Kohler 8.5RES Service Manual
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Kohler 8.5RES Service Manual

Residential/commercial generator sets
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Service
Residential/Commercial Generator Sets
Models:
8.5RES
12RES
Controller:
Advanced Digital Control
TP-6196 5/04

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Summary of Contents for Kohler 8.5RES

  • Page 1 Service Residential/Commercial Generator Sets Models: 8.5RES 12RES Controller: Advanced Digital Control TP-6196 5/04...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Introduction .
  • Page 4 Table of Contents, continued Controller Configuration and Adjustment ....... . . 4.5.1 Controller Time Out .
  • Page 5 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 from your body before touching Exhaust System Fuel System batteries by first touching a grounded metal surface away from the battery. To WARNING avoid sparks, do not disturb the battery WARNING charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.
  • Page 7 LP liquid withdrawal fuel leaks. Welding on the generator set. Can WARNING Explosive fuel vapors can cause cause severe electrical equipment severe injury or death. Fuel leakage damage. Before welding on the can cause an explosion. Check the LP generator set perform the following liquid withdrawal gas fuel system for steps: (1) Remove the battery cables, leakage by using a soap and water...
  • Page 8 Heavy Equipment Moving Parts Notice NOTICE WARNING WARNING This generator set has been rewired from its nameplate voltage Moving rotor. Hazardous voltage. Can cause severe injury or death. Unbalanced weight. Improper lifting can cause severe Operate the generator set only when 246242 injury or death and equipment all guards and electrical enclosures...

  • Page 9: Introduction

    Information in this publication represents data available parts for your generator set or for models or spec at the time of print. Kohler Co. reserves the right to numbers not listed here. change this publication and the products represented...

  • 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

    GENERAL GUIDELINES FOR DERATING: ALTITUDE: Derate 4% per 305 m (1000 ft.) elevation above 153 m (500 ft.). TEMPERATURE: Derate 1.5% per 5.5_C (10_F) temperature increase above 16_C (60_F). 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.

  • Page 12: Engine Specifications

    1.5 Engine Specifications Engine Specification 8.5RES (60 Hz) 12RES (60 Hz) Manufacturer Kohler Model CH20 CH740 Cycle Number of cylinders Compression ratio 8.5:1 9.0:1 Displacement, cc (cu. in.) 624 (38.0) 725 (44.0) Rated power, propane fuel, kw (hp) 11.5 (15.4) 17.6 (23.6)

  • Page 13: Alternator Specifications

    1.6 Alternator Specifications 1.7 Torque Specifications Alternator Specification 8.5/12RES Torque Specifications, Nm (ft. lb.) 8.5/12RES Frequency Hz 50/60 Alternator overbolts 7 (5) Phase Single-Phase Alternator thrubolt 40 (28) Number of leads Cylinder head nuts 30 (40.7) Excitation method Static Excited Generator adapter screws 40 (28) Voltage regulator type...

  • Page 14: Service View

    1.8 Service View ADV6823 Starter (non-service side) Fuel System Detail 1. Enclosure 17. Oil filter 2. Muffler 18. Air intake, alternator 3. Oil check 19. Exhaust 4. Oil fill 20. Spark arrestor (not visible in this view) 5. Air cleaner 21.

  • Page 15: 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 16 Action Refer to Refer to Section Inspect Check Change Clean Test Interval System—Component Lubrication Oil level 2.2.2 8 hrs. or before use Crankcase breather hose Yearly or 500 Hrs. Change oil 2.2.4 Yearly or 100 Hrs. Replace filter(s)* 2.2.4 Yearly or 200 Hrs. Fuel 5.10 Flexible lines and connections [...

  • Page 17: Lubrication System

    See Figure 2-2 for the dipstick and oil fill locations. Do not check the oil level Model L (Qt.) when the generator set is running. Shut down the 8.5RES 1.9 (2.0) generator set and wait several minutes before checking 12RES 2.0 (2.1) the oil level.

  • Page 18: Oil Change Procedure

    2.2.4 Oil Change Procedure b. Apply a light coat of clean oil to the rubber seal of the new oil filter. Whenever possible, drain the oil while it is still warm. c. Install the new oil filter following the instructions 1.

