KOCH - Berkel Sales & Service

KOCH 

KOCH/RAMON SC-100 FLOOR MODEL STAINLESS 

STEEL HYDRAULIC PISTON STUFFER 

Owner’s 

Manual 


EQUIPMENT

KOCH EQUIPMENT LLC 

Owner’s Manual 

Koch/Ramon SC-100 

Hydraulic Piston Stuffer 

W I T H 

HYDRAULIC POWER, STAINLESS STEEL CYLINDER, 

LID AND PISTON, AND VARIABLE SPEEDS 

Rev. 2003 

D

I N T R O D U C T I O N PAGE I 


EQUIPMENT 

KOCH EQUIPMENT LLC 

Koch/Ramon SC-100 Hydraulic Piston Stuffer Owner’s Manual 

Manufactured by 

Koch Equipment LLC 

1414 West 29 th Street 

Kansas City, MO 64108-3604 

INTRODUCTION 

Congratulations on your Koch/Ramon SC-100 Hydraulic Piston Stuffer purchase. This 

piston stuffer was designed to give you years of trouble free operations and to help in 

the preparation and packaging of your quality food products. 

Please read this owner’s manual to gain the maximum benefits of your piston stuffer 

and its different components. 

A note about cleaning: Given all the various ways equipment is used in different 

environments, we recommend the owner consult sanitation experts on how to properly 

clean each piece of machinery in their plant and to do bacterial testing to insure that the 

equipment is cleaned properly. 

For Sales, Call: 

Phone (816) 753-2150 • Fax (816) 753-4976 

Toll-Free (800) 777-5624 

For Replacement Parts, Call: 

Phone (816) 753-2150 • Fax (816) 561-2854 

Toll-Free (800) 746-1723 

For Technical Support, Call: 

Phone (816) 753-2150 • Fax (816) 531-1477 

Toll-Free (800) 777-5624 

© Copyright 2005 Koch Equipment LLC 

Koch Equipment LLC Last printed 1/21/2005 2:47:00 PM 

1414 West 29th Street Version Rev. 2003D-0 


Phone: (816) 753-2150 • Fax: (816) 753-4976 

info@kochequipment.com • kochequipment.com

I N T R O D U C T I O N PAGE II 

General 

Please read these instructions carefully before performing any installation, use, or 

maintenance operation. 

In case of damage caused during transportation to your plant, claims should be made 

immediately to the truck line and driver. Koch Equipment LLC is not responsible for 

damage or handling of the machine once it leaves our warehouse. 

Koch Equipment LLC cannot be held responsible for drawbacks, breakdowns, accidents, 

etc. as a result of the lack of knowledge or non-application of the rules contained in this 

operating instruction manual. The same is true for any change, modification and/or for 

the installation of non-authorized parts. 

Receiving Problems: As in all cases, before signing the bill of lading, be sure all items 

have been received as listed and there is no damage in shipment. If needed, a claim must 

be made immediately to the local truck line office and noted on the bill of lading. 

Model Nr. ________ Serial Nr. ___________ 

Ship Date: ___________________________ 

Owner: ___________________________ 

Location: ___________________________ 

Electrical service for your SC-100 Piston Stuffer: 220 volt, 60 Hertz, 3 phase 


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I N T R O D U C T I O N PAGE III 

Table of Contents 


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INTRODUCTION...........................................i 

General .......................................................ii 

SECTION 1 

SAFETY ....................................................... 1 

Warning .................................................... 2 

General Safety Guidelines........................... 5 

SECTION 2 

STARTUP ..................................................... 6 

SECTION 3 

OPERATION.............................................. 10 

SECTION 4 

MAINTENANCE......................................... 13 

SECTION 5 

SCHEMATIC.............................................. 16 

SECTION 6 

PARTS ....................................................... 21 

SECTION 7 

SERVICE HISTORY ..................................... 26 

ICONS 

................................... Warning 

..................................... Caution 




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I N T R O D U C T I O N PAGE IV 

