaselubrication
Long-life
greaselubrication
Greaselubrication

Y5, G5

Y6, G6

0.7
0.7
0.8
1.4
1.4

0.9
1.0
1.0
1.9
1.9

1.7

2.2

2.3

3.1

2.5
3.0
5.1
5.8
6.2

3.3
3.7
5.7
6.4
6.8

Y5, G5

Y6, G6

0.9
1.1
1.1
1.4
1.4
2.4
2.4
2.6
2.6
5.1
5.2
5.2
5.9
6.0

1.0
1.1
1.1
2.0
2.0
3.2
3.2
3.4
3.4
5.7
5.7
5.8
6.5
6.5

Bevel Gear 1 Stage + Cyclo 2 Stage Reduction
Frame Size
5Z10DA
5Z12DA
5Z12DB
5A12DA
5A12DB
5B12DA
5B12DB
5B14DA
5B14DB
5C14DA
5C14DB
5C14DC
5C16DA
5C16DBY1, G1

Y2, G2

Y3, G3

0.9
0.9
1.0
1.7
1.8
2.7
2.8
2.9
3.0
5.5
5.5
5.5
6.1
6.2

1.6
1.8
1.8
3.2
3.2
5.2
5.3
5.5
5.5
10.8
10.8
10.9
11.6
11.7

0.9
0.9
1.0
1.7
1.8
2.7
2.8
2.9
3.0
5.5
5.5
5.5
6.1
6.2

Mounting Location
Y4, G4
Output side
Input side
0.7
0.8

Long-life
greaselubrication

1.6

3.5

Greaselubrication

Note: 1. The symbol □ in frame size can be “0” or “5”.
2. Output side: Bevel gear unit, Input side: Cyclo unit or Planetary gear unit
3. Depending on the viscosity or temperature of the lubricating oil, it takes time to replenish oil.
4. For grease replenishment amount for the grease lubrication part, refer to P51.

45

Common

8. Daily Inspection and Maintenance■ Helical BUDDYBOXTable 8-11 Approximate Oil Fill Quantity (L)Helical Gear 1 Stage + Cyclo or Planetary Gear 1 Stage Reduction
Mounting Location
Frame
Size

Y1, F1

Y2, F2

Y3, F3

Y4, F4

Y5, F5

Y6, F6

Output
Side

Input
Side

Output
Side

Input
Side

Output
Side

Input
Side

Output
Side

Input
Side

Output
Side

Input
Side

Output
Side

Input
Side

0.6

0.5

0.6

1.1

0.7

0.9

Long-life
greaselubrication

1.0

0.9

Long-life
greaselubrication

Z609 □

0.6

A610 □

0.8

B612 □

1.0

Long-life
greaselubrication

1.5

Long-life
greaselubrication

1.0

Long-life
greaselubrication

1.5

Long-life
greaselubrication

C614 □

1.7

0.4

2.1

0.4

1.3

0.4

2.1

0.4

4.7

D616 □

2.7

0.7

3.5

0.7

2.0

0.7

3.5

0.7

7.0

E617 □

3.5

0.9

4.2

0.9

2.5

0.9

4.2

0.9

9.0

Input
Side

Output
Side

1.5
2.0

Greaselubrication

1.4
1.8
3.5

Greaselubrication

5.5
7.0

Helical Gear 1 Stage + Cyclo 2 Stage Reduction
Mounting Location
Frame
Size
Z609DAA610DA
B612DA
B612DBC614DAC614DBY1, F1
Output
Side

Input
Side

0.6
0.8
1.0

Y2, F2
Output
Side

Input
Side

0.6
Long-life
greaselubrication

1.7

0.9
1.5

Y3, F3
OutputSide

Y4, F4

Input
Side

0.5
Long-life
greaselubrication

2.1

0.7
1.0

OutputSide
0.6

Long-life
greaselubrication

1.3

0.9
1.5

Y5, F5
Input
Side

1.1
Long-life
greaselubrication

2.1

1.5
2.0

Y6, F6
Output
Side

Input
Side

1.0
Long-life
greaselubrication

4.7

1.4
1.8

Long-life
greaselubrication

3.5

D616DAD616DB

2.7

D616DC

Greaselubrication

3.5

Greaselubrication

2.0

Greaselubrication

3.5

Greaselubrication

7.0

Greaselubrication

5.5

E617DA
E617DB

3.5

4.2

2.5

4.2

9.0

E617DC
Note: 1. The symbol □ in frame size can be “0” or “5”.
2. Output side: Helical gear unit, Input side: Cyclo unit or Planetary gear unit
3. Depending on the viscosity or temperature of the lubricating oil, it takes time to replenish oil.
4. For grease replenishment amount for the grease lubrication part, refer to P51.

46

7.0

Greaselubrication

8. Daily Inspection and Maintenance Common(4) Oil Fill and Drain Procedures■ Bevel BUDDYBOX 4 and 5 Series (except for Mounting Location Symbols Y2, F2, G2, K2, V2, and W2)- Oil Fill Procedure[1] Remove the air breather from the oil filler port.
[2] Pour oil into the oil filler port, keeping an eye on the oil gauge to check the oil level.
[3] Some time after the oil is lubricated, confirm that the oil level is at the center position of the oil gauge.
[4] A ttach the air breather to the oil filler port.
[5] When attaching the air breather, make sure that the seal washer is assembled and the air breather cap is securely closed. (The air
breather cap may become loose due to vibration. Periodically check it is tightened securely.)- Oil Drain Procedure[1] Before draining oil, remove drain plugs from all oil drain ports.
[2] When attaching the drain plug, make sure that the seal washer is assembled.

Oil filler port

Oil filler port

Oil gauge

Oil drain port

Oil drain port

Figure 8-1 Locations of Oil Filler Port and Oil Drain Port
(Example: Bevel BUDDYBOX 4 Series LHYM-Y1)

Figure 8-2 Locations of Oil Filler Port and Oil Drain Port
(Example: Bevel BUDDYBOX 5 Series LHYM-Y1)

Air breather cap

Air breather
Seal washer
CasingFigure 8-3 Oil Filler Port

Oil gauge

Figure 8-4 Oil Gauge

For locations of oil filler ports and oil drain ports other than the above, refer to P12 to 13.

47Common

8. Daily Inspection and Maintenance■ Bevel BUDDYBOX 4 and 5 Series (Mounting Location Symbols Y2, F2, G2, K2, V2, and W2)- Oil Fill Procedure[1] Remove the oil filler port A and the oil fill cup lid. (It is not necessary to remove the air breather from the oil fill cup lid.)[2] Pour oil into the oil filler port A, keeping an eye on the oil gauge to check the oil level.
- For Bevel BUDDYBOX 4 Series, lubrication time can be shortened by using oil filler port B together.
- First, remove the plug of oil filler port B, and pour oil into the gear case on the output side. Confirm that the output side is filled withthe lubricating oil, and then attach the plug of the oil filler port B. Make sure that the seal washer is assembled to the plug.
- Next, pour oil from the oil filler port A to fill the inside the gear case on the input side with the lubricating oil.
[3] Some time after the oil is lubricated, confirm that the oil level is at the center position of the oil gauge.
[4] A ttach the oil fill cup lid and the air breather to the oil filler port.
[5] When attaching the oil fill cup lid and the air breather, make sure that the seal washer is assembled and the air breather cap issecurely closed. (The air breather cap may become loose due to vibration. Periodically check it is tightened securely.)- Oil Drain Procedure[1] Before draining oil, remove the drain plug from the oil drain port.
[2] When attaching the drain plug, make sure that the seal washer is assembled.

Oil gauge

Oil filler
port A Oil filler
port AOil gauge

Oil filler
port AOil gauge
Oil filler
port BOil filler
port BOil gauge

Oil drain port

Oil drain port

Oil drain port

Oil bath lubricated models

Oil drain port

Bevel Gear 1 Stage + Cyclo 2 Stage type
Input side (Cyclo part) Grease lubricated typeFigure 8-5 Locations of Oil Filler Port
(Example: Bevel BUDDYBOX 4 Series LHYM-Y2)

Oil filler port A
Oil gauge

Air breather cap

Oil gauge

Air breather
Oil fill cup lid
Seal washer
Oil fill cup
Oil drain port

Oil drain port

Figure 8-6 Locations of Oil Filler Port andOil Drain Port
(Example: Bevel BUDDYBOX
5 Series LHYM-Y2)

Figure 8-7 Oil Filler Port

Figure 8-8 Oil Gauge

Note) I n the case of Input side (Cyclo part) of Bevel Gear 1 Stage type + Cyclo 2 Stage type is lubricated by grease, there is no oil filling
port A and oil fill cup, and plug of oil filling port B is changed to air breather (check from its appearance). Fil oil by following the
instruction of P47.

48

8. Daily Inspection and Maintenance Common■ Helical BUDDYBOX- Oil Fill Procedure[1] Remove the air vent plug from the oil filler port. (Depending on the type, lubrication is required at two locations.)[2] Pour oil into the oil filler port, keeping an eye on the oil gauge to check the oil level.
[3] Some time after the oil is lubricated, confirm that the oil level is at the center position of the oil gauge.
[4] Attach the air vent plug to the oil filler port.
- Oil Drain Procedure[1] Before draining oil, remove drain plugs from all oil drain ports.
[2] F or Helical BUDDYBOX frame size Z6090 to C6145 F5 and Y5, remove the two drain plugs from the oil drain ports of the gear case on
the output side.

Oil filler
Oilportfiller port

Oil filler
Oilportfiller port
Air vent plug

Oil gauge
Oil gauge
CasingDrainDrain
at twoatlocations
two locations
Oil drain
Oil drain
port port
Oil drain
Oil drain
port port
Figure 8-9 Locations of Oil Filler

Port and Oil Drain Port
(Example: Helical BUDDYBOX
EHYM-Y1)

Figure 8-10 Locations of Oil Filler
Port and Oil Drain Port
(Example: Helical BUDDYBOX
EVYM-Z6090 to C6145-Y5)

Figure 8-11 Oil Filler Port

Figure 8-12 Oil Gauge

For locations of oil filler ports and oil drain ports other than the above, refer to P12 to 13.
‐ Only fill oil when the machine is stopped.
‐ Depending on the viscosity or temperature of the lubricating oil, it takes time to replenish oil. Be careful not to allow the oil tooverflow or to be replenished too much.
‐ Supply the oil to the center of the oil gauge.
‐ Even if the oil level is adjusted to the center of the oil gauge at the time of oil supply, the oil level may drop when operation is
stopped because the air inside of the reducer is released during operation. Therefore, be sure to check the oil level after test
operation. If the oil level is low, replenish the lubricating oil.
‐ Check the oil level some time after operation is stopped. The oil level cannot be checked during operation and immediately after
operation is stopped.
‐ For daily oil level management, see Table 8-1 on P41.

(5) Long Term Inactivity
Table 8-12 Long Term Inactivity
Period ofInactivity

Approximately 1 monthMore than 1 month

Before resting the machine, change to new oil and run the machine for a few minutes.
Before resting the machine, flush once, fill with rust preventing oil and run for a few
minutes under no load.

When resuming operation after a long period of inactivity, change to new oil because the existing oil may degrade.

49

8. Daily Inspection and MaintenanceCommon8-4 Grease Lubrication Part (Input Side: Cyclo Part or Planetary Gear Part)(1) Grease Replenishment Intervals
Table 8-13 Grease Replenishment Intervals
Type

Grease Replenishment and Change Intervals

Long-life greaselubricated models

Although these models use long-life grease and can run for a long time without replenishment,
maintenance with disassembly after approximately 20,000 hours or 3 to 5 years will increase lifetime.

Grease Lubricated Machines

Replenish as shown in Table 8-14. Maintenance with disassembly after approximately 20,000 hours or
3 to 5 years will increase lifetime.

Table 8-14 Grease Replenishment Intervals (Except Long-Life Grease Lubricated Models)Operation Time

Replenishment IntervalLess than 10 hours per day

Remarks

Once every 3–6 months
Shorten the replenishment interval when the operating conditions are
Once every 500–1,000 hours severe or the frame size is large.

10–24 hours per day(2) Recommended Grease (Grease Used When Shipped)
Table 8-15 Recommended Grease (Grease Used When Shipped)
Type

Bevel
BUDDYBOX
4 Series

Mounting Location
Cyclo 2 Stage
Reduction
Y2, F2, G2
K2, V2, W2
Y4, F4, G4
K4, W4Bevel
BUDDYBOX
5 Series

Y4, G4

Y1, Y2
Y3, Y4
F1, F2
F3, F4
HelicalBUDDYBOXAll

Y5, Y6
F5, F6

Frame Size
4A10 □, 4A11 □, 4A12 □4B12 □
4A14 □
4B14 □, 4B16 □4C14 □, 4C16 □, 4C17 □4D16 □, 4D17 □, 4D18 □4E17 □, 4E18 □, 4E19 □4F18 □, 4F19 □5Z10 □, 5Z11 □, 5Z12 □5A11 □, 5A12 □5B12 □
5A14 □
5B14 □, 5B16 □5C14 □, 5C16 □, 5C17 □Reduction Z6090, Z6095
ratio
A6100, A6105
11–18 B6120, B6125
Z609 □
A610 □
B612 □
Reduction C614DA, C614DB
ratio
D616DA, D616DB, D616DC
21–4365 E617DA, E617DB, E617DC
C6140, C6145
D6160, D6165
E6170, E6175

Grease Type

Manufacturer

Description

Long-life grease

NIPPECO
Mobil

BEN10-No.2
UNIREX N2

GreaseCOSMOCOSMO GREASEDYNAMAX SH No.2

Ambient
Temperature-10–50℃
NIPPECOBEN10-No.2

Mobil

UNIREX N2

GreaseCOSMOCOSMO GREASEDYNAMAX SH No.2

Long-life grease

Shell

Shell Alvania
EP Grease R0

NIPPECOBEN10-No.2

Mobil

UNIREX N2

GreaseCOSMOCOSMO GREASEDYNAMAX SH No.2

GreaseCOSMOCOSMO GREASEDYNAMAX SH No.2

Long-life greaseLong-life grease-10–40℃-10–50℃‐ The symbol □ in frame size can be "0”, "5”, “DA”, “DB” or “DC” .
‐ Only use grease listed in Table 8-15.
‐ For order placement of grease, contact Sumitomo Heavy Industries Power Transmission & Controls Sales Co., Ltd. Service Center (seeback cover).
‐ When regularly used in ambient temperatures outside the 0 to 40℃ range, some specifications will differ. Please consult with us.
‐ Cyclo 2 Stage type of Bevel Buddy Box 4 Series with Installing position ■2 applies different lubrication method depending on the
manufacture date and specification. You can identify them from the appearance. See P48.
‐ When using Helical BUDDYBOX with frame size E617 □ in severe conditions, please consult with us.

