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TSM-Shaft MountOperating and Maintenance Manual

THEAVAILABLESOLUTION,WORLDWIDE.

Manual

07.001.60.001

FPO

CONTENTS

2

Mounting Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Installation of Taper-Grip® SMSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Belt Drive and Torque Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Parts Identification and Parts Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Bearings and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Backstops Sizes A to S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Backstops Sizes K, L, and M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Removing the Reducer from the Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

MOUNTING SPECIFICATIONS

Shaft dia. Tolerance3⁄4˝ - 1 1⁄8˝ + 0 - .005˝

13⁄16˝ - 2˝ + 0 - .006˝

21⁄16˝ - 31⁄8˝ + 0 - .007˝

33⁄16˝ - 43⁄4˝ + 0 - .008˝

413⁄16˝ - 61⁄2˝ + 0 - .009˝

Table 1 - Permissible Shaft Tolerance

Size Screw Size & Qty.Screw Torque

(lb. ft.) Nm

103-B 6 x M10 x 20 23 31

107-C 6 x M10 x 20 23 31

115-D 6 x M10 x 20 23 31

203-E 6 x M12 x 20 37.6 51

207-E 6 x M12 x 20 37.6 51

215-G 6 x M16 x 25 94 128

307-H 6 x M20 x 30 181 245

315-J 6 x M20 x 30 181 245

407-S 6 x M20 x 30 181 245

415-K 10 x M20 x 30 181 245

507-L 10 x M20 x 30 181 245

608-M 12 x M20 x 30 181 245

Table 2 - Bushing Screw Tightening Torques

Unit Sizes Inch Sizes Min. Bore**

103-B 13⁄16 13⁄16

107-C 17⁄16 13⁄16

115-D 115⁄16 17⁄16

203-E 23⁄16 111⁄16

207-F 27⁄16 115⁄16

215-G 215⁄16 23⁄16

307-H 37⁄16 27⁄16

315-J 315⁄16 215⁄16

407-S 47⁄16 37⁄16

415-K 415⁄16 315⁄16

507-L 57⁄16 47⁄16

608-M 61⁄2 57⁄16

Table 3 - Stock Bushing Bores

Inch ToleranceMetric Tolerance*(mm) (mm)

13⁄16 - 11⁄8 +.003 / .000 40 - 50 .064 /.025

13⁄16 - 31⁄8 +.003 / .001 50 - 65 .076 / .030

33⁄16 - 411⁄16 +.004 / .001 65 - 80 .076 / .030

43⁄4 - 57⁄16 +.005 / .001 80 - 100 .090 / .036

51⁄2 - 61⁄2 +.005/.001 120 - 180 .106 / .043

Table 4 - Bushing Bores Tolerances

* Metric Tolerances are F8.

Note: Shaft runout TIR should be no greater than .001˝.

** Min. Bore is also stock but needs slitting.

3

0 1 3 0

INCH BORE CODE

103 13⁄16

107 17⁄16

115 115⁄16

203 23⁄16

207 27⁄16

215 215⁄16

307 37⁄16

315 315⁄16

407 47⁄16

415 415⁄16

507 57⁄16

608 61⁄2

SIZEB

C

D

E

F

G

H

J

S

K

L

M

BORE SIZE

OUTPUT SPECIFICATION

5 = Taper-Grip® (standard)1 = Standard metric straight bore2 = Alternative metric straight bore4 = Inch straight bore

NOMENCLATURE

Bushing

Reducer

RATIO

05

14

25

CODE NUMBER/SIZE

103 B

107 C

115 D

203 E

207 F

215 G

307 H

315 J

407 S

415 K

507 L

608 M

ASSEMBLY AND INPUT SHAFTSPECIFICATION

0 = Standard metric

1 = Standard inch

2 = Flange mount metric

3 = Flange mount inch

4

INSTALLATION OF TAPER-GRIP® SMSR

Fig. 1

Fig. 2

Fig. 3

The SMSR Taper-Grip® bushing is designed to giveeasy on, easy off fit to the shaft for assembly andmaintenance while giving a firm grip to the shaft duringoperation. The Taper-Grip® bushing is fitted from theend of the hub; you should insure you have adequateaccess for correct tightening of the screws.

NOTE: Satisfactory performance depends on properinstallation, lubrication and maintenance. Therefore allinstructions on this page and in this manual must befollowed carefully.

Fitting the Reducer on the Shaft

1. Check the size and condition of the shaft to whichthe reducer will be fitted. Permissible shafttolerances are given in Table 1 (Page 2).

2. Ensure all mating surfaces of the hub, the insideand outside diameters of the Taper-Grip® bushingand the shaft are free from burrs and corrosion.Clean each surface with a solvent to remove alltraces of grease and oil.

