Sumitomo Cyclo BBB4 User manual

Cyclo® BBB4 Bevel Buddybox®
Right Angle Spiral Bevel Gearbox
with Cyclo® Reducer Input
Operation and
Maintenance
Manual
Manual 13.604.60.005

Operation & Maintenance Manual 1
Cyclo® BBB4
Cyclo® BBB4
Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection Upon Delivery . . . . . . . . . . . . . . . . . . . . . .3
Nameplate Inspection . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubrication Inspection . . . . . . . . . . . . . . . . . . . . . . . . 3
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Storing and Transporting . . . . . . . . . . . . . . . . . . . . . . 6
Storage Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Storage Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operation After Storage . . . . . . . . . . . . . . . . . . . . . . .6
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation Precautions. . . . . . . . . . . . . . . . . . . . . . . . 7
Installation Location. . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Severe Loading Conditions . . . . . . . . . . . . . . . . . . . . . 7
Installation onto the Driven Machine . . . . . . . . . . . . . . . 7
Installation onto Driven Shaft . . . . . . . . . . . . . . . . . . . 8
Taper-Grip® Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . 8
Keyed Hollow Bore. . . . . . . . . . . . . . . . . . . . . . . . . . 12
Shrink Disc Type Hollow Bore . . . . . . . . . . . . . . . . . . . 13
Torque Arm Installation . . . . . . . . . . . . . . . . . . . . . . 16
Torque Arm Introduction . . . . . . . . . . . . . . . . . . . . . . 16
Turnbuckle Type Torque Arm . . . . . . . . . . . . . . . . . . . 16
Tie Rod Type Torque Arm . . . . . . . . . . . . . . . . . . . . . . 18
Flange Mount (Banjo) Type Torque Arm. . . . . . . . . . . . . 20
T-Type Torque Arm. . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal from Driven Shaft . . . . . . . . . . . . . . . . . . . . 24
Cyclo® BBB4 with Taper-Grip® Bushing . . . . . . . . . . . . . 24
Cyclo® BBB4 with Keyed Hollow Bore . . . . . . . . . . . . . . 25
Cyclo® BBB4 with Shrink Disc . . . . . . . . . . . . . . . . . . . 26
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Taconite Seal Lubrication Procedure . . . . . . . . . . . . . . . 27
Lubrication Introduction . . . . . . . . . . . . . . . . . . . . . . 29
Lubrication Nomenclature . . . . . . . . . . . . . . . . . . . . . 29
Lubrication Method . . . . . . . . . . . . . . . . . . . . . . . . . 30
Bevel Gear Portion and Cyclo® Portion Recommended Oils . 31
Cyclo® Portion Recommended Greases . . . . . . . . . . . . . 31
Oil Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Oil Supply Procedure . . . . . . . . . . . . . . . . . . . . . . . . 33
Oil Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . 33
Grease Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Grease Replenishment and Draining Procedures . . . . . . . 35
Grease Replacement . . . . . . . . . . . . . . . . . . . . . . . . 35
Y2 Oil Fill & Drain Procedures . . . . . . . . . . . . . . . . . . . 36
Motor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Measuring Insulation Resistance . . . . . . . . . . . . . . . . . 40
Motor Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table of Contents
Motor Wiring Method . . . . . . . . . . . . . . . . . . . . . . . . 41
Brake Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Varistor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 42
U.S. Standard and CSA Approved Motor Brake Wiring . . . . 43
Models FB-01A through FB-15B/FB-15E with Inverter . . . . 44
CE Motor Brake Wiring . . . . . . . . . . . . . . . . . . . . . . . 45
CE Motors Models FB-8B/FB-8E through FB-15B/FB-5E . . . 46
Brake Rectifiers and Power Modules . . . . . . . . . . . . . . . 47
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cyclo® BBB4 Reducer Parts . . . . . . . . . . . . . . . . . . . . . 48
Cyclo® Planetary Reduction Component Parts
(Cyclo® Ratios 11 – 18:1). . . . . . . . . . . . . . . . . . . . 49
Cyclo® Reduction Component Parts
(Cyclo® Ratios ≥ 19:1) . . . . . . . . . . . . . . . . . . . . . 50
Bearings and Oil Seals. . . . . . . . . . . . . . . . . . . . . . . . 52
Bevel Gearing Parts and Tooth Count . . . . . . . . . . . . . . 53
Cyclo® BBB4 Screw Conveyor Options. . . . . . . . . . . . . . 54
Screw Conveyor Components . . . . . . . . . . . . . . . . . . . 54
Screw Conveyor Assembly Instructions . . . . . . . . . . . . . 54
Cyclo® Portion Disassembly/Assembly . . . . . . . . . . . . . 57
Cyclo® Portion - General Disassembly . . . . . . . . . . . . . . 57
Cyclo® Portion - General Reassembly . . . . . . . . . . . . . . 61
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Cyclo® BBB4
2Operation & Maintenance Manual Cyclo® BBB4
Important Notes
Safety Symbols
These safety symbols appear throughout this manual to indicate
important warnings:
DANGER: Incorrect handling of the unit and/or
failure to follow the instructions may cause physical
damage, serious personal injury, and/or death.
CAUTION: Incorrect handling of the unit and/or
failure to follow the instructions may cause physical
damage and/or personal injury.
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
making this manual easily accessible for reference at the machine
location.
• Only properly trained personnel should
transport, install, align, wire, inspect, operate, and
maintain the unit.
• Whentheunitistobeusedinasystemfor
transport of human beings, a secondary safety
device should be installed to guard against
accidents that may result in injury, death, or
damage to the system.
• Whentheunitistobeusedforanelevator,installa
safety device on the elevator side to prevent it from
falling; otherwise, serious injury, death, or damage
to the elevator may result.
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o-lineimmediatelyanddo
not resume operation until properly repaired.
• Modicationsoralterationsofanykindtotheunit
will void the warranty and all subsequent claims.
• Donotremovetheratingplate.
Disposal
Please refer to local, state, and federal regulations governing
disposal of:
Steel Scrap:
• Housing(DuctileandGrayCastIron)
• Gears
• Shafts
• Bearings
Lubricants:
• GearOil
• Grease

