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Kohler 8.5RMY Service Manual

Industrial generator sets
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Industrial Generator Sets
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8.5RMY
11RMY
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Relay
TP-5867 11/02d

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Summary of Contents for Kohler 8.5RMY

  • Page 1 Service Industrial Generator Sets Models: 8.5RMY 11RMY Controllers: Relay TP-5867 11/02d...

  • Page 2: Product Identification Information

    California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference.

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ..........Inside front cover Safety Precautions and Instructions .
  • Page 4 Table of Contents, continued 6.3.2 Voltage Regulator Adjustment ........Main Field (Rotor) .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting WARNING INSTRUCTIONS. Electromechanical equipment, including generator sets, WARNING transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or Explosion. maintained. To prevent accidents be Can cause severe injury or death.
  • Page 6 Engine Backfire/Flash Carbon monoxide symptoms. caused by vibration. Do not operate the Carbon monoxide can cause severe generator set in the presence of fuel Fire nausea, fainting, or death. Carbon leaks, fuel accumulation, or sparks. monoxide is a poisonous gas present in Repair fuel systems before resuming exhaust gases.
  • Page 7 Hazardous Noise electrical leads or appliances when Electrical backfeed to the utility. standing in water or on wet ground Hazardous backfeed voltage can because these conditions increase the cause severe injury or death. Install CAUTION risk of electrocution. a transfer switch in standby power installations to prevent the connection High voltage test.
  • Page 8 Moving Parts Servicing the generator set when it NOTICE is operating. Exposed moving parts Hardware damage. The engine and can cause severe injury or death. generator set may use both American WARNING Keep hands, feet, hair, clothing, and Standard and metric hardware. Use test leads away from the belts and the correct size tools to prevent pulleys when the generator set is...

  • Page 9: Introduction

    12 050 01 Information in this publication represents data available Spark plug 12 132 02 at the time of print. Kohler Co. reserves the right to Voltage regulator fuse, 10 amp 223316 change this publication and the products represented Controller fuse, 10 amp...

  • Page 10: Service Assistance

    Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPowerSystems.com Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product...

  • Page 11: Section 1 Specifications

    12-volt battery, minimum 1.3 Alternator Leads: 1-2, 3-4 132V 33-44 132V The generator is equipped with Kohler’s PowerBoostt 55-33 145V voltage regulation system, which provides instant Rotor field voltage/current response to load changes. readings at rated output...

  • Page 12: Generator Set Specifications

    (500 ft.). TEMPERATURE: Derate 1% per 5.5_C (10_F) temperature increase above 25_C (77_F). Derate applies to actual conditions at the carburetor inlet. Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler Co. generator distributor for availability.

  • Page 13: Service Views

    Engine Specification 8.5RMY (60 Hz) 11RMY (60 Hz) Manufacturer Kohler Model CH20 CH25 Cycle Number of cylinders Compression ratio 8.5:1 9.0:1 Displacement, cc (cu. in.) 624 (38.0) 725 (44.0) Rated horsepower (propane fuel) 12.3 (16.5) 14.6 (19.6) 3600 Bore x stroke, mm (in.) 77 x 67 (3.03 x 2.64)
  • Page 14 RESET/ AUTO F1 10 AMP F2 10 AMP TYPE ABC TYPE ABC P-358000-C 1. Generator set sound enclosure (weather housing not shown) 11. Gas regulator assembly 2. Muffler 12. Rodent screens 3. Oil check 13. Engine starting battery location 4. Oil drain hose 14.
  • Page 15 GM24829A-A 1. Generator set sound enclosure 11. Gas regulator assembly 2. Muffler 12. Fuel solenoid valve 3. Oil check 13. Rodent screens 4. Oil drain hose 14. Engine starting battery location 5. Oil fill 15. Engine oil cooler 6. Spark plugs 16.
  • Page 16 Notes Section 1 Specifications TP-5867 11/02...

  • Page 17: Section 2 Scheduled Maintenance

    Section 2 Scheduled Maintenance See the Safety Precautions and Instructions at the WARNING beginning of this manual before attempting to service, repair, or operate the generator set. Have an authorized distributor/dealer perform generator set service. Alternator Service. Under normal operating conditions the generator set alternator does not require scheduled Accidental starting.

