Sumitomo Cyclo BBB5 User manual

Cyclo® BBB5 Bevel Buddybox®
Right Angle Spiral Bevel Speed Reducer
with Cyclo® or Planetary Input
Operation and
Maintenance
Manual
13.605.60.006 BBB5 O&M 2019

Operation & Maintenance Manual 1
Cyclo® BBB5
Cyclo® BBB5
Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection Upon Delivery . . . . . . . . . . . . . . . . . . . . . . 3
Nameplate Inspection . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubrication Inspection . . . . . . . . . . . . . . . . . . . . . . . . 3
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Storage 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
Keyed Hollow Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shrink Disc Type Hollow Bore . . . . . . . . . . . . . . . . . . . . 9
Torque Arm Installation . . . . . . . . . . . . . . . . . . . . . . 11
Torque Arm Introduction . . . . . . . . . . . . . . . . . . . . . . 11
Flange Mount (Banjo) Type Torque Arm . . . . . . . . . . . . 11
Removal from Driven Shaft . . . . . . . . . . . . . . . . . . . . 13
Removal of Cyclo® BBB5 with Keyed Hollow Bore. . . . . . . 13
Removal of Cyclo® BBB5 with Shrink Disc. . . . . . . . . . . . 14
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lubrication Introduction . . . . . . . . . . . . . . . . . . . . . . 15
Lubrication Nomenclature . . . . . . . . . . . . . . . . . . . . . 15
Lubrication Method . . . . . . . . . . . . . . . . . . . . . . . . . 16
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . 17
Lubrication Quantities . . . . . . . . . . . . . . . . . . . . . . . 18
Oil Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil Supply Procedures. . . . . . . . . . . . . . . . . . . . . . . . 19
Oil Discharge Procedures. . . . . . . . . . . . . . . . . . . . . . 19
Grease Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Grease Replenishment and Draining Procedures . . . . . . . 21
Grease Replacement . . . . . . . . . . . . . . . . . . . . . . . . 21
Y2 Oil Fill & Drain Procedures . . . . . . . . . . . . . . . . . . . 22
Motor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Measuring Insulation Resistance . . . . . . . . . . . . . . . . . 26
Motor Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Motor Wiring Method . . . . . . . . . . . . . . . . . . . . . . . . 27
Brake Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Varistor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 28
U.S. Standard and CSA Approved Motor Brake Wiring . . . . 29
CE Motor Brake Wiring . . . . . . . . . . . . . . . . . . . . . . . 31
CE Motor Brake Wiring with Inverter. . . . . . . . . . . . . . . 33
Brake Rectifiers and Power Modules . . . . . . . . . . . . . . . 35
Table of Contents
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cyclo® BBB5 Reducer . . . . . . . . . . . . . . . . . . . . . . . . 36
Cyclo® Planetary Reduction Component Parts
(Cyclo® Ratio 11 – 18:1) . . . . . . . . . . . . . . . . . . . . 37
Cyclo® Planetary Reduction Component Parts
(Cyclo® Ratio ≥ 19:1) . . . . . . . . . . . . . . . . . . . . . . 38
Reducer Component Parts . . . . . . . . . . . . . . . . . . . . . 39
Bearings and Oil Seals. . . . . . . . . . . . . . . . . . . . . . . . 40
Bevel Gearing Parts Tooth Count. . . . . . . . . . . . . . . . . 41
Cyclo® Portion Disassembly/Assembly . . . . . . . . . . . . . 42
Cyclo® Portion - General Disassembly . . . . . . . . . . . . . . 42
Cyclo® Portion - General Reassembly . . . . . . . . . . . . . . 46
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Reducer Troubleshooting . . . . . . . . . . . . . . . . . . . . . 48
Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 49

Cyclo® BBB5
2Operation & Maintenance Manual Cyclo® BBB5
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® BBB5 operation
• 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 personal 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.”
• 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.
Disposal
Please refer to local, state, and federal regulations governing
disposal of:
Steel Scrap:
• Housing (Aluminum and/or Gray Cast Iron)
• Gears
• Shafts
• Bearings
Lubricants:
• Gear Oil
• Grease