Operation & Maintenance Manual 3
Cyclo® BBB4
Cyclo® BBB4
Delivery
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 personal 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.
Nameplate Inspection
When contacting Sumitomo 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.
Lubrication Inspection
• 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 in this manual for detailed
lubrication information.
Nominal
Reduction
Ratio
Unit Model
Number
Unit Serial
Number
Non-Metallic Nameplate
(whenCycloinputis613orlarger)
Nominal
Reduction
Ratio
Unit Serial
Number
Unit Model
Number
Non-Metallic Nameplate
(whenCycloInputis6120orsmaller)
Nominal
Reduction
Ratio
Unit Serial
Number
Unit Model
Number
Metal Reducer Nameplate
Metal Gearmotor Nameplate
Unit Serial
Number
Unit Model
Number Nominal
Reduction
Ratio

Cyclo® BBB4
Type Prefix
Unit built with special mods S
Shrink Disc S
No special mods applied
Cyclo® BBB4
4Operation & Maintenance Manual4Operation & Maintenance Manual
Type of Input Reducer
Prefix
Gearmotor
Prefix
Gearmotor M
Free Input Shaft
w/ Input Adaptor J JM
w/Quill Adaptor X XM
Nomenclature
Nomenclature
Motor Power
(applies only to
1750 RPM)
Modification
Output Shaft Orientation
Frame Size
Shaft Specifications
AGMA Class
Brake(GearmotorOnly)
Input Connection
Mounting Style
Modification (Special feature) Mounting position and optional specification
Input connection Gearmotor or Reducer Specification
Mounting style AGMA class (Gearmotor only)
Output shaft orientation Shaft specification
Cyclo® BBB4 product code (always “L”)
Motor Power
Symbol (1750 RPM)
Frame Size Brake Ratio
HP (kW) Symbol
1/8 (0.1) 01
1/4 (0.2) 02
1/3 (0.25) 03
1/2 (0.4) 05
3/4 (0.55) 08
1(0.75) 1
1.5 (1.1) 1H
2(1.5) 2
3(2.2) 3
5(3.7) 5
7.5 (5.5) 8
10 (7.5) 10
15 (11) 15
20 (15) 20
25 (18.5) 25
30 (22) 30
40 (30) 40
50 (37) 50
60 (45) 60
75 (55) 75
Single Reduction
4A100 4B125 4C170 4E175
4A105 4B140 4C175 4E180
4A110 4B145 4D160 4E185
4A115 4B160 4D165 4E190
4A120 4B165 4D170 4E195
4A125 4C140 4D175 4F180
4A140 4C145 4D180 4F185
4A145 4C160 4D185 4F190
4B120 4C165 4E170 4F195
Double Reduction
4A10DA 4B16DA 4C17DC 4E17DC
4A12DA 4B16DB 4D16DA 4E18DA
4A12DB 4B16DC 4D16DB 4E18DB
4A14DA 4C14DA 4D16DC 4E19DA
4A14DB 4C14DB 4D17DA 4E19DB
4A14DC 4C14DC 4D17DB 4F18DA
4B12DA 4C16DA 4D17DC 4F18DB
4B12DB 4C16DB 4D18DA 4F19DA
4B14DA 4C16DC 4D18DB 4F19DB
4B14DB 4C17DA 4E17DA
4B14DC 4C17DB 4E17DB
Type Prefix
Horizontal H
Vertical V
Vertical Up (Solid Shaft) W
Type Prefix
Shaft Mount (Hollow Shaft) Y
Housing U
Flange (Solid Shaft) F
Foot (Solid Shaft) H
Input
Shaft
Hollow Output
Shaft Suffix
mm Key (mm)
Inch Key (Inch) K
mm Taper-Grip® M
Inch Taper-Grip® Y
Class Suffix
I A
II B
III C
Suffix
With Brake B
No Brake
LHYMS5 - 4A125 YY1 - B -- 28
Output shaft direction (shafted model only)
B
Our nomenclature details specific information about our products. Verify that the nomenclature of the unit delivered matches your order.
(as required)

