Sumitomo Cyclo BBB4 Manual de usuario

Quick Start Guide

Manual 13.604.61.003 January 2017

Cyclo® BBB4

Bevel Buddybox®

Quick Start Guide Cyclo® BBB4 1

Cyclo® BBB4 Quick Start Guide

Quick Start Guide

Cyclo® BBB4

Bevel Buddybox®

Table of Contents

Pages

Shaft and Bushing Installation 4

Taper-Grip Bushing 5

Keyed Hollow Bore 9

Shrink Disc 10

Torque Arm Mounting

Turnbuckle Type 12

Tie-Rod Type 15

T-Type 17

Flange Mount (Banjo) Type 19

Lubrication 21

Safety Precautions

Review and adhere to the instructions in this manual to ensure:

• trouble-free Cyclo® BBB4 operation

• your rights to make a warranty claim.

Read this manual and all accompanying documents thoroughly before use. Understand the machine, information on

safety, and all precautions for correct operation. Sumitomo recommends that this manual is easily accessible for refer-

ence at the machine location.

• Only properly trained personnel should transport, install, align, wire, inspect, operate, and maintain

the unit.

• The user should install secondary safety devices for applications involving passenger transportation.

Failure to do so may result in personnel injury, death, and/or equipment damage.

• The user should install secondary safety devices for applications involving elevators. Failure to do so may

result in personnel injury, death, and/or equipment damage.

• Be sure to install and operate Cyclo® BBB4 speed reducers and gearmotors in compliance with

applicable local and national safety codes. Appropriate guards for rotating shafts are available from

factory.

CAUTION:

• Operate the unit only within its design and performance specifications; otherwise, injury or damage to the

system may occur.

• Keep hands and all foreign objects from the internal moving parts of the unit; otherwise, injury or damage

to the system may occur.

• Take damaged units off-line immediately and do not resume operation until properly repaired.

• Modifications or alterations of any kind to the unit will void the warranty and all subsequent claims.

• Do not remove the rating plate.

Inspection Upon Delivery

In order to avoid injury, ensure that the unit is in a stable position before unpacking.

• Verify that the unit received matches your order. Using the incorrect product may cause equipment

damage or personnel injury.

• Do not remove the nameplate from the unit.

Upon delivery, inspect the unit for damage that may have occurred during shipment. Notify the shipping company

immediately if you ﬁnd any damage. Do not install or operate a damaged unit.

Upon receipt of the reducer/gearmotor, verify that:

• the model number on the unit nameplate matches the purchase order

• the unit was not damaged during shipping

• all bolts and nuts are fully tightened.

Please consult your Sumitomo agent, distributor, or sales oﬃce if you ﬁnd any defects or if you have any questions.

2 Cyclo® BBB4 Quick Start Guide Quick Start Guide Cyclo® BBB4 3

Inspection of the Nameplate

When contacting Sumitomo’agent, distributor, or sales oﬃce about this product, please be prepared to provide the

following information from the reducer/ gearmotor nameplate:

• reducer or gearmotor model number (nomenclature)

• reduction ratio

• serial number

Nominal

Reduction

Ratio

Unit Model

Number

Unit Serial

Number

Non- Metallic Nameplate

Nominal

Reduction

Ratio

Unit Serial

Number

Unit Model

Number

Metal Nameplate

Inspection of Lubrication Method

• Oil lubricated units are shipped without oil, unless the customer specified otherwise when the unit was

ordered. Always fill the unit with the correct type and quantity of lubricant prior to operation.

• Certain models must be filled with lubricant in two separate locations, the bevel gear portion (output) and

the input portion.

Refer to the Lubrication section (page 21) in this manual for detailed lubrication information.

Installation

• Do not use the reducer/gearmotor for specifications other than those shown on the nameplate or in the

manufacturing specification documents. Personnel injury and/or equipment damage may occur.

• Do not place combustible material on or around the unit; fire may occur.

• Do not place any objects around the unit that will prohibit proper ventilation. Inadequate ventilation may

lead to high unit temperature and/or fire.

