Kohler KDT Service Manual
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Kohler KDT Service Manual

Kohler KDT Service Manual

Power switching device
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Service
Transfer Switches
Models:
KDT/KMT/KDP/KMP
Power Switching Device:
Open-Transition 100--600 Amperes
Programmed-Transition 100--600 Amperes
Electrical Controls:
MPAC 1000t
TP-6226 7/04

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Summary of Contents for Kohler KDT

  • Page 1 Service Transfer Switches Models: KDT/KMT/KDP/KMP Power Switching Device: Open-Transition 100--600 Amperes Programmed-Transition 100--600 Amperes Electrical Controls: MPAC 1000t TP-6226 7/04...

  • Page 2: Product Identification Information

    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. Record field-installed kit numbers after installing the kits.

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ..........Inside front cover Safety Precautions and Instructions .
  • Page 4 ..........4.5.3 Solenoid Operation Diagrams, 40--225 Amp Model KDT/KMT Open Transition Switches .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Safety decals affixed to the equipment Battery INSTRUCTIONS. Electromechanical in prominent places alert the operator equipment, including generator sets, or service technician to potential transfer switches, switchgear, and hazards and explain how to act safely. WARNING accessories, can cause bodily harm The decals are shown throughout this...
  • Page 6 Battery electrolyte is a diluted Battery short circuits. Explosion DANGER sulfuric acid. Battery acid can cause can cause severe injury or death. severe injury or death. Battery acid Short circuits can cause bodily injury can cause blindness and burn skin. and/or equipment damage.

  • Page 7: Moving Parts

    Welding on the generator set. Can Servicing transfer switch. Heavy Equipment cause severe electrical equipment Hazardous voltage cause damage. Before welding on the severe injury or death. Deenergize all WARNING generator set perform the following power sources before servicing. Open steps: (1) Remove the battery cables, the main circuit breakers of all transfer negative (--) lead first.
  • Page 8 Disassembling solenoid. NOTICE NOTICE Spring-loaded parts can cause When replacing hardware, do not Foreign material contamination. severe personal injury or property substitute with inferior grade Cover the transfer switch during damage. The spring in the solenoid hardware. Screws and nuts are installation to keep dirt, grit, metal drill assembly exerts substantial force on available in different hardness ratings.

  • Page 9: Introduction

    Information in this publication represents data available Document Part at the time of print. Kohler Co. reserves the right to Document Number change this literature and the products represented ATS Operation and Installation Manual...

  • 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 Scheduled Maintenance

    Section 1 Scheduled Maintenance Introduction WARNING Regular preventive maintenance ensures safe and reliable operation and extends the life of the transfer switch. Preventive maintenance includes periodic testing, cleaning, inspecting, and replacing of worn or Hazardous voltage. missing components. Section 1.4 contains a service Can cause severe injury or death.

  • Page 12: Inspection And Service

    NOTICE WARNING Hardware damage. The transfer switch may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts. NOTICE Hazardous voltage. When replacing hardware, do not substitute with inferior Can cause severe injury or death.

  • Page 13: Internal Inspections And Maintenance

    1.2.2 Internal Inspections and Terminal Tightening. Loose connections on the power circuits can lead to overheating or explosion. Maintenance Tighten all lugs to the torque values shown on the label Internal Inspection. Have an authorized distributor/ on the switch. Tighten engine start, input/output, and dealer perform an annual inspection of the transfer auxiliary connections to the torque indicated on the switch.
  • Page 14 Programmed-Transition Switches replace the arc chute assembly. 6226 1. Arc chute assemblies Figure 1-1 Typical Arc Chute Assemblies, Model KDT/KMT Open-Transition Switches tp6226 1. Arc chute 2. Fixture 3. M6 nuts or retainer rings Figure 1-3 Removing Arc Chutes, 600-Amp Model...

  • Page 15: Testing

    Testing WARNING Periodic testing is important in any transfer switch application. It helps to ensure that the generator set will start and the transfer switch mechanisms and control circuits will operate when needed. Hazardous voltage. Can cause severe injury or death. 1.3.1 Weekly Generator Set Exercise Only authorized personnel should...

  • Page 16: Every Three Years

    4. Calculate the contact resistance using the Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have trained and following formula: qualified personnel take diagnostic measurements of live R = V ÷ I circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests.

