Service Parts 7ER 6EFR. Commercial Mobile Generator Sets. Models: TP /99. Specification Series 199

Transcription

1 Service Parts Commercial Mobile Generator Sets Models: 7ER EFR Specification Series TP-0 /

2 Description Page Introduction... Numbering System Significance... Illustrations... How to Find Part Numbers... Hardware References... Specification Number Index... Group : Cylinder and Crankcase... Group : Piston and Crankshaft... Group : Valves and Camshaft... Group : Lubrication and Oil Filter... Group : Ignition... Group : Governor... 7 Group 7: Carburetor... Group : Air Filter and Muffler... 0 Group : Starter... Group 0: Engine Cooling... Table of Contents Description Page Group 0: Fuel System... Group 0: Engine... Group 07: Nameplate and Decals... Group 0: Skid and Plant Mounting... Group : Exhaust... 7 Group 0: Generator and Mounting... Group 0: Controller and Mounting... 0 Group 70: Literature... Accessories (and Kit Sections)... Appendix A. Glossary of Abbreviations... A- Appendix B. Common Hardware Application Guidelines... A- Appendix C. General Torque Specifications... A- Appendix D. Common Hardware Identification.. A- Appendix E. Common Hardware List... A-

3 This manual lists service replacement parts for 7ER/EFR generator sets. At the time of print this manual applied to the generator set specification (spec) numbers listed in the Specification Number Index. On occasion this manual may apply to specs not listed in the Specification Number Index. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. This manual includes the following main sections: Table of Contents. Lists the sections of the manual. Introduction (and other information sections). Contains introductory material about part numbers, illustrations, and hardware. Index. Lists the generator set specs and groups. Group Parts Lists. List the part numbers of parts in the groups. Kit Sections. List modules and accessories and their parts. Appendices. Include Abbreviations, Common Hardware Application Guidelines, General Torque Specifications, Common Hardware Identification, and Common Hardware List. x:in:00:00 Numbering System Significance This manual uses the following numbering systems: Specification Number. A six-digit number with a PAprefix. The Specification Number Index does not show the prefix. Spec numbers break down into groups. Group Number. A unique number representing a parts group needed to assemble a generator set function. For example, Group 0 is the Air Intake group. Variation or Module Number. A group might have several variations. Each variation performs the same function with different parts lists. For example, a 0 Hz generator alternator and 0 Hz generator alternator both perform the same function, however, with different parts. Each difference requires a group variation or module number. Part Number. The part number identifies an individual assembly, subassembly, component, or accessory kit. Illustrations Introduction x:in:00:00 Illustrations (or exploded-view drawings) best representing the widest range of variations accompany most groups in this manual. Illustrations do not depict all details and may not show all parts. Do not use illustrations for assembly or disassembly instructions. x:in:00:00 How to Find Part Numbers Use the following steps to locate a service replacement part.. Locate the generator set nameplate to identify the generator set spec number.. Locate a second generator set nameplate listing accessories to identify installed modules. On some models the accessory nameplate is mounted inside the generator junction box.. Turn to the Specification Number Index. The first column lists the generator set spec numbers. The headings identify the groups of parts that make up the generator set.. Identify the group most likely to include the service part number.. Find the group variation number at the intersection of the spec number row and the group column. Note the variation number.. Page forward to locate the group identified in step or find the appropriate page in the Table of Contents. 7. Find the part on the illustration and note the item number of the part or find the part description in the parts list.. Select the part number that corresponds to your group variation. The first column lists the illustration item number. Find the variation identified in the Specification Number Index or the module number found on the generator set nameplate in the appropriate column on the right side of the parts list table. Find the quantity used at the intersection of the item number row and the variation column. A blank space at the intersection means the variation/module does not use that part number. Hardware References x:in:00:00 Many common hardware items do not appear in parts manuals or will appear as common hardware entries. A common hardware entry lists the size of the hardware. For example, an item that appears as Hardware, /- in the text means that the piece is /- size. Obtain common hardware locally or, if contacting the factory, use the Common Hardware List in the appendix to identify the common hardware part number and specifications. See Common Hardware Application Guidelines in the appendix for mating hardware instructions. Some hardware items require a specific size or some other characteristic. In that case, use the part number listedinthetext. When replacing hardware, do not substitute inferior grade hardware. Replacement hardware grade should be equal to or better than the grade of the manufacturer s original hardware. Use the Common Hardware List in the appendix to identify the common hardware hardness. x:in:00:00 TP-0 /

4 Specification Number Index GROUP TITLE AND NUMBER GROUP NO. 7 0 VARIATION NUMBER 0 GROUP TITLE AND NUMBER GROUP NO SPEC NO. VARIATION NUMBER 0 TP-0 /