Operation & Maintenance Manual 5
Cyclo® BBB4
Cyclo® BBB4
Nomenclature, continued
Gearmotor Specification Reducer Specification
Mounting Positions
Nomenclature Example:
LHYMS5-4A125YB-Y1-B-28
L- Cyclo® Bevel Buddybox
H- Horizontal
Y- Shaft Mount (Hollow Shaft)
M- Gearmotor
S- Special Modifications
5 - 5 HP (3.7kW), 1750 RPM
4A125 - Frame Size
Y- Inch Shaft Specification
B- AGMA Class
Y1 - Mounting Position
B- Brake (gearmotor only)
28 - Ratio
Specification Suffix
Three-Phase Motor
Single-Phase Motor SG
AF Motor (Adj. Frequency) AV
Servo Motor SV
DC Motor DV
Torque Limiter TL
Premium Efficient
Three-Phase Motor EP
Type Suffix
Standard
Baseplate BP
Shovel Base SB
DC Motor DV
Nominal and Exact Ratio
Y6
Y5
Y3 Y4Y2
Y1
Projects to Left Side L
Projects to Right Side R
Projects to Both Left/Right Sides T
Output Shaft Direction(shaftedmodelonly)
Y6
Y5
Y3
Y4
Y2Y1
Y6
Y5
Y3 Y4
Y2
Y1
Y6
Y5
Y3
Y4Y2Y1
Y6
Y5
Y3 Y4Y2Y1
Y6
Y5Y3 Y4Y2Y1
BBB with Planetary Input
Nominal Ratio Frame
Size
Exact
Ratio
Input Overall
3 11
4A10 10.50
4A12
4A14 10.89
4B14
4B16
10.85
4C16
4D16
4D17
4E17
4E18 10.50
4F18
4E19 10.82
4F19
4
13
4A10 12.99
4A12 12.80
4A14 12.95
4B14
4B16
12.804C16
4D16
4D17
13.09
4E17
4E18
4F18
4E19 13.01
4F19
14
4A10 14.21
4A12 14.00
4A14 14.16
4B14
4B16
14.004C16
4D16
4D17
14.32
4E17
4E18
4F18
4E19 14.23
4F19
5
16
4A10 15.36
4A12 15.65
4A14 16.00
4B14
4B16
16.264C16
4D16
4D17 16.17
4E17
4E18 15.63
4F18
4E19 15.47
4F19
18
4A10 16.80
4A12 17.12
4A14 17.50
4B14
4B16
17.784C16
4D16
4D17 17.68
4E17
4E18 17.10
4F18
4E19 16.92
4F19
BBB with Cyclo Input
Single Reduction
Nominal Ratio Frame
Size
Exact
Ratio
Input Overall
6 21
All
21.0
722 22.4
25 24.5
8 28 28.0
11 35 35.2
39 38.5
13 46 45.5
15 53 52.5
17 60 59.5
21 67 67.2
74 73.5
25 80 80.0
88 87.5
29 102 101.5
35 112 112.0
123 122.5
43 151 150.5
51 179 178.5
59 207 206.5
71 249 248.5
87 305 304.5
119 417 4A10 416.5
Double Reduction
Nominal Ratio Frame
Size
Exact
Ratio
Input Overall
104 364
All
364.0
121 424 423.5
143 501 500.5
165 578 577.5
195 683 682.5
231 809 808.5
273 956 955.5
319 1117 1116.5
377 1320 1319.5
473 1656 1655.5
559 1957 1956.5
649 2272 2271.5
731 2559 2558.5
841 2944 2943.5
1003 3511 3510.5
1247 4365 4364.5
1479 5177 5176.5
1849 6472 6471.5
2065 7228 7227.5
2537 8880 8879.5
3045 10658 10657.5
3481 12184 12183.5
4437 15530 15529.5
5133 17966 17965.5
6177 21620 21619.5
7569 26492 26491.5

Cyclo® BBB4
6Operation & Maintenance Manual Cyclo® BBB4
Storing and Transporting
Storage Location