  • Page 17: Service Schedule

    Service Schedule Follow service schedule below authorized distributor/dealer inspect the switch annually recommended service intervals. The transfer switch and perform all service marked by a D. operator can perform tasks marked by an X. Have an Adjust, Repair, or Visually System Component or Procedure Interval Replace...
  • Page 18 Notes Section 1 Scheduled Maintenance TP-6226 7/04...

  • Page 19: Section 2 Controller Troubleshooting

    Section 2 Controller Troubleshooting Introduction to DANGER Troubleshooting Use a personal computer (PC) running the MPAC Setup Program as a troubleshooting tool. The program’s event log and system setting displays are useful tools for Hazardous voltage. identifying the cause of most problems. Refer to the Will cause severe injury or death.

  • Page 20: Pc Connection

    PC Connection Note: The controller must have power in order to communicate with the PC. A cable to 120-volt Refer to the setup program operation manual for controllers through a 120 VAC wall outlet is available. See Section 3.4.3. hardware requirements and communication information. Use a null modem cable to connect a PC to the To verify that the controller is communicating with the controller’s serial port, P6.
  • Page 21 System Events and Faults Fault or Event Message Possible cause Check Overfrequency, Frequency settings Check that the system frequency setting matches the actual source Underfrequency frequency (50 or 60 Hz). Check the over/underfrequency pickup and dropout settings. See Section 3.7.3 and the setup program operation manual. Check that the frequency debounce setting is long enough to prevent nuisance faults caused by brief frequency variations.
  • Page 22 Fault or Event Message Possible cause Check Failure to Acquire Generator set did not See Failure to Start Generator Set, below. Standby start Open circuit breaker Check and close ATS source and generator set circuit breakers. ATS does not recognize Check source voltage, frequency, phase rotation settings and compare the standby source to actual values.

  • Page 23: Troubleshooting Transfer Switch Operation

    Troubleshooting Transfer Switch Operation Problem Possible Cause Check Generator set Engine start time delay is Check the time delay LED on the user interface. Wait for time delays to engine does not running expire. Check time delay settings. See Section 3.8. start Loose engine start Check connections.
  • Page 24 Problem Possible Cause Check Exercise interval different Check 1 week/2 week DIP switch and calendar settings. than expected ATS does not Unloaded test or exercise Check DIP switch positions. transfer Pretransfer load control Check Time Delay and Load Control Active LEDs and Active Time Delay time delays operating window in the Setup Program.

  • Page 25: Faults

    Faults 2.5.3 Failure to Acquire Standby Source This section describes transfer switch faults indicated by the Service Required LED on the controller’s user A fault occurs if the unit attempts to start the generator interface. Refer to the table in Section 2.3 for set but the standby source does not appear after the recommendations for correcting the faults described Acquire Standby Source to Failure time delay.

  • Page 26: I/O Module Faults And Diagnostics

    2.5.6 I/O Module Faults and Diagnostics I/O Module Not Installed. If the software detects an I/O module that is connected but not expected by the setup When power is applied to the system, the controller program, the Service Required LED flashes and the attempts to initiate communication with each connected software logs the message, I/O Module Not Installed.

  • Page 27: Section 3 Controller Test And Replacement

    Section 3 Controller Test and Replacement Initial Tests Controller LEDs Perform these initial tests to check the ATS controller Check the Service Required LED for fault indication. operation. See Figure 3-1. To reset the service required LED, press and hold the LAMP TEST button until all LEDs Figure 3-2 shows the locations of the pushbuttons and flash, which takes approximately 5 seconds.

  • Page 28: Controller Reset

    LED Indicator Color LED Illumination Exercise Amber Steady: Unloaded exercise is running. Slow Flash: Loaded exercise is running. Rapid Flash: When EXERCISE button is pressed and held, rapid flashing indicates the exercise has been started and set. Rapid flashing at any other time indicates that the exercise is inhibited by the Exerciser Disable/Enable DIP switch setting.

  • Page 29: Power Supply

    Power Supply check procedure in Section 3.7.2 to check voltage at the Source N (normal) or Source E (emergency) lugs. DANGER 3.4.2 Controller Power Supply Check for voltage to the controller using the following procedure. Hazardous voltage. Procedure to Check Voltage to the Controller Will cause severe injury or death.