50

8. Daily Inspection and Maintenance Common(3) Grease Replenishment Quantity‐ The table shows the replenishment quantity when the input side (Cyclo unit or Planetary gear unit) is lubricated with grease.
Replenish by using the value in the tables as a guideline.
‐ The output sides (Bevel gear unit and Helical gear unit) of all models are lubricated with oil.
‐ For the Bevel BUDDYBOX with Torque Limiter, refer to P92.
Grease Replenishment Quantity (g) (Guidelines)■ Bevel BUDDYBOX
4 Series
Mounting Location
Frame Size
Y4, F4, G4, K4, W4■ Bevel BUDDYBOX
5 Series
Mounting Location
Frame Size
Y4, G4■ Helical BUDDYBOX

4A10 □
4A11 □
4A12 □
4A14 □

5Z10 □
5Z11 □
5Z12 □
5A11 □

Z609 □
A610 □
B612 □C614 □

Long-life greaselubrication

4B14 □

150–225
Long-life greaselubrication
150–225

5A14 □

4B16 □

250–375

5B12 □

4B12 □

4C14 □
4C16 □
4C17 □
4D16 □
4D17 □
4D18 □
4E17 □
4E18 □
4E19 □
4F18 □
4F19 □

150–225
250–375
335–500
250–375
335–500
370–550
335–500
370–550
500–750
370–550
500–750
Mounting Location
Frame Size Y2, F2, G2, K2, V2, W2
Y4, F4, G4, K4, W4
4A10DA
4A12DA
Long-life grease
4A12DBlubrication
4B12DA
4B12DB
4B14DA
8.5–12.5
4B14DB
20–30
4C14DA
8.5–12.5
4C14DB
20–30
4C14DC
40–60
4C16DA
20–30
4C16DB
40–60
4D16DA
20–30
4D16DB
40–60
4D17DA
20–30
4D17DB
40–60
4D17DC
85–125
4D18DA
40–60
4D18DB
150–225
4E17DA
20–30
4E17DB
40–60
4E17DC
85–125
4E18DA
40–60
4E18DB
150–225
4E19DA
110–165
4E19DB
150–225
4F18DA
40–60
4F18DB
150–225
4F19DA
110–165
4F19DB
150–225

Long-life greaselubrication

5A12 □

5B14 □
5B16 □
5C14 □
5C16 □
5C17 □
5Z10DA
5Z12DA
5Z12DB
5A12DA
5A12DB
5B12DA
5B12DB
5B14DA
5B14DB
5C14DA
5C14DB
5C14DC
5C16DA
5C16DB

Frame Size

D616 □
150–225
Long-life greaselubrication
150–225
250–375
150–225
250–375
335–500

Long-life greaselubrication

Mounting Location
Y1, Y2, Y3, Y4
Y5, Y6, F5, F6
F1, F2, F3, F4
Long-life greaselubrication

Long-life greaselubrication
150–225

Oil lubrication

250–375

E617 □

335–500

Z609DAA610DA
B612DA
B612DBC614DAC614DBD616DAD616DBD616DCE617DA
E617DBE617DC

Long-life grease lubrication

8.5–12.5
20–30
20–30
40–60
85–12520–30
40–60
85–125

8.5–12.5
20–30
8.5–12.5
20–30
40–60
20–30
40–60

- Long-life grease lubricated models do not require grease replenishment.
- The symbol □ in frame size can be “0” or “5”.
- Input side (Cyclo part) of Cyclo 2 Stage type with Installing position ■2
applies different lubrication method depending on the manufacture date andspecification. You can identify them from the appearance. See P48.
- For replenishment amount for the oil lubrication part, refer to P44 to P46.

51							

Common

8. Daily Inspection and Maintenance(4) Procedures for Filling and Discharging
Grease replenishment procedure for grease lubrication parts (excluding long-life grease lubricated models)[1] Remove the grease discharge plug.
[2] U se a grease gun to replenish the grease from the grease fitting, referring to the quantity of grease shown in Table 8-16 on P51 as
guidelines. If a grease fitting has a metal cap, remove the cap before replenishing. After replenishing, attach the metal cap.
[3] Replace the grease discharge plug.

Metal cap

Grease fitting
Greasedischarge plug
Grease fitting

Figure 8-13 Location of Grease Fill andDischarge Port
(Example: Bevel BUDDYBOX 4 Series LHYM-Y4)

Greasedischarge plug

Figure 8-14 Location of Grease Fill andDischarge Port
(Example: Helical BUDDYBOX EHYM-Y3)

Figure 8-15 Grease Fitting with
Metal Cap

‐ Replenish grease while the machine is running to improve grease distribution.
‐ In addition to being used for discharging grease, the grease discharge plug also functions as a pressure vent when replenishinggrease. Make certain to remove it when replenishing.
‐ Replenish grease slowly.
‐ Replenishing more than the quantity shown in Table 8-16 may cause agitation heat, which raises the temperature, and may cause
grease to leak into the motor unit.
‐ Grease may leak out of the grease fitting after starting the machine. In such a case replace the grease fitting with one that has ametal cap.
‐ Be careful when handling the metal cap for the grease fitting as dropping it from a high place is dangerous.
‐ Contact the nearest authorized maintenance shop concerning changing all of the grease in a grease lubricated model.

8-5 Main Unit Maintenance‐ Although it will depend on operation conditions, maintenance with disassembly after approximately 20,000 hours or 3 to 5 years will
increase lifetime. Contact the nearest authorized maintenance shop regarding maintenance with disassembly.
‐ Oil seals have a lifetime. During long use, natural degradation and frictional wear will reduce effectiveness. Reducer operating
conditions and ambient environment will cause lifetime to widely vary. Given normal operation, (uniform load, running 10 hours perday, normal temperature) it is recommended to change them every 1 to 3 years. If the sliding surfaces of oil seals or V-rings show signs
of wear or corrosion, replace them with new ones. Because sliding surfaces for oil seals are made of carbon steel, take periodic rustprevention measures not to spread rust on them by applying rustproof oil, if there are exposed surfaces of steel. Please consult with
the nearest maintenance shop for the replacement of oil seal or V-ring.
‐ If the unit stops and starts frequently, mounting bolts (or nuts) and ring gear housing fastening bolts (or nuts) may come loose.
Periodically check for looseness as this is a source of miss-alignment, oil leakages, and load unbalance.

52

8. Daily Inspection and MaintenanceCommon

8-6 Motor Bearing Maintenance‐ Standard motors manufactured by Sumitomo use sealed bearings without grease filling and discharging structure.
‐ When using another manufacturer’s motor (There are some models made by other manufacturers.), follow the operation manual forthat motor.
‐ Although it will depend on operation conditions, maintenance with disassembly after approximately 20,000 hours or 3 to 5 years will
increase lifetime.
‐ Contact the nearest authorized maintenance shop regarding maintenance with disassembly.

8-7 Brake Maintenance and Inspection
DANGER‐ Do not handle the unit when cables are energized. Be sure to turn off the power when working on the unit; otherwise, electric
shock may result.
‐ When using the product for lifting, do not release the brake while an object is suspended; otherwise it could fall, causing an
accident.
‐ Do not operate the machine while the brake is released by the manual brake release bolt; otherwise, falling, going out of control,
or damage to the equipment may result.
‐ Before operation, turn power on and off to check brake action; otherwise falling or running out of control could occur.
‐ Do not bring water or oils in contact with the brake. Brake torque degradation could cause falling or running out of control.

CAUTION‐ After gap inspection and adjustment, do not operate with the fan cover removed; otherwise loose clothing may became caught inthese rotating parts and cause serious injury or death.
‐ Changing brake linings requires experience. Consult with the nearest authorized maintenance shop.

Given normal operation conditions, brake mechanical lifetime is quite long at 2 million times (1 million times for FB-30, ESB-250
and ESB-250-2). These conditions include the moment of inertia for the load being no greater than the moment of inertia for thebrakemotor. However, please periodically inspect the brake gap (G). The brake lining wears after long hours of running time, making
it impossible for the brake to release. When operating times exceed 2 million (1 million times for FB-30, ESB-250 and
ESB-250-2), wear and damage to mechanical parts may cause dropping or overdrive problems.

8-8 Brake Construction and Gap Inspection and Adjustment‐ The brake is spring activated (power-off type).
‐ The brake lining wears after long hours of operating the brake, making it impossible for the brake to release. Therefore please
periodically inspect the brake gap (G).
‐ If on inspection, the gap is close to the limit value, adjust the gap.
‐ In FB-1E – FB-4E, a shock absorber is inserted between the stationary core and the armature plate to reduce the noise that results fromthe braking action.
When inspecting, be careful so that the gap gauge, other measuring tool or anything else does not damage the shock absorber orcause it to fall out.
There is danger that brake noise will increase and the brake will not function properly if the shock absorber is damaged or falls out.
Table 8-17 Pages Containing Information on Brake Construction and Gap Inspection and Adjustment
Brake Type
FB-01A1, FB-02A1, FB-05A1
FB-1D
FB-1E
FB-1HE, FB-2E
FB-3E, FB-4E
FB-5E, FB-8E
FB-10E, FB-15E
FB-20
FB-30
ESB-250, ESB-250-2

Indoor
P54
P55
P56
P57
P58
P59
P60
P61
P62
P63

Please refer to P76 for the way to remove and attach one-touch release lever.

53

Outdoor
P65
P66
P67
P68
P69
P70
P71
P72
P73
P74

8. Daily Inspection and Maintenance■ FB-01A1, FB-02A1, FB-05A1 (Indoor Type)

8 7

6

5

4

3 2 1

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Ｇ

Part Name
Stationary core
SpacerBrake lining
Attachment bolt
Boss
Shaft-retaining C-ring
Cover
Fan set screw
Fan
Leaf spring
Fixed plate
Armature plate
SpringElectromagnetic coil
Bearing
Motor shaft

Note: FB-01A1 does not come with [8] and [9].

910 11 12 13

14 15

16

Figure 8-16

‐ Gap Inspection(1)

Remove the cover [7].

(2)	Insert a gap gauge between the stationary core [1] and the armature plate [12],measuring the gap. Measure in 3 locations around the circumference.
(3)

Adjustment is required if the gap value is near the limit.

Gap Value G (mm)Required value
Limit value(original value)
0.2–0.35
0.5‐ Gap Adjustment(1)

Remove the cover [7].

(2)Loosen the fan set screw [8] and remove the fan [9].

(3)	Slightly loosen the attachment bolts [4] and rotate the fixed plate [11] counterclockwise, as far as it will go. Then tighten theattachment bolts [4]. After tightening, measure the gap (G) and check to see if the gap value is between the required value andthe limit. (This operation will reduce the gap by 0.3mm.)(4)Turn the power on and off to check brake action.

(5)	Attach the fan [9] and cover [7]. Use a fan set screw [8] coated with Three Bond TB2365 (Sumitomo part number: EW444WW-01),
and tighten with a torque of 0.3–0.5N·m.
Note : If the the optional brake release bolt is installed, disassemble after removing the release bolt.

54

8. Daily Inspection and Maintenance■ FB-1D (Indoor Type)12 11 10 9

8

7

6

5

4

3 2

1

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Ｇ

13

14

15 16 17 18 19 20Part Name
Stationary core
Brake release
Manual release protection
spacerBrake release bolt
Spacer
Gap adjusting shims
Attachment bolt
Brake lining
Leaf spring
Boss
Shaft-retaining C-ring
Fan set screw
Cover
Fan
Fixed plate
Armature plate
SpringElectromagnetic coil
Bearing
Motor shaft

Figure 8-17

‐ Gap Inspection(1)

Remove the brake release bolt [4] and the manual release prevention
spacer [3].

(2)Remove the cover [13].

(3)	Insert a gap gauge between the stationary core [1] and the armature plate [16],Gap Value G (mm)Required value
Limit value(original value)
0.3–0.4
0.6

measuring the gap. Measure in 3 locations around the circumference.
(4)	Adjustment is required if the gap value is near the limit.
(Gap adjustment shim thickness is approximately 0.2–0.25mm. Adjustment cannot be made at a lower value.)‐ Gap Adjustment(1)

Remove the brake release bolt [4] and the manual release prevention spacer [3].

(2)Remove the cover [13].

(3)Remove the fan set screw [12] and remove the fan [14].

(4)	Loosen the attachment bolts [7] and remove the spacers [5], gap adjustment shims [6], attachment bolts [7] and fixed plate [15]as a set. When removing the attachment bolts [7], make certain not to fall the gap adjustment shims [6].
(5)	The gap adjustment shims [6] have a thickness of 0.2–0.25mm. Reduce the number of shims according to the wear conditions,then reassemble the spacers [5], gap adjustment shims [6], attachment bolts [7] and the fixed plate [15] as a set.
(6)

Check the gap G, and readjust the shims if there is a large difference between the gap and the required value.

(7)

Turn the power on and off to check brake action.

(8)	Attach the fan [14], fan set screw [12] and cover [13]. Use a fan set screw [12] coated with Three Bond TB2365 (Sumitomo partnumber: EW445WW-01), and tighten with a torque of 0.85–1.05N·m. Finally, attach the brake release bolt [4] and the manual
release prevention spacer [3].

55

8. Daily Inspection and Maintenance■ FB-1E (Indoor Type)

12

11

10

9

8

7

6

5

4

3

2

Code
1
2
3

1

4

22
Ｇ
X

Details for X
13

14

15

16

17

18

19

20

21

5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Part Name
Stationary core
Brake release
Seal washer
Manual release prevention
spacerBrake release bolt
Spacer
Gap adjusting shims
Attachment bolt
Brake lining
Leaf spring
Boss
Shaft-retaining C-ring
Cover
Shaft-retaining C-ring
Fan
Fixed plate
Armature plate
SpringElectromagnetic coil
Ball bearings
Motor shaft
Shock absorber

Figure 8-18

‐ Gap Inspection(1)

Remove the brake release bolt [5] and the manual release prevention
spacer [4].

(2)Remove the cover [13].

(3)	Insert a gap gauge between the stationary core [1] and the armature plate [17],Gap Value G (mm)Required value
Limit value(original value)
0.25–0.35
0.6measuring the gap. Measure in 3 locations around the circumference.
(4)

Adjustment is required if the gap value is near the limit.
(Gap adjustment shim thickness is approximately 0.2–0.25mm. Adjustment cannot be made at a lower value.)‐ Gap Adjustment(1)

Remove the brake release bolt [5] and the manual release prevention spacer [4].

(2)Remove the cover [13].

(3)Remove the shaft-retaining C-ring [14], and remove the fan [15].

(4)	Loosen the attachment bolts [8] and remove the spacers [6], gap adjustment shims [7], attachment bolts [8] and fixed plate [16]as a set. When removing the attachment bolts [8], make certain not to fall the gap adjustment shims [7] or the shock absorber [22].
(5)	The gap adjustment shims [7] have a thickness of 0.2–0.25mm. Reduce the number of shims according to the wear conditions,then reassemble the spacers [6], gap adjustment shims [7], attachment bolts [8] and the fixed plate [16] as a set.
(6)

Check the gap G, and readjust the shims if there is a large difference between the gap and the required value.

(7)

Turn the power on and off to check brake action.

(8)

Attach the fan [15], shaft-retaining C-ring [14] and cover [13].

(9)Finally, attach the brake release bolt [5] and the manual release prevention spacer [4].

56

8. Daily Inspection and Maintenance■ FB-1HE, FB-2E (Indoor Type)

12

11

10

9

8

7

6

5

4

3

2

Code
1
2
3

1

4

22
Ｇ
X

Details for X

13

14

15

16

17

18

19

20

21

5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Part Name
Stationary core
Brake release
Seal washer
Manual release prevention
spacerBrake release bolt
Spacer
Gap adjusting shims
Attachment bolt
Brake lining
Leaf spring
Boss
Shaft-retaining C-ring
Cover
Shaft-retaining C-ring
Fan
Fixed plate
Armature plate
SpringElectromagnetic coil
Ball bearings
Motor shaft
Shock absorber

Figure 8-19

‐ Gap Inspection(1)

Remove the brake release bolt [5] and the manual release prevention
spacer [4].

(2)Remove the cover [13].

(3)	Insert a gap gauge between the stationary core [1] and the armature plate [17],Gap Value G (mm)Required value
Limit value(original value)
0.25–0.35
0.75

measuring the gap. Measure in 3 locations around the circumference.
(4)

Adjustment is required if the gap value is near the limit.
(Gap adjustment shim thickness is approximately 0.35–0.45mm. Adjustment cannot be made at a lower value.)‐ Gap Adjustment(1)

Remove the brake release bolt [5] and the manual release prevention spacer [4].

(2)Remove the cover [13].

(3)Remove the shaft-retaining C-ring [14], and remove the fan [15].

(4)	Loosen the attachment bolts [8] and remove the spacers [6], gap adjustment shims [7], attachment bolts [8] and fixed plate[16] as a set. When removing the attachment bolts [8], make certain not to fall the gap adjustment shims [7] or the shock
absorber [22].
(5)

The gap adjustment shims [7] have a thickness of 0.35–0.45mm. Reduce the number of shims according to the wear conditions,then reassemble the spacers [6], gap adjustment shims [7], attachment bolts [8] and the fixed plate [16] as a set.

(6)

Check the gap G, and readjust the shims if there is a large difference between the gap and the required value.