• Storetheunitinaclean,dryarea.
• Do not store outdoors or in an area with high humidity, dust,
sudden temperature changes, or corrosive gases.
Generally, the Cyclo® BBB4 gearbox is to be stored indoors, in an
ordinary factory or a warehouse. The unit should be sealed,
wrapped in plastic and additionally packed with desiccant.
Desiccant should be replaced periodically to keep the inside
of the box dry. Use of color changing desiccant will aid in
identifying when desiccant should be changed.
Storage Period
• Do not store the unit for longer than 3 months without
following long-term storage procedures recommended by
Sumitomo.
• ConsultSumitomowhenstoringtheunitformorethan3
months. Rust proofing procedures are required.
• ConsultSumitomowhenexportingtheunit.Rustproong
procedures may be required.
If the Cyclo® BBB4 gearbox will be inactive for a long period of
time, long-term storage preparation is required to prevent rust
or other degradation to the gearbox.
LONG-TERM STORAGE SPECIFIED WITH ORDER:
If long-term storage is specified at the time of order entry, Shell
VSI Circulating Oil #32 or NP-20 [JIS] equivalent rust preventative
is already sprayed into the Cyclo® BBB4 reducer and the air vent is
replaced with a sealing plug before shipping the reducer from
Sumitomo factory. External machined surfaces are coated with a
suitable NP-19 [JIS] petroleum base corrosion preventative such
as Black Bear Par-Al-Ketone, Houghton Rust Veto 342, Daphne
Ever Coat No.1 or equivalent.
Consult Sumitomo for Long Term Storage procedures:
• Storagewithoutfactorypreparations
• Ongoingmaintenanceduringstorageperiod
Operation After Storage
Before operating the unit after an extended storage period, flush
unit of rust preventative and 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.
Transporting
• Do not stand directly under a unit suspended by a
lifting mechanism. Injury or death may occur if the
unit is dropped.
• Before lifting the unit, determine its weight (refer
to catalog, packing list, etc.) and ensure that the
moving equipment will support the unit’s weight.
• Never hoist or move a unit that exceeds the
moving equipment’s rated capacity or else
personal injury and/or equipment damage may
occur.
• Do not allow the unit to drop or fall while moving.
Always use the eye bolts attached to the gear
housing (and on motor if supplied) when moving
the unit. After securing the unit to the machine,
remove the moving hooks/straps from the eyebolts.