3. Lightly oil each screw and insert into the bushingflange; ensure they do not protrude beyond therear face.

4. Insert the face keys of the thrust collar into theslots on hub and center. Screw the Taper-Grip®

bushing into the hub in a clockwise directionuntil the flange contacts the thrust collar. SeeFigure 1.

5. Unscrew the Taper-Grip® bushing until the screwsare aligned with the pockets in the face of thethrust collar and a gap of 1 mm minimum existsbetween the flange and thrust collar. This may beeasier if one of the screws are removed and thepocket viewed through the threaded hole. Fingertighten all screws into the pocket. See Figure 2.

6. Slide the reducer onto the shaft at least as far asthe counter bore in the Taper-Grip® bushing. Besure that bushing and shaft are aligned andgearbox weight is supported for correct mountingalignment. Gradually tighten each screw in a starpattern to the torque levels shown in Table 2(Page 2). A torque wrench is required.

CAUTION: Slippage of the Taper-Grip® bushing canbe avoided by proper shaft and bushing selection andcorrect pretensioning of the bushing locking screws.If repeated slippage occurs, bushing disassemblyand reducer removal may be difficult.

7. Grease fill the cavity between the bushingcounterbore and shaft to prevent a build-up ofcorrosion on the shaft end which may affectsubsequent removal of the reducer. This is to bedone after assembly of the unit.

8. Install the torque arm assembly if one is used. See Installing the Torque Arm.

NOTE: Be sure to use a torque arm or other device toprevent rotation when mounting by shaft only.

9. Install pulley on gearbox input shaft as close to thereducer as possible. See Fig. 3. Failure to do thiswill cause excess loads in the input shaft bearingsand could cause premature failure.

10. After mounting is complete, the SMSR can then befilled with oil. Please follow proper guidelines for oillubrication.

11. After the reducer has been running for 20 to 30hours retorque the screws to the values in Table 2(Page 2) using a torque wrench. Screw torquesshould be checked at normal service intervals(every 6 months).

5

BELT DRIVE AND TORQUE ARMINSTALLATIONInstalling the Motor and Belt DriveInstall the motor and belt drive with the belt pull atapproximately 90° to the centerline between the drivenand input shafts. See Fig. 4. This will permit tensioningof the belt drive with the torque arm, which shouldpreferably be in tension. If the output hub runs counter-clockwise, the torque arm should be positioned to theright. See Fig. 5.

Installing the Torque Arm

1. Remove the cotter pins or nuts (6) from the bolts(5) on the torque arm. See Fig. 5.

2. Insert the bolts through the torque arm clevis,casing (3) and mount (1). Reinstall cotter pins ornuts (6). See Fig. 5.

3. Adjust the length of the torque arm by looseningthe locknuts (4), turning the body of the torque arm(2), and retightening the locknuts (4). See Fig. 5.

4. Install the torque arm mount (1) on a rigid supportso that the torque arm will be at 90°(±30°) to a linebetween the torque arm case bolt and the outputshaft. This ensures the torque arm will be loaded intension. Retighten case bolts to torque loadingsshown in Table 5; recheck torque loading afterrunning for a few days. See Fig. 6.

5. The torque arm should be attached to a firmmounting position with the torque arm mount (1)provided or a suitable substitute. The attachmentpoints at each end of the torque arm (gearcase andbracket) should be on the same plane on centerlinewhen viewed from the side. See Fig. 6.

6. The torque arm should be attached and tightenedwhile maintaining correct gearcase position (top,bottom, side, etc.). The torque arm turnbuckleshould be hand tightened to avoid overtightening.

7. If an audible sound of metal to metal contact isheard upon start-up of the drive it is likely one orboth of the following:

a) Torque arm setting up due to some slack in thelinkage. This is normal.

b) The output gears in the SMSR contacting dueto backlash in the gear set. This is alsonormal.

Note: Whenever possible, the torque arm should beinstalled in tension not in compression.

8. For shaft mounted units the reducer will tend torotate in the direction opposite that of the outputshaft (see arrows). The torque arm will prevent thismotion thus being in tension.

Fig. 4

Fig. 5

Fig. 6

Belt drive may belocated to theright if desired.

Belt drive may belocated in anyconvenient position.If the torque arm is tobe used to tightenthe belts, the driveshould be at about90° to line betweenthe input and outputshafts.

If output hubrotates clockwise,position belt driveand torque arm inopposite directionto that shown inthe illustration.

This angle shouldbe a right anglebut may vary up toa maximum of 30°either way.

Torque arm andbelt take-up.

Torque arm may

be mounted to theright if desired.

Size B C&D E F&G H&J S K L M

lb. ft. 12 22 37 5937

59105 204 354

59* 204* 354* 701*

Nm 16 30 50 8050

80142 277 480

80* 277* 480* 950*

Table 5 - Bolt Torque Loadings

*Torque arm case bolts only.