  • Page 19: Spark Plugs

    2.3 Spark Plugs 2.4 Air Cleaner Element and Precleaner Reset the spark plug gap or replace the plugs with new plugs as necessary. The engine has a replaceable high-density paper air cleaner element with an oiled foam precleaner. See Spark Plug Maintenance Procedure Figure 2-7.
  • Page 20 Air Cleaner Service Procedure 5. Reinstall the air cleaner. 1. Disable the generator set. a. Install the precleaner over the paper element. a. Place the generator set master switch in the b. Check the air cleaner base. Make sure it is OFF/RESET position.

  • Page 21: Cooling System

    2.5 Cooling System 2.7 Battery Fans in the engine and generator draw cooling air WARNING through the louvered openings in the sides and end of the sound enclosure. The cooling air mixes with the engine exhaust and is discharged through the outlet end.

  • Page 22: Cleaning The Battery

    Battery short circuits. Explosion can cause severe injury After reconnecting the battery cables, coat the battery or death. Short circuits can cause bodily injury and/or terminals with petroleum jelly, silicone grease, or other equipment damage. Disconnect the battery before generator nonconductive grease.

  • Page 23: Internal Engine Components (Gas/Gasoline-Fueled Engines)

    3. Run the generator set until the engine stops. 1. Clean the exterior surface of the generator set. 4. Place the generator set master switch in the 2. Seal all engine openings except for the air intake OFF/RESET position. with nonabsorbent adhesive tape. 3.
  • Page 24 Notes Section 2 Scheduled Maintenance TP-6196 5/04...

  • Page 25: Section 3 Troubleshooting

    Section 3 Troubleshooting 3.1 Introduction battery charger fuse is located in the positive battery lead. Always check and replace the fuses before Corrective action and testing in many cases requires replacing other components. knowledge of electrical systems and electronic circuits. Incorrect controller settings.
  • Page 26 Troubleshooting Chart Problem Possible Cause Corrective Action Reference Generator Weak or dead battery Recharge or replace battery. Generator Set set does If battery is weak or dead, check battery charger fuse, not crank power supply, and operation. Battery connections Check for reversed or poor battery connections. —...
  • Page 27 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Cranks but No fuel Open (turn on) manual fuel valve. Check fuel supply — does not tank (LP). start Insufficient fuel pressure Check fuel pressure to the generator set. Verify Section 5.10.3 adequate fuel pressure and pipe size for the generator set plus all other gas appliances.
  • Page 28 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Stops Fault shutdown Check for a fault shutdown code on the controller’s LED Section 4.4 suddenly display. Correct the fault and then move the generator Section 5.9 set master switch to OFF/RESET to reset the controller. No fuel Turn on fuel supply.
  • Page 29 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Lacks Air intake restriction, inadequate Inspect air intakes and exhaust for obstructions. Section 2.5 power cooling Check air cleaner. Section 2.4 Generator overloaded Reduce load. Section 1.2 Spark plug(s) Replace and regap plug(s). Section 2.3 Spark plug wire(s) Replace spark plug wires.
  • Page 30 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference High Incorrect controller configuration Check and adjust the controller configuration Section 4.5.2 output parameters. voltage Incorrect controller voltage Check and adjust the controller voltage settings. Section 4.5.3 settings Engine speed too high Check engine speed using tachometer or frequency Section 5.8 meter.

  • Page 31: Section 4 Controller

    Section 4 Controller 4.1 Introduction configuration and adjustment are covered in Section 4.5. This section covers operation, configuration, A silicon controlled rectifier (SCR) module works with adjustment, and replacement of the ADC 2100 the controller to regulate the output voltage. controller.

  • Page 32: Controller Display And Keypad

    4.2 Controller Display and Keypad Controller Display Item Description The controller has an LED display and a three-button Crank indication Displays CC_1, CC_2, or CC_3 to indicate keypad. See Figure 4-2. The LED display shows the first, second or third attempt to start the runtime hours, fault codes, application program version engine.