Operation & Maintenance Manual 3
Cyclo® BBB5
Cyclo® BBB5
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 the order.
Using the incorrect product may cause equipment
damage or personal injury.
• Do not remove the nameplate from the 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
• notify the shipping company immediately any damage is
found. Do not install or operate a damaged unit.
• all bolts and nuts are fully tightened.
Please consult a Sumitomo representative, distributor, or sales
office if any defects are found or if there any questions.
Nameplate Inspection
When contacting Sumitomo’s 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.
Lubrication Inspection
• Oil lubricated units are shipped without oil,
unless the customer specied 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 lled 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
Unit Serial
Number
Unit Model
Number
Nominal
Reduction
Ratio
Metal Nameplate Tesa® Nameplate
Non-Metallic Nameplate
(when Cyclo Input is 6120 or smaller)
Nominal
Reduction
Ratio
Unit Serial
Number
Unit Model
Number
Metal Gearmotor Nameplate
Unit Serial
Number
Unit Model
Number Nominal
Reduction
Ratio

Cyclo® BBB5
Type Prefix
Unit built with special modifications
S
Shrink Disc S
No special modifications applied
Type of Input Reducer
Prefix
Gearmotor
Prefix
Gearmotor M
Free Input Shaft
w/ Input Adapter J JM
w/Quill Adapter 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 (as required)
Input connection Gearmotor or Reducer Specification
Mounting style AGMA class (Gearmotor only)
Output shaft orientation Shaft specification
Cyclo® BBB5 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
5Z100 5A110 5B120 5C140
5Z105 5A115 5B125 5C145
5Z110 5A120 5B140 5C160
5Z115 5A125 5B145 5C165
5Z120 5A140 5B160 5C170
5Z125 5A145 5B165 5C175
Double Reduction
5Z10DA 5A12DA 5B12DA 5C14DA
5Z12DA 5A12DB 5B12DB 5C14DB
5Z12DB 5B14DA 5C14DC
5B14DB 5C16DA
5C16DB
Type Prefix
Horizontal H
Vertical V
Type Prefix
Flange (Hollow Shaft) F
Housing Mount (Hollow Shaft) U
Shaft Mount (Hollow Shaft) Y
Input
Shaft
Hollow Output
Shaft Suffix
mm Key (mm)
Inch Key (Inch) K Class Suffix
I A
II B
III C
Suffix
With Brake B
No Brake
LHYMS2 - 5Z100 KY1 - B -- 28
B
Cyclo® BBB5
4Operation & Maintenance Manual4Operation & Maintenance Manual
The nomenclature details specific information about Sumitomo products. Verify that the nomenclature of the unit delivered matches the
order.

Operation & Maintenance Manual 5
Cyclo® BBB5
Cyclo® BBB5
Gearmotor Specification Reducer Specification
Mounting Positions
Nomenclature Example:
LHYMS2-5Z100-KB-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
5Z100 - Frame Size
K- Inch Shaft Specification
B- AGMA Class
Y1 - Mounting Position
B- Brake (gearmotor only)
28 - Ratio
Type Suffix
Standard
Shovel Base SB
DC Motor DV
Nominal and Exact Ratio
Nomenclature continued
Y1 Y2
Y3 Y4
Y5 Y6
BBB with Planetary Input
Nominal BBB Frame
Size Exact Ratio
Input
Ratio Overall Ratio
3 11
5Z10
10.50
5Z11
5Z12
5A11
5A12
5B12
5B16 10.85
5C16
5C17 10.86
5A14
10.895B14
5C14
4
13
5Z11
12.80
5Z12
5A11
5A12
5B12
5B16
5C16
5A14
12.955B14
5C14
5Z10 12.99
5C17 13.09
14
5Z11
14.00
5Z12
5A11
5A12
5B12
5B16
5C16
5A14
14.165B14
5C14
5Z10 14.21
5C17 14.32
5
16
5Z10 15.36
5Z12
15.655A12
5B12
5Z11 15.89
5A11
5A14
16.005B14
5C14
5C17 16.17
5B16 16.26
5C16
18
5Z10 16.80
5Z12
17.125A12
5B12
5Z11 17.38
5A11
5A14
17.505B14
5C14
5C17 17.68
5B16
17.785C16
5B14
5B16 17.78
5C16
BBB with Cyclo Input
Nominal BBB Frame
Size Exact Ratio
Input
Ratio Overall Ratio
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
Double Reduction
Nominal BBB Frame
Size Exact Ratio
Input
Ratio Overall Ratio
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
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