5 6

6

PARTS IDENTIFICATION & NUMBER – SIZES 103B TO 407S

When ordering parts for reducer, please specify

1 Reducer Size No.

2 Reducer Serial No.

3 Part Name

4 Code Number

5 Quantity Required

Note: Inclusion of a gearbox size in this leaflet doesnot imply availability in all markets.

7

Ref. Description No. 103B 107C 115D 203E 207F 215G 307H 315J 407SNo. Req’d

2 Case R. H. 1 16B6002 16C6002 16D6002 16E6002 16F6002 16G6002 16H6002 16J6002 16S60023 Case L. H. 1 16B6003 16C6003 16D6003 16E6003 16F6003 16G6003 16H6003 16J6003 16S60034 Hollow Dowel 2 16A7004 16C7004 16C7004 16E7004 16F7004 16F7004 16H1004 16H7004 16K70045 Case Bolt See (1) 943702 943830 943831 943840 943850 943851 943841 943842 16S70056 Case Nut See (1) 943810 943811 943811 943812 943813 943813 943812 943812 9438137 Case Plain Washer 4 943820 943821 943821 943822 943823 943823 943822 943822 9438238 Case Lockwasher See (2) 943870 943871 943871 943872 943873 943873 943872 943872 9438739 Input Shaft & Pinion (14:1) 1 16B6130 16C6130 16D6130 16E6130 16F6130 16G6130 16H6130 16J6130 16S61309 Input Shaft & Pinion (25:1) 1 16B6134 16C6134 16D6134 16E6134 16F6134 16G6134 16H6134 16J6134 16S61349 Input Shaft 5:1 B. Stop 1 16B6132 16C6132 16D6132 16E6132 16F6132 16G6132 16H6132 16J6132 16S613210 Input Shaft Oilseal 14:1 & 25:1 1 946043 946301 946302 946443 946303 946304 946305 946022 946320

11A Input Shaft Brg. - Shaft Side 14:1 - 25:1 1 941801 941802 941803 941804 941805 941806 941807 941808 94180911B Input Shaft Brg. - B. Stop 14:1 - 25:1 1 941038 941017 941013 941032 941033 941035 941036 941039 94104111A Input Shaft Brg. - Shaft Side 5:1 1 941801 941802 941803 941804 941805 941806 941807 941808 94180911B Input Shaft Brg. - B. Stop 5:1 1 941038 941017 941013 941032 941033 941035 941036 941039 94104112 Backstop Cover 1 16B7012 16C7012 16D7012 16E7012 16F6012 16G6012 16H6012 16J6012 16S601213 Backstop Cover Gasket 1 16B7013 16C7013 16D7013 16E7013 16F7013 16G7013 16H7013 16J7013 16S701314 Backstop Cover Screw 6 943480 943480 943490 943490 943490 943690 943690 943690 94349015 Backstop Cover Lockwasher 6 943686 943686 943687 943687 943687 943680 943680 943680 94368016 Torque-Arm Case Bolt 2 – – – – – – 943852 943853 –17 Torque-Arm Case Bolt Nut 2 – – – – – – 943813 943813 –18 Torque-Arm Case Bolt Lockwasher 2 – – – – – – 943684 943684 –20 1st. Reduction Gear (14:1) only 1* 16B6101 16C6101 16D6101 16E6101 16F6101 16G6101 16H6101 16J6101 16S610120 1st. Reduction Gear (25:1) only 1* 16B6125 16C6125 16D6125 16E6125 16F6125 16G6125 16H6125 16J6125 16S612521 1st. Reduction Gear Key 1* 16B7021 16C7021 16D7021 16E7021 16F7021 16G7021 16H7021 16J7021 16S702122 Intermediate Pinion (14:1 & 25:1) 1* 16B6022 16C6022 16D6022 16E6022 16F6022 16G6022 16H6022 16J6022 16S602223 Intermediate Pinion Distance Piece 1* 16B6023 16C6023 16D6023 16E6023 16F6023 16G6023 16H6023 16J6023 16S602324 Intermediate Bearing 2* 941038 941017 941013 941032 941033 941035 941036 941039 94104125 Intermediate Cover 2 16B7025 16C7025 16D7025 16E7025 16F7025 16G7025 16G7025 16J7025 16S702526 2nd. Reduction Gear (14:1 & 25:1)

Reduction Gear (5:1) 1 16B6026 16C6026 16D6026 16E6026 16F6026 16G6026 16H6026 16J6026 16S602627 Gear Key 1 16B6027 16C6027 16D6027 16E6027 16F6027 16G6027 16H6027 16J6027 16S6027