  • Page 18: Service Schedule

    The low oil pressure shutdown feature protects the engine against internal damage if the oil pressure drops Model L (Qt.) below preset limits because of oil pump failure or other 8.5RMY 1.9 (2.0) malfunction. It does not protect against damage 11RMY 2.0 (2.1)
  • Page 19 Action Visually Inspect Check Change Clean Test Interval System—Component Fuel Flexible lines and connections Weekly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level Weekly Crankcase breather Quarterly Change oil Yearly or 50 Hrs Replace filter(s)* Yearly or 50 Hrs Cooling Air cleaner to room/enclosure Weekly...

  • Page 20: Oil Change Procedure

    2.2.4 Oil Change Procedure 2. Replace the oil filter. Whenever possible, drain the oil while it is still warm. a. Remove filter rotating counterclockwise with an oil filter wrench. 1. Drain the oil. b. Apply a light coat of clean oil to the rubber seal a.

  • Page 21: Spark Plugs

    2.3 Spark Plugs Keep the area around the air cleaner housing free of dirt and debris. Reset the spark plug gap or replace the plugs with new Note: Operating the engine with loose or damaged air plugs as necessary. cleaner components could allow unfiltered air into the engine, causing premature wear and Spark Plug Maintenance Procedure failure.

  • Page 22: Cooling System

    3. Wash and oil the foam precleaner. 2.5 Cooling System a. Wash the precleaner in warm soapy water. Fans in the engine and generator draw cooling air through the opening in the base next to the battery. The b. Rinse the precleaner with warm water until the air flows through a duct in the skid to the alternator at the water runs clear.

  • Page 23: Exhaust System

    2.6 Exhaust System chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. Remove combustible materials from the exhaust Battery gases. Explosion can cause severe injury or location. Combustible materials include building death. Battery gases can cause an explosion. Do not smoke materials as well as natural surroundings.

  • Page 24: Cleaning The Battery

    Clean the battery and cables and tighten battery terminals using the service schedule recommendations. Clean the battery by wiping it with a damp cloth. Keep the electrical connections dry and tight. Generator sets that are used as a standby to utility power and not used regularly require an external battery charger to keep the starting battery fully charged.

  • Page 25: Storage Procedure

    2.8 Storage Procedure ° ° Correction 71.1 + .032 Perform the following storage procedure before taking a + .030 generator set out of service for three months or longer. 65.6 + .028 Example 1: Follow the engine manufacturer’s recommendations, if + .026 °...

  • Page 26: Internal Engine Components (Gas/Gasoline-Fueled Engines)

    2.8.3 Internal Engine Components 2.8.4 Exterior (Gas/Gasoline-Fueled Engines) Prepare the exterior for storage as follows: If you have access to a fogging agent or SAE 10 oil, 1. Clean the exterior surface of the generator set. prepare the pistons and cylinders for storage as follows: 2.

  • Page 27: Section 3 Troubleshooting

    Section 3 Troubleshooting Use the following tables as a quick reference in regarding the problem and solution. Corrective action troubleshooting individual problems. Generator set and testing in many cases requires knowledge of faults are listed in groups and include likely causes and electrical and electronic circuits.
  • Page 28 General Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Generator set Low oil pressure (LOP) shutdown Correct cause of shutdown. Sections 4, Controller starts but Check oil level, oil pump, etc. Troubleshooting, 6.8, Fault shuts down Shutdown Test Procedure, and Engine S/M No generator output voltage Check AC voltage.
  • Page 29 General Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Generator set Loss of generator output voltage Check AC voltage at rectifier Sections 6, Component Testing stops to K1 relay (LED1 not lit) (BR1). Check continuity of B1/B2 and Adjustment, and 9, Wiring suddenly, stator leads.
  • Page 30 General Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Emits black or Fuel mixture adjustment incorrect Adjust fuel mixture. Section NO TAG, Fuel System gray smoke Air intake restriction Check air cleaner and intake. Engine O/M Worn piston rings, valves, etc. Check compression.
  • Page 31 Problem Possible Cause Corrective Action Reference No generator Defective stator (open, grounded, or Test and/or replace. Section 6, Component output voltage shorted windings) Testing and Adjustment K1 relay (NC) contact open Check continuity. Section 4, Controller Troubleshooting and 9, Wiring Diagrams Brushes sticking in holder Check springs and alignment.
  • Page 32 Notes Section 3 Troubleshooting TP-5867 11/02...