5 Group : Cylinder and Crankcase _ Item Part No. Description 70 Head Gasket Complete Cylinder Head Complete Cylinder Head 70 Rocker Case 70 Rocker Case 70 Rocker Case Gasket Gasket 70 Crankcase Cover Gasket 70 Plate 0 70 Plate 7 Cover 7 Valve 7 Crankcase Cover 7 Complete Crankcase 7 Joint 7 Screw 7 70 Pin 7 Oil Seal 7 Oil Seal 0 7 Oil Seal 7 Plug 7 Collar 7 Bolt 0 77 Clamp 7 Tube 7 Flanged Bolt 7 70 Flanged Bolt 7 Flanged Bolt 7 Flanged Bolt 0 77 Stud TP-0 /

6 Group : Piston and Crankshaft 7 7 7_ Item Part No. Description 7 Piston 7 Piston, 0. OS AR 70 Piston, 0.0 OS AR 7 Piston Pin 7 Piston Ring Set 77 Piston Ring Set, 0.0 OS AR 7 PistonRingSet,0.0OS AR 7 Connecting Rod Assembly 7 Crankshaft Assembly 7 Gear Spur 7 7 Snap Ring 7 Connecting Rod Bolt 7 Dowel Pin AR As Required TP-0 /

7 Group : Valves and Camshaft Group : Lubrication and Oil Filter _ 7_ Item Part No. Description Intake Valve Exhaust Valve Valve Spring Retainer 7 Rocker Arm 7 Rocker Shaft 7 Tappet 7 7 Push Rod 77 Spring Seat Engine Valve Spring 0 7 Complete Camshaft 70 Screw 7 Nut 7 Oil Seal 7 Circlip 7 Collet Item Part No. Description 7 Drain Plug Gasket 7 Oil Pump Shaft 7 Plate 77 Cover 77 Oil Gauge 7 Oil Fill Cap 7 7 Oil Pump Rotor (in) 770 Oil Pump Rotor (out) 77 Oil Filter 0 77 Oil Filter 77 Gear Spur 77 Pin 0 Ring, 0.0 mm 77 Drain Plug 777 Spring 77 Flanged Bolt 7 77 Pan Screw 70 Steel Ball TP-0 /

8 Group : Ignition _ Item Part No. Description 7 Gasket 7 Voltage Regulator 7 Igniter 7 Ignition Coil 7 Spark Plug Cap 7 Flywheel Assembly 7 77 Harness 7 Harness 0 Harness 0 0 Harness 7 Oil Pressure Switch 70 Temperature Switch 7 Pulsing Coil 7 Charging Coil 07 Hex Nut Item Part No. Description 7 Washer 7 7 Clamp 7 Tube 7 Spark Plug 0 77 Band 7 Clamp 7 Clamp 00 Flanged Bolt 0 Flanged Bolt 0 Pan Screw 0 Pan Screw 7 0 Pan Screw 0 Pan Screw 0 Woodruff Key TP-0 /

9 Group : Governor 0 See groups 0 and 0 for additional fuel system parts _ Item Part No. Description 0 Bracket 0 Lever Link Pivot Arm Governor Spring Sleeve 7 Governor Arm Governor Assembly Control Panel 0 0 Bolt Screw Nut Washer 0 Spacer Spring Collar 7 Washer Stud Bolt 0 Bolt Hex Nut 7 Hex Nut Washer TP-0 / 7

10 TP-0 / Group 7: Carburetor _7 0 0

11 Item Part No. Description Gasket 0 Gasket Air Filter Gasket Carburetor Gasket Intake Pipe Gasket Intake Manifold Gasket 7 Intake Manifold Gasket Plate GM070 Carburetor Assembly 0 Pilot Air Screw Float Chamber 0 Throttle Stop Screw GM070 Throttle Valve Float Valve Float 7 Air Jet. GM070 Air Jet.0 Gasket 7 Carburetor Choke Shaft 0 Carburetor Shaft GM0707 Intake Pipe GM070 Intake Pipe Choke Valve GM070 Choke Link Solenoid 07 Wire Lead 7 Limiter GM070 Main Nozzle Main Jet Holder 0 Intake Manifold Group 7: Carburetor Item Part No. Description 7 Screw Screw Screw 70 Screw 7 Washer 7 Collar 7 7 Collar 7 Snap Ring 7 Clamp 0 7 Clamp 7 Pin 77 O-ring 7 O-ring 7 Tube GM07 Main Jet GM07 Pilot Jet 7 Plug Spring Spring 0 Seal Seal Spring Bolt Clamp GM07 Tube 0 Flanged Bolt 7 Flanged Bolt Flanged Bolt 0 Flanged Bolt 0 Flanged Bolt Screw TP-0 /