27A Gear Key - Taper-Grip® Bushing 1 16B6027 16C6027 16D6127 16E6027 16F6027 16G6127 16H6027 16J6027 16S612728B Output Shaft (Alternate Metric Bore) 1 16B6116 16C6116 16D6116 16E6116 16F6116 16G6116 16H6116 16J6116 16S611628C Output Shaft Taper-Grip® 1 16B6107 16C6107 16D6107 16E6107 16F6107 16G6107 16H6107 16J6107 16S610729 Output Shaft O-Ring 2 944187 944188 944189 944190 944191 944192 – – –30 Output Shaft Spacer 1 16B6030 16C6030 16D6030 16E6030 16F6030 16G6030 16H6030 16J6030 16S603031 Output Shaft Collar 2 16B6031 16C6031 16D6031 16E6031 16F6031 16G6031 16H6031 16J6031 16S603132 Collar Screw (std.) Over Key 1 942614 942700 942700 942711 942711 942711 942721 942722 94272433 Collar Screw (std.) Over Shaft 3 942615 942701 942701 942712 942713 942713 942724 942724 94272532 Collar Screw (alt.) Over Key 1 942614 942700 942700 942710 942710 932711 942721 942721 –33 Collar Screw (alt.) Over Shaft 3 942614 942700 942701 942711 942712 942712 942722 942722 –34 Output Shaft Oilseal 2 946306 946307 946308 946309 946310 946311 946312 946313 94632135 Output Shaft Bearing 2 941350 941351 941352 941353 941354 941355 941356 941357 94135836 Pipe Plug not shown 3 942395 942395 942395 942395 942395 942396 943396 942396 94239637 Breather Plug on drawing 1 946097 946097 946097 946097 946091 946098 946098 946098 94609841 Torque-Arm Rod End 1 16B7041 16C7041 16D7041 16E7041 16F7041 16F7041 16H7041 16H7041 16H704142 Rod End Locknut 1 943812 943812 943813 943813 943815 943815 943816 943816 94381643 Torque-Arm Extension 1 16B7043 16B7043 16D7043 16E7043 16BF7043 16F7043 16H7043 16H7043 16H704344 Extension Locknut 1 943790 943790 943791 943791 943792 943792 943793 943793 94379345 Turn-buckle 1 16B7045 16B7045 16D7045 16E7045 16F7045 16F7045 16H7045 16H7045 16H704546 Fulcrum 1 16B6046 16B6046 16D6046 16D6046 16F6046 16F6046 16H6046 16H6046 16H604647 Fulcrum Bolt 1 943832 943832 943843 943843 943854 943854 943855 943855 94385548 Fulcrum Bolt Nut 1 943811 943811 943812 943812 943813 943813 943813 943813 94381349 Fulcrum Bolt Lockwasher 1 943682 943682 943683 943683 943684 943684 943684 943684 943684

PART NUMBERS FOR INDIVIDUAL PARTS – SIZES 103B TO 407S

**

Notes: (1) 6 required sizes 103B - 215G, 8 required sizes 307H & 315J, 17 required size 407S(2) 6 required sizes 103B - 215G, 10 required sizes 307H & 315J, 17 required size 407S(*) Not required for 5:1 ratio gear units(†) For 5:1 units which may be fitted with a backstop - input shaft bearings are as ref. Nos. 11A & 11B.(**) Not required for Taper-Grip® bushings. The set screws and thrust plate parts are listed separately on

the Taper-Grip® bushing installation leaflet.