  • Page 30: Powering The Controller For Testing (Service Kit Gm25479)

    3.4.3 Powering the Controller for The 120-volt board shown in Figure 3-6 has two (2) capacitors in the power supply area of the circuit board. Testing (Service Kit GM25479) These boards can be powered directly from a 120 VAC It is sometimes useful to supply power directly to the wall outlet using service kit GM25479 .

  • Page 31: Test Sequence

    Test Sequence DANGER Use the following procedure to run a test to check the transfer switch operation. Watch the LEDs on the controller’s user interface as the time delays run and Source E becomes available when the generator set Hazardous voltage. starts.
  • Page 32 b. Programmed-Transition Models: After the Test started preferred-to-off time delay, verify that the (Test button pushed) Position N LED goes out and the Position OFF LED lights. After the off-to-standby time delay, check that the Position E LED lights, indicating Time delay engine start (TDES) that the switch has transferred the load to...
  • Page 33 Test started (Test button pushed) Time delay engine start (TDES) Test ended (Test button pushed) Generator set engine start contacts close Standby-to-preferred time delay Pretransfer load control (as programmed*) Pretransfer load control (as programmed*) Preferred-to-standby time delay In-phase monitor or transfer to off (as programmed*) In-phase monitor or transfer to off (as programmed*)

  • Page 34: Dip Switch Positions

    DIP Switch Positions scheduled exercise. The new DIP switch setting becomes effective after the next scheduled exercise. See the ATS operation and installation DANGER manual for more information about the exerciser. Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure.

  • Page 35: System Settings

    System Settings Use the procedure in the next section to measure the source voltage, frequency, and phase rotation and If the ATS does not recognize the source, check that the compare the measured values to the controller settings. source voltage and frequency settings on the controller Follow the instructions in the Software Operation and match the actual source parameters.

  • Page 36: Voltage And Frequency Pickup And Dropout Settings

    The voltage check procedure requires the following Note: The default setting for the phase rotation on the controller is ABC. If the application uses equipment: a phase rotation of CBA, use the Setup A digital voltmeter (DVM) with electrically insulated Program to change the phase rotation probes capable of measuring the rated voltage and setting on the controller.

  • Page 37: Meter Calibration

    pickup values for the controller to recognize the source Parameter Default Adjustment Range as restored. 101% of 101%--105% of Overfrequency dropout pickup pickup Choose pickup and dropout settings that allow a 110% of 105%--120% of Overfrequency tolerable variation in the source parameters to prevent pickup nominal nominal...

  • Page 38: Time Delays

    Time Delays Engine Start Check the time delays when troubleshooting problems DANGER with the transfer switch operation. Use the Active Time Delay Window in the Setup Program and observe the time delay LEDs on the controller’s user interface to identify which time delays Hazardous voltage.
  • Page 39 If the ATS engine start contacts do not close during the EXERCISE button pressed or scheduled Engine Start Contact Test Procedure, replace the ATS exercise signaled to begin controls. If the generator set engine does not start, check the Generator set engine start engine start connections to the generator set.

  • Page 40: 3.10 Position Microswitch Test

    3.11 Programmed-Transition Interface Board Model KDP/KMP switches are equipped with the programmed-transition interface board (PTIB). (PTIB) contains two replaceable 10-amp relays, K1 (NR1) and K2 (ER1). See Figure 3-19. Refer to the operation sequence diagrams in Section 4.5.2 and to the schematic diagram provided with the transfer switch to troubleshoot the relays.

  • Page 41: 3.12 Controller Replacement

    3.12 Controller Replacement Servicing the transfer switch. Hazardous voltage can cause severe injury or death. Deenergize all power sources before servicing. Open the main circuit breakers of all transfer Always check for open switches or circuit breakers, switch power sources and disable all generator sets as loose connections, or faulty wiring before replacing any follows: (1) Move all generator set master controller switches parts.
  • Page 42 14. Remove the plastic cover from the old controller 21. Connect the transfer switch harness to the and save it to install on the new controller connector on the bottom of the controller. assembly. To remove the cover, depress the latch 22.