Operation & Maintenance Manual 7
Cyclo® BBB4
Cyclo® BBB4
Installation Notes
Installation Precautions
• Donotusethereducer/gearmotorforspecications
other than those shown on the nameplate or in the
manufacturing specification documents. Personal
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aect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
the eye-bolt need to be removed 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
Ambient Conditions....................14°F minimum
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.
Torque arm clearance with machine structure is required to allow
for machine shaft run out. Refer to the Torque Arm Installation
section in this manual for additional information.
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 8.8 (or greater).
Installation onto the Driven Machine
• Beforecouplingthereducer/gearmotortothe
machine, verify the appropriate/desired rotation of
themachine.Dierencesintherotationaldirection
may cause personal injury and/or equipment dam-
age.
• 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.
• Whenjoiningthereducerorgearmotortotheload,
ensure that the center alignment, belt tension, and/
or parallelism of the coupling device are within the
coupling manufacturer’s established recommendations.
For applications with a belt, ensure that the belt is
properly tensioned to the manufacturer’s specification,
and the bolts securing the pulley and couplings
are sufficiently tightened. Failure to follow these
precautions may result in personal injury and/or
equipment damage.

8Operation & Maintenance Manual
Cyclo® BBB4
Cyclo® BBB4
Installation onto Driven Shaft
Taper-Grip® Bushing
Taper-Grip® Bushing Introduction
The keyless Taper-Grip® bushing system provides a simple and reliable shaft attachment
for Sumitomo speed reducers and gearmotors. This system allows bi-directional shaft
rotation operation with a powerful, slip-free grip. To assure peak performance of your
equipment, please read, understand and follow these installation instructions.
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.
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.
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.
Components of Taper-Grip® Bushing
As shown in the figure on the left, the Taper-Grip® bushing includes the bushing,
thrust collar, and socket head cap screws.
Table 1. Driven Shaft Tolerance [1]andMinimumShaftEngagement(TT)
Taper-Grip® Bushing Installation onto Driven
Shaft
1
Remove bushing cover if unit was supplied with one.
Taper-Grip® Bushing
Socket Head Cap Screws
Thrust Collar
TT
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 (mm) TT(in)
4A (208) 8.19
4B (242) 9.53
4C (279) 10.98
4D (326) 12.83
4E (359) 14.13
4F (412) 16.22
Shaft Diameter (mm)Tolerance (μm)
(30 - 50) (+0 / -39)
(50 - 80) (+0 / -46)
(80 - 120) (+0 / -54)
(120 - 180) (+0 / -63)
Note: [1] Based on ISO/JIS/DIN h8

Cyclo® BBB4
Operation & Maintenance Manual 9
Cyclo® BBB4
Installation onto Driven Shaft, continued
Taper-Grip® Bushing
Clean Driven
Shaft
2
Loosen socket head cap screws.
3
Remove (unscrew) Taper-Grip® bushing from the unit.
4
Clean all grease, oil and/or anti-seize paste from the driven shaft. Failure to do so
could result in damage to shaft.
Slide Taper-Grip® bushing onto driven shaft.
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.