†

8

PARTS IDENTIFICATION & NUMBER –SIZES 415K TO 608M

When ordering parts for reducer, please specify

1 Reducer Size No.

2 Reducer Serial No.

3 Part Name

4 Code Number

5 Quantity Required

9

PART NUMBERS FOR INDIVIDUAL PARTS -SIZES 415K TO 608M

Ref. Description No. 415K 507L 608MNo. Req’d

2 Case R. H. 1 16K6002 16L6002 16M60023 Case L. H. 1 16K6003 16L6003 16M60034 Hollow Dowel 2 16K7004 16L7004 16M70045 Case Bolt See (1) 16K7005 16L7005 16M70056 Case Nut See (1) 943813 943815 9438157 Case Plain Washer 4 943823 943825 9438258 Case Lockwasher See (1) 943684 943685 9436859 Input Shaft & Pinion (14:1 only) 1 16K6130 16L6130 16M61309 Input Shaft & Pinion (25:1 only) 1 16K6134 16L6134 16M613410 Input Shaft Oil Seal 1 946307 946308 94631411 Input Shaft Bearing 2 941257 941370 94137312 Backstop Cover 1 16K6012 16L6012 16M601213 Backstop Cover Gasket 1 16K7075 16L7075 16M707514 Backstop Cover Screw 6 943751 943762 94377315 Backsto Cover Lockwasher 6 943682 943683 94368416 Torque Arm Case Bolt 2 16K7016 16L7016 16M701617 Torque Arm Case Bolt Nut 2 943815 943816 94381818 Torque Arm Case Bolt Lockwasher 2 943685 943689 94388020 1st. Reduction Gear (14:1 only) 1 16K6101 16L6101 16M610120 1st. Reduction Gear (25:1 only) 1 16K6125 16L6125 16M612521 1st. Reduction Gear Key 3 16K7021 16L7021 16M702122 Intermediate Pinion (14:1, 25:1) 1 16K6022 16L6022 16M602223 Intermediate Pinion Distance Piece 1 16K6023 16L6023 16M602324 Intermediate Bearing 2 941258 941371 94137325 Intermediate Cover 2 16K6012 16L6012 16M601226 2nd. Reduction Gear 1 16K6026 16L6026 16M602627 2nd. Reduction Gear Key 1 16K6127 16L6127 16M612728 Output Hub - Plain Bore 1 16K6116 16L6116 16M611628 Output Hub - Taper-Grip® 1 16K6107 16L6107 16M610732 Output Hub Collar Screw (over key)** 1 942731 942730 94273033 Output Hub Collar Screw (over shaft)** 3 942732 942734 94273434 Output Hub Oilseal 2 946315 946316 94631735 Output Hub Bearing 2 941259 941372 94137436 Pipe Plug 7 942394 942394 94239437 Breather Plug 1 946093 946093 94609341 Torque Arm Rod End 1 16K7041 16L7041 16M704142 Rod End Locknut 1 943816 943817 94381743 Torque Arm Extension 1 16H7043 16L7043 16L704344 Extension Locknut 1 943793 943794 94379445 Turnbuckle 1 16H7045 16L7045 16L704546 Fulcrum 1 16H6046 16L6046 16L604647 Fulcrum Bolt 1 943855 16L6047 16L604748 Fulcrum Bolt Nut 1 943813 943818 94381849 Fulcrum Bolt Lockwasher 1 943684 943880 94388070 Input Shaft Cover 1 16K6070 16L6070 16M607071 Input & Intermediate Cover Screw 18 943751 943762 94377372 Input & Inter. Cover Screw Lockwasher 18 943682 943683 94368473 Input & Inter. Cover Shim (0.50mm) AR 16K7073 16L7073 16M707374 Input & Inter. Cover Shim (0.25mm) AR 16K7074 16L7074 16M707475 Input & Inter. Cover Shim (0.15mm) AR 16K7075 16L7075 16M707576 Input & Inter. Cover Shim (0.07mm) AR 16K7076 16L7076 16M707677 Input & Inter. Cover Shim (0.05mm) AR 16K7077 16L7077 16M707778 Output Cover 2 16K6078 16L6078 16M607879 Output Cover Screw See (2) 943762 943773 94372380 Output Cover Lockwasher See (2) 943683 943684 94368581 Output Cover Shim (0.50mm) AR 16K7081 16L7081 16M708182 Output Cover Shim (0.25mm) AR 16K7082 16L7082 16M708283 Output Cover Shim (0.15mm) AR 16K7083 16L7083 16M708384 Output Cover Shim (0.07mm) AR 16K7084 16L7084 16M708485 Output Cover Shim (0.05mm) AR 16K7085 16L7085 16M708587 Backstop Housing Dowel 3 16K6087 16L6087 16M608788 Input Bearing Distance Piece 1 16K6088 16L6088 16M608889 Backstop & Bearing Housing 1 16K6089 16L6089 16M608990 ‘O’ Ring 1 946422 946421 94642091 Housing Locking Screw 6 942781 942810 94280192 Housing Locking Screw Lockwasher 6 943682 943683 943684

Notes: (1) 10 required size 415S, 12 required size 507L, 15 required size 608M(2) 12 required sizes 415S & 507L, 16 required size 608M(**) Not supplied on Taper-Grip® bushings

10

LUBRICATION

Shaft Mounted Speed Reducers are shipped withoutoil. Before running they should be filled with anappropriate amount of the correct lubricant as shown inthe tables below. Fill to level plug when reducer is notrunning. Drain, flush and refill every six months of

operation; check oil level regularly. Positions of filter,breather and drain plug for various mounting positionsare shown in Fig. 7. CAUTION: Too much oil will causeoverheating; too little oil will cause gear failure.

