Master C150, C35, C262, C200 Service Manual

MASTER COMBOGEAR
RIGHT ANGLE C-FACE REDUCERS

®

SERVICE AND REPAIR

SIZES C150, C200, C262, C350

WARNING: Because of the possible danger to person(s) or property which may result from improper use of products, it is important that correct
procedures be followed. Products must be used in accordance with the Engineering information specified in the catalog. Proper installation, operation
and maintenance procedures must be observed. The instructions in the instruction manuals must be followed. Inspections should be made as
necessary to assure safe operation under prevailing conditions. Proper guards and other suitable safety devices or procedures as may be desirable or
as may be specified in safety codes should be provided, and are neither provided by Master Power Transmission nor are the responsibility of Master
Power Transmission. This unit and its associated equipment must be installed, adjusted and maintained by qualified personnel who are familiar with the
construction and operation of all the equipment in the system and the potential hazards involved. When risk to persons or property may be involved, a
failsafe device must be an integral part of the driven equipment beyond the speed reducer output shaft.

3300 Tenth St. / Columbus, IN 47201 / [phone]
www.master-pt.com

Master ComboGear Right Angle Reducer Instruction Manual 499430

10/2013

INSTRUCTION MANUAL 499430

TABLE OF CONTENTS

GENERAL INFORMATION ....................................................................................................................................3

PRODUCT DESCRIPTION ............................................................................................................

........................ 3

NOMENCLATURE..................................................................................................................................................3

APPLICATION INFORMATION..............................................................................................................................4

WARRANTY ...........................................................................................................................................................4

MOUNTING POSITIONS .......................................................................................................................................4

CHANGING OUTPUT SHAFT FROM K1 TO L1 (AND L1 TO K1).................................................................4

MOTOR INSTALLATION........................................................................................................................................5

COUPLING LOCATION..........................................................................................................................................5

INSTALLATION ......................................................................................................................................................6

TWIN TAPERED BUSHING INSTALLATION ........................................................................................................6

TWIN TAPERED BUSHING REMOVAL ................................................................................................................7

STRAIGHT BORE BUSHING INSTALLATION......................................................................................................7

TORQUE ARM MOUNTING POSITIONS ..............................................................................................................9

INPUT SEALING SYSTEM ....................................................................................................................................9

MAINTENANCE....................................................................................................................................................10

LUBRICATION – GENERAL .........................................................................................................................10

LUBRICATION – OIL FILL LEVELS..............................................................................................................10

LUBRICATION – VERTICAL OU TPUT SHAFT MOUNTING .......................................................................10

STANDARD INPUT SEAL REPLACEMENT.................................................................................................10

OUTPUT SEAL REPLACEMENT........................................................................................................

......... .11

BOLT TYPES AND TORQUES .........................................................................................................

.............12

LONG TERM STORAGE..............................................................................................................

........................ 12

2

3

GENERAL INFORMATION

MASTER Power Transmission manufactures the

the product described in this instruction manual.

PRODUCT DESCRIPTION

The MASTER ComboGear reducer is a double
reduction worm-helical speed reducer that utilizes
a C-Face motor adapt

er and 3-piece flexible coupling.

This product is available in two basic configurations:

NOMENCLATURE

The part number indicates all the essential characteristics of the MASTER ComboGear.

MASTER ComboGear

MASTER ComboGear

1. Solid Output Shaft: a standard solid output shaft
extension that can be specified as left hand, right hand
or double shaft configurations. See Mounting Position
diagrams.

2. Hollow Output Shaft: uses a hollow through-bore
output shaft in either of two configurations: 1) straight
bore shaft with locking set screws, or 2) twin tapered
bushings. Twin tapered bushing kits are available
separately in a range of inch and metric bore sizes.

4

APPLICATION INFORMATION

The MASTER ComboGear reducer is designed to
operate within the following temperature limits:

Ambient –10 to +165 °F

Oil Sump –10 to +200 °F

Where ambient temperatures exceed 100°F, care
should be taken not to exceed 200°F sump
temperature during unit operation.

The continuous rated input horsepower shown on
the reducer nameplate is for service factor of 1.0 at
an input speed of 1750 RPM. Before placing the
reducer into service, check the nameplate to confirm
that its horsepower rating is consistent with the
motor horsepower and the desired service factor.
Application versus service factor information and
reducer ratings for different speeds can be found in
your MASTER Engineering catalogs.

WARNING
TO ENSURE THAT DRIVEN EQUIPMENT IS NOT
UNEXPECTEDLY STARTED, TURN OFF AND
LOCK OUT AND TAG POWER SOURCE BEFORE
WORKING NEAR THE EQUIPMENT. FAILURE TO
OBSERVE THESE PRECAUTIONS COULD
RESULT IN BODILY INJURY OR PROPERTY
DAMAGE.

