"K" Series Food and Beverage Duty Reducer

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1 "K" Series Food and Beverage Duty Reducer "K" Series Food and Beverage Duty Reducer Installation and Maintenance Guide

2 16 STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide

3 Handling Instructions In order to obtain long-life and trouble-free operation, it is essential that the installation and operating procedures outlined in this manual be followed. Failure to follow these instructions will void the drive's warranty. The STOBER Food and Beverage Duty reducer's coating is very rugged but can be compromised by rough handling. Nylon bolts have been installed to reduce the risk of compromising the coating as the reducer is handled prior to and during installation. The nylon bolts are located on Side 1 and Side 5 of the reducer. These bolts should not be removed unless the holes are being utilized. If the coating is damaged, contact STOBER Technical Support for recommendations regarding proper touch up. The STOBER Food and Beverage Duty reducer is filled at the factory with the proper type and quantity of oil for mounting in any "horizontal output" position. DO NOT ADD OR REMOVE OIL or open the reducer oil fill plug during the warranty period. STOBER Drives Inc. offers 24 hour technical support. When seeking assistance regarding a reducer, provide the serial number located on the reducer's nameplate. It is recommended that the STOBER Food and Beverage Duty reducer be torque arm mounted. Rigid mounting of the reducer may cause excessive wear to shafts and bearings associated with your equipment and may void the reducer's warranty. Call STOBER Technical Support for information regarding proper torque arm mounting. WARNING: Safety is the most important consideration when operating any type of drive. Through proper application, safe handling methods, and wearing appropriate clothing, accidents and injury to yourself and fellow workers can be prevented. The torque required by the application must not exceed the reducer torque capacity shown on the nameplate. For safety purposes a safety coupling should be installed between the reducer and the driven load. Otherwise, overload may cause damage to the interior parts of the reducer which may result in breaking the reducer housing. As a result, persons could be injured by flying parts or splashing hot gear oil. The shafts of speed reducers rotate at very high speeds and can cut off or severely injure hands, fingers, and arms. Use appropriate guards for shafts and other rotating parts at all times. Follow all directions in the service instructions. Obey all federal, state, local, and your companies safety standards when operating the drive. Always be sure electrical power is off while making electrical connections and during installation and maintenance of the unit. Keep clothing, hands, and tools away from ventilation openings on motors and from all rotating parts during operation. Lift drives with a double rope sling or other proper lifting equipment of adequate strength. Make sure load is secured and balanced to prevent shifting when unit is being moved. Lifting drives by hand may be dangerous and should be avoided. The intended use of lifting lugs is to handle the weight of the unit only. Never use a lifting lug to lift attached assemblies. Never operate drive at speeds higher than those shown on the nameplate, or personal injury may result. Contact STOBER Drives Inc., if there is any change of operating conditions from those for which the unit was originally sold (as stamped on the nameplate). Failure to comply could result in personal injury and or machinery damage. Each drive is tested before delivery. Before installation however, it is advisable to examine the unit for possible damage which might have occurred during transit. If damage is discovered, it should be immediately reported to the transport agent. If installation is delayed after receipt of the reducer, it should be stored in a clean, dry place until put into service. Long term storage requires special procedures. If not kept in a heated, dry area, consult STOBER Drives, Inc. for storage instructions. NOTE: If it is necessary to clean drive shafts, take care to protect the oil seals. IMPORTANT: Do not use any device to hammer the unit onto the output shaft during installation since the bearing races could be damaged. If you have questions about installation, operation, or maintenance of your STOBER unit, please contact STOBER Technical Support. STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide 1

"K" Series Food & Beverage Standard 3 Year Warranty Standard Coating Industrial 316 Stainless Steel Epoxy Stainless Steel Nameplate All Stainless Steel Hardware Inside Split Cover Cap enables easy