  • Page 33: Section 4 Controller Troubleshooting

    358076 GM10615 Model No. Spec. No. procedures for 8.5/11RMY generator sets equipped 8.5RMY PA-195021 with relay controllers and related engine components. PA-195025 Refer to the generator set Operation Manual for GM16902-GA1 operating instructions. Refer to Figure 4-2 or Figure 4-3 to identify the controller internal components.

  • Page 34: Sequence Of Operation

    Top View 1. TB1 interconnect terminal block RESET/ AUTO 2. Ground (GRD) terminal 3. Neutral (L0) terminal 4. Circuit breaker 5. Hourmeter F1 10 AMP F2 10 AMP FAULT 6. Electronic governor circuit board TYPE ABC TYPE ABC 7. Controller circuit board (includes cyclic crank controls) 8.
  • Page 35 Relay Description Relay Label Starter K1 or SR Ignition K5 or IR Control Power Crank Cyclic Crank Off/Reset O/RS Figure 4-5 System Relays (not located on the controller circuit board) GM10064- 1. Overspeed adjustment potentiometer, R17 2. K4 crank disconnect relay 3.

  • Page 36: Starting Sequence

    4.2.1 Starting Sequence shuts down. To restart the generator set, first move the generator master switch to the OFF/RESET position to Placing the generator set master switch in the RUN reset the controlller. position closes the contact between wires N and 47, starting the generator set locally.
  • Page 37 Grounding electrical equipment. Hazardous voltage can board and generator fault detection. When the K1, K2, cause severe injury or death. Electrocution is possible K3, or K4 relays receive power, the corresponding LED whenever electricity is present. Open the main circuit lights.

  • Page 38: Cyclic Cranking

    4.4 Cyclic Cranking The cyclic cranking adjustment potentiometers located in the controller allow adjustment of the cranking cycle for improved starter motor engagement. The basic controller has a separate cyclic cranking circuit board. See Figure 4-10. The integrated controller has the adjustment potentiometers mounted on the controller circuit board.
  • Page 39 4. Remove the generator set housing roof to gain WARNING access to the controller. 5. Disconnect the leads connected to terminals 1, 2, and 3 of the cyclic crank circuit board. Remove the cyclic crank board from the controller. Figure 4-2 for the location of the circuit board. Accidental starting.
  • Page 40 Notes Section 4 Controller Troubleshooting TP-5867 11/02...

  • Page 41: Section 5 Generator/Relay Controller Troubleshooting

    Section 5 Generator/Relay Controller Troubleshooting Use the following flow chart as an aid in troubleshooting prescribed remedy does not correct the problem, the main circuit board and the entire generator set. If the replace the controller circuit board. Move generator set Master Go to Engine cranks? Switch to RUN position...
  • Page 42 Engine starts to B Check for 12 volts DC at fuel valve No voltage Voltage present Fault shutdown relay Engine fault LED lit? (check fuel supply, spark plug, ignition coil, etc.) Engine wiring harness Engine safety shutdown has defective? Check occurred: low oil pressure, continuity of harness overspeed, overcrank...
  • Page 43 Engine runs but Engine starts but cannot be stopped by shuts down after 30 seconds moving master switch to OFF/RESET position Check condition/connections of master switch Crank/disconnect relay LED lit? Switch okay? Check for 120 volts AC output from Replace stator 1-2 winding at V0 and V7.
  • Page 44 Notes Section 5 Generator/Relay Controller Troubleshooting TP-5867 11/02...