12 Group : Air Filter and Muffler 7 0 0_ Item Part No. Description Air Filter Case Air Filter Case Air Filter Element Air Filter Element Bracket 7 Muffler Gasket 7 Intake Pipe Complete Muffler 00 Collar 0 0 Bolt GM07 Clamp GM07 Bolt GM07 Hex Nut GM077 Spring Washer 0 TP-0 /

13 Group : Starter _ Item Part No. Description GM07 Clutch Assembly GM07 Brush Holder GM070 Shift Lever GM07 Cover GM07 Insulator GM07 Cover Assembly 7 GM07 Cover Assembly GM07 Brush GM07 Brush Spring 0 GM077 Armature Item Part No. Description GM07 Starter, electric GM07 Switch GM070 Stopper GM07 Bolt GM07 Nut GM07 Nut 7 GM07 Snap Ring 7 Bolt Flanged Bolt 0 GM07 Hex Nut GM07 Spring Washer TP-0 /

14 Group 0: Engine Cooling _0 TP-0 /

15 Item Part No. Description Cap GM077 Bracket, cooling fan 0 Bracket Bracket GM07 Bracket Water Pump Gasket 7 Water Pump Gasket Thermostat Cover Gasket GM07 Cooling Fan Guide 0 Impeller Shaft GM070 Radiator Screen Thermostat Cover 7 Pump Cover GM07 Radiator Assembly Cooling Hose GM07 Cooling Hose 7 Cooling Hose 0 Cooling Hose GM07 Cooling Hose 0 Reservoir Water Pump GM07 Thermostat Mechanical Seal GM07 Pressure Cap Assembly GM07 Cooling Fan Spur Gear 7 Joint Impeller 7 Pump Case 0 Nut Group 0: Engine Cooling Item Part No. Description GM077 Collar GM07 Clamp Clamp 0 Clamp Pin Oil Seal 7 Ball Collar GM07 Bolt 0 GM070 Damper Clamp Clamp 7 Tube Washer GM07 Flanged Bolt Flanged Bolt 7 GM07 Flanged Bolt 0 Flanged Bolt 70 Flanged Bolt 0 7 Flanged Bolt 7 Flanged Bolt 7 Flanged Bolt 7 Flanged Bolt 7 Dowel Pin 7 O-ring 77 O-ring Group 0: Fuel System STOP START AC CIRCUIT BREAKER INPUT BATT. CHRG. VOLT. REG. 0-- Item Part No. Description X-- Connector, 7/-0 x / X-0- Connector, hose, / x / 7 Elbow, street 70 Pump, fuel Line, fuel TP-0 /

16 Group 0: Engine 0,, 7 0, 7, To vacuum port on intake manifold Choke Housing Assembly STOP START AC CIRCUIT BREAKER INPUT BATT. CHRG. VOLT. REG. Lifting Eye View 0-- TP-0 /

17 Group 0: Engine Item Part No. Description A- Engine Assembly (see Groups -- for parts) X-- Screw, f.h.m., - x 0. X-- Fuel line, flexible X-- Screw, p.h.m., - x 0. slot X-- Screw, pan head metric X-- Screw, machine metric 7 X--7 Nut, hex 777 Lever Assembly, choke 777 Retainer, thermostat coil 0 77 Gasket 77 Pin 77 Piston, choke 777 Plate, baffle Valve, oil drain 707 Coupling, stepper motor 7 Bushing 7 Shaft, choke Bolt, banjo -BLK Eye, lifting 0 Housing Assembly, choke Heater Assembly, choke Washer, pressure sealing Washer, pressure sealing Bracket, choke mounting Linkage, choke TP-0 /

18 Group 07: Nameplate and Decals Item Part No. Description X-- Decal, Kohler Power System Decal, -00 number Decal, reconnection Marker, adhesive (pos. batt. connection) 7 Decal, warning (carbon monoxide) 0 Decal, warning (moving parts) 7 0 Decal, warning (hot engine) 0 Decal, warning (hot coolant) Decal, oil drain 0 Decal, equipment ground Decal, negative battery connnection Tag, hang Group 0: Skid and Plant Mounting STOP START AC CIRCUIT BREAKER INPUT BATT. CHRG. VOLT. REG. 7,, 0,, 0-- Item Part No. Description X-0- Nut, elastic stop, /- X-- Washer, lock, / int.-ext. tooth X-- Washer, lock, / int. tooth 7 Strap, ground Tray, drip 7 Vibromount 7 X-0-7 Nut spiralock X-- Screw, HC X-- Washer, plain 0 X-0-7 Stud TP-0 /