Table 6 - Oil Quantities (Quarts)

Mounting1 2 3 4 1 2 3 4Position

103B 3⁄8 1⁄2 1⁄2 1⁄2 1⁄2 1⁄2 1⁄2 1⁄2

107C 1⁄2 3⁄4 5⁄8 3⁄4 5⁄8 3⁄4 5⁄8 1⁄2

115D 7⁄8 15⁄8 11⁄4 13⁄8 11⁄8 11⁄2 11⁄4 1⁄2

203E 17⁄8 21⁄8 2 13⁄4 2 11⁄8 2 1⁄2

207F 21⁄2 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4

215G 31⁄4 45⁄8 35⁄8 41⁄4 31⁄2 41⁄2 31⁄2 5

307H 47⁄8 71⁄2 51⁄2 73⁄8 51⁄4 73⁄4 51⁄2 73⁄4

315J 81⁄8 151⁄4 12 14 10 171⁄4 13 171⁄4

407S 121⁄2 211⁄2 153⁄4 19 151⁄4 211⁄2 26 201⁄2

415K 131⁄2 141⁄2 28 121⁄2

507L 241⁄4 363⁄4 56 291⁄4

608M 39 54 85 49

Approx. Capacity—U.S. quarts

25:1 & 14:1 5:1

Table 7 - Recommended Oil

5:1 RATIO GEARBOX 14 & 25:1 RATIO GEARBOXES

Ambient 0-100 101-200 201-400 0-20 21-50 51-120 0-50 51-80Temp. RPM* RPM* RPM* RPM* RPM* RPM* RPM* RPM*

°F

103B-407S 103B-407S 103B & 107C 115D-407S 103B-407S 103B-115D 203E-407S 103B-115D 203E-407S 415K-608M

14 to 40 100 100 100 68 150 150 150 100 100 100 100

41 to 80 460 320 320 220 680 680 460 460 320 320 220

81 to 105 800 680 680 460 800 800 800 680 460 460 320

UnitSize

I.S.O.Viscosity

Grade

Table 8 - Manufacturers and Types

BP CASTROL MOBIL SHELL TEXACO EXXONENERGOL ALPHAZN MOBILGEAR OMALA MEROPA SPARTAN

GR-XP ORSP & SHC

NOTE: Do not use E.P. mineral oils other than those recommended when using a backstop.

▼ Filler plug ❍ Level plug ❍ Drain plug◗

Units are fitted with filter, level and drainplugs generally in the position shown.

Fig. 7

Normal operating positions are shown in Fig. 7. Notethat the reducer is supplied with four plugs. After thereducer has been mounted in its running position, theplugs must be located as shown in Fig. 7 for theappropriate mounting position.

If the reducer is not within 20° of one of the positionsshown, the oil level plug cannot be safely used tocheck the oil level. This can be overcome by

disconnecting the torque-arm and swinging the reduceraround to one of the positions shown.

Because of the many positions of the reducer, it maybe necessary or desirable to make special adaptationsusing the plug holes in the reducer with standard pipefittings, standpipes or oil level gauges; consult thefactory.

*Output speed.

11

HS HS INTERMED. SSAGMA HS. OIL SS. OIL BALL CYLINDRICAL BALL BALLSIZE

PART NO.SEAL** SEAL** BEARING ROLLER BEARING BEARING

BEARING (DBL. RED. ONLY)

103B Sumitomo P.N. 946043 946306 941038 941801 941038 941350

103B Size D20/40x10 D55/80x10 6303 NJ204EC 6303 6011

107C Sumitomo P.N. 946301 946307 941017 941802 941017 941351

107C Size D24/47x10 D65/90x10 6205 NJ205EC 6205 6013

115D Sumitomo P.N. 946302 946308 941013 941803 941013 941352

115D Size D28/52x10 D75/100x10 6206 NJ206EC 6206 6015

203E Sumitomo P.N. 946044 946309 941032 941804 941032 941353

203E Size D30/62x7 D85/120x10 6306 NJ306EC 6306 6017

207F Sumitomo P.N. 946303 946310 941033 941805 941033 941354

207F Size* 70x34x10 D100/140x12 6307 NJ307EC 6307 6020

215G Sumitomo P.N. 946304 946311 941035 941806 941035 941355

215G Size* 92x44x10 D110/160x12 6309 NJ309EC 6309 6022

307H Sumitomo P.N. 946305 946312 941036 941807 941036 941356

307H Size* 92x49x10 D130/190x12 6310 NJ310EC 6310 6026

315J Sumitomo P.N. 946022 946313 941039 941808 941039 941357

315J Size* 110x57.2x10 210x150x15 6312 NJ312EC 6312 6030

407S Sumitomo P.N. 946320 946321 941041 941809 941041 941358

407S Size* 120x64x13 CR 62940 6313 NJ313EC 6313 6032

BEARINGS & SEALS

Bearing and Seal Part Number Chart

* Oil Seal Size in Millimeters** Oil seals are double lip (dust proof and seal lip) type.

12

BACKSTOPS SIZES A TO S

Spare PartRef. No.

60

61

62

63

64

Description

Backstop Assembly

Backstop Outer Race Key

Backstop Inner Race Key

Backstop Inner Race Circlip

Backstop Spacer Ring

No. Req’d.