  • Page 43: Section 4 Transfer Switch Troubleshooting

    Many transfer problems can be high resistance, replace the power panel assembly. For traced to inappropriate controller settings. service procedures, refer to Section 5 for Model KDT/ KMT open-transition switches or Section 6 for Verify that the voltage on the nameplate matches the Model KDP/ KMP programmed-transition switches.

  • Page 44: Rectifier Test

    Rectifier Test Use an ohmmeter or a diode checker to test the rectifiers on model KDT/KMT open-transition switches when instructed to do so in service procedures in Section 5. COIL Note: The rectifiers on model KDP/KMP programmed- transition switches are built into the solenoid coils and are not accessible for testing.

  • Page 45: Solenoid Operation

    Note: The K1 (NR) and K2 (ER) relays are energized for 89.6 only 250 milliseconds to initiate transfer. 400--600 On 40--225 amp model KDT/KMT open-transition switches, control contacts SCN and SCE control the 16.4 amount of time that power is applied to the solenoid coil.

  • Page 46: Solenoid Operation Diagrams, 40--225 Amp Model Kdt/Kmt Open Transition Switches

    4.5.3 Solenoid Operation Diagrams, 40- -225 Amp Model KDT/KMT Open Transition Switches Source N position, Source N available. The solenoid coil is not energized. COIL Source N position, Source N lost. The coil is energized if Source E is available. The transfer switch is ready to transfer to Source E.

  • Page 47: Solenoid Operation Diagrams, 400--600 Amp Model Kdt/Kmt Open Transition Switches

    4.5.4 Solenoid Operation Diagrams, 400- -600 Amp Model KDT/KMT Open Transition Switches Source N position, Source N available. The solenoid coil is not energized. COIL Source N position, Source N lost. The coil is energized if Source E is available. The transfer switch is ready to transfer to Source E.

  • Page 48: Solenoid Operation Diagrams, Model Kdp/Kmp Programmed-Transition Models

    4.5.5 Solenoid Operation Diagrams, Model KDP/KMP Programmed-Transition Models Normal to OFF Source N position Source N is lost Emergency available ER is pulsed for 250 ms ATS1 BTS1 to energize trip coil TC. ATS1 AND ATS2: Closed in Normal Open in OFF BTS2 ATS2 OFF to Emergency...
  • Page 49 Emergency to OFF NR1 is pulsed for 250 ms to energize trip coil TC. BTS1 and BTS2: Closed in Emergency ATS1 BTS1 Open in OFF BTS2 ATS2 OFF to Normal NR is pulsed for 250 ms to energize closing coil CC. AX is closed in OFF.
  • Page 50 Notes Section 4 Transfer Switch Troubleshooting TP-6226 7/04...

  • Page 51: Section 5 Component Replacement, Model Kdt/Kmt Switches

    Section 5 Component Replacement, Model KDT/KMT Switches Introduction DANGER This section contains instructions for component replacement on model KDT/KMT open-transition transfer switches. See Section 6 for programmed- transition switches. Hazardous voltage. Will cause severe injury or death. Observe the following safety precautions when...

  • Page 52: Microswitch Replacement

    5. Note the location of the fast-on connectors to the microswitch terminals. See Figure 5-1. 1. End plate Figure 5-2 End Plate (required for assemblies with four microswitches) Figure 5-1 Microswitches Section 5 Component Replacement, Model KDT/KMT Switches TP-6226 7/04...

  • Page 53: 400--600 Amp

    Disconnect all power sources before opening the enclosure. Figure 5-5 Microswitch Holding Screws 5. Note the location of the fast-on connectors to the microswitch terminals. See Figure 5-3. 6. Disconnect fast-on connectors. Figure 5-4. TP-6226 7/04 Section 5 Component Replacement, Model KDT/KMT Switches...

  • Page 54: Power Panel Replacement

    3. Open the enclosure. 4. Check for zero volts on the normal and emergency power lugs. 5. Remove the tie wraps securing the harness. Figure 5-6 Installing the Power Panel Section 5 Component Replacement, Model KDT/KMT Switches TP-6226 7/04...