19 Group : Exhaust See Group Muffller for additional exhaust system parts., 7,, -- Item Part No. Description X-- Screw, h.c. X-7- Clamp, muffler 7 Pipe, exhaust Bracket, exhaust mounting (bottom) Bracket, exhaust mounting (top) Shield, heat 7 X-- Screw, h.c. X-- Washer, plain X-0-7 Nut, spiralock TP-0 / 7

20 Group 0: Generator and Mounting,, 7,,,, Item Part No. Description A- Rotor Assembly (includes item ) A- Rotor Assembly (includes item ) X-- Washer, lock # int. star X-- Screw, r.h.m. - x. slot X-- Screw, hex head /- 7 Bolt, thru X-- Screw, hex head X-7- Screw, self-tapping 7 X-7-0 Plug, pipe X-0- Washer, hardened X-7- Screw, hex head machine 0 0 O-ring 7 Bracket, brush holder 0 Spring 7 Retainer, wire Shim, brush holder 7 Holder, brush Brush 7 Adapter, generator Bracket, end 0 Overbolt 0 7 Stator Assembly 0 Guard, fan 77 Plate, end bracket Plate, end bracket X--7 Screw X-7- Bearing, ball X-00-7 Spacer X--7 Washer, plain X-- Screw, /-0 x / X-- Screw, hex socket head 7 X--0 Washer, plain X-- Key, square TP-0 /

21 Notes TP-0 /

22 Group 0: Controller and Mounting See Group Iginiton for additional controller parts supplied by the engine manufacturer. 7 Item 7 not shown.,, GRD LO K See Group for voltage regulator A7 0 TP-0 /

23 Group 0: Controller and Mounting Item Part No. Description X-- Washer, lock, / int.-ext. tooth X-- Screw, r.h.m., ---/ X-0- Breaker, circuit (See Acceessories for optional circuit breakers) X-7- Screw, hex head 0-7 Mount, controller Cover, controller 7 0 Harness, engine wiring (includes items --) A-7 Controller Assembly F-7 PCB Assembly (PBIIIE) 0 GM0 PCB Assembly, lopcon w/tm X-- Washer, lock, / int. tooth X-- Washer, lock, / int.-ext. tooth X-- Washer, lock, #0, int.-ext. tooth X-- Washer, lock, #, int. X--7 Washer, lock, #, int. tooth X-- Washer, lock, #0, int. tooth 7 X-- Screw, p.h.m., - x 0. slot X-- Screw, p.h.m., - x 0.0 slot X-0- Screw, r.h.m.,0- x / 0 X-- Screw, r.h.m., - x 7/ X-0- Grommet, nylon X-- Connector, cable X-- Tube, vinyl X-7- Nut, hex, - zinc X-- Nut, hex, /-0 green X-7- Screw, hex head machine Tab, id grd 00- Tab, id k 00- Tab, id Tab, ident Fuse, 0 A, 0 V, 0. x. Plate, cover Holder, fuse 0. x. 7 Hourmeter 0 Strap, ground 0 Switch, rocker white pm 7 Spacer Relay tab, 0 A VDC A/B Fuse, A, V, 0. x. 0 Holder, fuse 7 Screw, special 7 Spacer, aluminum, 0. x 0.0, - int. Box, silkscreened Harness, controller (includes items --) Connector Plug, -position 70 Connector Plug, -position 7 Diode, A, 00 V 0 Connector, receptacle Connector Panel, -position 0 Connector Plug, -position Connector Plug, -position Connector Plug, -position Connector Plug, -position Diode, A, 00 V TP-0 /

24 Group 70: Literature Item Part No. Description TP- Safety Precautions RV TP-00 Operation Manual, Kawaski FD0D TP-00 Service Manual, Kawaski FD0D TP-00 Service Manual Supplement, Kawaski FD0D TP-0 Operation Manual, 7ER Commercial Mobile TP-0 Installation Manual, 7ER Commercial Mobile 7 TP-0 Service Manual, 7ER Commercial Mobile TP-0 Parts Catalog, 7ER Commercial Mobile TP-0 /