Cyclo® BBB5
6Operation & Maintenance Manual Cyclo® BBB5
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® BBB5 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. Rustproofing procedures are required.
• Consult Sumitomo when exporting the unit. Rustproong
procedures may be required.
If the Cyclo® BBB5 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® BBB5 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
contact a 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® BBB5
Cyclo® BBB5
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 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
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
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 with a torque arm or similar
means to limit housing rotation.
NOTE: 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 a 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 mounting the reducer/gearmotor to the
machine, verify the appropriate/desired rotation of the
machine. Differences in the rotational direction may
cause personal 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.
• When mounting the reducer or gearmotor to the
driven shaft of the machine or conveyor, ensure that
the torque arm is properly tensioned, and the bolts
securing the torque arm are sufficiently tightened.
Failure to follow these precautions may result in
personal injury and/or equipment damage.

8Operation & Maintenance Manual
Cyclo® BBB5
Cyclo® BBB5
Installation onto Driven Shaft
Keyed Hollow Bore
Keyed Hollow Bore Introduction
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 of this manual.
CAUTION: The Cyclo® BBB5 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.
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 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.
If the fit is tight, use a jig such as the one shown in Table 1 to ease assembly.
Sumitomo does not supply a mounting jig. This information is
provided for reference only.
Grease
Size
a b c d e
CC (ISO/JIS) A2 Bearing Nut Threaded Rod
5Z 45 25 51104 M16 M16 x 250
5A 55 25 51104 M16 M16 x 250
5B 65 25 51105 M20 M20 x 300
5C 75 35 51105 M20 M20 x 300
Table 1. Jig Dimensions (mm)
Spacer b
Retaining Ring a
Ball
Bearing
c
Threaded Rod e Nut d
A2

Cyclo® BBB5
Operation & Maintenance Manual 9
Cyclo® BBB5
Installation onto Driven Shaft
Keyed Hollow Bore, Shrink Disc Type Hollow Bore
Retaining Ring a
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.
Degrease
these areas
Apply Molykote 321
to this shaft area only
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 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® BBB5 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® BBB5 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.
Shrink Disc Type Hollow Bore Installation onto Driven 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.
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.

10 Operation & Maintenance Manual
Cyclo® BBB5
Cyclo® BBB5
Installation onto Driven Shaft
Shrink Disc Type Hollow Bore
2
Align the driven shaft with the bore of the reducer/gearmotor and carefully slide unit
onto the driven shaft to desired location.
If the fit is tight, strike on the reducer 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 hollow
bore. Do not strike the reducer housing or oil seal
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.
Shrink Disc Bolt Tightening Torques
Size Model
(Typical) Bolt Bolt Torque
(lb•ft) (Nm)
5Z TAS-3071-45x55 8 x M6X25 ISO/JIS
grade 10.9 9(12)
5A TAS-3071-55x68 10 x M6x25
ISO/JIS grade 10.9 9(12)
5B TAS-3071-65x80 7 x M8x30
ISO/JIS grade 12.9 26 (34)
5C TAS-3071-75x100 12 x M8x35
ISO/JIS grade 12.9 26 (34)
Table 2. Shrink Disc Bolt Tightening Torques
3
• Set the (untightened) shrink disc on the reducer shaft.
• 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.
4
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.

