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Kohler 15/30RES, Service Manual

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Kohler 15/30RES Service Manual Download Page 27

TP-6198 3/15

27

Section 3 Troubleshooting

Troubleshooting Chart

Problem

Reference

Corrective Action

Possible Cause

Starts hard,

continued

Spark plug wire(s)

Check spark plug wires and connections. Replace spark plug

wires.

Engine S/M

Ignition components

(spark control or ignition

module)

Test/replace ignition components.

Engine S/M

Insufficient fuel pressure

Check fuel pressure

I/M

Worn piston rings, valves

Check compression.

Engine S/M

Starts but

shuts down

Fault shutdown

Check for a fault shutdown code on the controller’s LED display.

Correct the fault and then move the generator set master switch

to OFF/RESET to reset the controller.

Section 4.5
Section 5.10

Stops

suddenly

Fault shutdown

Check for a fault shutdown code on the controller’s LED display.

Correct the fault and then move the generator set master switch

to OFF/RESET to reset the controller.

Section 4.5
Section 5.10

No fuel

Turn on fuel supply.

—

Fuel line restriction

Inspect fuel lines.

—

Fuel lines too long

Check fuel line length.

I/M

Air cleaner clogged

Replace element.

O/M

Blown controller fuse (F3) Replace fuse.

Section 5.12

Blown auxiliary winding

fuse (F1)

Replace fuse. If fuse blows again, test generator components.

Section 5.12

Blown relay interface

board (RIB) fuse (F2)

Replace fuse.

Section 5.12

Spark plug(s)

Replace and regap plug(s).

Engine S/M

Engine overheated (hot

engine only)

Check air intake, fuel adjustment, oil level, air inlet/outlet.

O/M and I/M

Low oil pressure (LOP)

switch

Attempt startup. If unit shuts down, remove lead from LOP

switch and reset controller. A successful restart attempt

indicates a faulty LOP shutdown switch.

Note:

Check engine oil pressure before performing test and/or

replacing LOP shutdown switch.

Engine S/M

Fuel valve/fuel regulator

Check regulator/valve operation.

O/M and I/M

Engine overloaded

Reduce electrical load.

I/M

Loss of generator output

voltage to controller

Check connections at P15 plug.
Check continuity of AC sensing leads 11 and 44 (1-phase

models) or V7, V8, and V9 (3-phase models).

W/D

Ignition module

Test and/or replace.

Engine S/M

K3 (flash) relay

Check for Flash LED illumination. Check RIB fuse. Replace

relay board.

Section 4.6

Engine S/M: Engine Service Manual

I/M: Generator Set Installation Manual

O/M: Generator Set Operation Manual

W/D: Wiring Diagram Manual

Summary of Contents for 15/30RES

Page 1: ...Residential Commercial Generator Sets Models 15 30RES 15 30RESA 15 30REYG 15 30RYG Controller Advanced Digital Control TP 6198 3 15b Service ...

Page 2: ......

Page 3: ... 3 Troubleshooting Chart 25 Section 4 Controller 31 4 1 Introduction 31 4 2 Controller Display and Keypad 32 4 3 Master Switch 32 4 4 Sequence of Operation 33 4 4 1 Starting Sequence Master Switch Moved to RUN 33 4 4 2 Starting Sequence Remote Start 33 4 4 3 Running Sequence 33 4 4 4 Stopping Sequence Master Switch Moved to OFF RESET 33 4 4 5 Stopping Sequence Remote Stop 33 4 5 Faults 34 4 5 1 Wa...

Page 4: ...tdown Functions 57 5 10 2 Fault Shutdown Switches 57 5 11 Fuel Systems 58 5 11 1 Fuel System Troubleshooting 59 5 11 2 Fuel Solenoid Valve 59 5 11 3 Fuel Regulators 59 5 11 4 Fuel Conversion 60 5 12 Fuses 60 5 13 Continuity Checks 61 Appendix A Abbreviations 63 Appendix B Common Hardware Application Guidelines 65 Appendix C General Torque Specifications 66 Appendix D Common Hardware Identification...

Page 5: ...or set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop s...

Page 6: ... the generator set with the air cleaner removed Engine Fluids and Chemical Products Handling caustic engine fluids and chemical products Can cause severe chemical burns nausea fainting or death Most chemicals such as used engine oil antifreeze coolant rustproofing agent inhibiting oil degreasing agent spray paint and adhesives are hazardous to health Read and follow the user information found on t...