Index 

C 

Cleaning..................................................... i, 14 

D 

Data Plate........................................................ 8 

F 

Frequently Ordered Parts ............................... 25 

G 

General ............................................................ii 

General Part Identification ............................. 22 

General Safety Guidelines................................ 5 

General Warnings............................................ 4 

I 

Important Notice for Users ............................... 4 

Installation....................................................... 8 

INTRODUCTION............................................... i 

M 

Maintenance.................................................. 14 

MAINTENANCE.............................................. 13 

Mechanical Drawings..................................... 17 


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O 

OPERATION................................................... 10 

Operator Safety ............................................... 2 

P 

PARTS ............................................................ 21 

Power Requirements ........................................ 9 

Problems and Remedies ................................. 15 

R 

Recommended Use ........................................ 12 

S 

SAFETY ............................................................ 1 

SCHEMATIC................................................... 16 

Service History ............................................... 27 

Standard Operation ....................................... 11 

Startup............................................................. 7 

STARTUP .......................................................... 6 

T 

Troubleshooting............................................. 15 

W 

WARNING ....................................................... 2 

Warning Signals............................................... 5 




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S A F E T Y PAGE 1 

SAFETY 

Warning .................................................................................. 2 

Operator Safety ........................................................................ 3 

General Warnings..................................................................... 4 

Important Notice for Users ........................................................ 4 

Warning Signals........................................................................ 5 

General Safety Guidelines......................................................... 5 


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Section 

1 




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WARNING 

The following procedures and guidelines must be followed precisely to avoid 

problems that can result in property damage, personal injury, or death. If you have 

any questions related to this information, please contact the Koch Equipment LLC 

Service Department at (800) 777-5624. 

Read the entire Owner’s Manual before use and retain for future reference. Read and 

pay attention to all Warnings and Instructions on the machine. 

Place the machine on a stable surface. 

Only specialized and expert operators authorized by the manufacturer should carry out 

all routine and unexpected maintenance operations of the machine. 

Herein specified as “operator” is the person(s) charged with installing, running, 

adjusting, servicing, cleaning, repairing and transporting the machine. 

These operating instructions form an integral part of the machine and must accompany 

the piston stuffer for its entire lifetime until demolition. 

The manufacturer recommends that these instructions be read carefully before 

performing any installation/use/maintenance operation. All operators attending the 

machine must know the directions contained in this operating instructions manual. 

Provide this manual to any other user or successive owner of the machine. 

Perform service on the machine only as directed in this manual. 


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Operator Safety 

Before starting work with the machine, the operator must be clearly aware of the 

position and the working of all the controls and of the characteristics of the machine 

described in these operating instructions. 

Never tamper with the safety devices. 

Never remove or change the protection and safety devices, especially those installed at 

the meat inlet. 

Never tamper with the electric system. 

Always disconnect from power supply before performing any cleaning, servicing or 

maintenance operation. 

The use of the machine in environments with explosive atmosphere is forbidden. 

Do not touch the moving device if the machine is not completely stopped. 

The working position is in front of the start and stop push buttons. 

Never go near the machine with loose hair, clothes, bracelets, chains, rings, ties, etc. to 

avoid the chance that they become tangled in the moving parts of the machine. 

As a consequence, the operator shall wear suitable clothes for the working environment 

and the situation he/she is in. 

Always keep the working place clear and free from oil residues. 

The room where the machine is installed must not have dark areas, dazzling lights or 

stroboscopic effects due to the lighting system. 


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General Warnings 

Operations that may be dangerous for operators are indicated by the “CAUTION” 

symbol, shown above. 

Make sure that the voltage of the outlet is the same as the voltage required by the 

machine (refer to the label). 

The manufacturer must authorize any modification to the machine. 

Never use a spray of water to clean the machine. 

The voltage inside the machine is 208 volt or 230 volt. 

Always use original spare parts that guarantee perfect working order and the safety of 

the machine. 

The electric cable must be checked regularly and carefully (a worn cable or a cable in 

less than perfect condition is always a serious electrical danger). 

Important Notice for Users 

Removal of the safety device on the machine is not allowed. 

Koch Equipment LLC is not liable for any damage to humans, animals or material 

objects resulting from the following: 

• Removal of safety devices; 

• Unauthorized uses of the machine or uses not expressly listed in this operating 

instructions manual in the Technical Features section; or 

• Tampering of the machine. 

The manufacturer cannot take any responsibility for modifications made to the original 

piston stuffer other than those mentioned in these operating instructions. 


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The manufacturer takes no responsibility for damages caused by operating the machine 

incorrectly. 

The manufacturer does not take any responsibility for any anomaly that can happen in 

the operation and performance of the machine by not observing these operating 

instructions. 

Warning Signals 

WARNING non-indelible adhesive labels are placed on the machine. 

They must be replaced with the labels supplied when it becomes difficult to read them. 

Read these labels before operating the machine. 