  • Page 55: Arc Chute Replacement

    1. Prevent all connected generator sets from starting. a. Place the generator set master switch in the Figure 5-8 Movable Contacts (arc chute removed) OFF position. b. Disconnect the battery charger, if equipped. TP-6226 7/04 Section 5 Component Replacement, Model KDT/KMT Switches...

  • Page 56: Limit Switch Assembly Replacement

    4. Verify zero volts across each phase. mode. 5. Note the location of the fast-on connections to the SCN/SCE microswitch terminals. 6. Disconnect fast-on connectors. Figure 5-10. Figure 5-9 Manual Operation Handle Inserted Figure 5-10 Microswitch Fast-On Connectors Component Replacement, Model KDT/KMT Switches TP-6226 7/04...
  • Page 57 7. Remove the holding screws. Note the microswitch 12. Clean the inside of the ATS. labels on the insulators. See Figure 5-11. 13. Close and lock the enclosure. 8. Remove the microswitch assembly. 14. Connect power to the ATS. 9. Remove suspect microswitch.

  • Page 58: Solenoid And Rectifier Replacement

    11. Connect the AC fast-on connections to the AC terminals. Note: The AC terminals are in the upper left and Figure 5-14 Rectifier Connections (DC solenoid lower right hand corners. leads shown disconnected) Component Replacement, Model KDT/KMT Switches TP-6226 7/04...
  • Page 59 14. Loosen the rear bolt of the coil securing the strap. 15. Remove the coil. Note: The plunger assembly is spring-loaded. See Figure 5-18. Figure 5-17 Coil Securing Strap Figure 5-16 Checking Diode Operation of Rectifier Solenoid Replacement WARNING Spring-loaded parts. Can cause severe personal injury or property damage.

  • Page 60: Solenoid And Rectifier Replacement, 400--600 Amp Models

    (--) lead first. 24. Close the enclosure. 2. Disconnect main power and open the ATS 25. Reconnect power to the ATS. enclosure. 26. Enable the generator set startup. 3. Verify zero volts across each phase. Component Replacement, Model KDT/KMT Switches TP-6226 7/04...
  • Page 61 4. Remove the DC fast-on connections from the rectifier terminals. See Figure 5-20. Note: A red dot identifies one DC terminal. The other DC terminal is at the opposite corner of the rectifier. 5. Check the coil resistance. Note: If reading is infinite or shorted, replace coil. Figure 5-21 Checking Rectifier Diode Operation Solenoid Replacement...
  • Page 62 1. Mounting screws with washers (4 ea.) 4. Plunger 2. Linkage 5. Rectifier connections 3. Clip location (not visible this view) Figure 5-22 Solenoid Assembly (shown on the bench) Component Replacement, Model KDT/KMT Switches TP-6226 7/04...
  • Page 63 19. Insert four mounting screws with washers and align 27. Test the transfer switch operation by performing the mounting bracket with marks made in step 13. the Automatic Operation Test Procedure described in Section 3.5. 20. Tighten all four bolts to 10.8 Nm (96 in. lb). Note: Do not leave transfer switch in Test mode.
  • Page 64 Notes Component Replacement, Model KDT/KMT Switches TP-6226 7/04...

  • Page 65: Section 6 Component Replacement, Model Kdp/Kmp Switches

    Section 6 Component Replacement, Model KDP/KMP Switches Introduction Component Replacement, 100- -400 Amp Models This section contains instructions for component replacement Model KDP/KMP programmed- 6.2.1 Disassembly, 100- -400 Amps transition transfer switches. Disassemble the mechanical unit and the current- Illustrations in this section show the transfer switch carrying unit.

  • Page 66: Reassembly, 100--400 Amps

    3. Remove the auxiliary switches. See Figure 6-3. 6226 Figure 6-6 Mechanical Unit 6226 1. Auxiliary switches Figure 6-3 Auxiliary Switches 6.2.2 Reassembly, 100- -400 Amps 4. Loosen four bolts and separate the mechanical unit Reassemble mechanical unit from the current-carrying unit. See Figure 6-4, current-carrying unit.
  • Page 67 2. Replace the ON/OFF indicators and the cover. Note: The ON/OFF indicators are not identical. Locate them as shown in Figure 6-8. 6226 1. Auxiliary switch levers 2. Auxiliary switches Figure 6-9 100 and 200 Amp Models 6226 1. ON/OFF indicators Figure 6-8 Assembled Units 3.