• Do not step on or hang from the unit. Excessive weight may cause component breakage leading to

personal injury and/or equipment damage.

• Do not touch the shaft, keyway, or motor fan with bare hands; injury may occur.

• For applications in which lubricant leaks could adversely affect operations (i.e., package handling, food

processing), place an oil pan below the unit to protect against contamination that may occur if oil seals

become damaged or worn.

• Do not remove the eye-bolt from the motor, should you need to remove the eye-bolt for any reason,

install a replacement bolt in the tapped hole to prevent water from entering the motor.

Installation Location

Ambient Temperature Range: 14° - 104°F (-10° - 40°C)

Ambient Humidity: 85% or less

Altitude: 3,280 feet (1,000 m) or less

Atmosphere: The location should not contain corrosive gas, explosive gas, or

steam. The location should be free of dust and well ventilated.

Location: Indoor – free of dust and water

Consult Sumitomo when the unit will operate in conditions other than those speciﬁed above. Special unit

modiﬁcations may be required.

Units manufactured according to customer speciﬁed application requirements (i.e. outdoor modiﬁcations, high-

temperature modiﬁcations) are designed to operate within the speciﬁed environment.

Install the unit so inspection and/or maintenance procedures may be easily performed. Install all units that are not

shaft mounted on a suﬃciently rigid base.

Operation After Storage

Before operating the unit after an extended storage period, ensure that non-metal parts, i.e., oil seals, o-rings, air

breather, have not deteriorated. Non-metal parts may deteriorate easily from exposure to ambient conditions (i.e.,

extreme temperatures, UV rays). Replace deteriorated parts with new before unit start-up.

After starting the unit, verify that there is no abnormal noise, vibration, and/or temperature rise. Immediately stop

the unit and call your local distributor, Original Equipment Manufacturer or Sumitomo directly if you observe any

abnormality.

Installation Angle

Mount the unit in the speciﬁed position for which it was ordered. Conﬁrm the mounting position from the gearbox

nameplate.

Consult your local distributor, Original Equipment Manufacturer or Sumitomo directly if the mounting angle is to be

other than horizontal or vertical.

Severe Loading Conditions

For applications with severe vibration and/or frequent starts and stops, Sumitomo recommends the use of high-

strength mounting bolts of Grade 10.9 (or greater).

4 Cyclo® BBB4 Quick Start Guide Quick Start Guide Cyclo® BBB4 5

Taper-Grip® Installation onto

Driven Shaft

Prior to installation of the Cyclo® BBB4 onto the driven shaft,

ensure that the shaft length meets or exceeds the minimum shaft

engagement value “TT” detailed in Table 1.

Shaft Diameter

(in)

Tolerance

(in)

1-3/16 – 1-15/16 +0 / -0.0015

2 – 3-1/8 +0 / -0.0018

3-3/16 – 4-11/16 +0 / -0.0021

4-3/4 – 6-1/2 +0 / -0.0025

Cyclo® BBB4 Size TT (in) TT (mm)

4A 8.19 (208)

4B 9.53 (242)

4C 10.98 (279)

4D 12.83 (326)

4E 14.13 (359)

4F 16.22 (412)

Shaft Diameter

(mm)

Tolerance

(μm)

(30 - 50) (+0 / -39)

(50 - 80) (+0 / -46)

(80 - 120) (+0 / -54)

(120 - 180) (+0 / -63)

Table 1. Driven Shaft Tolerance and Minimum Shaft

Engagement

Taper-Grip® Bushing

Socket Head Cap Screws

Thrust Collar

Remove bushing cover if unit was supplied with one.

Loosen socket head cap screws.

Remove (unscrew) Taper-Grip® bushing from the unit.

Clean all grease, oil and/or anti-seize grease from the driven shaft.

Failure to do so could result in damage to shaft.

Slide Taper-Grip® bushing onto driven shaft.

Installation onto the Driven Machine

• Before coupling the reducer/gearmotor to the machine,

verify the appropriate/desired rotation of the machine.

Differences in the rotational direction may cause

personnel injury and/or equipment damage.

• Before operating the unit, ensure that all safety guards

around the rotating components are in-place and secure.