10 Operation & Maintenance Manual
Cyclo® BBB4
Cyclo® BBB4
Installation onto Driven Shaft, continued
Taper-Grip® Bushing
Apply thin layer of
anti-seize paste to male
threads of bushing only.
Do not apply anti-seize
paste to the female
threads in the hub.
6
Remove Taper-Grip® bushing from driven shaft.
7
Apply a thin layer of anti-seize paste to the male threads of the Taper-Grip®
bushing only.
Ensure that the anti-seize paste does not enter the Taper-Grip®
bushing bore.
Do not apply anti-seize paste to the female threads in the hub.
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 paste to the driven shaft or the
bushing bore before placing the unit onto driven shaft. Use of these friction-
minimizingproductswilladverselyaect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 to the desired location.
Do not rock or pry the unit.

Cyclo® BBB4
Operation & Maintenance Manual 11
Cyclo® BBB4
Installation onto Driven Shaft, continued
Taper-Grip® Bushing
Bushing
Flange
Feeler Gauge
Thrust Collar
1
64
2
5
3
Apply grease
to exposed
portion of
driven shaft.
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.
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.
Table 2. Taper-Grip® Bushing Bolt Tightening 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.
Cyclo® BBB4 Size Screw Qty x Size
Screw Torque
lb•ft (N•m)
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)

12 Operation & Maintenance Manual
Cyclo® BBB4
Cyclo® BBB4
Installation onto Driven Shaft, continued
Keyed Hollow Bore
Keyed Hollow Bore Installation
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.
CAUTION: The Cyclo® BBB4 must be externally supported prior to insertion of driven shaft into hollow bore.
Bore and Shaft Tolerance Specifications
•Unlessotherwisespecied,thetoleranceoftheHollowShaftBoreconformstoJISH8.
•Ifapplicationinvolveshighshockloadingand/orlargeradialloads,ashafttoleranceofJISjs6orJISk6isrecommended.
Anti-sieze
compound
Keyed Hollow Bore Installation
onto Driven Shaft
1
Apply anti seize compound to the driven shaft surface and inside the reducer keyed
hollow bore.
2
Align the driven shaft with the reducer/gearmotor bore and carefully slide unit onto
the driven shaft to the desired location.
If the fit is tight, strike on the keyed hollow bore with a wooden or hard rubber
mallet to assist in the assembly.
If using a mallet during installation, strike only against the unit’s steel keyed
hollow bore. Do not strike the reducer housing or oil seal as damage to the
bearings, housing and/or 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.

3
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 to the left, 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 section in this manual for instructions.
Cyclo® BBB4
Operation & Maintenance Manual 13
Cyclo® BBB4
Installation onto Driven Shaft, continued
Keyed Hollow Bore, Shrink Disc Type Hollow Bore
Size a b c d e
CC(ISO/JIS) A2 Bearing Nut Threaded Rod
4A 55 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(mm)
Spacer b
Retaining Ring a
Ball
Bearing
c
Threaded Rod e Nut d
A2
Shrink Disc Type Mounting Introduction
The keyless Shrink Disc provides a reliable commodity shaft attachment for Sumitomo speed reducers and gearmotors. This system allows
bi-directional shaft rotation operation with a powerful, slip-free grip.
To assure peak performance of your equipment, please read, understand and follow these installation instructions.
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.
CAUTION: The Cyclo® BBB4 must be externally supported prior to insertion of driven shaft into hollow bore. External support
MUST be maintained until all shrink disc socket head cap screws have been tightened to the appropriate operational torque.
Bore and Shaft Tolerance Specifications
• RefertothecertiedoutlinedrawingorCyclo®BBB4Catalogforrecommendedmachineshaftdimensions.
• Unlessotherwisespecied,thetoleranceoftheShrinkDiscBoreconformstoJISH8.
• Ifapplicationinvolveshighshockloadingand/orlargeradialloads,ashafttoleranceofJISjs6orJISk6isrecommended.