Cyclo® BBB5
Operation & Maintenance Manual 11
Cyclo® BBB5
Sumitomo Supplied Components of Flange Mount (Banjo) Type Torque Arm
Torque Arm Installation
Torque Arm Introduction, Flange Mount (Banjo) Torque Arm
Item Number Description
1 Torque Arm Bracket
2 Bracket Hardware
3 Rubber Bushing (quantity 3)
4 Washer (quantity 2)
Table 3. Torque Arm Components
1
Attach the torque arm bracket to the Cyclo® BBB5 using mounting hardware.
Table 4. Flange Mount (Banjo) Type Torque Arm Bolt Tightening
Unit Size Bracket
Bolt Size[1]
Torque
lb•ft (N•m)
5Z 8 x M8 17 – 19 (24 – 26)
5A 8 x M10 34 – 38 (46 – 51)
5B 8 x M12 59 – 65 (80 – 88)
5C 8 x M16 152 – 167 (206 – 227)
Note: 1Bolt ISO/JIS Class 8.8
Torque Arm
Bracket
Bracket
Mounting
Bolt(s)
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 a tie-rod or turn buckle type torque arm is used. Turnbuckle or tie-rod type shown below for reference:
Figure 1. Turnbuckle or Tie-Rod Type Schematics
Flange Mount (Banjo) Type Torque Arm Installation Procedure
2
43
1

12 Operation & Maintenance Manual
Cyclo® BBB5
Cyclo® BBB5
Torque Arm Installation
Flange Mount (Banjo) Torque Arm
Torque Arm
Bolt
(Customer
Supplied)
2
Place washer and rubber bushing on bolt.
Insert torque arm bolt (supplied by customer) through mounting tab on Flange
Mount (Banjo) type torque arm.
Make sure bolt is parallel to Banjo type torque arm side surface when fully
installed
3
Follow these steps to attach the torque arm to
mounting structure or mounting angle
bracket (customer supplied):
• Verify that the mounting structure or
mounting angle bracket hole is the
correct diameter (refer to Table 5).
• Place rubber bushing and mounting
angle bracket on bolt.
• Ensure the bolt passes through mounting
structure or mounting angle bracket hole.
• 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.
4
Confirm that the rubber bushings can still be rotated by hand. This indicates the
bushing has not been over tightened.
Compressed bushings will not allow the bushings to properly absorb the
loads of the shaft mounted gearbox. This can lead to premature failure.
Mounting Angle Bracket must be secured to the machine structure.
Rubber
Bushing
Washer
When installed,
bolt must be
parallel to this
surface
Mounting
Structure or
Angle Bracket
(Customer
Supplied) Washer
Rubber Bushings
Nuts
(Customer
Supplied)
Washer
Table 5. Flange Mount Torque
Arm Bolt Dimensions
Unit Size Bracket Tab
Bore
Typical Bolt
Size[1]
5Z Ø18mm M16
5A Ø18mm M16
5B Ø22mm M20
5C Ø26mm M24
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.
During full rotation of driven shaft, there must be no
metal-to-metal contact between mounting angle bracket
and torque arm.
5
Confirm the mounting angle bracket
does not interfere with the torque
arm. There should be no metal-to-metal
contact between the two during a
complete revolution of the driven
equipment.
Metal-to-Metal contact
between these two
components may lead to
catastrophic failure of the
reducer/gearmotor.
Bushings are free to rotate by hand