4 "K" Series Food & Beverage Standard 3 Year Warranty Standard Coating Industrial 316 Stainless Steel Epoxy Stainless Steel Nameplate All Stainless Steel Hardware Inside Split Cover Cap enables easy assembly onto the shaft NEMA C-face Input O-ring between motor and reducer Easy mount, maintenance free coupling Outside Cover Cap with O-ring to protect seals from high pressure washing Patented* (U.S. Patent No. 5,496,127) Stainless Steel Double Sided Bushing Mounted into Stainless Steel Output Quill easily mounts onto standard cold finished, ground, or stainless shafting Double Sealed Output with a dual lip outer seal and a single lip inner seal Lubricated for Life One Standard Unit for ALL Horizontal Mounting Positions Without Changing the Oil Level EL1 EL2 EL5 EL6 Possible but not recommended STOBER Part No. Explanation: K402WG0250MR200/180B WFB4-107 K...Right Angle Helical/Bevel Unit WFB...Double Wobble Free Bushing Size 4, 0 Generation, 2 Stage Gearing 4...Fits K402/K403 Reducer W...Wobble Free Bushing Output Style Bore Size (1 7 /16") G...Tapped Hole Housing Style :1 Approximate Ratio MR200...Size of Motor Adapter Fits NEMA 182/184TC Motor Frame B...Beverage Duty Unit 2 STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide

5 Year Warranty New, Improved Input Synthetic Oil Application Specific Mounting Position "K" Series Food & Beverage Long Life 5 Year Warranty Maintenance Free Long Life New Input Design SHC630

Dual Output Seals Gears Supported with Dual Bearings in one piece housing for structural rigidity Application Specific Mounting Positions E12 E34 EL5 STOBER Part No.

5 5 Year Warranty New, Improved Input Synthetic Oil Application Specific Mounting Position "K" Series Food & Beverage Long Life 5 Year Warranty Maintenance Free Long Life New Input Design SHC630 Synthetic Oil Flexible Input Coupling Stainless Steel Oil Fill Plug Bushing covers, with weep holes, protect seals against high pressure washing. Dual Output Seals Gears Supported with Dual Bearings in one piece housing for structural rigidity Application Specific Mounting Positions E12 E34 EL5 STOBER Part No. Explanation: K402WG0250MR200/180BLL EL34 WFB4-107 K...Right Angle Helical/Bevel Unit WFB...Double Wobble Free Bushing Size 4, 0 Generation, 2 Stage Gearing 4...Fits K402/K403 Reducer W...Wobble Free Bushing Output Style Bore Size (1 7 /16") G...Tapped Hole Housing Style :1 Approximate Ratio MR200...Size of Motor Adapter Fits NEMA 182/184TC Motor Frame B...Beverage Duty Unit LL...Long Life 5 Year Warranty EL34...Mounting Position Must be Specified STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide 3

6 WFB Double Bushing Kit Sizes Table No. 1 Stock Bushing Kits - Inch Bore Size Bushing Inches Part No. 1 WFB WFB /16 WFB WFB /16 WFB /4 WFB /8 WFB /16 WFB /2 WFB WFB /16 WFB /4 WFB /8 WFB /16 WFB /2 WFB /16 WFB /2 WFB /8 WFB /16 WFB /4 WFB /8 WFB /16 WFB WFB /16 WFB /2 WFB /8 WFB /16 WFB /4 WFB /16 WFB WFB /16 WFB /16 WFB WFB /16 WFB /8 WFB /16 WFB /8 WFB /16 WFB /4 WFB8-212 Table No. 2 Stock Bushing Kits Metric Bore Size Bushing mm Part No. 25 WFB WFB WFB WFB WFB WFB WFB STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide

7 Mounting Dimensions Recommended Shaft Length OL J L SUPPORT SIDE P CLAMP SIDE BH F Bore DC Ref. FA C 1 /4" Max. See Note 1 G GA GL CL Cover to Cover Length Important: A 1 /32 x 45 chamfer minimum is recommended for the shaft end. Table No. 1 Mounting Dimensions (Inches) Unit Size BH C CL DC F FA G GA GL J L OL P K M K202/K M K302/K M K402/K M K513/K M K613/K M K713/K M K813/K M Table No. 2 Recommended Shaft Length (Inches) Unit Size K1 K2 K3 K4 K5 K6 K7 K8 Length STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide 5