Failure to do so may result in personal injury.

Do not operate shaft mounted units until the torque arm has been attached to the unit and ﬁxed to a

rigid structure. The Torque Arm prevents counter-rotation during unit operation. Refer to Torque Arm

Installation section of this manual (page12).

CAUTION: The Cyclo® BBB4 must be externally supported prior to insertion of driven shaft into bushing.

External support MUST be maintained until unit is secured and mounting bolts have been tightened to the

appropriate torque.

Clean Driven

Shaft

External

Support

6 Cyclo® BBB4 Quick Start Guide Quick Start Guide Cyclo® BBB4 7

Inspect and test Taper-Grip® bushing on shaft.

• Check shaft for burrs, corrosion, or warpage. Repair or

replace shaft as necessary.

• Slide bushing back and forth along shaft, checking for

surface irregularities and fit.

• Verify bushing is sized correctly for the shaft diameter.

Remove Taper-Grip® bushing from driven shaft.

Apply a thin layer of anti-seize grease to the male threads of the

Taper-Grip® bushing only.

Ensure that the anti-seize grease does not enter the Taper-

Grip® bushing bore.

Do not apply anti-seize grease to the female threads in the

hub.

Screw Taper-Grip® bushing into Cyclo® BBB4 leaving approximately

1 mm gap between the bushing flange and thrust collar.

Do not apply grease, oil, or anti-seize grease to the

driven shaft or the bushing bore before placing the unit

onto driven shaft. Use of these friction-minimizing products

will adversely aﬀect the ability of the unit to transmit

torque.

CAUTION: The Cyclo® BBB4 must be externally supported

prior to insertion of driven shaft into bushing. External

support MUST be maintained until all bushing socket

head cap screws have been tightened to the appropriate

operational torque.

Mount or slide the Cyclo® BBB4 onto the driven shaft

Do not rock or pry the unit.

Screw Bolts into Taper-Grip® bushing.

• Lightly oil threads of each bolt before inserting.

• Finger tighten each bolt to secure in place.

• Be sure to maintain the 1 mm (approximate) gap

between the thrust collar and the bushing flange.

Apply thin layer of

anti-seize grease to male

threads of bushing only.

Do not apply anti-seize grease

to the female threads in the

hub.

Feeler Gauge

Bushing

Flange

Thrust Collar

8 Cyclo® BBB4 Quick Start Guide Quick Start Guide Cyclo® BBB4 9

Tighten bushing bolts to the correct torque value.

• Following a star pattern, use a torque wrench to

gradually tighten each socket head cap screw in 20%

increments.

• Refer to Table 2, Taper-Grip® Bushing Bolt Tightening

Torques, for the correct operational screw torques.

In order to prevent corrosion, apply grease to the exposed portion of the

driven shaft.

• After installing and tightening the bushing bolts with

a torque wrench, apply grease or an anti-corrosion

product to the exposed portion of the shaft.

After the reducer has been running for 20 to 30 hours, re-torque the

screws to the values in Table 2. Screw torques should be

subsequently checked at normal service intervals (i.e. every 6

months).

For units that include a bushing safety cover, reinstall the guard over

the Taper-Grip® bushing.

Do not operate unit until the torque arm has been attached

to the unit and fixed to a rigid structure. The torque arm

prevents counter-rotation during unit operation. Refer

to torque arm Installation section in this manual for

instructions.

Keyed Hollow Bore Installation onto

Driven Shaft

Apply molybdenum disulfide grease or similar anti-seize compound,

to the driven shaft surface and inside the reducer keyed hollow bore.

Align the driven shaft with the reducer/gearmotor bore and carefully

slide unit onto the driven shaft.

If the fit is tight, strike on the keyed hollow bore with a soft

mallet to assist in the assembly.

If using a soft mallet during installation, strike only against

the unit’s steel keyed hollow bore. Do not strike the reducer

housing or oil seal, damage to the bearings, the housing,

and/or the seals may occur.

Note: If the ﬁt is tight, you may use a jig such as the one shown here

to ease assembly. Sumitomo does not supply a mounting jig. This

information is provided for reference only.