1

1

1

1

1

To Install Backstop

If reducer is filled with oil, drain off before proceedingthrough the following steps.

Step 1

Remove backstop cover and gasket (ref. 12 & 13,Fig. 11).

Step 2

Determine direction of required shaft rotation.

Sizes A & B

The shaft is free to rotate in the direction of the arrowmarked on the backstop cage. If the opposite directionof rotation is required, turn the backstop and outerrace end for end. Press assembly into housing.

Sizes C, D, E, F & S

With the chamfered face of the backstop facing you,feed the assembly into the housing. Rotating the shaftin its free direction will assist this process.

If the opposite direction of rotation is required, removethe assembly and rotate the sprag assembly 180˚;reassemble.

When the outer race is fully home, rotate the shaft inits backstopping direction. If the assembly is correct,the outer race will now rotate with the shaft; use this toalign the keyways. Slide in key (ref. 61, Figs. 8-10).

Sizes G, H & J

With the chamfered end of the backstop outer racefacing you, determine the direction of rotation usingthe inner race. If the opposite direction is required,slide out the sprag assembly and replace in outerrace. Check direction of rotation then remove innerrace. Place key(s) into keyway(s) and press inner raceinto shaft; insert circlip (ref. 63, Fig. 10) into groove onshaft. Press outer race and sprag assembly intohousing. Rotating the input shaft in its free directionwill assist this process. When the outer race is fullyhome, rotate the input shaft in its backstoppingdirection. If the assembly is correct, the outer racewill now rotate with the shaft; use this to align thekeyways. Slide the key (ref. 62, Fig. 10).

Step 3

Replace the gasket and cover (ref. 12 & 13, Fig. 11).

Step 4

Refill the reducer with correct grade of oil.

Important

When pressing the backstop into the housing, it isimportant not to hammer the assembly at any time.The assembly may be tapped gently if necessary.

To change the backstopping direction at any time, it isnecessary to remove the sprag assembly and turn itend for end. Two M3 tapped holes are provided toremove the outer race. On size C no holes areprovided. Use two bent pieces of wire to hook andwithdraw the sprag, turn end for end and replace.

Backstops cannot be fitted to 5:1 reducers with taperroller bearings. Any 5:1 unit with a backstop fitted hasball bearings to spares (ref. 11A & 11B, Page 7).

Fig. 8

Fig. 9

Fig. 10Table 9

13

BACKSTOPS SIZES K, L & M

Spare PartRef. No.

14

15

60

61

62

63

Description

Backstop Cover Screw

Backstop Cover Lockwasher

Backstop Assembly

Outer Race Key

Inner Race Key

Inner Race Circlip

No. Req’d.

6

6

1

1

1

1

Step 1

Remove backstop cover (ref. 12, Fig. 11), gasket (ref.13, Fig. 11) and input bearing distance piece (ref. 88,Page 9).

Step 2

Marked on the outer race of the backstop is an arrow.This indicates that the input shaft will rotate freely inthis direction and will lock in the reverse direction. It isimportant to correctly determine the required directionof rotation, since to reverse the direction after thebackstop has been installed, it is necessary to removeit, turn it end for end and re-install it. Match the freearrow on backstop to direction of rotation desired forthe input shaft.

Step 3

Place the two inner race keys (ref. 62, Fig. 11) in theinput shaft keyways. For ease of installation, thebackstop complete with inner race should be pushedinto the reducer as a unit.

When pushing backstop into reducer, it is importantnot to hammer on the backstop, but it can be tappedgently if necessary.

Place circlip (ref. 63, Fig. 11) into groove in inputshaft.

Step 4

Line up keyway in backstop outer race with keyway inbackstop housing by rotating the input shaft in thedirection opposite to its driving rotation. If thebackstop is properly installed, it will rotate with theinput shaft.

Step 5

Insert key (ref. 61, Fig. 11) in the aligned keyways.

Step 6

Replace gasket and backstop cover and refill reducerwith oil.

Step 7

Check input shaft for end-float 0.1mm.

IMPORTANTIf for any reason it is necessary to remove a backstopfrom an operational unit, it is essential that Part No. 88(Page 9), the input bearing distance piece, is fittedinto the vacant backstop housing and the input shaftend-float is checked before restarting the unit.

DO NOT USE E.P. OILS WHEN BACKSTOP IS FITTED ON ANY SIZE OF UNIT.

Fig. 11

Table 10

14

REMOVING THE REDUCER FROM THE SHAFT

Follow these steps to remove the reducer from the shaft:

1. Ensure that the reducer is supported and cannot fallfree when the grip of the Taper-Grip® bushing isreleased.

2. Release each screw gradually until they are freefrom the pockets of the thrust collar.

3. If the Taper-Grip® bushing does not self release,give the flange a sharp tap with a brass or coppermallet to break free the taper. This will free thereducer from the shaft. Be careful not to damagethe tapped holes.