General Safety Guidelines 

Obvious safety guidelines should be observed. 

⇒ Be sure to turn off power to your piston stuffer before any maintenance work is 

performed. 

⇒ Never reach into or put anything into the ventilation slots of the machine. 

⇒ Care should be taken at all times, especially when there is a need to remove any of 

the internal, overhead panels. 

⇒ The best safety precaution around any machine is to keep it clean! Always keep a fire 

extinguisher (Type BC) close to the machine. (See more on cleaning in following 

pages.) 


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S T A R T U P PAGE 6 

STARTUP 

Startup...................................................................................... 7 

Installation................................................................................ 8 

Data Plate................................................................................. 8 

Power Requirements ................................................................. 9 

Section 

2


Startup 

Before starting the machine for the first time, the oil tank (44) must be filled. To do this, 

remove the machine side cover, take out the filler cap (58) and fill the oil tank. 

The following oils are recommended (15-liters): 

TELLUS 33 (SHELL) 

TERESSO 52 (ESSO) 

NUTO 32 (ESSO) 

343 HYDRAULIC (GULF) 

After filling the oil tank, replace the filler cap and cover to normal position. Replace the 

handle (20), to facilitate opening the cover (15), and also the control lever (47). 

Before starting every cycle of operation it is essential to clean the machine with 

biodegradable soap in order to eliminate any bacteria that might be present. 

Once the machine is switched on and has started operating, check that the start and 

stop pushbuttons, as well as all of the other safety devices, operate properly. Afterward, 

make sure that the hydraulic pump rotates in the right direction. To check it, just press 

the green start switch (I), then push pedal (47) forward. If the meat pressing piston does 

not move, it means that the motor is rotating in the wrong direction. To correct this 

problem, the two cores in the plug wire must be interchanged. 

Once all this has been carried out, work can start as follows: 

Loosen nut (4) and open cylinder cover (15). Load the cylinder with meat. We 

recommend that the operator press the meat down with his/her hands to expel as much 

air as possible from the cylinder. Then choose the correct funnel size (1, 2, 3) and fix the 

selected funnel to the cover with nut (14). Push lever forward (47) to lift piston (71). 

Then release the lever so that it springs back to neutral position. To bring the piston 

down, move lever (47) backward. To do this, it is not necessary to keep pressing the 

lever backward, as it will remain in that position until you restore it to its neutral 

position. When the piston reaches the lowest point, there is no reason to be concerned, 

because a safety valve will open to prevent stress on the machine. 

To select the meat output speed desired, adjust command (29). Turn it clockwise to 

increase the speed by raising the pressure or turn it counterclockwise if a lower meat 

output speed is required. 


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Installation 

The piston stuffer must be unpacked carefully and the shipment label checked to ensure 

that it is the correct machine. Once unpacked, please read the instructions carefully and 

take the following precautions: 

1. Make sure that the personnel in charge of installing the piston stuffer are fully 

qualified in dealing with this kind of machine. 

2. Check that the mains into which the machine will be plugged has the right 

current. 

3. Check that all the components of the piston stuffer are correctly placed and 

that they have not in any way been affected by transportation. 

Data Plate 

Place the data plate on the right-hand side of the machine base, at the right lower 

angle, in accordance with the drawing below. 


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Power Requirements 

The piston stuffer must be plugged into a grounding outlet. If for any reason no 

grounding outlet is available, a 10A differential switch with a maximum sensitivity of 

15mA should be installed. 

The feed line, if in a fixed conduit, must be a 750 VAT wire with a double insulation 

layer. If the piston stuffer is plugged to a wire not fixed in a conduit, the wire must be of 

1,000 VAC. 

Before switching on the machine, make sure that it is correctly installed and that the 

safety devices are attached to the machine. Carry out overload tests and wire insulation 

tests to guarantee minimum causes of direct or indirect contact. 

Before connecting the machine to the mains, please make sure that the electric system 

conforms to the features set out on the data plate. If not, perform the following: 

1. Change connections in motor terminal box, as indicated in Fig. 1. 

2. Change the contact. 


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Fig. 1 

220V 380V 

Take into account that the piston stuffer motor operates only on one voltage and cannot 

be changed. If the piston stuffer voltage needs to be changed, please contact our 

technical service staff, as a great deal of specialized hard work is required. 

If the above-mentioned verifications are not applied, the piston stuffer motor and 

electric components can suffer serious damage. Koch Equipment LLC will not accept any 

responsibility for damages that the machine may suffer by not observing the precautions 

outlined. 