Table 2. Taper-Grip® Bushing Bolt Tightening Torques

Cyclo® BBB4

Size Screw Qty x Size

Screw Torque

ft-lb (Nm)

4A 6 x M12 56 (75)

4B 6 x M12 104 (140)

4C 6 x M16 185 (250)

4D 6 x M16 223 (300)

4E 8 x M16 223 (300)

4F 10 x M16 223 (300)

Apply grease to

exposed portion

of driven shaft

Grease

Size a b c d e

CC (ISO/JIS) A2 Bearing Nut Threaded Rod

4A 3 25 51104 M16 M16 x 250

4B 65 25 51105 M20 M20 x 300

4C 75 25 51105 M20 M20 x 300

4D 85 35 51107 M24 M24 x 400

4E 100 35 51107 M24 M24 x 400

4F 120 46 51109 M30 M30 x 450

Table 3. Jig Dimensions

Spacer b

Retaining Ring a

Ball

Bearing

Threaded Rod e Nut d

Unit: mm

10 Cyclo® BBB4 Quick Start Guide Quick Start Guide Cyclo® BBB4 11

Once driven shaft has been completely inserted into the unit’s keyed

hollow bore, secure the shaft in place using a keeper plate as shown

in this example, or some other means of securing the unit to the

driven shaft.

Do not operate unit until the torque arm has been

attached. Refer to the Torque Arm Installation (page12)

section in this manual for instructions.

Shrink Disc Type Hollow Bore Installation

onto Shaft

Before placing unit onto driven shaft, do not apply grease,

oil, or anti-seize grease to the entire driven shaft or to the

bore of the shrink disc. Use of these friction-minimizing

products will adversely affect the ability of the unit to

transmit torque.

Never tighten locking screws before shaft installation. Inner ring may

become permanently contracted even at low tightening torques.

Clean and degrease contact surfaces; reducer shaft and bore, and the

machine driven shaft.

Apply Molykote 321 or an equivalent dry film lubricant to the driven

shaft projection opposite from the shrink disc.

Do Not apply any friction minimizing compound to the

driven shaft at or near the shrink disc.

Align the driven shaft with the bore of reducer/gearmotor bore and

carefully slide unit onto the driven shaft.

If the ﬁt is tight, strike on the reducer hollow bore with a mallet to assist in

the assembly.

If using a mallet during installation, strike only against the

unit’s steel hollow bore. Do not strike the reducer housing

or oil seal, damage to the bearings, the housing, and/or the

seals may occur.

Note: If the ﬁt is tight, use a jig such as the one shown in Table 3 to

ease assembly. Sumitomo does not supply a mounting jig. This

information is provided for reference only.

Set the (untightened) shrink disc on the reducer shaft.

Tighten bolts to the correct torque value.

• For 3-piece design shrink disc, make sure that both plates

are parallel when tightening bolts.

• After confirming that the shrink disc is set correctly,

tighten the bolts uniformly, in a clockwise pattern while

keeping both plates parallel (not diagonally or ‘star’

pattern).

• It is recommended to tighten respective bolts by 30

degrees each time – until the specified torque is reached.

For units with a safety cover, reinstall the guard over the shrink disc.

Do not operate unit until the torque arm has been

attached. Refer to the Torque Arm Installation section in

this manual for instructions.

Size Model (Typical) Bolt Bolt Torque

ft-lb (Nm)

4A TAS-3071-55 x 68 10 x M6x25 ISO/JIS grade 10.9 9 (12)

4B TAS-3071-65 x 80 7 x M8x30 ISO/JIS grade 12.9 26 (34)

4C TAS-3071-75 x 100 12 x M8x35 ISO/JIS grade 12.9 26 (34)

4D TAS-3071-85 x 110 9 x M10x40 ISO/JIS grade 12.9 51 (68)

4E TAS-3071-100 x 140 10 x M12x45 ISO/JIS grade 12.9 87 (118)

4F TAS-3071-120 x 165 8 x M16x55 ISO/JIS grade 12.9 214 (290)

Table 4. Shrink Disc Size and Tightening Torque

Degrease

these areas

Apply Molykote 321

to this shaft area only

12 Cyclo® BBB4 Quick Start Guide Quick Start Guide Cyclo® BBB4 13

Turnbuckle Torque Arm Installation

Procedure

Attach the torque arm threaded extension rod to the bevel housing,

at the housing corner eyelet, using the appropriate nut, bolt and

lockwasher.