Page 7: ...mptoms include but are not limited to the following D Light headedness dizziness D Physical fatigue weakness in joints and muscles D Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision D Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall a...

Page 8: ...te the generator set only when all guards and electrical enclosures are in place Moving parts WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply WARNING Hazardous voltage Will cause ...

Page 9: ...mproper test procedure can damage equipment or lead to generator set failure Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Short circuits Haz...

Page 10: ...cing the engine heater Hot parts can cause minor personal injury or property damage Install the heater before connecting it to power Operating the heater before installation can cause burns and component damage Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts Notice NOTICE Canadian installations only For standby service connect the output of the gener...

Page 11: ...gine service manual also contains wiring diagrams for the engine only The document part numbers are shown in the List of Related Materials List of Related Materials Separate manuals contain operation installation and parts information not provided in this manual A separate engine service manual is also available Figure 1 lists the available manual part numbers Document Description Part Number Inst...

Page 12: ...Europe Middle East Africa EMEA Kohler Power Systems Netherlands B V Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone 31 168 331630 Fax 31 168 331631 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East...

Page 13: ...fications Engine Specification 15 kW 30 kW Manufacturer GM Model 1 6L OHC Cycle 4 Number of cylinders 4 Compression ratio 9 4 1 Displacement L cu in 1 6 98 Rated power propane fuel kWm BHP 19 0 25 5 37 2 50 Rpm 60 Hz 1800 3600 Rpm 50 Hz NA 3000 Bore x stroke mm in 79 x 81 5 3 11 x 3 21 Valve exhaust material High alloy steel Cylinder head material Aluminum Piston rings 2 compression 1 oil control ...

Page 14: ...15RYG 15REYG 15RYG 30REYG 30RYG 30REYG 30RYG 30RES 30RESA 30REYG 30RYG 30REYG 30RYG Alternator model 4H7 4J7 2F5 2G5 2F7 2G7 Stator leads qty 4 12 4 12 4 12 Phase 1 3 1 3 1 3 Rotor resistance ohms cold 3 0 3 0 5 2 5 2 5 6 5 6 Stator resistance ohms cold Main winding 1 2 3 4 0 07 0 06 0 02 Main winding 1 4 2 5 3 6 7 10 8 11 9 12 0 04 0 09 0 06 Aux winding 55 66 1 26 1 3 0 60 0 19 0 44 0 18 Stator o...

Page 15: ...14 Belt guard 15 Battery charging alternator 16 Low oil pressure switch 17 Coolant overflow bottle daily coolant check fill location 18 Secondary fuel regulator 19 Fuel solenoid valve 20 Oil drain valve 21 Positive battery connection point 22 Fuel inlet 23 Engine control module ECM 24 AC line circuit breaker panel 25 Exhaust connection 26 Spark plugs 27 Remote customer interface connector 28 Custo...

Page 16: ...ll on valve cover 20 Engine fuses 21 Oil check dipstick 22 Remote customer interface connector 23 Customer load lead access 24 Battery cables 25 Battery location battery not shown 26 Lube oil filter 27 Negative battery connection point 28 Coolant drain 29 Cooling air inlet 30 Oil makeup assembly with sight gauge optional for 30 kW 31 Oil reservoir 32 Load lead access behind panel 33 Customer inter...

Page 17: ...ction box 9 Overbolts qty 4 Upper left overbolt as viewed from inside the junction box requires a lock washer 10 End bracket assembly 11 Brushes See Section 5 6 12 Circuit breaker cover 13 Stator assembly 14 Fan guard 2 GM78230 1 9 8 10 12 13 Note See Section 1 4 for torque values See Section 5 for alternator test procedures 14 9 7 6 5 4 See Note 11 3 Figure 1 3 Alternator Assembly ...

Page 18: ...TP 6198 3 15 18 Section 1 Specifications Notes ...

Page 19: ... the generator set until it cools WARNING Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator field or exciter armature When shorted the alternator field and exciter armatur...

Page 20: ...o the following generator set service schedule the engine service schedule and the runtime hours displayed on the ADC 2100 to determine when to schedule routine maintenance Service the generator set more frequently if it is subject to extreme weather long operating hours or dusty or dirty conditions Service Schedule Perform maintenance on each item in the service schedule at the designated interva...