25 Accessories Description Part No. Circuit Breaker Kits Circuit Breaker PA- Instructions, installation TT-7 Screw, r.h.m., - -/ X-- Breaker, circuit, 0 A X-0- Plate, cover Decal, notice Circuit Breaker PA- Instructions, installation TT-7 Screw, r.h.m., - -/ X-- Breaker, circuit, A X-0-7 Plate, cover Decal, notice Circuit Breaker PA- Instructions, installation TT-7 Screw, r.h.m., - -/ X-- Breaker, circuit, 0 A X-0- Terminal, jumper Circuit Breaker PA-0 Instructions, installation TT-7 Screw, r.h.m., - -/ X-- Breaker, circuit, 0 A X-0- Decal, notice Circuit Breaker PA- Instructions, installation TT-7 Screw, r.h.m., - -/ X-- Breaker, circuit, A X-0-0 Decal, notice Circuit Breaker PA- Instructions, installation TT-7 Screw, r.h.m., - -/ X-- Breaker, circuit, 7 A X-0- Plate, cover Decal, notice Description Part No. Harness Kits Harness, Remote Pigtail PA- Harness, extension Harness for Remote Panel ( ) PA- Strap, wire, / X-- Harness, extension Harness for Remote Panel ( ) PA- Strap, wire, / X-- Harness, extension Panel and Meter Kits Panel, Remote Start PA- Decal, warning Panel Assembly (includes the following) A- Panel, control Meter, run time, 0000 hour 7 Switch, rocker, pole 0 Panel, Remote Start and Meter ( V) PA-00 Instructions, installation TT-07 Decal, warning Panel Assembly (includes the following) A-0 Panel 0 Harness, wiring 0 Gauge, water temperature 0 Gauge, oil pressure 0 Switch, rocker 0 Panel, Remote Start and Meter ( V) PA-0 Instructions, installation TT-07 Decal, warning Panel Assembly (includes the following) A-0 Panel 00 Harness, wiring 0 Gauge, water temperature 0 Gauge, oil pressure 0 Voltmeter 07 Hourmeter 0 Switch, rocker 0 Sender Kits Sender Kit 7 Terminal, ring, male, -- AWG X--7 Bushing, adapter, /- x M x. in. 7 Switch, sensor Sender, oil pressure 0 Adapter, sender Lifting Eye Tool Lifting Eye Kit PA-7 Eye, lifting 7 Black Paint (aerosol can) TP-0 /

26 Notes TP-0 /

27 Appendix A. Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimensional drawing AHWT anticipatory high water temperature AISI American Iron and Steel Institute ALOP anticipatory low oil pressure alt. alternator Al aluminum ANSI American National Standards Institute (formerly American Standards Association, ASA) AO anticipatory only API American Petroleum Institute approx. approximate, approximately AR as required, as requested AS as supplied, as stated, as suggested ASE American Society of Engineers ASME American Society of Mechanical Engineers assy. assembly ASTM American Society for Testing Materials ATDC after top dead center ATS automatic transfer switch auto. automatic aux. auxiliary A/V audio/visual avg. average AVR automatic voltage regulator AWG American Wire Gauge AWM appliance wiring material bat. battery BBDC before bottom dead center BC battery charger, battery charging BCA battery charging alternator BCI Battery Council International BDC before dead center BHP brake horsepower blk. black (paint color), block (engine) blk. htr. block heater BMEP brake mean effective pressure bps bits per second br. brass BTDC before top dead center Btu British thermal unit Btu/min. British thermal units per minute C Celsius, centigrade cal. calorie CARB California Air Resources Board CB circuit breaker cc cubic centimeter CCA cold cranking amps ccw. counterclockwise CEC Canadian Electrical Code cfh cubic feet per hour cfm cubic feet per minute CG center of gravity CID cubic inch displacement CL centerline cm centimeter cmm cubic meters per minute CMOS complementary metal oxide substrate (semiconductor) cogen. cogeneration COM communications (port) conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards Association CT current transformer Cu copper cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter db decibel dba 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-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems Association EIA Electronic Industries Association EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection Agency EPS emergency power system ER emergency relay ES engineering special, engineered special ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth) exh. exhaust ext. external F Fahrenheit, female fglass. fiberglass FHM flat head machine (screw) fl. oz. fluid ounce flex. flexible freq. frequency FS full scale ft. foot, feet ft. lbs. foot pounds (torque) ft./min. feet per minute g gram ga. gauge (meters, wire size) gal. gallon gen. generator genset generator set GFI ground fault interrupter gnd. ground gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross gr. wt. gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temperature hex hexagon Hg mercury (element) HH hex head HHC hex head cap HP horsepower hr. hour HS heat shrink hsg. housing HVAC heating, ventilation, and air conditioning HWT high water temperature Hz hertz (cycles per second) IC integrated circuit ID inside diameter, identification IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronics Engineers IMS improved motor starting in. inch in. H O inches of water in. Hg inches of mercury in. lbs. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP iron pipe ISO International Organization for Standardization J joule JIS Japanese Industry Standard k kilo (000) K kelvin ka kiloampere KB kilobyte ( 0 bytes) kg kilogram TP-0 / Appendix A-