(7)

Turn the power on and off to check brake action.

(8)

Attach the fan [15], shaft-retaining C-ring [14] and cover [13].

(9)Finally, attach the brake release bolt [5] and the manual release prevention spacer [4].

57

8. Daily Inspection and Maintenance■ FB-3E, FB-4E (Indoor Type)

11

10

9

8

7

6

5

4

3

2

Code
1
2

1

3

21
Ｇ
X

12

13

14

15

16

17

18

19

20

Details for X

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

Part Name
Stationary core
Brake release
Manual release prevention
spacerBrake release bolt
Spacer
Gap adjusting shims
Attachment bolt
Brake lining
Leaf spring
Boss
Shaft-retaining C-ring
Cover
Shaft-retaining C-ring
Fan
Fixed plate
Armature plate
SpringElectromagnetic coil
Ball bearings
Motor shaft
Shock absorber

Figure 8-20

‐ Gap Inspection(1)

Remove the brake release bolt [4] and the manual release prevention
spacer [3].

(2)Remove the cover [12].

(3)	Insert a gap gauge between the stationary core [1] and the armature plate [16],Gap Value G (mm)Required value
Limit value(original value)
0.25–0.35
0.85

measuring the gap. Measure in 3 locations around the circumference.
(4)

Adjustment is required if the gap value is near the limit.
(Gap adjustment shim thickness is approximately 0.45–0.55mm. Adjustment cannot be made at a lower value.)‐ Gap Adjustment(1)

Remove the brake release bolt [4] and the manual release prevention spacer [3].

(2)Remove the cover [12].

(3)Remove the shaft-retaining C-ring [13] and the fan [14].

(4)	Loosen the attachment bolts [7] and remove the spacers [5], gap adjustment shims [6], attachment bolts [7] and fixed plate [15]as a set. When removing the attachment bolts [7], make certain not to fall the gap adjustment shims [6] or the shock absorber [21].
(5)	The gap adjustment shims [6] have a thickness of 0.45–0.55mm. Reduce the number of shims according to the wear conditions,then reassemble the spacers [5], gap adjustment shims [6], attachment bolts [7] and fixed plate [15] as a set.
(6)

Check the gap G, and readjust the shims if there is a large difference between the gap and the required value.

(7)

Turn the power on and off to check brake action.

(8)

Attach the fan [14], shaft-retaining C-ring [13] and cover [12].

(9)Finally, attach the brake release bolt [4] and the manual release prevention spacer [3].

58

8. Daily Inspection and Maintenance■ FB-5E, FB-8E (Indoor Type)13 12 11 10

9

8

7

6

5

4

3

2

1

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Ｇ

14 15 16 17 18 19 20 21 22
Figure 8-21

Part Name
Stationary core
Brake release
Seal washer
Manual release prevention
spacerBrake release bolt
Stud bolt
Adjusting washer
Spring washer
Gap adjusting nut
Brake lining
Leaf spring
Boss
Shaft-retaining C-ring
Cover
Shaft-retaining C-ring
Fan
Fixed plate
Armature plate
SpringElectromagnetic coil
Ball bearings
Motor shaft‐ Gap Inspection(1)

Remove the brake release bolt [5] and the manual release prevention
spacer [4].

(2)Remove the cover [14].

(3)	Insert a gap gauge between the stationary core [1] and the armature plate [18],Gap Value G (mm)Required value
Limit value(original value)
0.35–0.45
1.0measuring the gap. Measure in 3 locations around the circumference.
(4)

Adjustment is required if the gap value is near the limit.

‐ Gap Adjustment(1)

Remove the brake release bolt [5] and the manual release prevention spacer [4].

(2)Remove the cover [14].

(3)Insert a gap gauge between the stationary core [1] and the armature plate [18], rotating to the right the gap adjusting nuts [9]that are attached to ends of the stud bolts [6]. If large adjustments to the gap are not possible, decrease the number of adjusting
washers [7]. There are 3 gap adjusting nuts [9]. Adjust these in turn so that 3 positions on the circumference are uniformly at therequired gap.

(4)

Turn the power on and off to check brake action.

(5)

Attach the cover [14].

(6)Finally, attach the brake release bolt [5] and the manual release prevention spacer [4].

59

8. Daily Inspection and Maintenance■ FB-10E, FB-15E (Indoor Type)13 12 11 10

9

8

7

6

5

4

3

2

1

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

Ｇ

14 15 16 17 18 19 20 21 22 23
Figure 8-22

Part Name
Stationary core
Brake release
Seal washer
Manual release prevention
spacerBrake release bolt
Stud bolt
Adjusting washer
Spring washer
Gap adjusting nut
Brake lining
Leaf spring
Boss
Shaft-retaining C-ring
Cover
Shaft-retaining C-ring
Fan
Fixed plate
Armature plate
SpringElectromagnetic coil
Ball bearings
Motor shaft
Bearing cover‐ Gap Inspection(1)

Remove the brake release bolt [5] and the manual release prevention
spacer [4].

(2)Remove the cover [14].

(3)	Insert a gap gauge between the stationary core [1] and the armature plate [18],Gap Value G (mm)Required value
Limit value(original value)
0.35–0.45
1.2

measuring the gap. Measure in 3 locations around the circumference.
(4)

Adjustment is required if the gap value is near the limit.

‐ Gap Adjustment(1)

Remove the brake release bolt [5] and the manual release prevention spacer [4].

(2)Remove the cover [14].

(3)Insert a gap gauge between the stationary core [1] and the armature plate [18], rotating to the right the gap adjusting nuts [9]that are attached to ends of the stud bolts [6]. If large adjustments to the gap are not possible, decrease the number of adjusting
washers [7]. There are 3 adjusting nuts [9]. Adjust these in turn so that 3 positions on the circumference are uniformly at therequired gap.

(4)

Turn the power on and off to check brake action.

(5)

Attach the cover [14].

(6)Finally, attach the brake release bolt [5] and the manual release prevention spacer [4].

60

8. Daily Inspection and Maintenance■ FB-20 (Indoor Type)14 13 12 11 10

9

8

7

6

28

5

4

3

2

1

Code
1
2
3
4

Ｇ

15 16 17 18 19 20 21 22 23 24 25 26 27
Figure 8-23

5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

Part Name
RollerBrake release bolt
Rubber packing
Manual release prevention
spacerSeal washer
Stationary core
Electromagnetic coilStud bolt
Brake lining
Adjusting washer
Spring washer
Gap adjusting nut
Boss
Shaft-retaining C-ring
Fan
Cover
Fan set screw
Leaf spring
Fixed plate
Armature plate
SpringNut
Tap-end studBall bearings
Release lever
Bearing cover
Motor shaft
Grommet‐ Gap Inspection(1)

Remove the grommet [28] and cover [16].

(2)	Insert a gap gauge between the stationary core [6] and the armature plate [20],measuring the gap. Measure in 3 locations around the circumference.
(3)

Adjustment is required if the gap value is near the limit.

Gap Value G (mm)Required value
Limit value(original value)
0.6–0.7
1.5‐ Gap Adjustment(1)

Remove the grommet [28] and cover [16].

(2)	Insert a gap gauge between the stationary core [6] and the armature plate [20], rotating to the right the gap adjusting nuts [12]that are attached to ends of the stud bolts [8]. If large adjustments to the gap are not possible, decrease the number of adjusting
washers [10]. There are 3 gap adjusting nuts [12]. Adjust these in turn so that 3 positions on the circumference are uniformly at
the required gap.
(3)

Turn the power on and off to check brake action.

(4)

Attach the cover [16] and grommet [28].

618. Daily Inspection and Maintenance■ FB-30 (Indoor Type)14 13 12 11 10

9

8

7

6

28

5

4

3

2

1

Code
1
2
3
4

Ｇ

15 16 17 18 19 20 21 22 23 25 27 24 26
Figure 8-24

5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

Part Name
RollerBrake release bolt
Rubber packing
Manual release prevention
spacerSeal washer
Stationary core
Electromagnetic coilStud bolt
Brake lining
Adjusting washer
Spring washer
Gap adjusting nut
Boss
Shaft-retaining C-ring
Fan
Cover
Fan set screw
Leaf spring
Fixed plate
Armature plate
SpringNut
Tap-end studBall bearings
Release lever
Bearing cover
Motor shaft
Grommet‐ Gap Inspection(1)

Remove the grommet [28] and cover [16].

(2)	Insert a gap gauge between the stationary core [6] and the armature plate [20],measuring the gap. Measure in 3 locations around the circumference.
(3)

Adjustment is required if the gap value is near the limit.

Gap Value G (mm)Required value
Limit value(original value)
0.6–0.7
1.5‐ Gap Adjustment(1)

Remove the grommet [28] and cover [16].

(2)	Insert a gap gauge between the stationary core [6] and the armature plate [20], rotating to the right the gap adjusting nuts [12]that are attached to ends of the stud bolts [8]. If large adjustments to the gap are not possible, decrease the number of adjusting
washers [10]. There are 3 gap adjusting nuts [12]. Adjust these in turn so that 3 positions on the circumference are uniformly at
the required gap.
(3)

Turn the power on and off to check brake action.

(4)

Attach the cover [16] and grommet [28].

628. Daily Inspection and Maintenance■ ESB-250, ESB-250-2 (Indoor Type)11 12 13 14 15 16 17 18 19 20 21

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Ｇ

10 9

8

7

6

5

4

3

2

1

21

Note: 1. Motor configuration differs for
fan motor ventilation type.

Figure 8-25
Items
Rated input voltage
Maximum input voltage
Minimum input voltage
InstantaneousStandard output
voltagevoltage
Steady voltage
Maximum output current
Over excitation time
Insulation resistance
Insulation withstand voltage
Maximum freInching
Constant
quencyAllowable ambient temperaturePart Name
Center ring
Gap adjusting screw
Attachment bolt
Field
Brake coil
Actuating spring
Fan
Cover
Motor shaft
Fan set screw
Lock bolt
Armature
Inner discOuter disc
Spacer bush
Stopper
Hub
Brake adapter plate
Opposite drive end cover
Opposite drive end bearing
Opposite drive end bearingcover

2. There are 3 of [13][14] for ESB-250(horizontal types) and 2 for
ESB-250-2 (vertical types).

Specifications
AC200/220V 50/60Hz
AC240V 50/60Hz
AC170V 50/60Hz
DC180V (for AC200V input)
DC90V (for AC200V input)
DC1.8A (Steady output)
0.4–1.2s
100MΩ or larger (When measured with
1000V megohmmeter)
AC2000V for one time or more
When on-time 1.2s or less: 8 cycles/min
When on-time exceeds 1.2s: 30 cycles/min- 20℃ – 60℃■ Accessory Rectifier (DC Power Supply Unit) Model HD-110M3
Outline Drawing
96

Internal Circuit (Diagram)

84
74
30.5

6

1

3

51

CONTACTOR

4

5

AC
200V

Instant
activation

5.5

7

41

66

4.5

BRAKE

6

2
13.5

13.5 13.5

Terminal screw M4

Figure 8-26

Note: 1. Model HD-110M3 is an indoor model. Take care to avoid water, etc.
2. Transformer is necessary for operation with 400V class power source. Secondary voltage is 200–220V.

63

4Arc-extinguishing circuit

AC200V/220V

2

5

Timer and gate circuit

1

SW

MB

3

8. Daily Inspection and Maintenance‐ Gap Inspection(1)

Remove cover [8].

(2)	Insert a gap gauge between the field [4] and armature [12], measuring thegap. Measure in 4 locations around the circumference.
(3)

Adjustment is required if the gap value is near the limit.

Gap Value G (mm)Required value
Limit value(original value)
0.7
2.0‐ Gap Adjustment(1)

Manually release the brake following the procedure on P79.

(2)	Loosen the stopper [16] on the periphery of the center ring [1], and remove it. This will free the gap adjusting screws [2].
(See Figure 8-27)(3)	Insert the gap adjusting bar (customer to prepare an angle plate. See Figure 8-29) from between the outer disc [14] and thecenter ring [1] into a hole for a gap adjusting screw [2].
Rotating to the left as seen from the field [4] side, will narrow the gap. (See Figure 8-28)(4)

Six attachment bolts [3] and 6 lock bolts [11] alternately pass through the space between the outer disc [14] and the center ring[1]. Rotating the gap adjusting bar will contact these bolts. There are 8 equally distributed holes for gap adjusting screws [2].
Adjust the gap G to the required value by repeating (3) each time the gap adjusting bar contacts a bolt.

(5)

Select the point where hole and screw hole are closest to the required gap and attach the stopper [16] there.

(6)

After returning the manual brake release to its original state, turn power on and off to check brake action.

(7)

Attach the fan [7] and cover [8]. At this time coat the fan set screw [10] with Three Bond TB2365.

Gap adjusting bar dimensions

Gap adjusting bar
4

16

1
1

150mm

14

2

2

Figure 8-27

Figure 8-28

3.5mm

14

14.7±0.1mm

Figure 8-29

64

8. Daily Inspection and Maintenance■ FB-01A1, FB-02A1, FB-05A1 (Outdoor Type)14 13 12 11 10 9

8

7

6

5

4

3

2

1

C

28
29
30
31
32
33

Part
Number
1
2
3
4
5
6
7
8
9
10
11
12
13

Ｇ

15 16 17 18 19 20 21 22 23 25 27 24 26
Figure 8-30

14
15
16
17
18
19
20

Part Name
Armature plate
Brake lining
Spacer
Attachment bolt
Fixed plate
Fan
V-ringShaft-retaining C-ring
Boss
Leaf spring
Cover
Waterproof cover
Waterproof cover attachment
bolts
Waterproof seal
SpringElectromagnetic coil
Stationary core
Bearing
Motor shaft
Fan set screw

Note: FB-01A1 does not come with [6][7][20].

‐ Gap Inspection(1)

Remove the cover [11].

(2)Loosen the fan set screw [20] and remove the fan [6].

(3)Remove the waterproof seal [14].

(4)	Insert a gap gauge between the stationary core [17] and the armature plate [1],measuring the gap. Measure in 3 locations around the circumference.
(5)

Adjustment is required if the gap value is near the limit.

Gap Value G (mm)Required value
Limit value(original value)
0.2–0.35
0.5‐ Gap Adjustment(1)

Remove the cover [11].

(2)Loosen the fan set screw [20] and remove the fan [6].

(3)Remove the waterproof seal [14].

(4)

Pull off the V-ring [7].

(5)Remove the waterproof cover attachment bolts [13], and remove the waterproof cover [12].

ＡＢ(6)	Slightly loosen the attachment bolts [4] and rotate the fixed plate [5] counter clockwise, as far as it will go.
Then tighten the attachment bolts [4]. After tightening, measure the gap (G) and check to see if the gap value
is between the required value and the limit. (This operation will reduce the gap by 0.3mm.)(7)

Attach the waterproof cover [12] by using the attachment bolts [13]. Attach the waterproof cover [12] so thatthe gap (A) between its hole and the motor shaft [19] is nearly uniform around the circumference.

(8)

Clean the surface of the waterproof seal [14] to remove impurities.

(9)

As shown in the construction diagram, install the waterproof seal [14] between the stationary core [17] and the waterproof
cover [12]. Insert the waterproof seal [14] with its arrow mark pointing toward the load side. (Align the hole in the waterproof
seal [14] for the release bolt with the position of the release bolt.) Attach the waterproof seal [14] so that its protrusion fitssnugly around the entire circumference of the groove for the stationary core [17]. Otherwise water could leak in.

(10) Turn the power on and off to check brake action.
(11)	Attach the V-ring [7]. Wipe off the lip and surface near the lip of the V-ring [7], lightly coat the lip contact surface with grease andattach. Observe the attaching dimension (B = 4.5mm).
(12) Attach the fan [7] and cover [11]. Use a fan set screw [20] coated with Three Bond TB2365 (Sumitomo part number:
EW444WW-01), and tighten to a torque of 0.3–0.5N·m.
Note : If the the optional brake release bolt is installed, disassemble after removing the release bolt.

