Sumitomo Cyclo BBB4 Quick Start Manual
Quick Start Guide
Manual 13.604.61.002 March 2016
Cyclo® BBB4
Bevel Buddybox®
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 22
Quick Start Guide Cyclo® BBB4 1
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 reference 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
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.
Quick Start Guide Cyclo® BBB4 3
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, hightemperature 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 highstrength mounting bolts of Grade 10.9 (or greater).
4 Cyclo® BBB4 Quick Start Guide
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 (TT)
TT
Taper-Grip® Bushing
Socket Head Cap Screws
Thrust Collar
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.
External
Support
Quick Start Guide Cyclo® BBB4 5
1
Remove bushing cover if unit was supplied with one.
2
Loosen socket head cap screws.
3
Remove (unscrew) Taper-Grip® bushing from the unit.
4
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.
Clean Driven
Shaft
6 Cyclo® BBB4 Quick Start Guide
5
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.
6
Remove Taper-Grip® bushing from driven shaft.
7
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.
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.
Quick Start Guide Cyclo® BBB4 7
8
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.
9
Mount or slide the Cyclo® BBB4 onto the driven shaft
Do not rock or pry the unit.
10
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.
Feeler Gauge
Bushing
Flange
Thrust Collar
8 Cyclo® BBB4 Quick Start Guide
11
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.
12
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.
13
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).
14
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.
1
2
3
4
5
6
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
Loading...