28 kg/cm kilograms per square centimeter kgm kilogram-meter kg/m kilograms per cubic meter khz kilohertz kj kilojoule km kilometer kohm, k kilo-ohm kpa kilopascal kph kilometers per hour kv kilovolt kva kilovolt ampere kvar kilovolt ampere reactive kw kilowatt kwh kilowatt-hour kwm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb. pound lbm/ft pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd. load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side L wa sound power level, A weighted LWL low water level LWT low water temperature m meter, milli (/000) M mega (0 when used with SI units), male m cubic meter m /min. cubic meters per minute ma milliampere man. manual max. maximum MB megabyte ( 0 bytes) MCM one thousand circular mils meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mj millijoule mm millimeter mohm, m milliohm MOhm, M megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m/sec. meters per second MTBF mean time between failure MTBO mean time between overhauls mtg. mounting MW megawatt mw milliwatt F microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards NC normally closed NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond O/C overcrank OD outside diameter OEM original equipment manufacturer O/F overfrequency opt. option, optional O/S oversize, overspeed OSHA Occupational Safety and Health Administration O/V overvoltage oz. ounce p., pp. page, pages PA packed accessory PC personal computer PCB printed circuit board pf picofarad PF power factor ph. phase PHC Phillips head crimptite (screw) PHH Phillips 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 pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart qty. quantity R replacement (emergency) power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote RFI radio frequency interference RH round head RHM round head machine (screw) rly. relay rms root mean square rnd. round ROM read only memory rot. rotate, rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d unites, International System of Units SI/EO side in/end out sil. silencer SN serial number SPDT single--pole, double--throw SPST single--pole, single--throw spec, specs specification(s) sq. square sq. cm square centimeter sq. in. square inch SS stainless steel std. standard stl. steel tach. tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal TIF telephone influence factor TIR total indicator reading tol. tolerance turbo. turbocharger typ. typical (same in multiple locations) U/F underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal U/S undersize, underspeed UV ultraviolet U/V undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer A- Appendix TP-0 /

29 Appendix B. Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made. Bolt/Screw Length: When bolt/screw length is not given, use Figure as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of / the bolt/screw diameter beyond the nut is the preferred method. Washers and Nuts: Use split lock washers as a bolt locking device where specified. Use SAE flat washers with whiz nuts, spiralock nuts, or standard nuts and preloading (torque) of the bolt in all other applications. See General Torque Specifications and other torque specifications in the service literature. Preferred Nut/Bolt Clearance Steps for common hardware application:. Determine entry hole type: round or slotted.. Determine exit hole type: fixed female thread (weld nut), round, or slotted. For round and slotted exit holes, determine if hardware is greater than / inch in diameter, or / inch in diameter or less. Hardware that is greater than / inch in diameter takes a standard nut and SAE washer. Hardware / inch or less in diameter can take a properly torqued whiz nut or spiralock nut. See the diagram below.. Follow these SAE washer rules after determining exit hole type: a. Always use a washer between hardware and a slot. b. Always use a washer under a nut (see above for exception). c. Use a washer under a bolt when the female thread is fixed (weld nut).. Refer to the diagram below, which depicts the preceding hardware configuration possibilities. Unacceptable Nut/Bolt Clearance G-. / of Bolt Diameter. Min. Full Thread Beyond Top of Nut. Below Top of Nut Figure. Acceptable Bolt Lengths G-. Cap screw. Entry hole types. Standard nut and SAE washer. Whiz nut or spiralock: up to / dia. hardware. Weld nuts: above / dia. hardware. Exit hole types Figure. Acceptable Hardware Combinations TP-0 / Appendix A-

30 Appendix C. General Torque Specifications Use the following torque specifications when service literature instructions give no specific torque values. The charts list values for new plated, zinc phosphate, or oiled threads. Increase values by % for nonplated threads. All torque values are +0%/--0%. Size American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Torque Measurement Grade Grade Grade Assembled into Aluminum Grade or - in.lbs.(nm) (.) 0 (.) (.) 0- in.lbs.(nm) (.) (.) (.) 0- in.lbs.(nm) (.) (.) (.) /-0 in.lbs.(nm) 0 (.) (0.) (.) 0 (.) /- in.lbs.(nm) 7 (.) 0 (.) (.) 7 (.) /- in.lbs.(nm) 0 (.) (.7) (.) 0 (.) /- in.lbs.(nm) (.) 0 (.) (.) (.) /- ft. lbs. (Nm) () () () () /- ft. lbs. (Nm) 0 (7) () (0) 0 (7) 7/- ft. lbs. (Nm) () (0) () 7/-0 ft. lbs. (Nm) () 0 () 70 () /- ft. lbs. (Nm) (0) () (0) /-0 ft. lbs. (Nm) () 7 (0) 0 () /- ft. lbs. (Nm) 0 () () (7) /- ft. lbs. (Nm) 7 () 0 () (0) /- ft. lbs. (Nm) () () () /- ft. lbs. (Nm) () (0) () /-0 ft. lbs. (Nm) 7 () 0 () () /- ft. lbs. (Nm) () () 7 () - ft. lbs. (Nm) () (7) (0) - ft. lbs. (Nm) 0 () (7) () Metric Fasteners Torque Specifications, Measured in ft. lbs. (Nm) Assembled into Cast Iron or Steel Assembled into Aluminum Size (mm) Grade. Grade. Grade 0. Grade. or. M x.00 (.) 7 (.) 0 () (.) M x. 0 (.) () () 0 (.) M x.00 () () () () M0 x.0 0 (7) () 0 () 0 (7) M0 x. () () 0 () () M x.7 (7) () (7) M x.0 () () () M x.00 (7) 7 () () M x.0 7 (00) 0 (0) () M x.00 () (00) 0 () M x.0 0 () (0) () M x.0 () 0 (7) (0) M x.0 () (0) () A- Appendix TP-0 /