Removal of Cyclo® BBB5 with Keyed Hollow Bore
Before starting unit removal process, ensure that electrical power to unit
has been safely locked out and that electrical connections to the unit have
been disconnected.
1
Externally support the Cyclo® BBB5 unit such that all unit weight is removed from the
driven shaft.
The weight of the Cyclo® BBB5 must be externally supported throughout the
entire removal process.
Do not raise the unit too high. Shaft binding may occur.
2
Remove the safety cover and the shaft-retaining device from the driven shaft.
3
Apply a liquid penetrant to the shaft where it contacts the keyed hollow bore.
Allow time for the liquid to penetrate between the shaft and the wall of the keyed
hollow bore.
4
Once the penetrant has settled adequately, carefully remove the Cyclo® BBB5 from the
driven shaft.
If shaft removal is difficult, a jig such as the one shown in Table 6 may be used
to ease the removal process. Sumitomo does not supply the removal jig.
This information is supplied for reference only.
Cyclo® BBB5
Operation & Maintenance Manual 13
Cyclo® BBB5
Removal from Driven Shaft
Removal of Cyclo® BBB5 with Keyed Hollow Bore

14 Operation & Maintenance Manual
Cyclo® BBB5
Cyclo® BBB5
Removal from Driven Shaft
Removal of Cyclo® BBB5 with Keyed Hollow Bore, Removal of Cyclo® BBB5 with Shrink Disc
Table 6: Removal Jig Dimensions
Internal Snap Ring a
Spacer: Threaded f
Bolt
g
Thrust Disc h
A3
A8
Removal of Cyclo® BBB5 with Shrink Disc
Before starting unit removal process, ensure that electrical power to unit has
been safely locked out and that electrical connections to the unit have been
disconnected.
1
Externally support the Cyclo® BBB5 unit such that all unit weight is removed from the
driven shaft.
The weight of the Cyclo® BBB5 must be externally supported throughout the
entire removal process.
Do not raise the unit too high. Shaft binding may occur.
2
If required, remove the safety cover and apply liquid penetrant to the shrink disc
bolts and shaft/bore allowing adequate time for proper penetration.
Loosen the locking bolts on the shrink disc. Complete bolt removal should not be
required.
Tapping the shrink disc flanges with a wooden or hard rubber mallet may be
required if any fretting corrosion has occurred.
3
Remove the gearbox from the shaft.
If shaft removal is difficult, a jig such as the one shown in the Keyed Hollow Bore
section may be used to ease the removal process: Sumitomo does not supply the
removal jig. This information is supplied for reference only.
Size a f g h
CC (ISO/JIS) A3 BOLT A8
5Z 45 19 M24×250 5
5A 55 19 M24×250 5
5B 65 19 M24×300 5
5C 75 19 M24×300 5
Loosen Locking Bolts

Cyclo® BBB5
Operation & Maintenance Manual 15
Cyclo® BBB5
Lubrication
Lubrication Introduction, Lubrication Nomenclature
Lubrication Introduction
Sumitomo Cyclo® BBB5s are shipped from the factory without lubricating oil, unless the customer specified otherwise when the
unit was ordered.
The unit must contain the correct type and amount of lubrication before operating.
For all Y4 motor down mounting configuration models, the Cyclo® portion is filled at the factory with grease. For these units,
the Cyclo® portion does not need to be filled with lubricant before start-up. The Bevel Gear portion of models built for the Y4
mounting configuration requires filling with gear oil before start-up. Refer to the Lubrication Method section for details.
For the Cyclo® BBB5 built for the Y4 mounting configuration, the Cyclo® and the bevel gear portions must be filled with lubricant
separately and maintained separately. Lubricant does not flow from one portion to the other.
Lubrication Nomenclature
Refer to the Model portion of the unit’s nameplate to determine the unit size, reduction ratio, and mounting configuration:
Reduction Ratio (Nominal)
Unit Mounting Configuration
LHYJ-5A100 K-Y1-21
Cyclo® Size
Separate
Lubrication
Bevel Gear Portion
Cyclo® Portion
Cyclo®BBB5 in Y4 Assembly
Bevel Gear Size
Series