  • Page 45: Section 6 Component Testing And Adjustment

    Section 6 Component Testing and Adjustment 6.1 Theory of Operation, 1-Phase Generator Sets with Power Boost IIIE Voltage Regulator + - - Single-phase 8.5/11RMY generator sets utilize a rotating-field alternator to produce AC current. Upon activation of the generator master switch, DC current from the battery magnetizes the rotor (field).

  • Page 46: Voltage Regulator

    Grounding electrical equipment. Hazardous voltage can 6.3 Voltage Regulator cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit Single-phase generator sets use the Power-BoosttIIIE breakers of all power sources before servicing the equipment. voltage regulator.

  • Page 47: Voltage Regulator Test

    6.3.1 Voltage Regulator Test Voltage Regulator Test Procedure 1. Connect the components as shown in Figure 6-5. If the regulator 10-amp fuse blows, the generator set shuts down. Verify that the regulator fuse is good before 2. Turn the variable transformer setting to zero. Plug proceeding with the test.

  • Page 48: Voltage Regulator Adjustment

    6.3.2 Voltage Regulator Adjustment The factory sets the voltage regulator for correct generator operation under a variety of load conditions. Usually, the voltage regulator needs no further adjustment. Adjust the regulator according to the following procedure after voltage reconnection or if the regulator has been tampered with or replaced.

  • Page 49: Main Field (Rotor)

    Short circuits. Hazardous voltage/current can cause measured by the voltmeter begins to drop. When severe injury or death. Short circuits can cause bodily injury set, the generator (as load is applied) attempts to and/or equipment damage. Do not contact electrical maintain normal output until the engine speed connections with tools or jewelry while making adjustments or drops below the cut-in frequency set in step 7.

  • Page 50: Slip Rings

    High voltage test. Hazardous voltage can cause severe 6. Perform a megohmmeter test to determine injury or death. Follow the instructions of the test equipment whether the rotor is shorted to ground. manufacturer when performing high-voltage tests on the rotor or stator.
  • Page 51 shorted windings (heat discoloration) indicate a WARNING stator in good condition. Moving rotor. Hazardous voltage. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. High voltage test. Hazardous voltage can cause severe injury or death.

  • Page 52: Brushes

    of less than 500 kOhms indicates deterioration Replace the brushes if they show uneven wear or are of the winding insulation and possible current worn to one half their original length. flow to ground. Leads Continuity 1 and 2 3 and 4 33 and 44 3 and 44 55 and 3...

  • Page 53: Engine/Generator Components

    6.7 Engine/Generator Components 3. Replace the gas valve if it does not actuate in step 2. WARNING 6.7.2 Voltage Checks The wiring harness and some engine/generator components can be checked with the generator set battery connected. See Figure 6-14. Place the Hazardous voltage.
  • Page 54 Generator Set Master Switch Ohmmeter Ohmmeter Ohmmeter Readings for Operative Component Position Connections Scale Components* Generator set master P1-2 (47) and P1-14 (N) R x 1000 Zero ohms (continuity). Any other reading switch switch indicates a defective switch. OFF/RESET No reading (open circuit). Any other reading indicates a defective switch.

  • Page 55: Fault Shutdown Test Procedure

    6.8 Fault Shutdown Test generator set shuts down after approximately 25--35 seconds of operation. Remove the jumper wire from the Procedure LOP switch and ground. Start the generator set and run it for at least 25--35 seconds to verify that the generator Verify the operation of the generator set overspeed, set does not shut down.

  • Page 56: Electronic Governor

    controller. Restart the generator set and verify that it A gain adjustment may be required if an unstable does not shut down. A successful restart indicates a (hunting/surging) condition occurs. Adjusting the gain faulty LOP switch. Replace the switch. may require readjustment of the engine speed. See Section 6.9.3.

  • Page 57: Hunting/Surging

    6.9.3 Hunting/Surging 6.9.4 Governor System Operation Test Often hunting/surging problems thought to be caused If the engine continues to operate erratically after the by the governor are actually caused by engine or previous checks, test the governor system operation carburetor problems. Check engine speed stability using the following procedure.
  • Page 58 Check the throttle linkage connection. See step 1 and Figure 6-16. Check for broken or loose wiring or con- nections and other items in step 2. Check stepper motor operation at startup. Does it move to fully open and then move to and stay in the fully closed position? See step 3.