Double Side Bushing Installation 4 3 Unit with

Side 5 Support Side Bushing Components The Support

Installation Clamp Side Installation 3 Be sure the

do not have tapered Install Flanged Cone Assembly

opposite the slot in the tapered cone (3).

the spacer bolts (see opposite page) must be

spacer bolts until the unit is mounted on the shaft.

Cone Assembly (7) with it's slot opposite the slot

8 Double Side Bushing Installation 4 3 Unit with Pressure Rings Installed Support Side Clamp Side 5 Support Side Bushing Components The Support Side is the bushing with the coating on the cone. Do NOT use cleaner on the coated cone. 2 6 Clamp Side Bushing Components Support Side Installation Clamp Side Installation 3 Be sure the inside of the quill is free of grease and oil before installing the tapered cones. 6 Insert Tapered Cone K1 units do not have tapered cones. Maintain "U" Dimension Insert Tapered Cone K1 units do not have tapered cones. Install Flanged Cone Assembly Install the Flanged Cone Assembly (4) with it's slot opposite the slot in the tapered cone (3). 4 The "U" distance (between the rings) determined by the spacer bolts (see opposite page) must be maintained throughout assembly of the bushing and mounting onto the shaft. Therefore DO NOT tighten the capscrews or remove the spacer bolts until the unit is mounted on the shaft. 7 Install Flanged Cone Assembly Install the Flanged Cone Assembly (7) with it's slot opposite the slot in the tapered cone (6). 5 VERY IMPORTANT Do NOT Remove Spacer Bolts 8 Hand Tighten Capscrews Hand Tighten Capscrews 6 STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide

Double Side Bushing Installation Unit with Complete

Shaft End Clean the Shaft Guide Unit onto Shaft 13 14

Tighten Clamp Side First More Than One Rotating

Recommended Torque 17 18 19 20 Tighten Capscrews More

Cover Tighten all capscrews to the torque shown in

The tightening should be done gradually in a rotating

After two hours (minimum) running time, check

21 Install Split Cover Installed Unit with

1 Recommended Tightening Torque Base Capscrews Tight.

lbs. mm ins. Bolts mm KL202 6 M5 0.8 25 6 53 4.

25 20 K513/K514 8 M8 1.25 30 25 221 7.28 M8 1.

9 Double Side Bushing Installation Unit with Complete Bushing Installed /32 x 45 Chamfer on Shaft End Clean the Shaft Guide Unit onto Shaft Shaft Does Not Protrude Remove the Spacer Bolts Tighten Clamp Side First More Than One Rotating Sequence Use a Torque Wrench (See Table 1) for Recommended Torque Tighten Capscrews More Than One Rotating Sequence Use a Torque Wrench (See Table 1) for Recommended Torque Install Closed Cover Tighten all capscrews to the torque shown in Table 1. Use a torque wrench. The tightening should be done gradually in a rotating sequence and will require more than one rotation. After two hours (minimum) running time, check capscrews and retighten, if necessary. 21 Install Split Cover Installed Unit with Bushings/Covers Table No. 1 Recommended Tightening Torque Base Capscrews Tight. Torque U Spacer Module Qty. Size x mm Lgth Nm. in. lbs. mm ins. Bolts mm KL202 6 M M KSS102 6 M M KSS202 8 M M KSS302/303 8 M M K102 6 M M K202/K203 6 M M K302/F303 8 M M K402/K403 8 M M K513/K514 8 M M K613/K614 8 M M K713/K714 8 M M K813/K814 8 M M STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide 7

Motor Mounting Instructions CAUTION: If the motor coupling is not installed correctly, the input bearing may fail due to pre-load.