Insert the bolt through the brackets, torque arm sleeve (if supplied)

and reducer housing eyelet.

Place the lockwasher on the bolt and secure with nut.

Item Description Item Description

1 Hex Nut 7 Lock Washer

2Lock Washer 8 Fulcrum Mounting Bracket

3 Threaded Extension Rod 9 Hex Bolt

4 Turnbuckle 10 Locking Nut (if supplied)

5 Threaded Arm 11 Locking Nut (if supplied)

6 Hex Nut 12 Hex Bolt

BBB4 Size Bolt Size[1] Torque

ft-lb (Nm)

4A M16 x 75 152 - 167 (206 – 227)

4B M20 x 100 290 – 319 (392 – 431)

4C M24 x 105 507 - 558 (686 – 755)

4D M24 x 125 507 - 558 (686 – 755)

4E M24 x 125 507 - 558 (686 – 755)

4F Consult Factory

Note: [1] Bolt ISO/JIS Class 8.8

1011

Table 6. Bolt Tightening Torque

Table 5. Turnbuckle Type Torque Arm Parts

Insert Bolt

Tighten Nut

Figure 1. Turnbuckle Type Torque Arm

Install the turnbuckle onto the threaded extension rod (gearbox side)

and then threaded arm (foundation side) to the turnbuckle.

If the assembly was supplied with hex nuts to secure the turnbuckle,

install the nuts loosely, ensuring the left hand nut is used on the

threaded arm, prior to installing the turnbuckle and threaded arm.

Position the torque arm so

it will be in tension during

unit operation and mount

the fulcrum mounting

bracket to suitable

structure or foundation.

Mounting hardware for

fulcrum mounting bracket

are NOT supplied by

Sumitomo.

Position the torque arm as close as possible to 90° relative to the unit

output bore / driven equipment shaft.

Sumitomo does not recommend the use of multiple torque arm

assemblies to achieve a greater overall length.

14 Cyclo® BBB4 Quick Start Guide Quick Start Guide Cyclo® BBB4 15

Assemble the threaded arm to the fulcrum mounting bracket,

as shown. Some adjustment of the turnbuckle may be required

to lengthen or shorten the overall length. Secure it with the

appropriate nut, bolt and lockwasher.

• Insert the bolt through the brackets and threaded arm

eyelet.

• Place the lockwasher on the bolt and secure with nut.

If turnbuckle hex nuts were supplied, secure the turnbuckle position

by adjusting the previously installed turnbuckle nuts.

BBB4 Size Bracket

Bolt Size[1]

Torque

ft-lb (Nm)

4A M16 x 65 152 - 167 (206 – 227)

4B M16 x 80 152 - 167 (206 – 227)

4C M16 x 80 152 - 167 (206 – 227)

4D M16 x 80 152 - 167 (206 – 227)

4E M16 x 80 152 - 167 (206 – 227)

4F Consult Factory

Table 7. Bolt Tightening Torque

BBB4 Size Nut Size[1] Torque

ft-lb (Nm)

4A M20 290 – 319 (392 – 431)

4B M24 507 - 558 (686 – 755)

4C M24 507 - 558 (686 – 755)

4D M24 507 - 558 (686 – 755)

4E M24 507 - 558 (686 – 755)

4F Consult Factory

Table 8. Nut Tightening Torque

Note: [1] Bolt ISO/JIS Class 8.8

Mounting

Bracket

Bolt

Threaded Arm

Lock Washer

Nut

Tie Rod Torque Arm Installation

Procedure

Assemble the torque arm mounting brackets or wishbone clevis to

the threaded arm, and attach the torque arm assembly to the bevel

housing, at the housing corner eyelet, using the pin and cotter pin.