WARRANTY

The MASTER ComboGear Reducer is war­ranted under the MASTER “Standard Terms and
Conditions of Sale” to be free of defects in material
and workmanship. Warranty claims must be
submitted to the company within one (1) year from
the date of installation or three (3) years from the
date of manufacture, whichever comes first. The
warranty is valid providing the product is properly
applied, installed, operated and maintained in
accordance with our instruction manual. This
warranty covers product replacement or repair only
and excludes labor, equipment and/or downtime for
removal and installation. This warranty shall not
apply where equipment is operated above rated load
capacity or is subject to accident, alteration, misuse
or abuse. This warranty is in lieu of and excludes all
other expressed or implied warranties.

NOTE: Service and repair under warranty should be
performed only by a MASTER authorized service
shop. Contact MASTER Warranty Administration for
the nearest location.

MOUNTING POSITIONS

Reducers should always be ordered for the
expected mounting position as different oil fill
quantities are required and grease fittings are

required on the upper bearings of vertical shaft units.
See Lubrication section.

NOTE: The following mounting positions are generic
in that many other assemblies of feet and flanges
are available. The relationship of the input and
output shafts to earth (down) are significant.

CHANGING THE OUTPUT SHAFT
FROM K1 TO L1 (AND L1 TO K1)

Units should always be ordered to the required
mounting position. However, it is possible to change
output shaft location.

1. Drain oil from case. Remove the open bearing
housing. Remove the output seal and discard.

2. Lift out the output shaft assembly and the
intermediate shaft assembly.

3. Remove the closed bearing housing. Clean
machined surfaces.

4. Remove tapered roller bearing cups and shims from
each bore in each bearing housing and switch them .
(Place cups and shims removed from bores in open
bearing housing in closed bearing housing and vice
versa.)

5. Apply a 1/16” bead of Loctite 515 or equivalent
sealant to the closed bearing housing machined
sealing surfaces. The bead of sealant must go
completely around all bolt and dowel holes. Install the
closed bearing housing. Evenly tighten the housing
bolts. Lay the unit on the bench, closed bearing
housing down.

5

REDUCER

SIZE

MOTOR

FRAME

MOTOR

COUPLING

REDUCER

COUPLING

REDUCER

SIZE

MOTOR

FRAME

MOTOR

COUPLING

REDUCER

COUPLING

C150 56 .090 / (3/32) .00 (EVEN) C200 56 .090 / (3/32) .00 (EVEN)

C150 140 .030 / (1/32) .00 (EVEN) C200 140 .030 / (1/32) .00 (EVEN)

C150 180 N.A. N.A. C200 180 .171 / (11/64) .188 / (3/16)

C150 IEC71 .090 / (3/32) .00 (EVEN) C200 IEC71 .090 / (3/32) .00 (EVEN)

C150 IEC80 .156 / (5/32) .00 (EVEN) C200 IEC80 .156 / (5/32) .00 (EVEN)

C150 IEC90 .141 / (9/64) .00 (EVEN) C200 IEC90 .141 / (9/64) .00 (EVEN)

C262 56 .090 / (3/32) .00 (EVEN) C350 56 .070 / (5/64) .00 (EVEN)

C262 140 .030/ (1/32) .00 (EVEN) C350 140 .125 / (1/8) .00 (EVEN)

C262 180 .090 / (3/32) .00 (EVEN) C350 180 .156 / (5/32) .00 (EVEN)

C262 210 N.A. N.A. C350 210 .090 / (3/32) .00 (EVEN)

C262 IEC71 .141 / (9/64) .250 / (1/4) C350 IEC71 .141 / (9/64) .250 / (1/4)

C262 IEC80 .141 / (9/64) .250 / (1/4) C350 IEC80 .141 / (9/64) .250 / (1/4)

C262 IEC90 .109 / (7/64) .250 / (1/4) C350 IEC90 .109 / (7/64) .250 / (1/4)

C262 IEC100/112 .188 / (3/16) .015 /(1/64) C350 IEC100/112 .188 / (3/16) .015 /(1/64)

C262 IEC132 .047 / (3/64) .00 (EVEN) C350 IEC132 .047 / (3/64) .00 (EVEN)

N.A. (NOT APPLICABLE)
NOTE: IEC Motors are B5 flanges.

6. The position of the wormgear must be adjusted so
the worm contacts the center of the wormgear teeth.
Failure to make this adjustment may cause reduced
efficiency and life as well as overheating and tooth
breakage.

7. Apply Prussian Blue lightly but evenly to both sides
of five adjacent teeth on the bronze wormgear.

8. Install the intermediate shaft assembly into the
gearcase so that the intermediate shaft pinion will be
on the same side as the output gear when the reducer
is reassembled. Install the open bearing housing and
secure with two bolts at diagonal corners. The hollow
dowel pins must be in place.