4. Hand tighten two screws against the thrust collarbefore attempting to slide the reducer off theshaft. This will stop the hub from pulling up theopposite taper flanks of the Taper-Grip® bushingand prevent it from relocking on the shaft as thereducer is removed.

5. Slide the reducer from the shaft. If corrosion orpaint prevents the reducer from sliding off theshaft, it is possible to utilize two of the screw holesto secure a puller plate to the bushing.

GENERAL INFORMATION

Important

Using tools normally found in a maintenancedepartment, the reducer can be dismantled andreassembled. Cleanliness is very important to preventthe introduction of dirt into the bearings and otherparts of the reducer. A tank of clean solvent, Arborpress and equipment for heating bearings and gearsshould be available for shrinking these parts on theshafts.

Lip-type oilseals are fitted and great care should betaken during dismantling and reassembling to avoiddamage to the rubbing surfaces.

The keyseat in the input shaft and the six holes in theoutput hub should be covered with masking tape orother suitable material. Any burrs in shaft or hubsurfaces should be carefully removed.

Ordering Parts

When ordering parts for a reducer, specify reducersize, serial no., and quantity required.

It is strongly recommended that when a pinion or gearis replaced, the mating gear or pinion be replacedalso.

If any parts must be pressed from a shaft or from theoutput hub, this should be done before ordering partsto make sure that none of the bearings or other partsare damaged upon removal. Do not press against theouter race of the output bearing.

Because old shaft oilseals and gaskets may bedamaged during disassembly, oilseals and gasketsmust be replaced when overhauling or repairing.

Since no gasket is used between the case halves,care should be taken to avoid damage to the jointfaces. When reassembling, a suitable joint sealantshould be used. Silicone adhesive (3 Bond 1215) isrecommended.

If replacing a bearing or shaft, it is advisable to order aset of shims for adjustment of the bearings in the shaftassembly. The taper bearings should be adjusted togive 0.1mm end float.

Central & South America Sales,Engineering, Stocking & AssemblyBrazilSM-CYCLO REDUTORES DO BRASIL LTDA.Av. Dr. Ulysses Guimarães, 353309990-080 Diadema São Paulo, BrazilTel.: 011-55-11-445-4388 • FAX: 011-55-11-456-2922ChileSM-CYCLO DE CHILE LTDA.Napoleon 3565, Of. 510Las Condes - Santiago, ChileTel.: 011-56-2-203-7300 • FAX: 011-56-2-203-7195

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Headquarters and ManufacturingSumitomo Machinery Corporation of America

4200 Holland Boulevard, Chesapeake, VA 23323(757) 485-3355 • FAX: (757) 485-3075

Toll Free: 1-800-SM-CYCLO (762-9256)www.smcyclo.com • e-mail: smcamktg@series2000.com

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North American Regional OfficesStocking & Assembly Facilities

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SUMITOMO“QuaDelta” PROGRAM

Providing

THE AVAILABLE SOLUTION, WORLDWIDE

▲ GEAR BOXES

▲ MOTORS

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SPEED REDUCER

SM-CYCLOConcentric

GEARMOTOR

SM-CYCLOConcentric

LOW RATIO PLANETARY

SM-CYCLOConcentric

PRECISION CYCLO

Concentric

SHAFT MOUNTSPEED REDUCER

SM-SHAFT MOUNTParallel Offset

BEVEL GEARMOTOR

SM-BEVEL BUDDYBOXRight Angle

PARTS & SERVICE

WORLDWIDE

SHAFT MOUNTSPEED REDUCER

SM-SHAFT MOUNTParallel Offset

WORM GEARMOTOR

SM-ULYSSES Right Angle

ALLDRIVES

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ALLSPEEDS

WORLD-WIDE

SHAFT MOUNTGEARMOTOR

SM-HYPONICRight Angle

SHAFT MOUNTSPEED REDUCER

SM-SHAFT MOUNTParallel Offset

DOUBLE ENVELOPINGWORM GEAR

SM-HEDCONRight Angle

ELECTRICALVARIABLE SPEED

AF-3100α NTAC-2000AC Drive AC Drive

MECHANICALVARIABLE SPEED

SM-BEIER

SHAFT MOUNTEDGEARMOTOR

SM-HELICAL BUDDYBOXParallel Offset

HELICALGEAR REDUCER

PARAMAXParallel Offset & Right Angle

Power Transmission Products4200 Holland Blvd., Chesapeake, VA 23323(757) 485-3355 • FAX: (757) 485-3075

Toll Free: 1-800-SM-CYCLOWeb: http://www.smcyclo.com • E-mail: smcamktg@series2000.com

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