31 Appendix D. Common Hardware Identification Screw/Bolts/Studs Head Styles Nuts Nut Styles Hardness Grades American Standard Hex Head or Machine Head Hex Head Grade Hex Head or Machine Head with Washer Lock or Elastic Grade Flat Head (FHM) Square Grade Round Head (RHM) Cap or Acorn Grade / (Hex Socket Head) Pan Head Hex Socket Head Cap or Allen Head Cap Hex Socket Head or Allen Head Shoulder Bolt Wing Washers Washer Styles Plain Metric Number stamped on hardware;. shown. Sheet Metal Screw Split Lock or Spring Stud Spring or Wave Drive Styles Hex External Tooth Lock Hex and Slotted Internal Tooth Lock Phillips Internal-External Tooth Lock Slotted Hex Socket Allen head screw is a trademark of Holo-Krome Co. Phillips screw is a registered trademark of Phillips Screw Company. Sample Dimensions American Standard (Screws, Bolts, Studs, and Nuts) /-0 x Length In Inches (Screws and Bolts) Threads Per Inch Major Thread Diameter In Fractional Inches Or Screw Number Size Metric (Screws, Bolts, Studs, and Nuts) M-. x 0 Length In Millimeters (Screws and Bolts) Distance Between Threads In Millimeters Major Thread Diameter In Millimeters Plain Washers / x/x / Lock Washers / Thickness External Dimension Internal Dimension Internal Dimension TP-0 / Appendix A-

32 Appendix E. Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Hex Head Bolts (Grade ) X--7 /-0 x. X-- /-0 x.0 X-- /-0 x. X-- /-0 x.7 X-- /-0 x. X--7 /-0 x.00 X-- /-0 x. X-- /-0 x.0 X--0 /-0 x.7 X-- /-0 x.00 X-- /-0 x. X-- /-0 x.7 X-- /-0 x.00 X-- /- x. X--0 /- x.00 X-- /- x.0 X-- /- x. X-- /- x.7 X-- /- x. X-- /- x.00 X-- /- x. X-- /- x.0 X-- /- x.7 X-- /- x /- x. X-- /- x.0 X--7 /- x.7 X-- /- x.00 X-- /- x.0 X-- /- x.00 X-- /- x.0 X-- /- x.00 X--0 /- x.0 X-- /- x.7 X-- /- x.0 X--0 /- x.7 X-- /- x.00 X-- /- x.7 X-- /- x. X--0 /- x.7 X-- /- x. X-- /- x.00 X-- /- x. X-- /- x.0 X-- /- x.7 X-- /- x.00 X--7 /- x. X--7 /- x.0 X-- /- x.7 X-- /- x.00 X-- /- x. X-- /- x.0 X--0 /- x.7 X-- /- x.0 X-- /- x.0 X-- /- x.0 Part No. Dimensions Hex Head Bolts, cont. X-- /- x.7 X-- /- x. X-- /- x.00 X-- /- x.0 X-0-7/- x.7 X-0-7/- x.00 X-0-7/- x. X-0-7/- x.0 X-0-7/- x.00 X-0-7/- x.7 X-0-7/- x.0 X-- /- x.7 X--7 /- x.00 X-- /- x. X-- /- x.0 X--0 /- x.7 X-- /- x.00 X-- /- x. X-- /- x.0 X-- /- x.7 X-- /- x.00 X--7 /- x.0 X-- /- x.00 X--0 /- x.0 X-- /- x.0 X-- /- x.00 X-- /-0 x.7 X-- /-0 x. X-- /-0 x.0 X-0- /- x.00 X-0- /- x. X-0- /- x.0 X-0- /- x.7 70 /- x.00 X-0- /- x. X-0- /- x.0 X-0-7 /- x.7 X-0- /- x.7 X-0- /- x.0 X-0-0 /- x.00 X-0- /- x.0 X-- /-0 x.00 X-- /-0 x. X-- /-0 x.0 X-- /-0 x.00 X-- /-0 x.0 X-- /-0 x.00 X-- /-0 x.0 X-7- - x. X-7- - x.00 X-7- - x.00 Part No. Dimensions Type Hex Nuts X Standard X-0- - Whiz X-0- - Whiz X-0-0- Whiz X-0-0- Whiz X-0- /-0 Spiralock X-0- /- Spiralock X-0-7 /- Spiralock X-0- /- Spiralock X-0- /- Spiralock X-0-0 /- Spiralock X-0-7/- Spiralock X-0- /- Spiralock X-0-7/-0 Spiralock X-0- Spiralock X-- /- Standard X-- /-0 Standard X-- /-0 Standard Washers Bolt/ Part No. ID OD Thick. Screw X # X # X # X #0 X / X / X / X / X / X / X--... / X A- Appendix TP-0 /