  • Page 59: Frequency Adjustment

    g. Reinstall the engine blower housing. 6.9.5 Frequency Adjustment h. Reinstall the junction box and housing panels The engine speed determines the generator output removed to gain access to the front of the frequency; 60 Hz units operate at 3600 rpm and 50 Hz engine.

  • Page 60: Overspeed Verification And Adjustment

    in 1/8 turn increments until the engine operation 6.9.6 Overspeed Verification and stabilizes. Adjustment 9. Remove the load and observe the frequency. The Check the overspeed setting when investigating a frequency should return to the value stated in shutdown problem. Also check it after adjusting the step 4.

  • Page 61: Speed Sensor

    6.10 Speed Sensor Use the following test procedure to verify that the speed sensor operates correctly. Speed Sensor Test Procedure 1. Place the generator set master switch in the OFF position. 2. Disconnect power to the battery charger, if equipped. 3.
  • Page 62 TP5867722 1. Governor controller circuit board 4. Carburetor 6. Magnetic pickup 2. Terminal block TB1 5. Ignition 7. Stepper motor 3. Antidieseling solenoid Figure 6-24 Electronic Governor Wiring Section 6 Component Testing and Adjustment TP-5867 11/02...

  • Page 63: Fuel Systems

    See Figure 6-27. Measure the fuel pressure with the generator set Maximum Pipe Length m (ft.) running at full load. The fuel pressure should be 8.5RMY 11RMY Pipe Size 178--280 mm (7--11 in.) water column or 1.7--2.7 kPa 3/4 in. NPT 18.3...

  • Page 64: Fuel Conversion, Single-Fuel Models

    A-227531-C TP-5868 1. Secondary pressure regulator 2. Fuel metering valve (single-fuel models) 3. Inlet pressure check location (plug) 4. Fuel solenoid valve 5. Fuel lockoff Figure 6-27 Fuel Regulator and Valve 6.11.4 Fuel Conversion, Single-Fuel Generator sets that do not have emission-certified engines can be converted from natural gas to LP or Models vice-versa in the field.
  • Page 65 A-358000A-J 1. Oxygen sensor plug 3. Fuel metering valve adjustment screw 2. Fuel metering valve 4. Oxygen sensor (Kohler part number A-345052) Figure 6-29 Fuel Metering Valve Adjustment Components, Single-Fuel Models Only TP-5867 11/02 Section 6 Component Testing and Adjustment...

  • Page 66: Fuel Conversion, Multi-Fuel Systems

    17. Disconnect the DVM leads from the oxygen sensor. 18. Remove the oxygen sensor from the exhaust manifold. 19. Apply a small amount of antiseize compound to exhaust plug and reinstall the plug into the exhaust manifold. 20. Check that the generator set master switch is in the OFF position.
  • Page 67 11. Disconnect both wires at the fuel solenoid valve. WARNING 12. Apply ±12 VDC to the fuel solenoid valve to actuate the valve. 13. Turn on the fuel supply and check for leaks at the fuel block using a gas leak detector or a soap solution.
  • Page 68 Notes Section 6 Component Testing and Adjustment TP-5867 11/02...

  • Page 69: Section 7 Generator Reconnection

    Section 7 Generator Reconnection 7.1 Voltage Reconnection Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator reconnection procedure explains voltage set as follows: (1) Move the generator set master switch to the reconnections only.

  • Page 70: Four-Lead (Single-Phase) Generator Sets

    7.2 Four-Lead (Single-Phase) 7.2.2 Reconnection Options Generator Sets The following reconnections can be made using the factory two-pole circuit breaker provided. It is the The following information illustrates the reconnection of responsibility individual performing 4-lead generator sets. Always follow the National reconnection to meet all the electrical codes.