  • Page 33: Sequence Of Operation

    4.3 Sequence of Operation cranking cycle seems shorter than the factory setting, check the engine starting battery. The following sections describe the controller sequence of operation during generator start, run, stop, and fault 4.3.2 Starting Sequence, Remote Start shutdown modes. Use this as a starting point for controller and relay board fault identification.

  • Page 34: Faults

    4.4 Faults Always identify and correct the cause of a fault shutdown before restarting the generator set. Refer to Section 3, Troubleshooting, for instructions to identify 4.4.1 Warnings and correct the cause of the fault. The fault conditions listed in Figure 4-4 will cause the Move the generator set master switch to the controller to display a fault code but will not shut down OFF/RESET position to reset the controller after a fault...
  • Page 35 Refer to Section Code Fault Description Check Auxiliary fault Not used on the model 8.5/12RES. — — High engine Shutdown occurs if the engine coolant Check for blocked air inlets and exhaust outlets. temperature temperature exceeds the maximum temperature for more than 5 seconds. This protective becomes active after the engine reaches the crank disconnect speed.

  • Page 36: Controller Configuration And Adjustment

    4.5 Controller Configuration and The controller’s configuration mode allows adjustment of the system parameters listed in this section. The Adjustment system voltage and frequency and unit configuration and engine type are factory-set for each type of The first step in troubleshooting the controller is to verify generator set and engine and should not require that the controller is correctly configured for the changes unless the controller is replaced.

  • Page 37: Voltage And Frequency Adjustments

    Advanced configuration mode (Adnc). The data adjustments required after controller input types, battery voltage, and communications replacement or other service procedures. setting can be changed in the advanced configuration The generator set must be running during these mode. Press the up arrow button when Adnc is adjustments.
  • Page 38 Controller Configuration Mode: Hold the Select button: Display: * Move the generator set master switch to the RUN position. (The generator set engine will not start.) Wait about 5 seconds until the display shows the 1 0 4 program version number. (The number may be different than the one shown here.) Press the down arrow key and then the up arrow key 3 times to enter the configuration mode.
  • Page 39 Pressing the up arrow key at the Adnc display (See Figure 4-7) puts you into the Advanced Configuration Mode. Press: E d 0 5 To set the engine data input type to Ed05. To enter battery voltage selection mode. To toggle between 12 and 24 VDC. Set this B t 1 2 parameter to 12 VDC.
  • Page 40 Output Voltage and Frequency Adjustment Mode: Display :* x x x x Move the generator set master switch to the RUN position. The generator set engine starts and the controller display shows the engine runtime hours. Hold: Wait about 5 seconds until the display changes from runtime hours to the program version number.
  • Page 41 Display : * Continued from Figure 4-10: Press: To enter engine governor speed coarse adjustment mode. To raise or lower the engine speed in large increments. To enter engine governor speed fine adjustment mode. To raise or lower the engine speed in smaller increments.

  • Page 42: Continuous Power Mode Jumper

    There are 3 options when the display says SAVE: S A V E Press: To return to the first parameter, coarse voltage adjustment, to check or change settings before saving. See Figure 4-7. To save changes. Y E S To discard changes without saving. “Yes”or “no”...

  • Page 43: Master Switch

    a. Disconnect engine wiring harness connector P1 plug (35-pin) from the controller. Disconnect the J15 and J16 connectors. See Figure 4-13. b. Remove the controller from the generator set housing in order to access the back of the controller. 3. Remove the controller’s back cover to access the jumper.

  • Page 44: Relay Interface Board (Rib)

    4.8 Relay Interface Board (RIB) connection of customer equipment to the K1 and K4 relays. See Figure 4-15 for optional relay connections. The standard relay interface board (RIB) contains the K2 crank, K3 flash, and K5 run relays. Three LEDs indicate relay operation.

  • Page 45: Silicon Controlled Rectifier (Scr) Module

    4.9 Silicon Controlled Rectifier 3. Connect the ohmmeter from AC1 to (+) on the SCR module. You should read high resistance in both (SCR) Module directions. The silicon controlled rectifier (SCR) module works with 4. Connect the ohmmeter from AC1 to (--) on the SCR the ADC 2100 to regulate the output voltage.