Page 21: ...m components X Check the installation and operation of CO detectors X Check the exhaust gas condition during operation X Inspect and clean the air cleaner element X Replace the air cleaner element X Inspect the complete exhaust system X Electrical System Keep the battery charged and in good condition w X Check and tighten electrical connections X Clean the battery cables as required X Engine and M...

Page 22: ...the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles R...

Page 23: ...gravity is below 1 215 at an electrolyte temperature of 80 F 26 7 C See Figure 2 3 Specific Gravity Corrected to 80 F 26 7 C Battery Condition Below 1 215 Needs charging 1 260 Fully charged Figure 2 3 Specific Gravity Interpretation Some battery testers have four or five beads in the test tube Draw electrolyte into the tube as performed with the battery hydrometer described previously Use the manu...

Page 24: ... battery charger operation and troubleshooting 2 3 Fuel System Maintenance Routine fuel system service items include draining water sediment from piping at petcock or pipe end cap checking for fuel leakage at pipe connections checking flexible sections for cracking or chafing and keeping components clean including fuel regulator vent holes A grease or wax residue tends to accumulate in the piping ...

Page 25: ...d primary or secondary fuel regulators loose connections to the fuel solenoid valve a damaged or closed fuel shutoff valve an empty LP fuel tank or other problems with the fuel supply Check the fuel supply pressure to the generator set See Section 5 11 Fuel Systems 3 3 Troubleshooting Chart Use the following table as a reference in troubleshooting individual problems Generator set faults are liste...

Page 26: ...nk LP Insufficient fuel pressure Check fuel pressure to the generator set Verify adequate fuel pressure and pipe size for the generator set plus all other gas appliances I M Fuel regulator valve Check regulator valve operation I M Spark plugs or spark plug connections Check spark plug wires and connections Replace or clean and regap spark plugs O M Loose connection or open circuit Check for loose ...

Page 27: ...ent O M Blown controller fuse F3 Replace fuse Section 5 12 Blown auxiliary winding fuse F1 Replace fuse If fuse blows again test generator components Section 5 12 Blown relay interface board RIB fuse F2 Replace fuse Section 5 12 Spark plug s Replace and regap plug s Engine S M Engine overheated hot engine only Check air intake fuel adjustment oil level air inlet outlet O M and I M Low oil pressure...

Page 28: ...e cooling Inspect air intakes and exhaust for obstructions Check air cleaner Generator overloaded Reduce load Spark plug s Replace and regap plug s O M Spark plug wire s Replace spark plug wires Engine S M Fuel select leads 65 and 70A incorrectly connected or disconnected Connect for natural gas Disconnect for LP I M Insufficient fuel pressure Check fuel pressure at carburetor outlet I M Fuel line...

Page 29: ...s Check the resistance through the brushes Resistance through the brushes should be low 0 1 0 2 ohms without meter lead resistance Section 5 6 Low engine speed causing voltage roll off Check system voltage frequency Uu and engine type Ec parameters Troubleshoot engine Section 4 9 2 Engine S M Light flicker Voltage stability gain setting Check and adjust the voltage stability gain setting using the...

Page 30: ...SCR module circuit Check continuity Section 5 13 W D Brushes Inspect brushes and replace if worn Section 5 6 Check for brushes sticking in brush holder or broken brush spring Section 5 6 Rotor connections Check for open circuit in rotor connection circuit leads FN and FP to SCR and RIB W D Rotor slip rings dirty or corroded Check slip ring condition Section 5 4 Rotor open grounded or shorted windi...

Page 31: ...used with the controller Section 4 6 describes the standard and optional RIBs A silicon controlled rectifier SCR module works with the controller to regulate the output voltage See Section 4 7 GM32850B 1 ADC 2100 controller 2 Fuse location F1 F2 and F3 Note Some earlier models had inline fuses located in the engine harness See Section 5 12 3 Line circuit breaker panel load connection 4 Generator s...

Page 32: ...ous fault conditions See Section 4 5 System parameters Displays 2 letter codes or 4 digit alphanumeric codes during system configuration or adjustment See Section 4 9 2 Application program version number Displays the version number of the controller s application program before entering the configuration or adjustment mode See Section 4 9 2 Figure 4 3 ADC Controller LED Display A password key sequ...

Page 33: ...lay energizes The cyclic cranking cycle is programmed into controller s application code and is not adjustable in the field The factory sets the cranking cycle for three cycles of 15 sec on time and 15 sec off time If the cranking cycle seems shorter than the factory setting check the engine starting battery 4 4 2 Starting Sequence Remote Start When the master switch is set to the AUTO position th...