  • Page 68: Printed Circuit Board Replacement, 100--400 Amps

    6.2.3 Printed Circuit Board Replacement, 100- -400 Amps Separate the current-carrying unit from the mechanical unit. See Section 6.2.1. 1. Note the connections (for reconnection later) and disconnect the printed circuit board leads. See Figure 6-11 or Figure 6-12. 2. Disconnect the control switch leads at three terminals.

  • Page 69: Closing Coil Replacement, 100--400 Amps

    6.2.4 Closing Coil Replacement, 4. Loosen the M6 bolt and remove the frame with the coil. See Figure 6-15 and Figure 6-16. 100- -400 Amps 5. Loosen the M12 nut and replace the closing coil. 1. Push the trip button. See Figure 6-16.

  • Page 70: Trip Coil Replacement, 100--400 Amps

    2. Remove two M4 bolts shown in Figure 6-18 and 6.2.6 Trip Coil Replacement, remove the select coil assembly. 100- -400 Amps Note: Remove the select coil first for easier access to the trip coil. See Section 6.2.5. 1. Locate the trip coil. See Figure 6-21. 6226 1.
  • Page 71 3. Remove two M4 bolts that secure the trip coil. See Figure 6-23. 6226 1. Trip shaft 2. M4 bolt 6226 Figure 6-24 Trip Shaft Location 1. Trip coil M4 bolts (2) 2. Trip shaft M4 bolt (and ring, not visible in this view) 3.

  • Page 72: Arc Chute Replacement, 100--400 Amps

    6. Reassemble in reverse order: Align the bosses on the coil with the holes in the L-shaped bracket. Be sure to reinstall the ring on the trip shaft bolt and align the parts so that the ring fits into the hole on the trip lever.

  • Page 73: Shaft Adjustment, 600 Amp Models

    6.3.2 Shaft Adjustment, WARNING 600 Amp Models Note: It is not necessary to remove the movable steel shaft when replacing the closing coil. 1. Turn the large round shaft in (clockwise) until the Spring-loaded parts. mechanism just latches when operated with the Can cause severe personal injury manual handle.

  • Page 74: Trip Coil Replacement, 600 Amp Models

    6.3.4 Trip Coil Replacement, 2. Remove two M4 bolts and replace the trip coil. Retain the small spring for the trip coil lever. See 600 Amp Models Figure 6-33 and Figure 6-34. 1. Note the connections and disconnect the trip coil 3.

  • Page 75: Select Coil Replacement, 600 Amp Models

    6.3.5 Select Coil Replacement, 6.3.6 Printed Circuit Board 600 Amp Models Replacement, 600 Amp Models 1. Note the connections and disconnect the select Note: The individual rectifiers are not replaceable. coil leads from the printed circuit board and the Replace the entire printed circuit board in the control switch.
  • Page 76 1. Remove the insulation plate. See Figure 6-38. 6226 tp6226 1. Remove this rod 1. Insulation plate 2. Fixture 3. M6 nuts or retainers Figure 6-38 600 Amp Contactor Figure 6-39 Fixture or Clamp, 600 Amp Models 2. Attach a clamp or fixture similar to the one shown in Figure 6-39.

  • Page 77: 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 78 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 79: 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 80: 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 81: 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 82: American Standard

    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-6238-14...
  • Page 83 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Hex Head Bolts (Full Thread), Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), continued continued M931-05055-60 M5-0.80 x 55 M931-06040-60 M6-1.00 x 40 M933-12016-60...
  • Page 84 Metric, continued Part No. Dimensions Type Hex Nuts M934-03-50 M3-0.50 Standard M934-04-50 M4-0.70 Standard M934-04-B M4-0.70 Brass M934-05-50 M5-0.80 Standard M934-06-60 M6-1.00 Standard M934-06-64 M6-1.00 Std. (green) M6923-06-80 M6-1.00 Spiralock M982-06-80 M6-1.00 Elastic Stop M934-08-60 M8-1.25 Standard M6923-08-80 M8-1.25 Spiralock M982-08-80 M8-1.25 Elastic Stop...
  • Page 88 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-6226 7/04 7 Jurong Pier Road Singapore 619159 E 2004 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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