  • Page 46: Controller Replacement

    9. Connect the positive (+) lead from the DC power ADC 2100 Controller Replacement Procedure source, with the lamp in series, to terminal AC1 on 1. Remove the enclosure service-side door. See the SCR module. The lamp should not glow. Figure 4-18.
  • Page 47 Note: Some versions of the controller mount from inside the controller compartment. Others are front-mounted. 6. For inside-mounted controllers: a. Remove 5 screws to remove the front panel on the air intake end of the enclosure. Remove the plastic caps to access the 2 side screws. See Figure 4-18.
  • Page 48 7. For front-mounted controllers: 12. Follow the instructions in Section 4.5.2 to change the new controller’s configuration settings to match a. Remove four mounting screws from the front of the generator set system voltage and frequency, the controller. unit configuration, engine type, engine data input types, battery voltage, and communications b.

  • Page 49: Section 5 Component Testing And Adjustment

    Section 5 Component Testing and Adjustment 5.1 Theory of Operation, 1-Phase Generator Sets Single-phase 8.5/12RES generator sets utilize a ADC 2100 rotating-field alternator to produce AC voltage. Upon activation of the generator master switch, DC current from the battery magnetizes the rotor (field). When the (--) magnetized rotor rotates within the stator windings, an electrical voltage develops within the stator.
  • Page 50 Grounding electrical equipment. Hazardous voltage can Main Field (Rotor), to test the rotor. If the ammeter cause severe injury or death. Electrocution is possible reading is stable, proceed to step 4. whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. 4.

  • Page 51: Stator

    5.3 Stator supply leads. Refer to the schematic in Figure 5-5 when performing the following The stator contains a series of coils of wire laid in a steps. laminated steel frame. The stator leads supply AC 6. Contact the ohmmeter leads and readjust the voltage to the load and voltage regulator.

  • Page 52: Main Field (Rotor)

    9. Use a megohmmeter to determine whether the 5.4 Main Field (Rotor) stator is shorted to ground. The two-pole rotor creates the magnetic field needed to a. Apply 500 volts DC to any stator lead and the produce alternating current in the stator windings. stator frame.
  • Page 53 Rotor Test Procedure 6. Perform a megohmmeter test to determine whether the rotor is shorted to ground. 1. Place the generator set master switch in the OFF position. a. Raise and secure the brushes away from the slip rings by inserting a retaining wire in the 2.

  • Page 54: Slip Rings

    5.5 Slip Rings Check the resistance through the brushes. Resistance through the brushes should be low, 0.1--0.2 ohms Slip rings acquire a glossy brown finish in normal without meter lead resistance. operation. Do not attempt to maintain a bright, newly-machined appearance on the slip rings. Cleaning with a dry, lint-free cloth is usually sufficient.

  • Page 55: Voltage

    5.7 Voltage WARNING 5.7.1 Voltage Regulation Voltage regulation is performed by the Advanced Digital Control (ADC) and the SCR module. The ADC monitors Moving rotor. Hazardous voltage. generator output voltage and adjusts the excitation Can cause severe injury or death. current to the rotor through the SCR module.

  • Page 56: Voltage Connections

    60 Hz) by adjusting the engine governor speed (parameter 4P) through the ADC controller. 9. Readjust the voltage gain (parameter 2P) until the light flicker minimizes, if necessary. 10. Check the voltage. Readjust the voltage (parameter 1P), if necessary. 11. Save the settings. Refer to Section 4.5 for instructions.

  • Page 57: Governor System

    5.8 Governor System Verify that the battery connections are clean and tight. Check for dirt buildup on the magnetic pickup. Metal The governor system consists an electromechanical filings or caked-on dirt or grease decreases the output stepper motor (actuator) and a magnetic pickup. The signal of the magnetic pickup.