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O P E R A T I O N PAGE 10 

OPERATION 

Standard Operation ................................................................ 11 

Recommended Use ................................................................. 12 


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Section 

3 




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Standard Operation 

The piston stuffer is intended for filling natural or synthetic skins with various types of 

meat and ingredients in order to obtain the kind of sausage desired. 

The piston stuffer is completely made of stainless steel (with the exception of the piston 

and cover, which are manufactured in corrosion-proofed anodized aluminum). The 

piston and cover can be provided in stainless steel as an option. 

The machine has been designed in such a way that it is easy to clean and practically no 

maintenance is required. The machine is also fitted with wheels so it can be moved 

when required. 

The piston stuffer construction fulfils all EEC safety requirements: 

• The machine is prevented from starting up unexpectedly when the electric supply 

is restored after electricity cut. 

• As the machine is accessible from all sides, the stop pushbutton can also be used 

as an emergency stop. 

• The hydraulic oil tank is tightly closed to prevent any risk of explosion or ignition 

in the machine in case it came into contact with an electric spark. 


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Recommended Use 

The piston stuffer was designed and built for the sole stuffing of all kinds of fresh meat 

and ingredients, in suitable casings and without bone parts, flesh or tendons. 

The main case is solid and built in stainless steel. The machine is equipped with 

supporting. It is fully equipped with safety devices for the operator’s safety. 

The minimum temperature of the meat to be processed must be not less than +1° C. 

It is not advisable to use the machine to stuff frozen meat. 

Any use different from the recommended use is not allowed and may be dangerous for 

the machine and the operator. Koch Equipment LLC is not liable for damage to humans, 

animals or material objects resulting from uses that are not expressly described in this 

operating instruction manual. 

Always and only use the attachments supplied. 

Only one operator at a time can operate the machine. 

For working operations, the operator must stay in front of the start and stop push 

buttons. 


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M A I N T E N A N C E PAGE 13 

MAINTENANCE 

Cleaning................................................................................. 14 

Maintenance........................................................................... 14 

Troubleshooting: Problems & Remedies ................................... 15 


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Section 

4 




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Cleaning 

1. Clean the machine in accordance with instructions in this section. 

2. Always clean the machine after use. 

3. Place the machine in a hygienically appropriate environment. 

To clean the piston, dismount as follows: 

Move piston (71) to its highest point, place part (77) into part (70) and turn 

counterclockwise in order to unscrew and remove part (82). This operation must be 

carried out with pedal (47) pressed forward to prevent eye (73) from turning. Then screw 

on part (78) into part (72) to remove piston. 

To replace piston, place it horizontally on the cylinder, with piston shaft (73) at the top. 

To get the piston back into the cylinder, keep screwing on part (72). 

Maintenance 

The piston stuffer has been made to reduce maintenance almost to zero. We 

recommend that the hydraulic oil be changed approximately every two years. 


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Phone: (816) 753-2150 • Fax: (816) 753-4976 



Troubleshooting 

Problems and Remedies 

A spare parts list is included so that parts can be obtained from Koch Equipment LLC. 

Our piston stuffers are manufactured with first class materials subject to very strict 

quality control and the components or additional equipment not manufactured by us are 

supplied to us with a reliability certificate. A breakdown, however, may occur: 

When trying to start the piston stuffer, if it does not go into motion: 

• Electric power can be lacking—the operator must wait. 

• Button on head blocked or dirty—clean it. 

• The power switch has deteriorated—it must be replaced. 

The piston stuffer stops after being in operation: 

• There may be a direct contact inside the motor—the motor will have to be 

rewound. 

• Defective insulation in some feed wire or in the machine control circuit—it will 

have to be checked with a voltage meter and the defective wire replaced. 

The motor is on, but the machine does not operate: 

• The pump rotates counterclockwise—correct by interchanging the two cores in the 

plug wire. 

• Lack of oil—add more oil. 

The piston moves up irregularly: 

• There is air in the hydraulic circuit—correct this by raising and lowering the piston 

a couple times. The air will be expelled automatically. 

• Lack of oil—add more oil. 


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S C H E M A T I C PAGE 16 

SCHEMATIC 

Mechanical Drawings.............................................................. 17 


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Section 

5 




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Mechanical Drawings 


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Mechanical Drawings (continued) 


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P A R T S PAGE 21 

PARTS 

General Part Identification ...................................................... 22 

Frequently Ordered Parts ........................................................ 25 


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Section 

6 




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General Part Identification 

Only use original spare parts and do not wait for the parts to be 

completely worn out before replacing them. 