65

8. Daily Inspection and Maintenance■ FB-1D (Outdoor Type)1312

14 15 16 17

18 19

20
21 22

11

23
24

10

9

8

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

7

16
17
18
19
20
21
22
23
24

Ｇ

6

5

4

3

2

1

Figure 8-31

‐ Gap Inspection(1) Remove the brake release bolt [17] and the manual release prevention spacer [18].
(2) Remove the cover [13].
(3) Loosen the fan set screw [9] and remove the fan [7].
(4) Remove the brake release [19]. (2 Places)(5) Remove the waterproof seal [16].
(6)	Insert a gap gauge between the stationary core [22] and the armature plate [1],measuring the gap. Measure in 3 locations around the circumference.
(7) Adjustment is required if the gap value is near the limit.
(Gap adjustment shim thickness is approximately 0.2–0.25mm. Adjustment
cannot be made at a lower value.)

Part Name
Armature plate
Brake lining
Spacer
Gap adjusting shims
Attachment bolt
Fixed plate
Fan
V-ringFan set screw
Shaft-retaining C-ring
Boss
Leaf spring
Cover
Waterproof cover
Waterproof cover attachment
bolts
Waterproof seal
Brake release bolt
Manual release protection spacer
Brake release
SpringElectromagnetic coil
Stationary core
Bearing
Motor shaft

Gap Value G (mm)Required value
Limit value(original value)
0.3–0.4
0.6‐ Gap Adjustment

Ａ(1) Remove the brake release bolt [17] and the manual release prevention spacer [18].
(2) Remove the cover [13].
(3) Loosen the fan set screw [9] and remove the fan [7].
(4) Pull off the V-ring [8].
(5) Remove the brake release [19]. (2 Places)
Ｂ(6) Remove the waterproof seal [16].
(7) Remove the waterproof cover attachment bolts [15], and remove the waterproof cover [14].
(8)	Loosen the attachment bolts [5] and remove the spacers [3], gap adjusting shims [4], attachment bolts [5], fixedplate [6] as a set. When removing the attachment bolts [5], make certain not to fall the gap adjustment shims [4].
(9)	The gap adjusting shims [4] have a thickness of 0.2–0.25mm. Reduce the number of shims according to the wear
conditions, then reassemble the spacers [3], gap adjustment shims [4], attachment bolts [5] and the fixed plate [6]as a set.
(10) Check the gap G, and readjust the shims if there is a large difference between it and the required value.
(11)	Attach the waterproof cover [14] by using the attachment bolts [15]. Attach the waterproof cover [14] so that thegap (A) between its hole and the motor shaft [24] is nearly uniform.
(12) Clean the surface of the waterproof seal [16] to remove impurities.
(13) As shown in the construction diagram, install the waterproof seal [16] between the stationary core [22] and the waterproof cover[14]. Then attach the brake release [19]. Insert the waterproof seal [16] with its arrow mark pointing toward the load side. Align thehole in the waterproof seal [16] for the release bolt with the position of release bolt [17]. Attach the waterproof seal [16] so that its
protrusion fits snugly around the entire circumference of the groove for the stationary core [22]. Otherwise water could leak in.
(14) Turn the power on and off to check brake action.
(15) Attach the V-ring [8]. Wipe off the lip and surface near the lip of V-ring [8], lightly coat the lip contact surface with grease, andattach. Observe the attaching dimension (B=4.5mm).
(16) Attach the fan [7] and cover [13]. Use a fan set screw [9] coated with Three Bond TB2365 (Sumitomo part number: EW445WW-01),
and tighten to a torque of 0.85–1.05N·m. Finally, attach the brake release bolt [17] and the manual release prevention spacer [18].

668. Daily Inspection and Maintenance■ FB-1E (Outdoor Type)
12

11

10

9

8

7

6

5

4

3

2

1

22
23
24
25

26

Ｇ
X

13

14

15

16

17

18

19

20

21

Details for X

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Figure 8-32

‐ Gap Inspection(1) Remove the brake release bolt [5] and the manual release prevention spacer [4].
(2) Remove the cover [13].
(3) Remove the shaft-retaining C-ring [14], and remove the fan [15].
(4) Remove the brake release [2] (2 locations) and remove the waterproof seal [22].
(5)	Insert a gap gauge between the stationary core [1] and the armature plate [17],measuring the gap. Measure in 3 locations around the circumference.
(6) Adjustment is required if the gap value is near the limit.
(Gap adjustment shim thickness is approximately 0.2–0.25mm. Adjustment
cannot be made at a lower value.)

25
26

Part Name
Stationary core
Brake release
Seal washer
Manual release prevention spacer
Brake release bolt
Spacer
Gap adjusting shims
Attachment bolt
Brake lining
Leaf spring
Boss
Shaft-retaining C-ring
Cover
Shaft-retaining C-ring
Fan
Fixed plate
Armature plate
SpringElectromagnetic coil
Ball bearings
Motor shaft
Waterproof seal
V-ringWaterproof cover attachment
bolts
Waterproof cover
Shock absorber

Gap Value G (mm)Required value
Limit value(original value)
0.25–0.35
0.6‐ Gap Adjustment

Ａ(1) Remove the brake release bolt [5] and the manual release prevention spacer [4].
(2) Remove the cover [13].
(3) Remove the shaft-retaining C-ring [14], and remove the fan [15].
(4) Pull off the V-ring [23].
(5) Remove the brake release [2] (2 locations) and remove the waterproof seal [22].
(6) Remove the waterproof cover attachment bolts [24], and remove the waterproof cover [25].
(7)	Loosen the attachment bolts [8] and remove the spacers [6], gap adjustment shims [7], attachment bolts [8] and fixed plate [16] asa set. When removing the attachment bolts [8] make certain not to take off the gap adjustment shims [7] or the shock absorber [26].
(8) The gap adjustment shims [7] have a thickness of 0.2–0.25mm. Reduce the number of shims according to the wear conditions,then reassemble the spacers [6], gap adjustment shims [7], attachment bolts [8] and the fixed plate [16] as a set.
Ｂ(9) Check the gap G, and readjust the shims if there is a large difference between it and the required value.
(10)	Attach the waterproof cover [25] by using the waterproof cover attachment bolts [24]. At this time align the
cutout area on the side of the waterproof cover [25] with the brake release bolt [5]. Attach the waterproof cover[25] so that the gap (A) between its hole and the motor shaft [21] is nearly uniform.
(11) Clean the surface of the waterproof seal [22] to remove impurities.
(12)	As shown in the construction diagram, install the waterproof seal [22] between the stationary core [1] and thewaterproof cover [25]. Then attach the brake release [2]. Insert the waterproof seal [22] with its arrow markpointing toward the load side. Align the hole in the waterproof seal [22] for the brake release bolt with theposition of the release bolt [5]. Attach the waterproof seal [22] so that its protrusion fits snugly around theentire circumference of the groove for the stationary core [1]. (Be careful that the waterproof seal [22] does notmeander. Otherwise water could leak in.)(13) Turn the power on and off to check brake action.
(14) Attach the V-ring [23]. Wipe off the lip and surface near the lip of the V-ring [23], lightly coat the lip contact surface with grease,and attach. Observe the attaching dimension (B=6mm).
(15) Attach the fan [15], shaft-retaining C-ring [14] and cover [13].
(16) Finally, attach the brake release bolt [5] and the manual release prevention spacer [4].

67

8. Daily Inspection and Maintenance■ FB-1HE, FB-2E (Outdoor Type)26
X

Details for X

Figure 8-33

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

‐ Gap Inspection

24(1) Remove the brake release bolt [5] and the manual release prevention spacer [4].
(2) Remove the cover [13].
(3) Remove the shaft-retaining C-ring [14], and remove the fan [15].
(4) Remove the brake release [2] (2 locations) and remove the waterproof seal [22].
(5)	Insert a gap gauge between the stationary core [1] and the armature plate [17],measuring the gap. Measure in 3 locations around the circumference.
(6) Adjustment is required if the gap value is near the limit.
(Gap adjustment shim thickness is approximately 0.35–0.45mm. Adjustment
cannot be made at a lower value.)

25
26

Part Name
Stationary core
Brake release
Seal washer
Manual release prevention spacer
Brake release bolt
Spacer
Gap adjusting shims
Attachment bolt
Brake lining
Leaf spring
Boss
Shaft-retaining C-ring
Cover
Shaft-retaining C-ring
Fan
Fixed plate
Armature plate
SpringElectromagnetic coil
Ball bearings
Motor shaft
Waterproof seal
V-ringWaterproof cover attachment
bolts
Waterproof cover
Shock absorber

Gap Value G (mm)Required value
Limit value(original value)
0.25–0.35
0.75‐ Gap Adjustment

Ａ(1) Remove the brake release bolt [5] and the manual release prevention spacer [4].
(2) Remove the cover [13].
(3) Remove the shaft-retaining C-ring [14], and remove the fan [15].
(4) Pull off the V-ring [23].
(5) Remove the brake release [2] (2 locations) and remove the waterproof seal [22].
(6) Remove the waterproof cover attachment bolts [24], and remove the waterproof cover [25].
(7)	Loosen the attachment bolts [8] and remove the spacers [6], gap adjustment shims [7], attachment bolts [8] and fixed plate [16] asa set. When removing the attachment bolts [8] make certain not to omit the gap adjustment shims [7] or the shock absorber [26].
(8) The gap adjustment shims [7] have a thickness of 0.35–0.45mm. Reduce the number of shims according to theＢwear conditions, then reassemble the spacers [6], gap adjustment shims [7], attachment bolts [8] and the fixedplate [16] as a set.
(9) Check the gap G, and readjust the shims if there is a large difference between it and the required value.
(10)	Attach the waterproof cover [25] by using the waterproof cover attachment bolts [24]. At this time align the
cutout area on the side of the waterproof cover [25] with the brake release bolt [5]. Attach the waterproof cover[25] so that the gap (A) between its hole and the motor shaft [21] is nearly uniform.
(11) Clean the surface of the waterproof seal [22] to remove impurities.
(12) As shown in the construction diagram, install the waterproof seal [22] between the stationary core [1] and thewaterproof cover [25]. Then attach the brake release [2]. Insert the waterproof seal [22] with its arrow mark pointing
toward the load side. Align the hole in the waterproof seal [22] for the brake release bolt with the position of therelease bolt [5]. Attach the waterproof seal [22] so that its protrusion fits snugly around the entire circumference ofthe groove for the stationary core [1]. (Be careful that the waterproof seal [22] does not meander. Otherwise water
could leak in.)(13) Turn the power on and off to check brake action.
(14) Attach the V-ring [23]. Wipe off the lip and surface near the lip of the V-ring [23], lightly coat the lip contact surface with grease,and attach. Observe the attaching dimension (B=6mm).
(15) Attach the fan [15], shaft-retaining C-ring [14] and cover [13].
(16) Finally, attach the brake release bolt [5] and the manual release prevention spacer [4].

68

8. Daily Inspection and Maintenance■ FB-3E, FB-4E (Outdoor Type)
11

10

9

8

7

6

5

4

3

2

1

21
22
23
24

25

Ｇ

X

12

13

14

15

16

17

18

19

Figure 8-34

20
Details for X

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

‐ Gap Inspection(1) Remove the brake release bolt [4] and the manual release prevention spacer [5].
(2) Remove the cover [12].
(3) Remove the shaft-retaining C-ring [13] and the fan [14].
(4) Remove the brake release [2] (2 locations) and remove the waterproof seal [21].
(5)	Insert a gap gauge between the stationary core [1] and the armature plate [16],measuring the gap. Measure in 3 locations around the circumference.
(6) Adjustment is required if the gap value is near the limit.
(Gap adjustment shim thickness is approximately 0.45–0.55mm. Adjustment
cannot be made at a lower value.)

Part Name
Stationary core
Brake release
Manual release prevention spacer
Brake release bolt
Spacer
Gap adjusting shims
Attachment bolt
Brake lining
Leaf spring
Boss
Shaft-retaining C-ring
Cover
Shaft-retaining C-ring
Fan
Fixed plate
Armature plate
SpringElectromagnetic coil
Ball bearings
Motor shaft
Waterproof seal
V-ringWaterproof cover attachment
bolts
Waterproof cover
Shock absorber

Gap Value G (mm)Required value
Limit value(original value)
0.25–0.35
0.85‐ Gap Adjustment

Remove the brake release bolt [4] and the manual release prevention spacer [5].
Remove the cover [12].
Remove the shaft-retaining C-ring [13] and the fan [14].
Pull off the V-ring [22].
Remove the brake release [2] (2 locations) and remove the waterproof seal [21].
Remove the waterproof cover attachment bolts [23], and remove the waterproof cover [24].
Loosen the attachment bolts [7] and remove the spacers [5], gap adjustment shims [6], attachment bolts [7] and fixed plate [15] asa set. When removing the attachment bolts [7], make certain not to omit the gap adjustment shims [6] or the shock absorber [25].
(8)	The gap adjustment shims [6] have a thickness of 0.45–0.55mm. Reduce the number of shims according to theＢwear conditions, then reassemble the spacers [5], gap adjustment shims [6], attachment bolts [7] and fixed plate[15] as a set.
(9) Check the gap G, and readjust the shims if there is a large difference between it and the required value.
(10)	Attach the waterproof cover [24] by using the waterproof cover attachment bolts [23]. At this time align the
cutout area on the side of the waterproof cover [24] with the brake release bolt [4]. Attach the waterproof cover[24] so that the gap (A) between its hole and the motor shaft [20] is nearly uniform.
(11) Clean the surface of the waterproof seal [21] to remove impurities.
(12)	As shown in the construction diagram, install the waterproof seal [21] between the stationary core [1] and thewaterproof cover [24]. Then attach the brake release [2]. Align the hole in the waterproof seal [21] for the brakerelease bolt with the position of the release bolt [4]. Attach the waterproof seal [21] so that its protrusion fitssnugly around the entire circumference of the groove for the stationary core [1]. (Be careful that the waterproof seal [21] does notmeander. Otherwise water could leak in.)(13) Turn the power on and off to check brake action.
(14) Attach the V-ring [22]. Wipe off the lip and surface near the lip of the V-ring [22], lightly coat the lip contact surface with grease,and attach. Observe the attaching dimension (B=6mm).
(15) Attach the fan [14], shaft-retaining C-ring [13] and cover [12].
(16) Finally, attach the brake release bolt [4] and the manual release prevention spacer [3].
Ａ

(1)
(2)
(3)
(4)
(5)
(6)
(7)

69

8. Daily Inspection and Maintenance■ FB-5E, FB-8E (Outdoor Type)
13 12

11 10

9

8

7

6

5

4

3

2

1

23
24
25
26

Ｇ

14 15 16 17 18 19 20

21 22

Figure 8-35

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Part Name
Stationary core
Brake release
Seal washer
Manual release prevention spacer
Brake release bolt
Stud bolt
Adjusting washer
Spring washer
Gap adjusting nut
Brake lining
Leaf spring
Boss
Shaft-retaining C-ring
Cover
Shaft-retaining C-ring
Fan
Fixed plate
Armature plate
SpringElectromagnetic coil
Ball bearings
Motor shaft
Waterproof seal
V-ringWaterproof cover attachment
bolts
Waterproof cover‐ Gap Inspection

26(1) Remove the brake release bolt [5] and the manual release prevention spacer [4].
(2) Remove the cover [14].
(3) Remove the shaft-retaining C-ring [15] and the fan [16].
(4) Remove the brake release [2] (2 locations) and remove the waterproof seal [23].
(5)	Insert a gap gauge between the stationary core [1] and the armature plate [18],measuring the gap. Measure in 3 locations around the circumference.
(6) Adjustment is required if the gap value is near the limit.