  • Page 58: Governor System/Magnetic Pickup Operation Test

    actuator (stepper motor) as the mounting holes If the air gap is correct, the voltage should be allow. 1.75 volts AC minimum during engine cranking. 5. If the voltmeter displays less than 1.75 volts AC, b. Refer to the Engine Service Manual for other check the air gap as described in the following engine diagnostic and service information.
  • Page 59 1. Ignition module A-358000B-C 2. Air gap, 0.5 mm (0.020 in.) 3. Top of flywheel ring gear tooth 4. Lock nut 5. Magnetic pickup Figure 5-14 Magnetic Pickup Air Gap Check that the carburetor throttle linkage is connected to the stepper motor as shown in Figure 5-12.

  • Page 60: Frequency Adjustment

    6. After adjusting the air gap, check the voltage again 5.8.5 Frequency Adjustment as described in step 4. If the voltage does not The engine speed determines the generator output measure 1.75 VAC minimum, replace the magnetic frequency; 60 Hz units operate at 3600 rpm and 50 Hz pickup.

  • Page 61: Fault Shutdown Tests

    carburetor throttle plate opens completely without 5.9 Fault Shutdown Tests sticking and check the carburetor adjustment. If these procedures do not correct the problem, Verify the operation of the generator set overspeed, replace the controller. overcrank, and low oil pressure shutdowns by performing the following tests.

  • Page 62: Controller Fault Shutdown Functions

    5.9.1 Controller Fault Shutdown Increase the engine speed (parameter 4P) to at least 115% of the rated engine speed, 69 Hz on 60 Hz models Functions or 58 Hz on 50 Hz models. Verify that the generator set Check the operation of the fault functions programmed shuts down on an overspeed fault (OS).

  • Page 63: Fault Shutdown Switches

    5.9.2 Fault Shutdown Switches Low Oil Pressure (LOP) Switch The low oil pressure (LOP) switch is located under the Check the low oil pressure and high engine temperature engine air cleaner. See Figure 5-18. shutdown switches on the engine by performing the following tests.

  • Page 64: Fuel Systems

    5.10 Fuel Systems Figure 5-20 lists the maximum gas flow rates for each model. 8.5RES 12RES WARNING Natural Natural Pipe Length, m (ft.) 8 (25) 15 (50) 30 (100) Explosive fuel vapors. 46 (150) 1 1/4 Can cause severe injury or death.

  • Page 65: Fuel Conversion

    The fuel lock-off prevents fuel flow when the engine is 5.10.4 Fuel Conversion not operating. See Figure 5-21. Do not try to adjust the fuel pressure, fuel mixture, or engine speed using the The multi-fuel system allows conversion from natural fuel lock-off.
  • Page 66 Fuel Conversion Procedure 9. Slide the hose onto the hose fitting and secure it with the clamp. Use the following procedure to convert from natural gas 10. For the 12RES only: Connect the digital to LP vapor. See Figure 5-22 for the fuel system spark-advance module (DSAM) leads together for component locations.

  • Page 67: Digital Spark Advance Module (Dsam)

    5.10.5 Digital Spark Advance Module the new part. Refer to the generator set Parts Catalog for the fuel block part number. (DSAM) Only trained, authorized service technicians may adjust The digital spark advance module (DSAM) on the Model the fuel metering valves. The adjustment procedure 12RES optimizes the engine timing for the selected fuel, requires a digital volt meter (DVM), UEGO oxygen natural gas or LP.
  • Page 68 16. Remove the oxygen sensor from the exhaust manifold. Oxygen Sensor Reading, 17. Apply a small amount of antiseize compound to Natural Gas Model exhaust plug and reinstall the plug into the exhaust 8.5RES 2.40±0.05 2.25±0.05 manifold. 12RES 2.60±0.05 2.60±0.05 18.

  • Page 69: Fuses

    5.11 Fuses To further check generator set components, disconnect the battery and remove wiring harness plugs from the controller circuit board. Use an ohmmeter to check the The engine harness contains three inline fuses. See continuity of the components listed in Figure 5-29. Also Figure 5-27.
  • Page 70 Generator Set Master Switch Ohmmeter Ohmmeter Ohmmeter Readings for Operative Component Position Connections Scale Components* Generator set master RUN and COM R x 100 Zero ohms (continuity). Any other reading switch switch (See Figure 5-28) (See Figure 5 28) indicates a bad switch. OFF/RESET No reading (open circuit).