14 Operation & Maintenance Manual
Cyclo® BBB4
Cyclo® BBB4
Size Model
(Typical) Bolt Bolt Torque
lb•ft (N•m)
4A TAS-3071-55x68 10 x M6x25
ISO/JIS grade 10.9 9(12)
4B TAS-3071-65x80 7 x M8x30
ISO/JIS grade 12.9 26 (34)
4C TAS-3071-75x100 12 x M8x35
ISO/JIS grade 12.9 26 (34)
4D TAS-3071-85x110 9 x M10x40
ISO/JIS grade 12.9 51 (68)
4E TAS-3071-100x140 10 x M12x45
ISO/JIS grade 12.9 87 (118)
4F TAS-3071-120x165 8 x M16x55
ISO/JIS grade 12.9 214 (290)
Table 4. Shrink Disc Bolt Tightening Torques
2
Align the driven shaft with the bore of reducer/gearmotor bore and carefully slide
unit onto the driven shaft to the desired location.
•Ifthet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, as damage to
the bearings, housing, and/or seals may occur.
If the fit is tight, use a jig such as the one shown in the Keyed Hollow Bore
Installation section to ease assembly. Sumitomo does not supply a
mounting jig. This information is provided for reference only.
Installation onto Driven Shaft, continued
Shrink Disc Type Hollow Bore
1
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 shoulder
opposite from the shrink disc.
Do Not apply any friction minimizing compound to the driven shaft at or
near the shrink disc.
Degrease
these areas
Apply Molykote 321
to this shaft area only
Shrink Disc Type Hollow Bore Installation onto Shaft
Before placing unit onto driven shaft, do not apply grease, oil, or anti-seize paste to the entire driven shaft or to the bore of
the shrink disc. Useofthesefriction-minimizingproductswilladverselyaect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.

Cyclo® BBB4
Operation & Maintenance Manual 15
Cyclo® BBB4
Installation onto Driven Shaft, continued
Shrink Disc Type Hollow Bore
3
• Setthe(untightened)shrinkdisconthereducershaft.
5
For units with a safety cover, install 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.
4
Tighten Bolts to the correct torque value.
• For3-piecedesignshrinkdisc,makesurethatbothplatesareparallelwhen
tightening bolts.
• Afterconrming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.

16 Operation & Maintenance Manual
Cyclo® BBB4
Cyclo® BBB4
16 Operation & Maintenance Manual
Cyclo® BBB4
Cyclo® BBB4
Torque Arm Introduction
A torque arm is a device used to prevent counter-rotation of the shaft mounted
reducer/gearmotor during operation.
The torque arm must be mounted in tension when torque arm
mounting point is greater than 6 inches (150mm) from machine
mounting point or, tie-rod or turn buckle type torque arm is used.
Torque Arm Installation
Torque Arm Introduction, Turnbuckle Type Torque Arm
1
Attach the torque arm threaded extension rod to the bevel housing, as shown
in Figure 1, 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.
Unit
Size Bolt Size[1] ft•lbf(N•m)
A M16 x 75 152 – 167 (206 – 227)
B M20 x 100 290 – 319 (392 – 431)
C M24 x 105 507 – 558 (686 – 755)
D M24 x 125 507 – 558 (686 – 755)
E M24 x 125 507 – 558 (686 – 755)
F Consult Factory
Table 6. Bolt Tightening Torques
Note: [1] Bolt Class equal to ISO/JIS Class 8.8
Turnbuckle Type Torque Arm Parts
Item Number Description Item Number Description
1 Hex Nut 7 Locke 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 Bolt 12 Hex Bolt
Table 5. Turnbuckle Type Torque Arm Parts
Insert Bolt
Tighten Nut
1 2 3 4 5 6 7
12 9
1011 8
Figure 1. Turnbuckle Rod Type Torque Arm Parts