Ref. 

Koch 

Nr. Mfg. Nr. Item Nr. Description 

1 500046 Nozzle, 35mm diameter 



4 500026 Column nut 

5 500016 

6 5011430 Screw M12 x 30 

7 

8 

51114 Flat washer, 12mm diameter 

9 5320612 Screw, stainless steel, 6 x 12 

10 

11 

60814 O-ring, ¼-in. 

12 30614 Copper washer, ¼-in. 

13 30514 Tin cap (¼-in.) 

14 

15 

300033 48 00 51 Nut cylinder cover 

16 6091550 48 00 20 O-ring, cylinder 

17 

18 

19 

500031 Stainless steel cylinder 

20 

21 

7010 Cable, ceneflex 

22 5320408 Screw M4 x 8 

23 

24 

6091050 48 00 21 O-ring, piston 

25 

26 

500009 Lower cap cylinder 

27 500061 Foot machine 

28 5020616 Allen screw 6 x 16 

29 

30 

500027 Handle 

31 607756507 48 00 53 Oil seal 

32 500050 Cap piston driving bushing 

33 606756513 48 00 55 Collar 

34 500007 Driving bushing 

35 60510145 48 00 57 O-ring 


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General Part Identification (continued) 

Ref. 

Koch 

Nr. Mfg. Nr. Item Nr. Description 

36 6051402 48 00 58 O-ring 

37 500006 Top plunger piston 

38 6049906 48 00 61 O-ring 

39 Collar 

40 500006 Bottom plunger piston 

41 51014 Flat washer 

42 

43 

44 

45 

46 

51714 Self-locking nut 

47 130196 48 00 63 Command lever 

48 

49 

6052203 48 00 64 O-ring (20 x 26 x 3) 

50 456141715 Bushing (Selfoil A.14.17.15) 

51 500033 Command axle, distributor 

52 649 Distributor 

53 

54 

5020860 Allen screw (M8 x 60) 

55 60838 Gasket (3/8-in.) 

56 657 Raccord (3/8-in. - 10) 

57 

58 

59 

60 

60510145 O-ring 

61 

62 

63 

500004 Hydraulic cylinder 

64 655 48 00 68 Oil filter 

65 

66 

657 Raccord (3/8-in. - 10) 

67 652 48 00 69 Coupling 

68 691 48 00 71 Pump 

69 

70 

71 

72 

73 

74 

5020620 Allen screw (M-6 x 20) 


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General Part Identification (continued) 

Ref. 

Koch 

Nr. 

75 

76 

77 

78 

79 

80 

81 

82 

83 

Mfg. Nr. Item Nr. Description 

84 300044 48 00 73 Screw, piston tightening 

85 500025 Piston 

86 500012 48 00 75 Coupling, piston-rod 

87 

88 

89 

500005 Rod 

90 130126 48 00 76 Handle 

91 300019 48 00 79 Extractor 

92 

93 

300045 48 00 81 Piston extractor 

94 1009 Drainpipe 

95 Circlip 

96 Wheel 

97 694 Coupling drainpipe 

98 500075 Cover oil tank 

99 30514 Cap level support 

100 500074 Set pression regulation 

101 130165 Support 

102 4441817 48 00 67 Engine 

103 31611 Clamp 

104 500070 Oil tank 

105 500071 Base 

106 7394 Pushbutton 


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Frequently Ordered Parts 

Date Part Nr. Qty. Part Ordered 


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S E R V I C E H I S T O R Y PAGE 26 

SERVICE HISTORY 

Service History ........................................................................ 27 


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Section 

7 




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S E R V I C E H I S T O R Y PAGE 27 

Service History 

Date Service Provided 


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Phone: (816) 753-2150 • Fax: (816) 753-4976 


Koch Equipment LLC 

1414 West 29th Street 


800-777-5624 

Regular Telephone: (816) 753-2150 

Fax: (816) 753-4976 

E-mail: info@kochequipment.com 

Internet: kochequipment.com 

Koch Replacement Parts 

(800) 746-1723 

Fax: (816) 561-2854 

Koch Equipment Services Inc. 

(800) 777-5624 

Fax: (816) 531-1447 


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KOCH - Berkel Sales & Service

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