  • Page 71: Section 6 Disassembly/Reassembly

    Section 6 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 beginning of this manual. 6.1 Disassembly disassembly procedure provides important information to minimize disassembly time and indicates...
  • Page 72 2. Disconnect the alternator leads inside the controller box. Note the locations of the alternator lead connections for reconnection later. Figure 6-4. a. Disconnect alternator leads 1 and 4 from the line circuit breaker. b. Disconnect alternator leads 2 and 3 from the load connection terminal L0.
  • Page 73 3. Remove the engine exhaust muffler and alternator heat shield. See Figure 6-5. a. Disconnect the muffler from the engine exhaust pipe at the two flange connections. b. Remove the bolts holding the muffler to the alternator heat shield and remove the muffler. c.
  • Page 74 c. Remove 4 screws securing the brush cover to 6. Check the brushes. the alternator end bracket. See Figure 6-9. a. Remove the brush holder from the end bracket. d. Raise the brushes in the brush holder and See Figure 6-9. insert a small piece of wire into the brush holder b.

  • Page 75: Reassembly

    7. Remove the stator and rotor. 6.2 Reassembly a. Remove the stator from the rotor. 1. Reinstall the generator adapter onto the engine. b. Loosen and remove the thrubolt. Use a strap a. Attach the generator adapter and alternator wrench on the rotor to keep the rotor from adapter guard to the engine using four turning during loosening, if necessary.
  • Page 76 c. Route the leads connected to the alternator end e. Thread the four overbolts with locating washers bracket through the opening in the base of the through the end bracket and into the generator alternator frame. adapter. Position the locating tab of each washer to the outer edge of the oblong d.
  • Page 77 4. Secure the generator set to the skid. b. Verify that the brushes are centered on the slip rings. If required, insert spacers between the a. Raise the alternator end of the generator set mounting surface and brush holder to center and remove the block of wood from beneath the the brushes on the slip rings.
  • Page 78 GM29253C-U 1. Alternator air inlet duct 2. Mounting screws (3 ea.) 3. Exhaust shield Figure 6-18 Alternator Air Inlet Duct 9. Install the exhaust system. See Figure 6-19. a. Install the heat shield onto the alternator exhaust support using M8 hardware. b.
  • Page 79 10. Connect the alternator leads inside the controller 11. Reinstall the enclosure panels in reverse order of box. See Figure 6-20. removal. See Figure 6-21 and refer to Step 1 of the disassembly instrructions. a. Connect alternator leads 1 and 4 to the line circuit breaker.
  • Page 80 Notes Section 6 Disassembly/Reassembly TP-6196 5/04...

  • Page 81: Section 7 Wiring Diagrams

    Schematic Diagram Sheet 1 ADV-6835A Figure 7-3 Model No. Spec. No. Sheet 2 ADV-6835B Figure 7-4 8.5RES GM29253-GA1 Point-to-Point Wiring Diagram GM29358 Figure 7-5 GM29253-GA3 Figure 7-2 Controller Wiring Diagrams 12RES GM29253-GA2 GM29253-GA4 Figure 7-1 Generator Set Specification Numbers...
  • Page 82 Figure 7-3 8.5/12RES Schematic Diagram, Single Phase, Sheet 1, ADV-6835A-E Section 7 Diagrams and Drawings TP-6196 5/04...
  • Page 83 Figure 7-4 8.5/12RES Schematic Diagram, Single Phase, Sheet 2, ADV-6835B-E TP-6196 5/04 Section 7 Diagrams and Drawings...
  • Page 84 Figure 7-5 8.5/12RES Point-to-Point Wiring Diagram, Single Phase, GM29358-D Section 7 Diagrams and Drawings TP-6196 5/04...

  • Page 85: 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 86 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 µF kg/cm kilograms per square microfarad rot.

  • Page 87: 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 88: 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 89: 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 90: 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 91 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 96 Phone 920-565-3381, Fax 920-459-1646 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-6196 5/04 7 Jurong Pier Road Singapore 619159 E 2004 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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