Secure the Motor Shaft Key. For ease of installation, secure the motor shaft key.

Accurate placement of the motor coupling on the shaft is vital to mounting the motor correctly.

The motor coupling should be located from the motor face the "XL" distance shown in Table No. 1. Table No. 1 Location of Motor Coupling Adapter "XL" Part No.

3 "XL" Tolerance +1mm / -0mm (+0.040 / -0.000 inches) Step 2. Tighten the Setscrew Step 4. Mount the Motor.

The coupling sleeve is already installed on the mating reducer coupling hub inside the motor adapter. The sleeve should move freely in an axial direction.

10 Motor Mounting Instructions CAUTION: If the motor coupling is not installed correctly, the input bearing may fail due to pre-load. This will void the warranty of the reducer and possibly fail the motor. Step 1. Locate the Motor Coupling on the Motor Shaft. Step 3. Secure the Motor Shaft Key. For ease of installation, secure the motor shaft key. Staking near the end of the keyway, on the sides of the key, or a temporary adhesive works well. Accurate placement of the motor coupling on the shaft is vital to mounting the motor correctly. Mount the coupling with the hub projection toward the step or shoulder of the motor. The motor coupling should be located from the motor face the "XL" distance shown in Table No. 1. Table No. 1 Location of Motor Coupling Adapter "XL" Part No. mm inches MR140/ MR160/ MR160/ MR200/ MR200/ MR200/ MR250/ MR250/ "XL" Tolerance +1mm / -0mm ( / inches) Step 2. Tighten the Setscrew Step 4. Mount the Motor. With the coupling secure, insert the motor shaft into the motor adapter. The coupling sleeve is already installed on the mating reducer coupling hub inside the motor adapter. The sleeve should move freely in an axial direction. (Axial displacement ±.040 inches.) With the motor in place, tighten the motor bolts. Some motor manufacturers provide a drain hole in the mounting face of washdown motors. In some mounting positions, water or other material can enter the motor adapter and fail the bearing. With the coupling hub located at the correct distance, tighten the setscrew in the coupling. Be sure this hole is covered during washing or when the unit is in a wet environment. This illustration shows the method that STOBER assembly personnel use to plug the hole. 8 STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide

Motor Mounting Instructions Shown in Table No. 1 is the motor coupling hub and sleeve part number for the STOBER Food and Beverage Duty MGS motor adapter.

For ease of motor coupling hub location and installation, as an option, STOBER has available a motor hub mounting gage (Part No.

Locate the side of the gage that matches the motor adapter of the reducer. The part number on the nameplate will indicate this number. Step 2. Place the coupling hub on the motor shaft. Step 3.

11 Motor Mounting Instructions Shown in Table No. 1 is the motor coupling hub and sleeve part number for the STOBER Food and Beverage Duty MGS motor adapter. These parts, with a coupling shaft component that is part of the reducer, make a complete coupling to connect the motor to the reducer. For ease of motor coupling hub location and installation, as an option, STOBER has available a motor hub mounting gage (Part No. GAGE2033) to fit the most popular sizes of motor adaper (MR160/050, MR160/140 and MR200/180). This simple-to-use gage rapidly positions the motor coupling hub on the shaft. Step 1. Locate the side of the gage that matches the motor adapter of the reducer. The part number on the nameplate will indicate this number. Step 2. Place the coupling hub on the motor shaft. Step 3. Place the gage on the motor face, over the motor shaft, and hold the coupling flush with the counterbore of the gage. Step 4. Tighten the setscrew. To order, contact sales@stober.com. Sleeve Motor Coupling Hub Table No. 1 Couplings for MR Motor Adapters Motor NEMA Motor Adapter Frame Hub Sleeve MR140/050B 56C M-19x 5 /8 M-19 MR160/050B 56C M-24x 5 /8 M-24 MR160/140B 143/145TC M-24x 7 /8 M-24 MR200/050B 56C M-32x /8 M-32 MR200/140B 143/145TC M-32x 7 /8 M-32 MR200/180B 182/184TC M-32x1 1 /8 M-32 MR250/180B 182/184TC M-38x1 1 /8 M-38 MR250/210B 213/215TC M-38x1 3 /8 M-38 STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide 9