Page 34: ...displayed if the engine starting battery voltage falls below 9 5 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than 10 sec when the engine is not running This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 sec Check the battery rating and condition Charge or replace ...

Page 35: ...n on an overcrank fault if no engine rotation is sensed Shuts down after 3 sec of cranking or 1 sec after the fault is detected Check for a locked rotor Section 5 4 OF Overfrequency Shutdown occurs when the governed frequency exceeds 110 of the system s frequency setpoint for more than 5 sec This protective becomes active 10 sec after engine start 10 sec inhibit Check system frequency setting para...

Page 36: ...B Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery WARNING Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disabl...

Page 37: ...nal relay connections Harness Lead Number Connector Pin Number Connection 88 6 Common fault normally open 89 2 Common fault common 90 3 Common fault normally closed 91 4 Run relay normally open 92 1 Run relay common 93 5 Run relay normally closed Figure 4 8 Optional Common Fault and Run Relay Board Harness Connections ...

Page 38: ...procedure SCR Module Test Procedure Required equipment D Ohmmeter D 12 volt test lamp or voltmeter D 12 volt DC power source D 100 500 ohm resistor D Jumper 1 Set the ohmmeter to the R X 1 scale 2 Connect the ohmmeter from to on the SCR module You should read high resistance in one direction and low resistance in the other reverse the leads 3 Connect the ohmmeter from AC1 to on the SCR module You ...

Page 39: ...fy a bad controller use the procedure in this section for controller replacement Always check the controller configuration fuse wiring and connections before replacing the controller For output voltage problems replace the SCR module and check the operation again before replacing the controller After replacing the controller verify that the new controller s configuration settings match the generat...

Page 40: ...instructions in Section 4 9 to change the new controller s configuration settings to match the generator set system voltage and frequency unit configuration engine type engine data input types battery voltage and communications settings 13 Use a voltmeter to checkthe outputvoltage Follow instructions in Section 5 7 2 Voltage Adjustment to adjust the output voltage and stability 14 Place the genera...

Page 41: ...n Note A digital voltmeter is required for these adjustments Use a voltmeter to checkthe outputvoltage If the output voltage is not within specifications use the ADC controller to adjust the output voltage while the generator set is running The flowcharts in Figure 4 13 and Figure 4 14 outline the adjustment procedures Note Be sure to save your settings before exiting the configuration mode Voltag...

Page 42: ...or To raise or lower the voltage stability gain in smaller increments To enter volts Hz adjustment mode To raise or lower the volts Hz 0 5 per step 00 0 09 4 5 or Hold Wait about 5 sec until the display changes from runtime hours to the program version number Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode This is the controller password x x x x x x 1 P 1 P ...

Page 43: ... switch is moved to the OFF RESET position To save changes To discard changes without saving or S A V E Y E S Now move the master switch to OFF RESET n o There are 3 options when the display says SAVE Press or To return to the first parameter coarse voltage adjustment to check or change settings before saving See Figure 4 13 Yes or no flashes when the up or down arrow is pressed and then the contr...

Page 44: ... Parameter Low Coolant Level Sensor Pressure Sensor Temperature Sensor Magnetic Pickup Ed00 Digital Switch Digital Switch Digital Switch No Ed01 Digital Switch Digital Switch Analog Sender No Ed02 Digital Switch Analog Sender Digital Switch No Ed03 Digital Switch Analog Sender Analog Sender No Ed04 Digital Switch Digital Switch Digital Switch Yes Ed05 Digital Switch Digital Switch Analog Sender Ye...

Page 45: ...s parameter sets the generator set type marine standby or mobile Engine configuration Ec The engine configuration must match the generator set engine type Advanced configuration mode Adnc The data input types battery voltage and communications setting can be changed in the advanced configuration mode Press the up arrow button when Adnc is displayed to enter the advanced configuration mode Engine d...

Page 46: ...ne type if necessary See Figure 4 15 U u 0 1 U c 0 1 U u 0 1 1 0 4 0 A d n c Press Now release the Select button or To enter advanced configuration mode Go to Figure 4 18 or To proceed to the save mode without entering the advanced configuration mode Go to Figure 4 19 Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs battery voltage and communicat...

Page 47: ... reverts to the last saved settings when the master switch is moved to the OFF RESET position Figure 4 18 Advanced Configuration Mode engine data input types battery voltage and engine communications To save changes To discard changes without saving or X in the runtime hours display above denotes any number from 0 to 9 S A V E Y E S Now move the master switch to OFF RESET n o There are 3 options w...