Gap Value G (mm)Required value
Limit value(original value)
0.35–0.45
1.0‐ Gap Adjustment

Ａ(1) Remove the brake release bolt [5] and the manual release prevention spacer [4].
(2) Remove the cover [14].
(3) Remove the shaft-retaining C-ring [15] and the fan [16].
(4) Pull off the V-ring [24].
(5) Remove the brake release [2] (2 locations) and remove the waterproof seal [23].
(6) Remove the waterproof cover attachment bolts [25], and remove the waterproof cover [26].
(7)	Insert a gap gauge between the stationary core [1] and the armature plate [18], rotating to the right the gap adjusting nuts
[9] that are attached to ends of the stud bolts [6]. If the gap is large, and adjustments are not possible, decrease the numberof adjustment washers [7]. There are 3 adjusting nuts [9]. Adjust these in turn so that 3 positions on the circumference areuniformly at the required gap.
(8) Attach the waterproof cover [26] by using the waterproof cover attachment bolts [25]. At this time align the cutout area on theside of the waterproof cover [26] with the brake release bolt [5]. Attach the waterproof cover [26] so that the gap (A) between its
hole and the motor shaft [22] is nearly uniform.
(9) Clean the surface of the waterproof seal [23] to remove impurities.
Ｂ(10)	As shown in the construction diagram, install the waterproof seal [23] between the stationary core [1] and thewaterproof cover [26]. Then attach the brake release [2]. Align the hole in the waterproof seal [23] for the brakerelease bolt with the position of the release bolt [5]. Next, attach along the machined surfaces around thestationary core [1]. Be careful so that the waterproof seal [23] does not meander. Otherwise water could leak in.)(11) Turn the power on and off to check brake action.
(12) Attach the V-ring [24]. Wipe off the lip and surface near the lip of the V-ring [24], lightly coat the lip contact
surface with grease, and attach. Observe the attaching dimension (B=6mm).
(13) Attach the fan [16], shaft-retaining C-ring [15] and cover [14].
(14) Finally, attach the brake release bolt [5] and the manual release prevention spacer [4].

70

8. Daily Inspection and Maintenance■ FB-10E, FB-15E (Outdoor Type)13 12 11 10

9

8

7

6

5

4

3

2

1

24
25
26
27

Ｇ

14 15 16 17 18 19 20 21 22 23
Figure 8-36

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

Part Name
Stationary core
Brake release
Seal washer
Manual release prevention spacer
Brake release bolt
Stud bolt
Adjusting washer
Spring washer
Gap adjusting nut
Brake lining
Leaf spring
Boss
Shaft-retaining C-ring
Cover
Shaft-retaining C-ring
Fan
Fixed plate
Armature plate
SpringElectromagnetic coil
Ball bearings
Motor shaft
Bearing cover
Waterproof seal
V-ringWaterproof cover attachment
bolts
Waterproof cover‐ Gap Inspection

27(1) Remove the brake release bolt [5] and the manual release prevention spacer [4].
(2) Remove the cover [14].
(3) Remove the shaft-retaining C-ring [15] and the fan [16].
(4) Remove the brake release [2] (2 locations) and remove the waterproof seal [24].
(5)	Insert a gap gauge between the stationary core [1] and the armature plate [18],measuring the gap. Measure in 3 locations around the circumference.
(6) Adjustment is required if the gap value is near the limit.

Gap Value G (mm)Required value
Limit value(original value)
0.35–0.45
1.2

(1)
(2)
(3)
(4)
(5)
(6)
(7)

(8)

(9)
(10)

(11)
(12)
(13)
(14)

Remove the brake release bolt [5] and the manual release prevention spacer [4].
Remove the cover [14].
Remove the shaft-retaining C-ring [15] and the fan [16].
Pull off the V-ring [25].
Remove the brake release [2] (2 locations) and remove the waterproof seal [24].
Remove the waterproof cover attachment bolts [26], and remove the waterproof cover [27].
Insert a gap gauge between the stationary core [1] and the armature plate [18], rotating to the right the gap adjusting nuts
[9] that are attached to ends of the stud bolts [6]. If the gap is large, and adjustments are not possible, decrease the numberof adjustment washers [7]. There are 3 adjusting nuts [9]. Adjust these in turn so that 3 positions on the circumference areuniformly at the required gap.
Attach the waterproof cover [27] by using the waterproof cover attachment bolts [26]. At this time align the
cutout area on the side of the waterproof cover [27] with position of the brake release bolt [5]. Attach theＢwaterproof cover [27] so that the gap (A) between its hole and the motor shaft [22] is nearly uniform.
Clean the surface of the waterproof seal [24] to remove impurities.
As shown in the construction diagram, install the waterproof seal [24] between the stationary core [1] and thewaterproof cover [27]. Then attach the brake release [2]. Align the hole in the waterproof seal [24] for the brakerelease bolt with the position of the release bolt [5]. Next, attach along the machined surfaces around thestationary core [1]. Be careful so that the waterproof seal [24] does not meander. Otherwise water could leak in.)
Turn the power on and off to check brake action.
Attach the V-ring [24]. Wipe off the lip and surface near the lip of the V-ring [25], lightly coat the lip contact
surface with grease, and attach. Observe the attaching dimension (B=6mm).
Attach the fan [16], shaft-retaining C-ring [15] and cover [14].
Finally, attach the brake release bolt [5] and the manual release prevention spacer [4].

71Ａ

‐ Gap Adjustment

8. Daily Inspection and Maintenance■ FB-20 (Outdoor Type)14 13 12 11 10

28

9

8

7

6

5

4

3

2

1

C

29
30
31
32
33

Ｇ

15 16 17 18 19 20 21 22 23 24 25 26 27
Figure 8-37

‐ Gap Inspection(1)

Remove the outdoor cover [33] and the cover [16].

(2)Loosen the fan set screw [17] and remove the fan [15].

(3)Remove the waterproof seal [32].

(4)	Insert a gap gauge between the stationary core [6] and the armature plate [20],measuring the gap. Measure in 3 locations around the circumference.
(5)

Adjustment is required if the gap value is near the limit.

Remove the outdoor cover [33] and the cover [16].

(2)Loosen the fan set screw [17] and remove the fan [15].

(3)

Pull off the V-ring [29].

(4)Remove the waterproof seal [32].

Part Name
RollerBrake release bolt
Rubber packing
Manual release prevention spacer
Seal washer
Stationary core
Electromagnetic coilStud bolt
Brake lining
Adjusting washer
Spring washer
Gap adjusting nut
Boss
Shaft-retaining C-ring
Fan
Cover
Fan set screw
Leaf spring
Fixed plate
Armature plate
SpringNut
Tap-end studBall bearings
Release lever
Bearing cover
Motor shaft
Waterproof cover
V-ringWaterproof cover attachment bolts
Waterproof cover gasket
Waterproof seal
Outdoor coverNote: The shape of the outdoor cover [33]differs for vertical type specification.

‐ Gap Adjustment
(1)

Part
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

Gap Value G (mm)Required value
Limit value(original value)
0.6–0.7
1.5(5)	Insert a gap gauge between the stationary core [6] and the armature plate [20], rotating to the right the gap adjusting nuts [12]that are attached to ends of the stud bolts [8]. If large adjustments to the gap are not possible, decrease the number of adjusting
washers [10]. There are 3 gap adjusting nuts [12]. Adjust these in turn so that 3 positions on the circumference are uniformly at
the required gap.
(6)

Turn the power on and off to check brake action.

(7)

Attach the waterproof cover [28] so that the gap (A) between its hole and the motor shaft [27] is nearly uniform. (Only when thewaterproof cover [28] has been removed)
Clean the surface of the waterproof seal [32] to remove impurities.

(9)

As shown in the construction diagram, install the waterproof seal [32] between the stationary core [6] and thefixed plate [19]. (Be careful so that the waterproof seal [32] does not meander. Otherwise water could leak in.)(10)	Attach the V-ring [29]. Wipe off the lip and surface near the lip of the V-ring [29], lightly coat the the lip contact
surface with grease, and attach. Observe the attaching dimension (B=7mm).
(11) Thoroughly coat the gap (C) between the gap adjusting nuts [12], the stud bolts [8] and the fixed plate [19] withwaterproof adhesive (Three Bond 1102).
(12) Attach the fan [15], cover [16] and outdoor cover [33].

72

Ｂ

Ａ

(8)

8. Daily Inspection and Maintenance■ FB-30 (Outdoor Type)14 13 12 11 10 9

8

7

6

5

4

3

2

1

C

28
29
30
31
32
33

Ｇ

15 16 17 18 19 20 21 22 23 25 27 24 26
注) 屋外立形仕様の場合、
屋外カバー 33 の形状は異なります。

Figure 8-38

‐ Gap Inspection
(1)
(2)
(3)
(4)
(5)

Remove the outdoor cover [33] and the cover [16].
Loosen the fan set screw [17] and remove the fan [15].
Remove the waterproof seal [32].
Insert a gap gauge between the stationary core [6] and the armature plate [20],measuring the gap. Measure in 3 locations around the circumference.
Adjustment is required if the gap value is near the limit.

Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

Part Name
RollerBrake release bolt
Rubber packing
Manual release prevention spacer
Seal washer
Stationary core
Electromagnetic coilStud bolt
Brake lining
Adjusting washer
Spring washer
Gap adjusting nut
Boss
Shaft-retaining C-ring
Fan
Cover
Fan set screw
Leaf spring
Fixed plate
Armature plate
SpringNut
Tap-end studBall bearings
Release lever
Bearing cover
Motor shaft
Waterproof cover
V-ringWaterproof cover attachment bolts
Waterproof cover gasket
Waterproof seal
Outdoor coverNote: The shape of the outdoor cover [33]differs for vertical type specification.

Gap Value G (mm)‐ Gap Adjustment

Required value(original value)

Remove the outdoor cover [33] and the cover [16].
Limit value
Loosen the fan set screw [17] and remove the fan [15].
0.6–0.7
1.5
Pull off the V-ring [29].
Remove the waterproof seal [32].
Insert a gap gauge between the stationary core [6] and the armature plate [20], rotating to the right the gap adjusting nuts [12]that are attached to ends of the stud bolts [8]. If large adjustments to the gap are not possible, decrease the number of adjusting
washers [10]. There are 3 gap adjusting nuts [12]. Adjust these in turn so that 3 positions on the circumference are uniformly at
the required gap.
(6) Turn the power on and off to check brake action.
(7) Attach the waterproof cover [28] so that the gap (A) between its hole and the motor shaft [27] is nearly uniform.
(Only when the waterproof cover [28] has been removed)Ｂ(8) Clean the surface of the waterproof seal [32] to remove impurities.
(9) As shown in the construction diagram, install the waterproof seal [32] between the stationary core [6] and thefixed plate [19]. (Be careful so that the waterproof seal [32] does not meander. Otherwise water could leak in.)(10) Attach the V-ring [29]. Wipe off the lip and surface near the lip of the V-ring [29], lightly coat the the lip contact
Ａ

(1)
(2)
(3)
(4)
(5)

surface with grease, and attach. Observe the attaching dimension (B=7mm).
(11) Thoroughly coat the gap (C) between the gap adjusting nuts [12], the stud bolts [8] and the fixed plate [19] withwaterproof adhesive (Three Bond 1102).
(12) Attach the fan [15], cover [16] and outdoor cover [33].

738. Daily Inspection and Maintenance■ ESB-250, ESB-250-2 (Outdoor Type)
Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

11 12 13 14 15 16 17 18 19 20 21

25
24
23
22

Ｇ

10 9

8

7

6

5

4

3

2

Part Name
Center ring
Gap adjusting screw
Attachment bolt
Field
Brake coil
Actuating spring
Fan
Cover
Motor shaft
Fan set screw
Lock bolt
Armature
Inner discOuter disc
Spacer bush
Stopper
Hub
Brake adapter plate
Opposite drive end cover
Opposite drive end bearing
Opposite drive end bearing
cover
Brake cover
V-ringBrake cover gasket
Outdoor cover

21

1

22
23
24
25

注) 屋外立形仕様の場合、
Figure 8-39
屋外カバー 25 の形状は異なります。
Items
Specifications
Rated input voltage
AC200/220V 50/60Hz
Maximum input voltage
AC240V 50/60Hz
Minimum input voltage
AC170V 50/60Hz
InstantaneousStandard output
DC180V (for AC200V input)
voltagevoltage
Steady voltage DC90V (for AC200V input)
Maximum output current
DC1.8A (Steady output)
Over excitation time
0.4–1.2s
100MΩ or larger (When measured with
Insulation resistance
1000V megohmmeter)
Insulation withstand voltage
AC2000V for one time or more
Maximum freInching
When on-time 1.2 s or less: 8 cycles/min
Constant
When on-time exceeds 1.2 s: 30 cycles/min
quencyAllowable ambient temperature - 20℃ – 60℃

Note: 1. Motor configuration differs for
fan motor ventilation type.
2. There are 3 of [13][14] for ESB-250(horizontal types) and 2 for
ESB-250-2 (vertical types).
3. The outdoor cover [25] for ESB-2502 (the vertical types) has a different
shape.

■ Accessory Rectifier (DC Power Supply Unit) Model HD-110M3
Outline Drawing
96

Internal Circuit (Diagram)

84
74
30.5

6

1

CONTACTOR

4

5

AC
200V

Instant
activation

5.5

3

41

66

4.5

BRAKE

7

51

2

6

2
13.5

13.5 13.5

Terminal screw M4

Figure 8-40

Note: 1. Model HD-110M3 is an indoor model. Take care to avoid water, etc.
2. Transformer is necessary for operation with 400V class power source. Secondary voltage is 200–220V.

74

Timer and gate circuit

AC200V/220V

54Arc-extinguishing circuit

1

SW

MB

3

8. Daily Inspection and Maintenance‐ Gap Inspection(1)

Remove the outdoor cover [25] and the cover [8].

(2)Loosen the fan set screw [10] and remove the fan [7].

(3)

Pull off the V-ring [23] and remove the brake cover [22].

Gap Value G (mm)Required value
Limit value(original value)
0.72.0(4)	Insert a gap gauge between the field [4] and the armature [12], measuring the gap. Measure in 4 locations around thecircumference.
(5)

Adjustment is required if the gap value is near the limit.

‐ Gap Adjustment(1)

Manually release the brake following the procedure on P79.

(2)

Loosen the stopper [16] on the periphery of the center ring [1], and remove. This will free the gap adjusting screws [2].
(See Figure 8-41)(3)Insert the gap adjusting bar from between the outer disc [14] and the center ring [1] into a hole for a gap adjusting screw [2](Customer needs to prepare an angle plate. See Figure 8-43).
Rotating to the left as seen from the field [4] side, will narrow the gap. (See Figure 8-42)(4)

Six attachment bolts [3] and lock bolts [11] alternately pass through the space between the outer disc [14] and the center ring [1].
Rotating the gap adjusting bar will contact these bolts. There are 8 equally distributed holes for gap adjusting screws [2]. Adjust
the gap G to the required value by repeating (3) each time the gap adjusting bar contacts a bolt,.

(5)

Select the point where hole and screw hole are closest to the required gap and attach the stopper [16] there.

(6)

After returning the manual brake release to its original state, turn power on and off to check brake action.

(7)

Attach the brake cover [22], V-ring [23], fan [7], fan set screw [10], cover [8] and outdoor cover [25]. At this time, coat the fan set
screw [10] with Three Bond TB2365.

Gap adjusting bar dimensions

Gap adjusting bar
4

16

1
1

150mm

14

2

2

Figure 8-41

Figure 8-42

3.5mm

14

14.7±0.1mm

Figure 8-43

75

8. Daily Inspection and Maintenance
8-9 Removing and Installing One-Touch Release Lever①②③

Part Number
1
2
3
4
5
6

Part Name
HolderRelease lever
Release pin
Retaining ring
Brake release
Fan cover

A

④

A

⑤② ④

⑥

③
Figure 8-44

A-A

‐ Removing One-Touch Release Lever(1)

Removing retaining ring [4] (E-retaining ring or shaft retaining C-ring) in 2 locations.

(2)

Remove release lever [2] from holder [1].

(3)Expand release lever [2] to the outside from each side of the lever in turn, removing it from release pin [3].
(Do not expand the release lever overly).
After removing the release lever [2], be careful not to allow the release pin [3] to come off.

(4)

Remove release pin [3].

(5)Remove fan cover [6].

‐ Installing One-Touch Release Lever(1)

Attach fan cover [6].

(2)Insert release pin [3] into brake release [5] with preventing pin to drop.