9. Rotate the input shaft so the “blued” wormgear teeth
are rotated through the gear mesh. Then rotate in the
opposite direction. Marks of contact will be made by
the worm in the bluing on the wormgear teeth.

10. Remove the open bearing housing and
intermediate shaft assembly. Examine the contact
pattern on the wormgear teeth. The ideal pattern is
centered in the wormgear teeth.

11. If the pattern is not centered, the intermediate shaft
must be moved in the direction where the contact
shows the heaviest. Remove a thin shim from the
bearing cup on the side that the contact is heaviest and
install it under the cup on the opposite side. Shims may
be moved from one side to the other but the total
number of shims must not be changed, as this controls
the endplay of the bearings.

COUPLING LOCATION

The motor and reducer coupling halves must be
properly located before assembly to prevent bearing
and coupling failure. Refer to the following chart and
reference diagram for proper locations.

MOTOR INSTALLATION

The MASTER ComboGear uses a standard NEMA C­face motor with a 3-piece flexible coupling. IEC motor
adapters and couplings are available.

12. Repeat the above steps, cleaning, rebluing and
inspecting each time, until the contact pattern is
centered on the wormgear.

13. Install the intermediate and output shaft
assemblies. Apply sealant to the gearcase machined
sealing surfaces. Install the open bearing housing and
tighten all bolts. Be sure all parts rotate freely.

14. Lubricate the shaft seal surface and seal bore
liberally with SHC 634. Install a new seal, taking care
not to cut or roll the lip or dislodge the seal garter
spring. Seat the seal flush with the outside of the
bearing housing. The use of a driver is recommended.

15. Fill unit with proper amount of lubricant. See
charts. Use sealant on plug threads. Test unit.

6

INSTALLATION

IMPORTANT!

While the basic MASTER ComboGear
reducer is suitable for any approved mounting
position, different oil levels are required for mounting
positions other than K1/L1/S1. You must add the
required amount of oil for the desired operating
position.

IMPORTANT: RIGID MOUNTING OF THE
REDUCER IS NOT RECOMMENDED.

System alignment problems indicate that rigid
mounting of a reducer in a rigid system may cause
“binding”, leading to premature bearing, shaft or
reducer failure. A system must have some flexible
element that allows it to self-align during operation.

The ideal mounting for a hollow shaft reducer is to
use a torque arm design. If a reducer uses a
flange/bracket mounting concept, it is highly
recommended that the reducer be mounted on the
conveyor head shaft using the conveyor pillow
block on the opposite side of the conveyor as a
support bearing. A system with a rigidly mounted
bearing close to a rigidly mounted reducer will
probably be impossible to align and maintain.

Units are shipped from the factory with the reducer half
of the input coupling installed.

1. Drive key into motor shaft. Slide the input coupling
half onto the motor shaft. Position the coupling half on
the motor shaft as shown in the preceding chart.
Tighten setscrews.

2. Insert the elastomer coupling element into the
reducer-side coupling half. Visually align the openings
in the coupling half with the ears on the motor side
coupling half. Slip the motor straight into the motor
adapter, insuring that the coupling engages properly.
Once the coupling engages, slide the motor tenon into
the motor adapter. Install and tighten four motor bolts.

WARNING: Keep fingers clear of mating flanges of
motor and reducer to prevent pinching injury.

3. Insure that there is no binding or excess clearance
between the coupling halves. The motor-side coupling
half may be loosened with a hex wrench inserted
through the adapter access hole; then use a
screwdriver to gently pry the motor coupling half
toward the reducer. The metal ears should not touch
the face of the opposite coupling hub and should have
no more than 1/32” clearance. Tighten setscrews
securely.

4. Install the plastic safety cap into the adapter access
hole.

TWIN TAPERED BUSHING INSTALLATION

WARNING: The output shaft bushings must be
shielded to prevent contact, which may result in injury.
Fabricate or contact MASTER for shields.

1. One bushing assembly is required to mount the
reducer onto the driven shaft. One assembly consists
of two tapered bushings, six bushing screws, bushing
keys and a shaft key.

2. The driven shaft must extend through the full length
of the reducer. The reducer should be mounted the
recommended minimum distance from the shaft
bearing (shown as dimension “A” in Fig. 2 and table.
Dimension “A” is required for bolt clearance/jackscrew
removal.)

3. Place one bushing on the shaft and position per
dimension “A”. If the reducer is positioned closer to the
bearing than “A”, place the screws (with lockwasher) in
the unthreaded holes in the bushing before positioning
the bushing on the shaft. Allow a minimum of 1/8”
between the screw heads and the bearing. Do not
grease the bushings.

4. Insert the output key in the shaft and bushing.

5. Place the reducer in position on the shaft aligning
the hub keyway with the shaft key.