Page 48: ...m the generator set housing a Disconnect the engine wiring harness connector P1 plug 35 pin from the controller Disconnect the J15 and J16 connectors See Figure 4 20 b Remove controller from generator set housing in order to access the back of the controller 3 Remove controller s back cover to access jumper a Note the labels on the three leads connected to the generator set master switch for recon...

Page 49: ...Figure 5 2 Before beginning the test procedures read all safety precautions at the beginning of this manual Many of the test procedures include additional safety precautions No Generator Output Separate Excitation Output within Specifications Check Rotor Check Wiring Fuses SCR Module and Controller Check Stator TP563273 Erratic or No Output Figure 5 2 Generator Troubleshooting Check the condition ...

Page 50: ...ing should be the battery voltage divided by the specified rotor resistance See Section 1 Specifications for specified rotor resistance values Example 12 volts battery voltage 3 0 ohms rotor resistance 4 0 amps rotor current 3 Start the engine and check that the ammeter reading remains stable An increasing meter reading indicates a shorted rotor A meter reading decreasing to zero or an unstable re...

Page 51: ...ts can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Stator Continuity and Resistance Tests 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger 3 Disconnect the generator set engine starting battery negativ...

Page 52: ...and 4 Yes 2 and 5 3 and 6 7 and 10 8 and 11 9 and 12 55 and 66 1 and 2 3 7 8 or 9 No 1 and 55 Any stator lead and ground Figure 5 8 Continuity Test Results on a Good Stator Three Phase 8 If the resistance test proves inconclusive use a megohmmeter to test the stator as described in the next step Note Because ohmmeter accuracy varies resistance readings are approximate readings Take readings of the...

Page 53: ...ment or lead to generator set failure Rotor Test Procedure 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger 3 Disconnect the generator set engine starting battery negative lead first 4 Remove the brush cover from the alternator end bracket 5 Check the rotor for continuity and resistance Raise the brushes from the slip rings while performing ohmm...

Page 54: ...e and the controller Weak springs damaged slip rings sticking brushes a loose brush holder or poor brush contact causes arcing The brushes must be free to move within the holder and be held in contact with the slip rings by the springs When correctly positioned spring pressure on the brush surface causes the brush to wear evenly The entire brush must ride on the ring or arcing occurs and causes bu...

Page 55: ... the load When the generator speed returns to normal 60 Hz or 50 Hz as load is accepted the generator output also returns to normal Voltage Adjustment Procedure Hazardous voltage Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Moving parts WARNING Short circuits Hazardous voltage current can cause severe injury or death Short c...

Page 56: ...and output voltage as loads are applied D If there is excessive droop in engine speed and little droop in voltage increase the 3P value D If there is little engine speed droop but excessive voltage droop decrease the 3P value The amount of voltage droop is approximately 0 5 of system voltage for each step of 3P 3P Voltage Droop for Each Cycle Hz Below Cut in Frequency 0 0 1 0 5 2 1 0 3 1 5 4 2 0 5...

Page 57: ...t the starter motor lead at the starter solenoid Move the controller master switch to the RUN position Observe that the generator set simulates cranking for 15 seconds and then rests for 15 seconds Check that the generator set shuts down after the third crank rest cycle High Engine Temperature Shutdown Remove the connector from the coolant temperature sensor CTS and connect a jumper across termina...

Page 58: ...ions before testing or replacing the LOP switch See Figure 5 15 To test the LOP switch reinstall the switch and start the generator set If the unit shuts down disconnect lead 13 from the LOP switch and resetthe controller Restartthe generator set and verify that it does not shut down A successful restart indicates a bad LOP switch Replace the switch 1 tp6198 1 Low oil pressure switch Figure 5 15 L...

Page 59: ...oting Most problems with gas fuels involve either fuel pressure or fuel regulator function Basic troubleshooting consists of verifying fuel pressures and checking each fuel system component Check the following items D Check primary fuel regulator outlet pressure This is the line pressure D Check the primary regulator vent for obstructions and clean if necessary D Check fuel shutoff inlet pressure ...

Page 60: ...uel system conversion and fuel mixture adjustment procedures 5 12 Fuses Three fuses protect the controller SCR module and relay interface board See Figure 5 17 for fuse locations See Figure 5 18 for fuse ratings and part numbers Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Section 3 Troubleshooting for conditions that may indicate a blown fuse ...