(3)

Attach release lever [2] to U-hole of release pin [3] by extending release lever [2] to the outside from each side of the lever in turn.
(Do not expand the release lever overly).

(4)

Attach retaining ring [4].

(5)Check that brake is released by pushing release lever [2].

(6)

Fix release lever [2] to holder [1].

76

8. Daily Inspection and Maintenance
8-10 Changing the Brake Lining and Inner DiscIf the following conditions occur, ask the nearest authorized maintenance shop to exchange the brake linings and inner discs with newones.

(1) FB Brakes (excluding FB-01A1 − FB-05A1), ESB-250, ESB-250-2
When the thickness of brake lining (FB brake) or inner disc (ESB-250, ESB-250-2) reaches the use limit thickness in Table 8-18(2) FB-01A1 − FB-05A1
When after gap adjustment the brake gap still reaches the limit (see P54, P65)
Table 8-18 Brake Lining, Inner Disc Dimensions
Brake Type

Brake Lining
Inner Disc
Dimension Drawing

FB-01A1
FB-02A1
FB-05A1

ESB-250
ESB-250-2

t0 (mm)Usable Thickness Limitt1 (mm)

t0
t0

t0

t1
t1

t0
t0

8.8

7.8

9.0

8.0
−

10.4

t0

t1

t1 (mm)

6.0

t0

t0
t0

t0 (mm)
−

7.0

FB-1D
FB-1E
FB-1HE
FB-2E
FB-3E
FB-4E
FB-5E
FB-8E
FB-10E
FB-15E
FB-20
FB-30

Original Thickness

t1

8.4

10

6.0

11

7.0

16

12

−

t1
t1

6.0

1.5

3.6

0.3

‐ Brake torque may not be at the prescribed level during initial operation. In such case, turn motor and brake power on and off underas lightest load as possible to rub the brake lining and the inner disc friction surfaces.
‐ When changing the brake lining and the inner disc, change the boss and leaf springs (for FB-5E – FB-15E, FB-20, FB-30, including
the gap adjusting nuts) as a set.
‐ After 2 million or more cycles of operation, (for FB-30, ESB-250, ESB-250-2 1 million cycles or more), or after 10 years or more havepassed since shipment from the factory, inspect to check whether continued operation is possible, even if the lining or the innerdisc has not reached the usable thickness limit.
‐ Check the following items concerning the condition of each mechanical part.
Are the material of linings split or chipped?
Is there any peeling or gap between the material of lining and the disc?
Does the spline unit of the brake lining and the inner disc exhibit any cracking, chipping, or stepped wear?
Is there any stepped wear on the surfaces around the stud bolts or armature plate?
‐ Change the brake lining and the inner disc, even if it has not reached the usable thickness limit in the following cases. [1] 10 ormore years have elapsed since the manufacturing date [2] the brake is used outdoors or in a high-humidity environment, [3] it isstored or rested for a long period of time.

8-11 Changing the V-Ring and Waterproof Seal (Outdoor Type)V-rings and waterproof seals degrade over the years, losing their waterproofing abilities. Contact the nearest authorized maintenanceshop about every 3 years. If the sliding surfaces of oil seals or V-rings show signs of wear or corrosion, replace them with new ones.
Sliding surfaces are made of carbon steel, so rain water, condensation and other factors could cause rust to form and spread. Because
this could lead to oil seal damage, take periodic rust prevention measures.

77

8. Daily Inspection and Maintenance
8-12 Manually Releasing the Brake
To manually release the brake without turning on the brake, operate the brake release mechanism as shown below.

■ FB Brakes (excluding FB-20, FB-30) (FB-01A1 – FB-05A1 are options)(1) F irst remove the brake release bolts from the 2 opposing angles and remove the release prevention spacers. Reinsert the bolts
and rotate it with a hexagonal wrench to release the brake. Be careful not to over rotate the brake release bolts. (Rotate the brakerelease bolts while checking if the brake is released.) (See Figures 8-45, 8-46)(2) A fter releasing the brake, to return it to its original condition, for safety, return the manual release prevention spacers that were
removed in (1) to their original positions. (See Figure 8-46)
Brake Type
FB-01A1 – FB-05A1
FB-1D
FB-1E – FB-2E
FB-3E – FB-4E
FB-5E – FB-15E(3) This table shows brake release bolt sizes.

Waterproof seal

Bolt Size
M5
M6
M8
M10
Brake release bolt
Manual release protection spacer

Brake release bolt

Waterproof cover

When Released

When Operating

Figure 8-45

Figure 8-46

Note : Indoor types do not come with waterproof seals or waterproof covers.

■ FB-20, FB-30(1) I n the case of outdoor types, remove the lid on the window part of the the outdoor cover [33]. Remove the grommet [28] (indoortype), remove the brake release bolt [2] by using a hexagonal wrench (for an M8 hole bolt), and remove the rubber gasket [3] andthe manual release prevention spacer [4]. The brake will release when you again rotate the bolt by using the hexagonal wrench.
Be careful not to over rotate the brake release bolt. (Rotate the brake release bolt [2] while checking if the brake is released.) (SeeFigure 8-47)(2) A fter releasing the brake, to return it to its original condition, for safety, return the manual release prevention spacer [4] and therubber gasket [3] that were removed in (1) to their original positions, and firmly tighten the brake release bolt [2]. (See Figure 8-48)
Next re-attach the grommet [28] (indoor type) in its original state. In the case of outdoor types, attach the lid on the window partof the the outdoor cover [33] as it was before.
‐ N ote that if the rubber gasket [3] and the seal washer [5] for the brake release bolt [2] unit are not attached when returning to theoriginal state, dust-proofing and waterproofing capabilities will be lost.
A lso, firmly tighten the brake release bolt [2]. Otherwise waterproofing capability may be lost.
A lso, make certain to return the grommet [28] (indoor type) or outdoor cover [33] window lid (outdoor type) to their original states.
‐ If the machine is operated when the brake release bolt [2] has not been returned to its original position, in the worst case it
is possible that the manual release would function before maximum gap is obtained, and the brake would cease to function.
Therefore, make certain to always operate with the manual release prevention spacer [4] attached.

Brake release bolt
Manual release prevention spacer

Seal washer
Rubber packing

When Released

When Operating

Figure 8-47

Figure 8-48

78

8. Daily Inspection and Maintenance■ ESB-250, ESB-250-2(1) I n the case of outdoor types, remove outdoor cover [25]. Remove the cover [8], fan [7], and brake cover [22] (outdoor type).
(2) I nsert M12×65 hexagon socket head bolts (customer needs to prepare) through the manual releasing holes, to the field. (Note that
if the hexagon socket head bolts are too long they will hit the outer disc and deform it.)(3) There are two manual release holes at opposing angles. Using a hexagonal wrench equally tighten the bolts in turn.
(4) To release the brake, tighten the bolts until the armature and field stick together.
(5) A fter returning the brake to its original state, attach the brake cover [22] (outdoor type), fan [7], and cover [8].
At this time coat the fan set screw [10] with Three Bond TB2365.
In the case of outdoor types, attach the outdoor cover as it was before.

Manualrelease hole

Armature
Outer disc
Inner disc

Field
Gap

Hexagon socket
head bolt

AdheresHexagonal
wrenchManualrelease hole

Figure8-49
Figure8-48

Figure8-50 8-49
FigureFigure8-51 8-50
Figure■ One-Touch Release Lever Method (Optional on all FB brakes except FB-20, FB-30)
Just pushing down the release lever enables brake releasing operation. (See Figure 8-52)(1) To release the brake, pull the release lever out of the holder, and push it toward the load or anti-load side.
(Some specifications do not allow pushing the release lever toward the load side.)Be careful not to push the lever too far. Pushing the lever too far could damage the brake.
(Push the release lever while checking if the brake is released.)(2) When operating the motor, make certain to return the lever to its original position and set it inside the holder. Start operation after
confirming that the brake operates properly.
Note: The brake is released as long as the lever is pushed down, but it works when the lever is released from the hand.
When Operating

When Brake is Manually Released

Other Than Premium Efficiency Motor

Premium Efficiency Motor
Figure 8-52

79

9. Troubleshooting

CommonIf any abnormal condition occurs, refer to Table 9-1, 9-2 and promptly take appropriate measures.
If these actions do not solve the issue, immediately contact the nearest authorized maintenance shop.
Table 9-1 Troubleshooting
Problem

The motor will not operate under no load

The motor rotates without a load but theoutput shaft does not rotate

When a load is applied

The output shaft turns without a load

The switch overheats
Fuse tripping

Correction
Contact the electric power company.

Defective electric circuit

Check the circuit.

Blown fuse

Replace the fuse.

Protective device is operating

Fix the problem and recover.

Load locking

Check the load and safety device.

Poor switch contact

Adjust the contact unit.

Motor stator coil disconnect

Confer with authorized maintenance shop.

Bearing damage

Confer with authorized maintenance shop.

3-phase is functioning as single-phase

Check the power supply with a voltmeter.
Check the motor, transformer coil, contactor,
fuse, etc. and repair or replace them.

Friction surface of brake is corroded

Request brake cleaning from authorized
maintenance shop.

Incorrect brake gap adjustment

Re-adjust brake gap.
(See P54–75)

Damage to gear unit due to overloading ofgears, etc.

Confer with authorized maintenance shop.

Insufficient switch capacity

Replace with specified switch.

Overload

Decrease the load to the specified value.

Insufficient fuse capacity

Replace with specified fuse.

Overload

Decrease the load to the specified value.

Voltage drop
The speed will not increase andOverload
the motor is overheating
Short-circuited motor stator coilContact the electric power company.
Decrease the load to the specified value.
Confer with authorized maintenance shop.

The key is not inserted

Insert key.

Bearing burnout

Confer with authorized maintenance shop.

Poor adjustment of protection device

Adjust the protection device.

Wiring error

Change the connection.

The lead wire is short circuited.

Confer with authorized maintenance shop.

Poor contact between motor and starter

Make good connection.

Overload

Decrease the load to the specified value.

Voltage drop or riseContact the electric power company.

The ambient temperature is highImprove the ventilation method.

Damaged bearing

Confer with authorized maintenance shop.

Abnormal wear of reducer parts due tooverload, etc.

Confer with authorized maintenance shop.

Blot or drip of a small amount of oilor grease from seal section of input
or output shaft

Grease applied to the oil seal seeps out at an
early stage.

Wipe off around the oil seal, and observe.

Leakage of oil or grease from input
or output shaft section

Damaged oil seal or possibly damaged shaft(or collar)

Confer with authorized maintenance shop.

Leakage of oil/grease from thecontact surfaces of frame, casing,
etc.

Loose fastener bolts

Tighten fastener bolts correctly.

Damage to oil seals, or slinger collar

Confer with authorized maintenance shop.

Excessive oil supply

Remove oil.

It stops
The motor runs in the reverse
direction
Fuse tripping

Excessive temperature rise

Oil leakage

CausePower failure

Leakage of oil/grease into motor80

9. Troubleshooting Common
Table 9-2 Troubleshooting
ProblemAbnormal sound
Excessive vibration

With torque limiter, makes chatteringsound

Abnormal motor sounds

Brake is ineffective

Does not activate

Slips(Braking takes a longtime)

Correction

Dust and foreign matter in bearings, or
damaged bearings

Confer with authorized maintenance shop.

Reducer parts grinding on foreign matter

Confer with authorized maintenance shop.

Reducer parts are damaged

Confer with authorized maintenance shop.

Warping of housing because the installation
surface is not flat

Make the installation base flat or makeadjustment using liners, etc.

Resonance due to insufficient rigidity of
installation baseReinforce the installation base to increase
rigidity.

Nonalignment of shaft with driven machine

Align the shaft centers.

Transmission of vibration from the driven
machineIndividually operate the products to checkthe source of the sound.

In rare cases this will occur in a low load
range. The influence of load fluctuation andvibration from the device causes it.

Performance and lifetime are not affected.
It is OK to continue operation.

Foreign objects have enteredConfer with authorized maintenance shop.

Bearing damage

Confer with authorized maintenance shop.

Improper brake gap adjustment

Adjust the brake gap.
(See P54–75)

Brake lining or inner disc wear

Request brake lining or inner discreplacement from an authorized maintenanceshop.

Brake unit electromagnetic coil burnout

Confer with authorized maintenance shop.

Rectifier damage

Confer with authorized maintenance shop.

Leaf spring in the brake boss unit has comeoff or is damaged

Confer with authorized maintenance shop.

Forgot to restore the brake release bolt to its
original position

Restore the release bolt.

Improper adjustment after disassembly

Request authorized maintenance shop to
re-adjust.

Not using the quick braking circuit

Change to quick braking circuit.
(See P26–35)

Foreign objects in brake lining or inner discunit, oil adhesion

Request cleaning from authorized
maintenance shop.

Brake lining or inner disc wear

Adjust the brake gap.
Request brake lining or inner discreplacement from an authorized maintenanceshop.

Brake gap not uniform

Adjust the brake gap.

Overload

Decrease the load to the specified value.

Brake release bolt not sufficiently restored

Restore the release bolt.

Sudden speed changes

Increase the time for speed changes.

Extreme load fluctuation

Decrease load fluctuation.

Overcurrent due toground fault

Ground fault on out side

Take measures to prevent ground fault.

Direct current
overcurrent

Short on output side

Take measures to prevent short.
Inspect wiring.

Overcurrent shut-off

Tripping
Inverter

Cause

Regenerative overvoltage
Sudden speed reduction
shut-off

Increase the time for speed reduction.
Decrease brake frequency.

Thermal operation

Decrease the load to the specified value.

Overload8110. Construction Drawings

Common7
13(Bevel4 Series)
1 10-1
2 Gear3 Unit4 Construction
5
6 Drawings
8
9
10
11 BUDDYBOX
12 14 51
52 53

1

22

25

27

26

22

2

25

25

3

24

27

4

23

26

7
6

5

22

25

24

21

20

23

8

19

22

9

17
18

21

20

55

56

53

54

58

57

64

65

11

13
12

14

51

52

15

60

59

58

57

17
18

16

15

60

59

10

16

54

19

55

56

Figure 10-1 Type LHYM (Gearmotor), (Example: Frame size 4C145-Y1)

61

69

62

68

63

64

65

61

62

63

67

66

Figure 10-2 Type LHY (Reducer), (Example: Frame size 4C145-Y1)
Table 10-1 Gear Unit, Principal Parts (Bevel BUDDYBOX 4 Series)
Part
NumberParts Name

Part
Number1

Casing

15

2

Gear

16

3

Both corner parallel key

17

4

Hollow shaft

18

5Output shaft cover

6

Parts Name

Part
NumberFlanged casing

69

68

Parts Name

67

66

Part
NumberParts Name

51

Slow speed shaft pin

65

Oil seal

52

Ring gear housing

66

Input shaft

53

Ring gear pin

67

CollarSpring washer

54

Spacer ring

68

Distance

19

Holder plate

55

Eccentric cam

69

DistanceBushing

20

Collar56

Slow speed shaft roller

7

Air vent plug

21

Hexagon socket flange
head plug

57

Cycloid disc8

Pinion shaft

22

Oil seal

58

Distance

9

Pinion shaft A bearing

23

Finished bolt

59

Retaining ring

10

O-ring24

O-ring60

Pin carrier

11

Shim

25

Shim

61

Retaining ring

12

Finished bolt

26

Nilos ring

62

Input shaft A bearing

13

Spring washer

27

Output shaft bearing

63

Retaining ring

14

Pinion shaft B bearing

64

Input shaft B bearing

Hexagon socket flange
head plug
Hexagon socket head
bolt

82

10. Construction Drawings Common
10-2 Gear Unit Construction Drawings (Bevel BUDDYBOX 5 Series)

18

1

3

12

34

25

7
46

58

24

18
23

24
22

23
21

22
20

21
19

20
18

7
69

810

911

1917 18 16 1715

10
51

11
52 5153 5254 5355 5456 55

16
14 1512 14
59 1258 5957 58
13
13

56

57

Figure 10-3 Type LHYM (Gearmotor), (Example: Frame size 5Z115-Y1)

60

61 6062 6163 62

63

Figure 10-4 Type LHY (Reducer), (Example: Frame size 5Z115-Y1)

Table 10-2 Gear Unit, Principal Parts (Bevel BUDDYBOX 5 Series)
Part
Part
Parts Name
NumberNumberParts Name

Part
NumberParts Name

1

Casing

14

Holder plate

51

Slow speed shaft pin

2

Gear

15

Hexagon socket flange head plug

52

Ring gear housing

3

Both corner parallel key

16

Collar53

Ring gear pin

4

Hollow shaft

17

Hexagon socket flange head plug

54

Spacer ring5

Output shaft cover18

Oil seal

55

Slow speed shaft roller

6

Bushing

19

Shim

56

Eccentric cam

7

Air vent plug20

O-ring57

Cycloid disc8

Pinion shaft

21

Output shaft A bearing

58

Pin carrier

9

Pinion shaft A bearing

22

Output shaft B bearing

59

Input shaft A bearing

10

Shim

23

Shim

60

Distance

11

Pinion shaft B bearing

24

Retaining ring

61

Input shaft B bearing

12

Hexagon socket head bolt

62

Oil seal

13

Spring washer

63

Input shaft

Code 21 and Code 22: Frame size Z uses ball bearings, and frame sizes A to C use roller bearings.