Reducer Removal Instructions LOCK OUT TAG OUT Before beginning

your companies procedures for lock out, tag out.

reducer. This should be the outside bushing.

back out holes and tighten slightly to apply pressure to the

Step 3 Place a wedge between the two bushing rings and tap with a

If the bushing does not break free, apply more pressure by

Place 2 of the hex head bolts into the bushing.

Excessive tightening can twist off the bolt head.

Step 2 Remove the split cover from the Support Side of the reducer.

12 Reducer Removal Instructions LOCK OUT TAG OUT Before beginning maintenance on your STOBER food and beverage duty reducer, follow your companies procedures for lock out, tag out. Step 1 Remove the solid cover from the Clamp Side bushing of the reducer. This should be the outside bushing. Loosen and remove all of the hex head bushing bolts from the Support Side. If there is room to do so, place two of the hex head bolts into the back out holes and tighten slightly to apply pressure to the bushing. Loosen and remove all the hex head bushing bolts. Step 3 Place a wedge between the two bushing rings and tap with a hammer. If the bushing does not break free, apply more pressure by tightening the bolts, and tap again. The bushing should break free. Place 2 of the hex head bolts into the back out holes and tighten slightly to apply pressure to the bushing. DO NOT try to use the bolts to break the bushing free. Excessive tightening can twist off the bolt head. Step 4 Remove the Clamp Side bushing. Step 2 Remove the split cover from the Support Side of the reducer. The inside bushing should be the Support Side, if the reducer was installed properly. This side has the Teflon coated cone and should break free easily. Step 5 Remove the reducer from the shaft. 10 STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide

13 Reducer Removal Instructions When tightening capscrews in any STOBER MGS reducer, use the values in the following table. These values apply to capscrews for foot mounting, fl ange mounting, or torque arm mounting. Table No. 1 Capscrew Tightening Torque Capscrew Standard Steel Stainless Steel Size Nm. in. lbs. Nm. in. lbs. M M M M , M , ,858 M , ,761 M24 1,050 9, ,460 M30 2,100 18,585 1,450 12,832 M36 3,700 32,745 2,600 23,010 STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide 11

14 Competitive Comparison 1 /4 Max. To meet safety standards D H C F A G L Table No. 1 Unit Dimensions (Ins.) Part No. A D F G H L STOBER K302/K K402/K K513/K K613/K SEW KA KA KA KA DODGE 30Q Q Q Q NORD SK SK SK SK BOSTON SF SF SF SF WINSMITH E E E E E E E Table No. 2 C Dims. (Ins.) STOBER 56C 140TC 180TC K K K K K K K K SEW KA KA KA KA DODGE 30Q Q Q Q NORD SK SK SK SK BOSTON SF N/A SF N/A SF SF WINSMITH E E E E E E E STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide

15 Competitive Comparison F FA J Dia. x I Deep GA G J Dia. x I Deep D H F FA G GA Table No. 1 Unit Dimensions (Ins.) Part No. D FA F GA G H I J STOBER K M8 K202/K M10 K302/K M10 K402/K M12 BOSTON / / / / / / /2-13 STOBER Drives Inc. Food and Beverage Duty Reducer Maintenance Guide 13

16 Contact Information to send an order, request a sales call, or ask for product information by . lit@stober.com to request any literature (catalogs, brochures, price sheets, etc.) drawings@stober.com to request a product drawing that is not currently available on the web site Customer Service (Day) Customer Service Fax Customer Service On-call Toll Free Shipping Address 1781 Downing Drive, Maysville KY STOBER Drives web site STOBER Drives Inc Downing Drive Maysville KY Form No Printed in U.S.A. May 2013

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