Page 61: ...nt can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Note Disconnect the generator set battery before performing continuity checks to prevent damage to the ohmmeter To further check generator set components d...

Page 62: ...TP 6198 3 15 62 Section 5 Component Testing and Adjustment Notes ...

Page 63: ...es cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dB A decibel A weighted DC direct current DCR direct current resistance deg degree dept department dia diameter DI EO dual inlet end outlet DIN Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss DIP dual inline package DPDT double pole double ...

Page 64: ...Phillipsr head Crimptiter screw PHH Phillipsr hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts per million PROM programmable read only memory psi pounds per square inch psig pounds per square inch gauge pt pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt quart quarts qt...

Page 65: ...p of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a ...

Page 66: ...0 895 Metric Fasteners Torque Specifications Measured in Nm ft lb Size mm Assembled into Cast Iron or Steel Assembled into Aluminum Grade 5 8 or 8 8 Grade 5 8 Grade 8 8 Grade 10 9 M6 x 1 00 6 2 4 6 9 5 7 13 6 10 See Note 3 M8 x 1 25 15 0 11 23 0 17 33 0 24 M8 x 1 00 16 0 11 24 0 18 34 0 25 M10 x 1 50 30 0 22 45 0 34 65 0 48 M10 x 1 25 31 0 23 47 0 35 68 0 50 M12 x 1 75 53 0 39 80 0 59 115 0 85 M12...

Page 67: ...nal External Tooth Lock Hardness Grades American Standard Grade 2 Grade 5 Grade 8 Grade 8 9 Hex Socket Head Metric Number stamped on hardware 5 8 shown 5 8 Allent head screw is a trademark of Holo Krome Co Phillipsr screw is a registered trademark of Phillips Screw Company Sample Dimensions 1 4 20 x 1 Major Thread Diameter In Fractional Inches Or Screw Number Size Length In Inches Screws and Bolts...

Page 68: ...4 2 7 16 14 x 1 00 X 6024 8 7 16 14 x 1 25 X 6024 3 7 16 14 x 1 50 X 6024 4 7 16 14 x 2 00 X 6024 11 7 16 14 x 2 75 X 6024 12 7 16 14 x 6 50 X 129 15 1 2 13 x 75 X 129 17 1 2 13 x 1 00 X 129 18 1 2 13 x 1 25 X 129 19 1 2 13 x 1 50 X 129 20 1 2 13 x 1 75 X 129 21 1 2 13 x 2 00 X 129 22 1 2 13 x 2 25 X 129 23 1 2 13 x 2 50 X 129 24 1 2 13 x 2 75 X 129 25 1 2 13 x 3 00 X 129 27 1 2 13 x 3 50 X 129 29...

Page 69: ... 00 x 160 M931 24200 60 M24 3 00 x 200 Hex Head Bolts Full Thread M933 04006 60 M4 0 70 x 6 M933 05030 60 M5 0 80 x 30 M933 05035 60 M5 0 80 x 35 M933 05050 60 M5 0 80 x 50 M933 06010 60 M6 1 00 x 10 M933 06012 60 M6 1 00 x 12 M933 06014 60 M6 1 00 x 14 M933 06016 60 M6 1 00 x 16 M933 06020 60 M6 1 00 x 20 M933 06025 60 M6 1 00 x 25 M933 06030 60 M6 1 00 x 30 M933 06040 60 M6 1 00 x 40 M933 06050 ...

Page 70: ...12 1 75 Spiralock M982 12 80 M12 1 75 Elastic Stop M982 14 60 M14 2 00 Elastic Stop M6923 16 80 M16 2 00 Spiralock M982 16 80 M16 2 00 Elastic Stop M934 18 80 M18 2 5 Standard M982 18 60 M18 2 50 Elastic Stop M934 20 80 M20 2 50 Standard M982 20 80 M20 2 50 Elastic Stop M934 22 60 M22 2 50 Standard M934 24 80 M24 3 00 Standard M982 24 60 M24 3 00 Elastic Stop M934 30 80 M30 3 50 Standard Washers B...

Page 71: ......

Page 72: ... Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455 For the nearest KOHLER authorized installation service and sales dealer in the US and Canada Call 1 800 544 2444 or visit KOHLERPower com E 2004 2009 2015 by Kohler Co All rights reserved TP 6198 3 15b ...

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