16 Operation & Maintenance Manual
Cyclo® BBB5
Cyclo® BBB5
Lubrication Method
Using the model number and mounting configuration, refer to Tables 7 and 8 to determine the unit’s lubrication method.
Table 7. Lubrication Method for Congurations Y1, Y2, Y3, Y5, Y6
Mounting Configuration
Unit Size
Lubrication Method
Bevel
Gear Size Cyclo® Size
5Z – 5C
100, 105,
110, 115,
120, 125,
140, 145
160, 165,
170. 175,
10DA, 12DA,
12DB, 14DA,
14DB, 14DC,
16DA
Complete Unit
(Bevel Gear Portion
and Cyclo®)
Common Oil Sump
Table 8. Lubrication Method for Y4 Configuration
Mounting Configuration
Unit Size
Lubrication Method
Bevel
Gear Size Cyclo® Size
5Z – 5A
100, 105,
110, 115,
120, 125,
10DA, 12DA, 12DB
Cyclo® Portion Maintenance Free
Grease[1]
Bevel Gear Portion Oil
5A – 5C
140, 145,
160, 165,
170, 175
12DA, 12DB ,
14DA, 14DB, 14DC,
16DA
Cyclo® Portion Grease[2]
Bevel Gear Portion Oil
Notes: [1] Maintenance Free Grease: the input Cyclo® portion is grease lubricated as standard from the factory and usually does not require replacement or replenishment.
[2] Grease: the input Cyclo® portion is grease lubricated as standard from the factory. Please refer to Tables 12 and 13 for the proper grease replenishment and change interval.
Lubrication, continued
Lubrication Method
Y4
Y5
Y6
Y1
Y2
Y3

Lubrication, continued
Recommended Lubricants
Bevel Gear Portion and Cyclo® Portion Lubricants
Recommended Oils
Table 9, Recommended Oils, lists the oils that may be used to lubricate the Bevel Gear portion of the unit. These oils may also be used in the
Cyclo® portion if it is oil lubricated.
Table 10. Recommended Oil Viscosity
Minimum allowable viscosity 15 cSt (mm2/s) or more at operating temperature Viscosity that ensures oil film strength
adequate for load transmission.
Maximum allowable viscosity 4300 cSt (mm2/s) max. Viscosity that permits start-up of
Buddybox®
• Consult local distributor, nearest authorized agent or Sumitomo directly when the unit will be operated in ambient temperatures other
than 14° – 104°F (-10°– 40°C). Special unit modifications may be necessary.
Cyclo® Portion Approved Greases
Table 11, Cyclo® Portion Approved Greases, lists the greases that may be used to lubricate the Cyclo® portion if grease is the specified
lubrication method (refer to the Lubrication Method section for details).
Table 11. Cyclo® Portion Approved Greases
Ambient Temp.
°F (C)
Overall
Reduction Ratio All Unit Sizes
14° – 122°F
(-10º – 50ºC)
11:1 through 18:1 Shell Gadus S2 V220 NLGI 00
19:1 and higher ExxonMobil Unirex N2 grease
Cyclo® portions have unique operating characteristics that require specific lubricant properties. Please consult Sumitomo if alternate
lubricants are required.
Operation & Maintenance Manual 17
Cyclo® BBB5
Cyclo® BBB5
ExxonMobil:
ExxonMobil:
ExxonMobil:
Food Grade Oil:
Kluber:
Idemitsu Oil:
BP Oil:
Total:
Shell Oil:
Caltex:
Castrol:
Gulf Oil:
Spartan EP
Mobilgear 600XP
Mobil SHC Gear Hi-Shock 150
Klübersynth UH1 6-460
Kluberoil GEM1
Daphane Mechanic
Energol GR-XP
Carter EP
Omala S2 G
Meropa
Alpha SP
EP Lubricant HD
°F 14 32 50 68 86 104 122
°C -10 0 10 20 30 40 50
ISO VG
68
(14 °F to 41 °F)
100/150
(32 °F to 95 °F)
220/320/460
(86 °F to 122 °F)
Table 9. Recommended Oils
• Use lubricants with low viscosity for operation during winter or at relatively low temperatures.
• Use lubricant with a viscosity within the range listed in Table 10, Recommended Oil Viscosity.