8310. Construction Drawings

Common10-3 Gear Unit Construction Drawings (Helical BUDDYBOX)

1

3
2

7
6

5

4

8

9

10

11

12

13

51

52

9
10
11

53

54

61

62

63

64

69

68

67

66

65

25
24
23
22
21
20
19

18

17

16

15

14

60

59

58

57

56

55

Figure 10-5 Type EHYM (Gearmotor) (Example: Frame size C6145-Y3)
Table 10-3 Gear Unit, Principal Parts (Helical BUDDYBOX)
Part
Part
Parts Name
Parts Name
NumberNumber1
Casing
14 Hexagon socket plug

Figure 10-6 Type EHY (Reducer), (Example: Frame size C6145-Y3)

Part
Parts Name
Number51 Slow speed shaft pin

PartParts Name
Number
64 Input shaft B bearing

2

Bushing

15

Pinion shaft B bearing

52

Ring gear housing

65

Oil seal

3

Air vent plug

16

Pinion shaft spacer

53

Ring gear pin

66

Input shaft

4

Cover

17

Oil seal

54

Spacer ring

67

Collar

5

Gear

18

Hexagon socket plug

55

Eccentric cam

68

Distance

6

Finished bolt

19

Seal cap

56

Slow speed shaft roller

69

Distance

7

Spring washer

20

Pinion shaft

57

Cycloid disc8

Retaining ring

21

Retaining ring

58

Distance

9

Retaining ring

22

Pinion shaft A bearing

59

Retaining ring

10

Output shaft bearing

23

Retaining ring60

Pin carrier11

Oil seal

24

Hollow shaft

61

Retaining ring

12

Distance

25

Both corner parallel key

62

Input shaft A bearing

13

Retaining ring

63

Retaining ring84

10. Construction Drawings Common
10-4 Motor Unit Construction Drawing

9

8

7

6

Table10-4 Principal Parts of Motor

5

10

Code

4

11

3

12

2

13

1

14
Figure 10-7 BUDDYBOX Reducer Direct Connection Motor (Example: N-100L 2.2kW 4P)

85

1

Part Name
Anti-load side motor shaft
bearing2

Fan3

Fan cover4

Anti-load side cover5

Rotor conductor

6

Rotor core

7

Stator core

8

Stator windings

9Motor flange bracket

10

Load side motor shaft bearing

11

Oil seal

12

Oil seal collar

13Motor shaft

14

Frame

MEMO

86

BUDDYBOX Reducer with Torque Limiter

Application
Product

Application Product®

BUDDYBOX Reducer with
Torque Limiter
This manual covers the torque limiter unit.
For information on handling the reducer unit and the motor unit, see P1–85.

Contents
11. Wiring………………………………………………………………………………………………………………… 88
12. Adjusting Preset Torque……………………………………………………………………………………………… 90
13. Daily Inspection and Maintenance………………………………………………………………………………… 91
14. Torque Indicator……………………………………………………………………………………………………… 93
15. Construction Drawings……………………………………………………………………………………………… 94

87

Application
Product

11. Wiring

BUDDYBOX Reducer with Torque Limiter
DANGER‐ Do not handle the unit when cables are energized. Be sure to turn off the power when working on the unit; otherwise,electric shock may result.
‐ Connect a power cable to the unit in accordance with the maintenance manual; otherwise, electric shock or fire may result.
‐ Do not forcibly bend, pull, or clamp the power cable and lead wires; otherwise, electric shock or fire may result.

CAUTION‐ When wiring, follow the the domestic laws and standards to prevent burns, electric shocks, injuries, and fire.

11-1 Wiring for a Spring-Loaded Limit Switch(1) Limit Switch Type (1-Point Signal, 2-Point Signal, 3-Point Signal)

Dog‐ When the preset torque is reached, the dog activates the limit switch, which
outputs a signal.
‐ Depending on manufacturing specifications, 1–3 point signal output isavailable. (Types that have 1–3 limit switches.)

Limit switch for
sub-motor(Type Z-15GQ-B)

Limit switch for
auxiliary signal(Type Z-15GQ-B)

Limit switch for main motor(Type Z-15GQ-22B)

Figure 11-1 Limit Switch(2) Limit Switch Wiring[1] R emove the terminal cover on the terminal box, pass
the cabtyre cable through the cable gland for marine
use and connect it to the limit switch terminals.

Dog

Terminal box[2] Of the three lead wires, connect as follows:

Terminal cover‐ For contact point a, terminal symbols C (COMMON) andNO (NORMALLY OPEN)

Switch box‐ For contact point b, terminal symbols C (COMMON) and
Limit switch
lead terminals

NC (NORMALLY CLOSED)[3] M
 ake wiring within the terminal box. The construction
Limit switchof the terminal box makes wiring there possible.
[4] The limit switch may activate at startup if startup torqueexceeds preset torque (when shock occurs at startup, orCable gland for marine use

when the motor is equipped with a brake, etc.). In thisFigure 11-2 Terminal Box, Switch Boxcase, install a motor timer to disable the limit switch
until the load torque becomes less than the preset
torque.

Note: 1. F or 2-point signal systems, there are two terminal boxes; for 3-point signal systems,
there are three terminal boxes.

C

2. The cable gland for marine use conforms to JIS F 8801 (for boxes) and 15-b.

NO NC

Figure 11-3 Type of Contact (1c)‐ To prevent moisture from entering the cable port, seal openings with sealant (for example, putty).
‐ Do not move the position of the limit switch; otherwise, preset torque value changes and the torque limiter does not work
properly.

8811. Wiring BUDDYBOX Reducer with Torque Limiter

Application
Product(3) Limit Switch Specifications
Table 11-1 Model
Rotation Direction
SignalMain motor OFF
Submotor or alarm ON
Auxiliary signal

Products of OMRON Corporation.
Right or Left

Reversible Direction

Z−15GQ22−B (1 piece)
Z−15GQ−B (1 piece)
Z−15GQ−B (2 piece)
Z−15GQ−B (1 piece)
Please consult with us.

Table 11-2 Rating
Rated Voltage(V)
AC 125
250
500
DC
8
14
30
125
250

Noninductive Load (A)Inductive Load (A)Resistance Load
Lamp Load
Inductive Load
Motor Load
Normally
Normally
Normally
Normally
Normally
Normally
Normally
Normally
Closed Circuit Open Circuit Closed Circuit Open Circuit Closed Circuit Open Circuit Closed Circuit Open Circuit
15
3
1.5
15
5
2.5
15
2.5
1.25
15
3
1.5
10
1.5
0.75
6
1.5
0.75
15
3
1.5
15
5
2.5
15
3
1.5
10
5
2.5
6
3
1.5
5
5
2.5
0.5
0.5
0.5
0.05
0.05
0.05
0.25
0.25
0.25
0.03
0.03
0.03

Table 11-3 Contact Point Specification
Inrush Current

Normally Closed
CircuitMax. 30A

Normally OpenCircuitMax. 15A

Note: 1. Values shown in the table indicate steady-state current.
2. An inductive load is a power factor of 0.4 (AC) or more, or a time constant of 7ms (DC) or less.
3. A lamp load is a load with an inrush current 10 times as high.
4. A motor load is a load with inrush current 6 times as high.
5. Working ambient temperature: General type -25 to 80℃ (no ice)
Working ambient humidity: General type 35 to 85% RH (no condensation)(4) Example of How to Connect a Spring-Loaded Limit Switch (2-Point Signal, Dual Safety, Reversible Rotation)
MCF

R

M

S

T
THR

MCR

S

R

BSF

MCF

LS

E

E

F

E

BSES

THR

TR

MCR

E

E

MCF
BSR

KS

MCR
MCF

TR

MCR

（ON. Delay）
LSF

TR

BL

LSR
MCF

MCR

Note: 1. L imit switches LS, LSF and LSR surrounded bysupplied by customer.

are built-in on BUDDYBOX Reducer with torque limiter. Other devices should be

2. If there is an overload, LSF (LSR) and LS operate in order.
3. Devices within

M……… Motor
MCF…… Electromagnetic switch for forward motor rotation
MCR…… Electromagnetic switch for reverse motor rotation
BSF…… Pushbutton switch for forward rotation
BSR…… Pushbutton switch for reverse rotation
BSES…… Pushbutton switch for stopping
THR…… Thermal relay
LS……… Limit switch (for forward, reverse and stop)
LSF…… Limit switch (for forward alarm)
LSR…… Limit switch (for reverse alarm)
KS…… Knife switch
TR…… Motor timer
F……… Fuse
BL…… Alarm

are not required for 1-point signals.

89

Application
Product

12. Adjusting Preset Torque BUDDYBOX Reducer with Torque Limiter
CAUTION‐ Increasing the preset torque will cause the torque value at which the torque limiter functions to exceeds the initial setpoint.
Damage to the machine may occur.

12-1 Adjusting Preset Torque for the Spring-Loaded Limit Switch Model‐ The preset torque is shown at the center of the adjusting scale plate [1] in the figure below.
Torque values indicated by T1 and T2 are positioned at ± 150° from the center. Use T1 and T2 as points of reference when changing
the preset torque.
‐ When it is necessary to increase or decrease the original preset torque, use the adjustment bolt [2].
Adjust torque within a range of ± 25% of the preset torque.
Overscaling T1 and T2 is permitted within ± 25%. However, do not make adjustment in excess of the maximum preset torque. (See theselection table in the catalog.)‐ An index [4] is stamped in the cut on the side of the threaded section of the adjustment bolt [2]. The index [4] is aligned with the end
face of the case cover [3] when the mark [5] on the adjusting bolt [2] is located at the position of the preset torque on the adjusting
scale plate [1]. Make fine adjustments by using this alignment as a base. If the adjustment bolt is too tight or too loose, first reset theadjustment bolt to align the index [4] with the end face of the case cover [3]. Then make adjustments.

Case cover
Adjustment
scale plate

Mark

PRE SETTORQUE

Adjustment bolt
Indicator

N・m(Indicator scale details)
Torque rating
30°

Shows the rated torque when theadjustment bolt is turned 150° to the left.

T1

N・m

T2

Shows the rated torque when the adjustment
bolt is turned 150° to the right.

Figure 12-1 Adjusting Preset TorqueNote: 1. For the reversible rotation specification, an adjustment bolt and adjustment scale plate will be located on both sides.
2. In the case of the B-type torque indicator (indicating a load factor of 0–100%), it is not possible to adjust the preset torque.

9013. Daily Inspection and Maintenance

BUDDYBOX Reducer with Torque Limiter

Application
Product

13-1 Torque Limiter, Daily Check
Open the switch box and check every time that oil is replenished or changed.

(1) Limit Switch‐ Use a tester to see if the limit switch activates normally.
‐ If it is possible to run the device, force the limit switch to activate while the machine is running to determine whether the torquelimiter works properly.

(2) Dog‐ Check to determine whether the nut that secures the dog is loose.
‐ If it is possible to run the device, confirm that, on startup, the dog moves from its stopped condition.

(3) Oil leakage‐ Check whether oil has leaked into the switch box.
‐ If oil leaks in, the limit switch may not activate, preventing the torque limiter from working.
‐ Do not move the position of the limit switch; otherwise, preset torque value changes and the torque limiter does not work
properly.
‐ A load test is performed and preset torque is adjusted when the device is shipped from the factory.
If the customer disassembles and reassembles the device, the preset torque could change, causing the torque limiter to stop
working properly. This is a source of damage to the device. Therefore, if disassembly or reassembly is required, contact the nearest
accredited maintenance shop.

91

Application
Product

13. Daily Inspection and Maintenance BUDDYBOX Reducer with Torque Limiter13-2 Lubrication‐ For the Bevel BUDDYBOX with Torque Limiter, the frame size and lubrication method may differ from those of models without torquelimiter. Check the manufacturing specifications. Lubricating oil fill quantity and grease replenishment quantity, refer to Table 13-1 andTable 13-2.
‐ Lubricating oil fill quantity and grease replenishment quantity for Helical BUDDYBOX with Torque Limiter is the same as those without
torque limiter.
‐ Lubricating oil change intervals, recommended lubricating oils, oil fill and drain procedures, grease replenishment intervals,
recommended grease, oil fill and drain procedures, etc., refer to “8. Daily Inspection and Maintenance”.
‐ If information you need is not in the tables, please consult with us.
■ Bevel BUDDYBOX 4 Series

Approximate Grease Replenishment
Quantity (g)Table 13-1 Approximate Oil Fill Quantity (L)Frame Size
4A10DA
4A12DA
4A12DB
4B12DA
4B12DB
4B14DA
4B14DB
4C14DA
4C14DB
4C14DC
4C16DA
4C16DB
4C17DB
4D16DA
4D16DB
4D17DA
4D17DB
4D17DC
4D18DA
4D18DB
4E17DA
4E17DB
4E17DC
4E18DA
4E18DB
4E19DA
4E19DB
4F18DA
4F18DB
4F19DA
4F19DBY1, F1, G1
K1,V1
1.7
1.7
1.8
3.3
3.4
3.5
3.6
5.6
5.6
5.6
6.0
6.1
6.7
10.1
10.1
10.2
10.5
10.7
10.8
11.7
14.6
14.7
14.8
14.8
15.7
17.5
17.7
20.1
21.0
22.6
22.8

Y2, F2, G2, K2, V2, W2
Output side Input side
1.0

Long-life
grease

2.0

3.5

5.0
Grease7.3

12.0

Mounting Location
Y4, F4, G4, K4, W4
Y3, F3, G3
K3, V3, W3 Output side Input side
1.7
1.7
1.1
Long-life
1.8
grease
3.3
3.4
1.7
3.5
3.6
5.6
5.6
5.6
2.9
6.0
6.1
6.7
10.1
10.1
10.2
10.5
4.6
10.7
Grease
10.8
11.7
14.6
14.7
14.8
14.8
6.3
15.7
17.5
17.7
20.1
21.0
7.3
22.6
22.8

■ Bevel BUDDYBOX 5 Series

5Z10DA
5Z12DA
5Z12DB
5A12DA
5A12DB
5B12DA
5B12DB
5B14DA
5B14DB
5C14DA
5C14DB
5C14DC
5C16DA
5C16DBY1, G1Y3, G3

0.9
0.9
1.0
1.7
1.8
2.7
2.8
2.9
3.0
5.5
5.5
5.5
6.1
6.2

0.9
0.9
1.0
1.7
1.8
2.7
2.8
2.9
3.0
5.5
5.5
5.5
6.1
6.2

Mounting Location
Y4, G4
Output side Input side
0.7
0.8

Long-life
grease

1.6

Grease
3.5

Y6, F6, G6
K6, V6
1.9
2.0
2.0
3.3
3.3
3.5
3.5
5.9
5.9
6.0
6.4
6.4
7.3
10.5
10.5
10.6
10.9
11.0
11.2
12.1
16.1
16.2
16.3
16.3
17.2
19.0
19.2
21.5
22.4
24.0
24.2

Frame Size
4A10DA
4A12DA
4A12DB
4B12DA
4B12DB
4B14DA
4B14DB
4C14DA
4C14DB
4C14DC
4C16DA
4C16DB
4C17DB
4D16DA
4D16DB
4D17DA
4D17DB
4D17DC
4D18DA
4D18DB
4E17DA
4E17DB
4E17DC
4E18DA
4E18DB
4E19DA
4E19DB
4F18DA
4F18DB
4F19DA
4F19DB

Mounting Location
Y2, F2, G2, K2, V2, W2
Y4, F4, G4, K4, W4

8.5–12.5
20–30
8.5–12.5
20–30
40–60
20–30
40–60
40–60
20–30
40–60
20–30
40–60
85–12540–60
150–225
20–30
40–60
85–12540–60
150–225
110–165
150–225
40–60
150–225
110–165
150–225

Approximate Grease Replenishment
Quantity (g)Table 13-2 Approximate Oil Fill Quantity (L)Frame Size

Y5, F5, G5
K5, V5
1.4
1.5
1.5
3.4
3.4
3.6
3.6
5.3
5.4
5.4
5.8
5.9
6.2
9.8
9.8
9.8
10.2
10.3
10.5
11.4
13.1
13.2
13.3
13.3
14.2
16.0
16.2
18.6
19.5
21.1
21.3

Mounting Location
Y5, G5

Y6, G6

0.9
1.1
1.1
1.4
1.4
2.4
2.4
2.6
2.6
5.1
5.2
5.2
5.9
6.0

1.0
1.1
1.1
2.0
2.0
3.2
3.2
3.4
3.4
5.7
5.7
5.8
6.5
6.5

Frame Size
5Z10DA
5Z12DA
5Z12DB
5A12DA
5A12DB
5B12DA
5B12DB
5B14DA
5B14DB
5C14DA
5C14DB
5C14DC
5C16DA
5C16DB

Note: 1. Output side: Bevel gear unit, Input side: Cyclo unit
2. Replenishment is not required for frame sizes indicated with

92

since they are long-life grease series.