  • Page 71: 220 And 240 Volt Configuration

    220 and 240 Volt Configuration LO (Neutral) A jumper lead is not used. After connection adjust the Ground voltage regulator to obtain the desired voltage. Load LO (Neutral) Side Factory two-pole circuit breaker Ground Line Side Field installed Load jumper lead Factory two-pole Side circuit breaker...
  • Page 72 Notes Section 7 Generator Reconnection TP-5867 11/02...

  • Page 73: Section 8 Disassembly/Reassembly

    Section 8 Disassembly/Reassembly This section provides instructions for the disassembly and reassembly of the generator set alternator. Before beginning the generator disassembly or reassembly procedure, carefully read all safety precautions at the POWER SYSTEM beginning of this manual. 8.1 Disassembly disassembly procedure provides...
  • Page 74 3. Disconnect the alternator wiring. See Figure 8-3. a. Disconnect alternator leads 1, 2, 3, and 4. Note the locations of the lead connections for reconnection later. b. Disconnect brush leads FP and FN. c. Disconnect the speed sensor harness. 4.
  • Page 75 c. Remove the screws securing the brush cover to the alternator end bracket. See Figure 8-7. d. Disconnect the white, red, and black leads connected to the speed sensor. Figure 8-8. e. Raise the brushes in the brush holder and insert a small piece of wire into the brush holder retainer wire hole.

  • Page 76: Reassembly

    c. Remove the rotor assembly by striking the side of the rotor repeatedly with a soft-faced hammer to loosen it from the tapered crankshaft fitting. See Figure 8-9. Rotate the rotor and strike it on alternate sides. Set the rotor assembly aside. 9.
  • Page 77 b. Reinstall the screws and washers that secure the alternator frame vibromount mounting plate to the generator set skid. See Figure 8-12. 5. Tighten the hardware to the specified torques. a. Tighten the rotor thrubolt to 28 ft. lb. (38 Nm). It may be necessary to keep the engine flywheel from turning while torquing the rotor thrubolt.
  • Page 78 7. Install the exhaust system. See Figure 8-15. 8. Reconnect leads to the controller. a. Secure the lower portion of the exhaust duct to a. Insert the leads from the alternator assembly the alternator exhaust support with 1/4-20 into the convoluted conduit leading to the hardware.
  • Page 79 9. Reinstall the enclosure panels. See Figure 8-17 or 10. Return the generator set to operation. Figure 8-18. a. Check that the generator set master switch is in a. Install the non-service side housing panel. the OFF position. b. Install the alternator end housing panel. b.
  • Page 80 Notes Section 8 Disassembly/Reassembly TP-5867 11/02...

  • Page 81: Section 9 Wiring Diagrams

    Model No. Spec. No. Version No. listed below, such as when similar new specs are 195007 8.5RMY created prior to the updated reprint or in cases where the 195016 manual is deemed an acceptable substitute for a 195017 manual under development.
  • Page 82 Notes Section 9 Wiring Diagrams TP-5867 11/02...

  • Page 89: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute exh. exhaust ABDC after bottom dead center center of gravity ext. external alternating current cubic inch displacement Fahrenheit, female analog to digital centerline fglass.
  • Page 90 kilo (1000) MTBF mean time between failure round head machine (screw) kelvin MTBO mean time between overhauls rly. relay kiloampere mtg. mounting root mean square kilobyte (2 bytes) megawatt rnd. round kilogram milliwatt read only memory kg/cm kilograms per square microfarad rot.

  • Page 91: Appendix B Common Hardware Application Guidelines

    Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.

  • Page 92: Appendix C General Torque Specifications

    Appendix C General Torque Specifications Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated literature instructions give no specific torque values. threads. All torque values are +0%/--10%. The charts list values for new plated, zinc phosphate, or American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel...

  • Page 93: Appendix D Common Hardware Identification

    Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)

  • Page 94: Appendix E Common Hardware List

    Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6024-5...
  • Page 95 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (full thread) Hex Head Bolts (partial thread) Hex Nuts M933-04006-60 M4-0.70 x 6 M931-05055-60 M5-0.80 x 55 M934-03-50 M3-0.50 Standard...
  • Page 98 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters TP-5867 11/02d 7 Jurong Pier Road Singapore 619159 E 1998, 2002 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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