18 Operation & Maintenance Manual
Cyclo® BBB5
Cyclo® BBB5
Lubrication, continued
Oil Quantities
Oil Quantities
Table 12. Single Reduction Approximate Oil Quantity
Units: U.S. liquid gallon (liter) Note: Output = Bevel Gear Portion Input = Cyclo®
Bevel Gear
Unit Size
Mounting Configuration
Output Input
5Z10 0.21 (0.80) 0.42 (1.58) 0.18
(0.67) Grease
0.17 (0.66) 0.24 (0.90)
5Z11 0.22 (0.85) 0.44 (1.65) 0.19 (0.71) 0.25 (0.95)
5Z12 0.25 (0.93) 0.47 (1.79) 0.21 (0.79) 0.27 (1.03)
5A11 0.42 (1.59) 0.81 (3.05) 0.22
(0.83) Grease
0.36 (1.35) 0.49 (1.85)
5A12 0.44 (1.68) 0.85 (3.23) 0.38 (1.44) 0.51 (1.94)
5A14 0.50 (1.90) 0.95 (3.58) 0.44 (1.66) 0.57 (2.16)
5B12 0.70 (2.66) 1.37 (5.17) 0.42
(1.60) Grease
0.60 (2.29) 0.81 (3.06)
5B14 0.76 (2.86) 1.46 (5.52) 0.66 (2.49) 0.86 (3.26)
5B16 0.88 (3.33) 1.63 (6.17) 0.78 (2.96) 0.99 (3.73)
5C14 1.41 (5.35) 2.84 (10.74) 0.93
(3.53) Grease
1.33 (5.05) 1.50 (5.66)
5C16 1.61 (6.08) 3.07 (11.62) 1.53 (5.78) 1.69 (6.39)
5C17 1.72 (6.52) 3.20 (12.13) 1.64 (6.22) 1.80 (6.83)
Table 13. Double Reduction Approximate Oil Quantity
Units: U.S. liquid gallon (liter) Note: Output = Bevel Gear Portion Input = Cyclo®
Bevel Gear
Unit Size
Mounting Configuration
Output Input
5Z10DA 0.24 (0.89) 0.42 (1.60) 0.18
(0.70) Grease
0.24 (0.91) 0.26 (1.00)
5Z12DA 0.24 (0.89) 0.47 (1.78) 0.29 (1.10) 0.29 (1.10)
5Z12DB 0.26 (0.99) 0.47 (1.78) 0.29 (1.11) 0.29 (1.10)
5A12DA 0.44 (1.68) 0.85 (3.23) 0.22
(0.83) Grease 0.38 (1.44) 0.54 (2.04)
5A12DB 0.47 (1.78) 0.85 (3.23) 0.38 (1.44) 0.54 (2.04)
5B12DA 0.70 (2.66) 1.37 (5.17)
0.42
(1.60) Grease
0.63 (2.39) 0.83 (3.16)
5B12DB 0.73 (2.76) 1.39 (5.27) 0.63 (2.39) 0.83 (3.16)
5B14DA 0.76 (2.86) 1.46 (5.52) 0.68 (2.59) 0.89 (3.36)
5B14DB 0.78 (2.96) 1.46 (5.52) 0.68 (2.59) 0.89 (3.36)
5C14DA 1.44 (5.45) 2.86 (10.84)
0.93
(3.53) Grease
1.33 (5.05) 1.50 (5.66)
5C14DB 1.44 (5.45) 2.86 (10.84) 1.36 (5.15) 1.50 (5.66)
5C14DC 1.44 (5.45) 2.89 (10.94) 1.36 (5.15) 1.52 (5.76)
5C16DA 1.61 (6.08) 3.07 (11.62) 1.55 (5.88) 1.71 (6.49)
5C16DB 1.63 (6.18) 3.1 (11.72) 1.58 (5.98) 1.71 (6.49)
Y5 Y6
Y1 Y2
Y3 Y4
Y5 Y6
Y1 Y2
Y3 Y4

Note: Units supplied with Mobil SHC Gear Hi-Shock 150 may double the oil change intervals.