Cyclo® BBB4
Operation & Maintenance Manual 17
Cyclo® BBB4
Cyclo® BBB4
Operation & Maintenance Manual 17
Cyclo® BBB4
Torque Arm Installation, continued
Turnbuckle Type Torque Arm
2
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
3
Position the torque arm so it will be in tension during unit operation and mount the
fulcrum mounting bracket to suitable structure or foundation. Consider installing
two torque arms for reversing applications to allow torque arm to be in tension for
each direction of rotation.
Mounting hardware for fulcrum mounting bracket are NOT supplied by Sumitomo.
4
Position the torque arm as close as possible to 90° relative to the unit output bore /
driven equipment shaft.
Sumitomo does not recommend combining torque arm assemblies to achieve a
greater overall length.
5
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.
OPTIMUM MOUNTING
ACCEPTABLE MOUNTING
Threaded Arm
Bolt
Nut
Lock Washer
Mounting Bracket
Unit
Size Bolt Size[1] ft•lbf(N•m)
A M16 x 65 152 – 167 (206 – 227)
B M16 x 80 152 – 167 (206 – 227)
C M16 x 80 152 – 167 (206 – 227)
D M16 x 80 152 – 167 (206 – 227)
E M16 x 80 152 – 167 (206 – 227)
F Consult Factory
Table 7. Bolt Tightening Torques
Note: [1] Bolt Class equal to ISO/JIS Class 8.8
90
30
30
15
15

18 Operation & Maintenance Manual
Cyclo® BBB4
Cyclo® BBB4
Torque Arm Installation, continued
Turnbuckle Type Torque Arm, Tie Rod Type Torque Arm
6
If turnbuckle hex nuts were supplied, secure the turnbuckle position by adjusting
the previously installed turnbuckle nuts.
Unit
Size Nut Size[1] ft•lbf(N•m)
A M20 290 – 319 (392 – 431)
B M24 507 – 558 (686 – 755)
C M24 507 – 558 (686 – 755)
D M24 507 – 558 (686 – 755)
E M24 507 – 558 (686 – 755)
F Consult Factory
Table 8. Nut Tightening Torques
Note: [1] Bolt Class equal to ISO/JIS Class 8.8
Tie Rod Type Torque Arm Parts
Item Number Description Item Number Description
1Flat Washer 7 Rubber Bushings
2 (2) Mounting Brckts or (1) Clevis 8 Washers
3 Hex Bolt 9 Lock Washer
4 Spacer 10 Clevis Pin
5 Threaded Arm 11 Cotter Pin
6 Hex Nut
Table 9. Tie Rod Type Torque Arm Parts
1
Assemble the torque arm mounting brackets or wishbone clevis to the threaded
arm, as shown in Figure 1 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 this table:
•Insert the clevis pin through the brackets and housing eyelet.
•Insert the cotter pin into clevis pin and secure assembly.
BBB4 Size Bracket
Bolt Size[1]
Torque
lb•ft (N•m)
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. Bolt Tightening Torques
Note: [1] Bolt Class equal to ISO/JIS Class 8.8
1
Figure 1. Tie Rod Type Torque Arm Parts
2 3
4 5 6 6
7
11
2
10 9 6
8

Cyclo® BBB4
Operation & Maintenance Manual 19
Cyclo® BBB4
Torque Arm Installation, continued
Tie Rod Type Torque Arm
2
Position the torque arm so it will be in tension during unit operation.
Consider installing two torque arms for reversing applications to allow torque arm to
be in tension for each direction of rotation.
3
Position the torque arm as close as possible to 90° relative to the unit output bore /
driven equipment shaft.
Sumitomo does not recommend combining torque arm assemblies to achieve a
greater overall length.
4
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o.
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.
UNIT ROTATION
OPTIMUM MOUNTING
ACCEPTABLE MOUNTING
Customer
Mounting
Surface
Bushings are free
to rotate by hand
90
30
30
15
15