Y4, G4

8.5–12.5
20–30
8.5–12.5
20–30
40–60
20–30
40–60

14. Torque Indicator

BUDDYBOX Reducer with Torque Limiter

Application
Product

14-1 Torque Indicator(1) Checking the Torque Indicator‐ The torque indicator is performed zero point adjustment, and the preset torque is adjusted before shipment.
After the reducer has been connected to equipment, if zero is not indicated when the reducer is at rest, it is possible that a small load
is already being applied to the output shaft. Do not readjust to the zero point.
‐ The relationship between the direction of pointer deflection and slow speed shaft rotation (seen from the slow speed shaft side) isshown below.
1 stage reduction type: pointer opposite direction of the slow speed shaft
2, 3 stage reduction types: pointer in the same direction as the slow speed shaft‐ The indicator scale displays the load factor, with 100% being the preset torque. Accuracy is within ±10% of the overall load range.

(2) A-Type Torque Indicator
The A-type torque indicator displays load factors of 60–100% (depending on the combination of preset torque and reduction ratio, it
displays 50–100%).

60

50

60

70

70

80

80

90
100

60

60

70

70

80

90

％

50

80
％

90

100

100

90
100

Figure 14-2 A-Type Torque Indicator(50–100% Load Factor Display)

Figure 14-1 A-Type Torque Indicator(60–100% Load Factor Display)‐ The pointer may deflect slightly when stopped or under no load. This is not a problem.
‐ For the reversible rotation specification, when left and right preset torques differ, the pointer position will be slightly moved over.

(3) B-Type Torque Indicator
The B-type torque indicator displays load factors of 0–100%.

0
25

25

50

75

50

75

％
100

100

Figure 14-3 B-Type Torque Indicator (0–100% Load Factor Display)‐ In the case of a B-type torque indicator, the pointer will stop in the range of‐ Preset torque cannot be changed. Do not turn the adjustment bolt.

930when load is removed.

Application
Product

15. Construction Drawings BUDDYBOX Reducer with Torque Limiter

15-1 Construction Drawings
35

20

36

34

Cross-section B-B

21

A
30

B

B

32
22
5
6

Input side

Output side

4

A

3

25

Figure 15-1 Bevel Gear or Helical Gear 1 Stage + Cyclo 2 Stage Reduction

94

31

15. Construction Drawings

BUDDYBOX Reducer with Torque Limiter

Application
Product

Table 15-1 Torque Limiter Principal Parts
No.

Part Name

1

Fixed ring gear housing

2

Ring gear housing

3

Intermediate cover

MIN MAX

4

cover
Intermediate cover ( Internal
Motor flange bracket )C〜

5

Dog bar6

Bushing7

Spring8

Spring holder plate A

PRE SETTORQUE

N・m

27

14

15

18

19

16

23 26 40

37

38

24

39

8

9

Spring holder plate B

10

Spring case

11

Case cover

12

Adjustment bolt

913Adjustment scale plate

13

14

Switch box

15

Bellows

16

Dog

18

Toothed washer

19

Dog clamping nut

20

Cable gland for marine use

21

Limit switch

22

Switch mounting bracket

7
27

C

33

29
12
11

23

Switch box cover28

24

Terminal cover

1025

Gasket26

Gasket27

Gasket28

O-ring29

Stopper

30

Flat washer

31

Bolts for fixed ring gear housing

32

Insulation board

33

Stopping nut

34

Cabtyre cable

35

Limit switch lead terminal

36

Terminal plate (with clamp)

37

Terminal box

38

Gasket39

Spacer40

Gasket1
2

Cross-section A-A

Figure 15-2 Bevel Gear or Helical Gear 1 Stage + Cyclo 2 Stage Reduction9515. Construction Drawings BUDDYBOX Reducer with Torque Limiter

Application
CommonProduct

15-2 Torque Indicator Construction Drawings
For type B torque indicator

For type A torque indicator

C
1

2

3

4

5

6

7

8

0

25

9 10 11 12
13
14

60

50

70
80

75

B

15
16
17

90

%

100

100

View from B
33 34 35 36

37 41 38 67 68 39

19

40

A

Input side

20
22
23
32

31

30

29

28

26

25

A〜A

Output side

A
43
53

52

44

45

46
47
View from C

51

48
49

50

54
55
56

66

57
59
58
60
61
62

63

70

For type B torque indicator

Part
Parts Name
Number
1
Bellows2
Switch box
3
Switch mounting bracket
4
Insulation board
5
Microswitch (for stopping motor)
6
Philips pan head machine screw
7
Motor assembly mounting base
8
Philips pan head machine screw
9
Gasket10 Switch cover
11 Gasket
12 Transparent cover
13 Holding plate for transparent cover
14 Finished bolt
15 Washer with rubber
16 Philips pan head machine screw
17 Pointer19 Scale plate
20 Philips pan head machine screw
22 Finished bolt
23 Washer with rubber

For type A torque indicator

Figure 15-3 Torque Indicator

Table 15-2 Torque Indicator Principal Parts

Part
Parts Name
Number25 Scale plate mounting base
26 Philips pan head machine screw
28 Spacer for rod
29 Upper nut
30 Toothed washer
31 Dog32 Flat washer
33 Finished bolt
34 Washer with rubber
35 Terminal cover
36 Gasket
37 Terminal box
38 Gasket
39 Philips pan head machine screw
40 Internal machine
41 Cable gland for marine use
43 Philips pan head machine screw
44 Sector
45 Nut46 Rod47 Bushing for rod

96

Part
Parts Name
Number
48 Microswitch (for alarm)
49 Dog bar
50 Bushing
51 Spring holder plate A
52 Spring case
53 Spring
54 Gasket
55 O-ring
56 Spring holder plate B
57 Preload plate
58 Lock nut
59 Adjustment bolt
60 Case cover
61 Finished bolt
62 Washer with rubber
63 Fixed ring gear housing
66 Adjustment scale plate
67 Terminal plate
68 Finished bolt
70 Spacer16. Warranty Common
The scope of warranty of our delivered products is limited only to what we manufactured.
Warranty (period and description)

Warranty
PeriodThe 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 andmaintenance & 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 or provide an

Description

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 other indirect 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 stored according 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.

Exclusionfrom thewarranty

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. (except
for items described in the operation manual such as brake gap inspection and adjustment, and manual release
operation for the brake)
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, andlightning 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.

97

Worldwide Locations
U.S.A
Sumitomo Machinery Corporation of America(SMA)
4200 Holland Blvd. Chesapeake, VA 23323, U.S.A.
TEL (1)757-485-3355 FAX (1)757-485-7490
CanadaSM Cyclo of Canada, Ltd. (SMC)
1453 Cornwall Road, Oakville, Canada ON L6J 7T5
TEL (1)905-469-1050 FAX (1)905-469-1055
MexicoSM Cyclo de México, S.A. de C.V. (SMME)
Fresnos #201, Pocket Park Oriente, 67258 Juárez, N.L.
MéxicoTEL (52)81-8144-5130
BrazilSumitomo Industrias Pesadas do Brasil Ltda.
(SHIB)
Rodovia do Acucar (SP-075) Km 26
Itu, Sao Paulo, Brasil
TEL (55)11-4886-1000 FAX (55)11-4886-1000
Chile
SM-Cyclo de Chile Ltda. (SMCH)
Camino Lo Echevers 550, Bodegas 5 y 6,
Quilicura, Región Metropolitana, Chile
TEL (56)2-892-7000
FAX (56)2-892-7001
Argentina
SM-Cyclo de Argentina S.A. (SMAR)
Ing Delpini 2230, B1615KGB Grand Bourg,
Malvinas Argentinas, Buenos Aires, Argentina
TEL (54)3327-45-4095 FAX (54)3327-45-4099
GuatemalaSM Cyclo de Guatemala Ensambladora, Ltda.
(SMGT)
Parque Industrial Unisur, 0 Calle B 19-50 Zona 3,
Bodega D-1 Delta Bárcenas en Villa Nueva, Guatemala
TEL (502)6648-0500 FAX (502)6631-9171
Colombia
SM Cyclo Colombia, S.A.S. (SMCO)
Parque Industrial Celta, Km 7.0 Autopista Medellín,
Costado Occidental, Funza, Cundinamarca, Colombia
TEL (57)1-300-0673

Austria
Sumitomo (SHI) Cyclo Drive Germany GmbH(SCG)SCG Branch Austria Office
Gruentalerstraße 30A, 4020 Linz, Austria
TEL (43)732-330958 FAX (43)732-331978

Korea
Sumitomo (SHI) Cyclo Drive Korea, Ltd. (SCK)Royal Bldg Room #913, 19, Saemunan-ro 5-gil,
Jongno-gu, Seoul, 03173, Korea
TEL (82)2-730-0151
FAX (82)2-730-0156

Belgium
Hansen Industrial Transmissions NV (HIT)
Leonardo da Vincilaan 1, Edegem, Belgium
TEL (32)34-50-12-11 FAX (32)34-50-12-20

TaiwanTatung SM-Cyclo Co., Ltd. (TSC)
22 Chungshan N. Road 3rd., Sec. Taipei, Taiwan 104,
R.O.C.
TEL (886)2-2595-7275 FAX (886)2-2595-5594

FranceSM-Cyclo France SAS (SMFR)
8 Avenue Christian Doppler, 77700 Serris, France
TEL (33)164171717
FAX (33)164171718
Italy
SM-Cyclo Italy Srl (SMIT)
Via dell' Artigianato 23, 20010 Cornaredo (MI), Italy
TEL (39)293-481101 FAX (39)293-481103
Spain
SM-Cyclo Iberia, S.L.U. (SMIB)
C/Gran Vía Nº 63 Bis, Planta 1, Departamento 1B
48011 Bilbao–Vizcaya, SpainTEL (34)9448-05389 FAX (34)9448-01550
United Kingdom
SM-Cyclo UK Ltd. (SMUK)Unit 29, Bergen Way, Sutton Fields Industrial Estate,
Kingston upon Hull, HU7 0YQ, East Yorkshire,
United Kingdom
TEL (44)1482-790340 FAX (44)1482-790321
TurkeySM Cyclo Turkey Güç Aktarım Sis. Tic. Ltd. Sti.
(SMTR)
Barbaros Mh. Çiğdem Sk. Ağaoğlu, Office Mrk. No:1 Kat:4 D.18
Ataşehir, İstanbul, Turkey
TEL (90)216-250-6069 FAX (90)216-250-5556
India
Sumi-Cyclo Drive India Private Limited (SDI)
Gat No. 186, Raisoni Industrial Park, Alandi Markal Road,
Fulgaon-Pune, Maharashtra, India
TEL (91)96-0774-5353

Peru
SM Cyclo de Perú, S.A.C (SMPE)
Jr. Monte Rosa 255, Oficina 702, Lima,
Santiago de Surco, PerúTEL (51)1-713-0342
FAX (51)1-715-0223

China
Sumitomo (SHI) Cyclo Drive Shanghai, Ltd.
(SCS)
11F, SMEG Plaza, No. 1386 Hongqiao Road,
Changning District, Shanghai, China 200336
TEL (86)21-3462-7877 FAX (86)21-3462-7922

Germany
Sumitomo (SHI) Cyclo Drive Germany GmbH
(SCG)
Cyclostraße 92, 85229 Markt Indersdorf, Germany
TEL (49)8136-66-0
FAX (49)8136-5771

Hong Kong
SM-Cyclo of Hong Kong Co., Ltd. (SMHK)
Room 19, 28th Floor, Metropole Square, No.2 On
Yiu Street, Shatin, New Territories, Hong Kong
TEL (852)2460-1881 FAX (852)2460-1882

Singapore
Sumitomo (SHI) Cyclo Drive Asia Pacific Pte.
Ltd. (SCA)
15 Kwong Min Road, Singapore 628718
TEL (65)6591-7800
FAX (65)6863-4238
Philippines
Sumitomo (SHI) Cyclo Drive Asia Pacific Pte. Ltd.
Philippines Branch Office (SMPH)
C4 & C5 Buildings Granville Industrial Complex, Carmona,
Cavite 4116, Philippines
TEL (63)2-584-4921
FAX (63)2-584-4922
Vietnam
SM-Cyclo (Vietnam) Co., Ltd. (SMVN)
Factory 2B, Lot K1-2-5, Road No. 2-3-5A,
Le Minh Xuan Industrial Park, Binh Chanh Dist.,
HCMC, Vietnam
TEL (84)8-3766-3709 FAX (84)8-3766-3710
Malaysia
SM-Cyclo (Malaysia) Sdn. Bhd. (SMMA)
No.7C, Jalan Anggerik Mokara 31/56, Kota Kemuning,
Seksyen 31, 40460 Shah Alam, Selangor Darul Ehsan,
Malaysia
TEL (60)3-5121-0455 FAX (60)3-5121-0578
Indonesia
PT. SM-Cyclo Indonesia (SMID)
Jalan Sungkai Blok F 25 No. 09 K, Delta Silicon III,
Lippo Cikarang, Bekasi 17530, Indonesia
TEL (62)21-2961-2100 FAX (62)21-2961-2211
Thailand
SM-Cyclo (Thailand) Co., Ltd. (SMTH)
195 Empire Tower, Unit 2103-4, 21st Floor, South
Sathorn Road, Yannawa, Sathorn, Bangkok 10120,
ThailandTEL (66)2670-0998
FAX (66)2670-0999
Australia
Sumitomo (SHI) Hansen Australia Pty. Ltd.
(SHAU)
181 Power St, Glendenning, NSW 2761, Australia
TEL (61)2-9208-3000 FAX (61)2-9208-3050
Japan
Sumitomo Heavy Industries, Ltd. (SHI)
ThinkPark Tower, 1-1 Osaki 2-chome, Shinagawa-ku,
Tokyo 141-6025, JapanTEL (81)3-6737-2511 FAX (81)3-6866-5160

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.CM2020E-5.1
EA15 Printed 2023.10