Tighten mounting bolts according to the values listed in Table10.

• Insert the clevis pin through the brackets and housing

eyelet.

• Insert the cotter pin into clevis pin and secure assembly.

Item Description Item Description

1Flat Washer 7 Rubber Bushing

2 (2) Mounting Brackets or (1) Clevis 8 Washers

3 Hex Bolt 9 Lock Washer

4 Spacer 10 Clevis Pin

5 Threaded Arm 11 Cotter Pin

6 Hex Hut

BBB4 Size Bracket

Bolt Size[1]

Torque

ft-lb (Nm)

4A 2 x M16 152 – 167 (206 – 227)

4B 2 x M20 290 – 319 (392 – 431)

4C 2 x M24 507 – 558 (686 – 755)

4D 2 x M24 507 – 558 (686 – 755)

4E 2 x M24 507 – 558 (686 – 755)

4F Consult Factory

Table 10. Bracket Bolt Tightening Torque

Note: [1] Bolt ISO/JIS Class 8.8

123

56 6

Table 9. Tie Rod Type Torque Arm Parts

Figure 2. Tie Rod Type Torque Arm

16 Cyclo® BBB4 Quick Start Guide Quick Start Guide Cyclo® BBB4 17

Position the torque arm so it will be in tension during unit operation.

Position the torque arm as close as possible to 90° relative to the unit

output bore / driven equipment shaft.

Sumitomo does not recommend the use of multiple torque

arm assemblies to achieve a greater overall length.

After inserting the torque rod into the mounting surface, carefully

tighten nuts on either side of torque rod.

Do not over tighten nuts. Tighten to point where rubber

bushings can still be hand rotated when the unit is turned

off.

Before starting unit, verify the following:

• The torque arm will be in tension when the unit is in

operation.

• The torque arm is aligned with the reducer housing.

• The torque arm is perpendicular to the axis of the

output / driven shaft.

• The threaded arm is not touching the reducer housing.

Customer

Mounting

Surface

Bushing are free to

rotate by hand

T-Type Torque Arm Installation

Procedure

Attach the T-Type Torque Arm Bracket to the Cyclo® BBB4 using the supplied

mounting hardware.

Tighten mounting bolts according to the values listed in Table 11.

Place washer and rubber bushing on bolt.

Insert torque arm bolt (supplied by customer) through mounting tab

on Banjo torque arm.

Make sure bolt is parallel toT-Type Torque Arm side

when fully installed.

Follow these steps to attach the mounting angle bracket:

• Place rubber bushing and mounting angle bracket on

the bolt.

• Verify that the mounting angle bracket hole is the correct

diameter for customer supplied bolt.

• Place remaining bushing, washer and two nuts on

the bolt.

Do not over-tighten nuts. Tighten to point where rubber

bushings can still be hand rotated.

Torque Arm

Bracket

Mounting Bolts

BBB4 Size Bracket

Bolt Size[1]

Torque

ft-lb (Nm)

4A 2 x M16 152 – 167 (206 – 227)

4B 2 x M20 290 – 319 (392 – 431)

4C 2 x M24 507 – 558 (686 – 755)

4D 2 x M30 1014 – 1115 (1373 – 1510)

4E 2 x M30 1014 – 1115 (1373 – 1510)

4F T-Type Not Available

Note: [1] Bolt ISO/JIS Class 8.8

Table 11. T-Bracket Bolt Torques

Washer

Rubber Bushing

When installed,

bolt must be

parallel to this

surface

Washer

Rubber Bushings

Mounting Angle

Bracket

(Customer

Supplied)

Nuts

(Customer Supplied)

Unit Size Bracket Tab Bore Typical Bolt Size [1]

4A Ø18mm M16

4B Ø18mm M16

4C Ø22mm M20

4D Ø26mm M24

4E Ø33mm M30

Note [1]Bolt class should be greater or equal to ISO/JIS Class 8.8. Application with

multiple start/stops and/or shock loading should use ISO/JIS 10.9 at a minimum.

Table 12. T-Bracket Mount Dimensions

CW LSS

Unit Rotation

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