33 Metric Hex head bolts are hardness grade. unless noted. Part No. Dimensions Part No. Dimensions Hex Head Bolts (partial thread) Hex Head Bolts (full thread) Part No. Dimensions Type Hex Nuts M M-.00 x 0 M-00-0 M-.00 x M M-.00 x 0 M M-.00 x 70 M M-.00 x 7 M M-.00 x 0 M-00-0 M-. x M M-. x 0 M-000- M-. x 0* M-00-0 M-. x M M-. x 0 M-00- M-. x * M M-. x 0 M M-. x 70 M M-. x 70* M M-. x 7 M M-. x 0 M M-. x 0 M-00-0 M-. x M M-. x 00 M M0-.0 x 0 M-00-0 M0-.0 x M M0-.0 x 0 M-00-0 M0-.0 x M M0-.0 x 0 M-00-0 M0-.0 x M M0-.0 x 70 M M0-.0 x 0 M M0-.0 x 0 M M0-.0 x 00 M-0-0 M-.7 x M-00-0 M-.7 x 0 M-0-0 M-.7 x M-00-0 M-.7 x 0 M-0-0 M-.7 x M-00-0 M-.7 x 0 M-00-0 M-.7 x 0 M-00-0 M-.7 x 00 M-0-0 M-.7 x 0 M-00-0 M-.00 x 0 M-00-0 M0-.0 x M-00-0 M0-.0 x 0 M-00-0 M0-.0 x 0 M-00-0 M-.0 x 0 M-0-0 M-.0 x 0 M-0-0 M-.0 x 0 M-00-0 M-.00 x 0 M-0-0 M-.00 x 0 M-0-0 M-.00 x 0 M M-0.70 x M M-0.0 x 0 M M-.00 x 0 M-00-0 M-.00 x M-00-0 M-.00 x M M-.00 x 0 M-00-0 M-.00 x M M-.00 x 0 M M-.00 x 0 M-00-0 M-. x M M-. x 0 M-00-0 M-. x M M-. x 0 M-00-0 M0-.0 x M M0-. x 0 M M0-.0 x 0 M-00-0 M0-.0 x M M0-.0 x 0 M-000- M0-.0 x 0* M-00-0 M0-. x M-00-0 M0-.0 x M-0-0 M-.7 x M-00-0 M-.7 x 0 M-0-0 M-.7 x M-0- M-.7 x * M-00-0 M-.7 x 0 M-00-0 M-.7 x 0 M-00- M-.7 x 0* M-0-0 M-.0 x M-0-0 M-.00 x M-0-0 M-.0 x M-0-0 M-.00 x M-00- M-.00 x 0* M-0-0 M-.00 x M-00-0 M-.00 x 0 M-00-0 M-.00 x 0 M-00- M-.00 x 0* M-00-0 M-.00 x 0 M-00-0 M-.0 x 0 M-00-0 M-.0 x 0 Pan Head Machine Screws M7A M-0.0 x 0 M7A-00-0 M-0.0 x M7A M-0.70 x 0 M7A M-0.0 x 0 M7A-00-0 M-0.0 x Flat Head Machine Screws MA-00-0 M-0.0 x M-0-0 M-0.0 Standard M-0-0 M-0.70 Standard M-0-0 M-0.0 Standard M-0-0 M-0.0 Elastic Stop M-0-0 M-.00 Spiralock M-0- M-.00 Std. (green) M-0-0 M-.00 Elastic Stop M-0-0 M-. Spiralock M-0-0 M-. Standard M-0-0 M-. Elastic Stop M-0-0 M0-.0 Spiralock M-0-0 M0-.0 Elastic Stop M--0 M-.7 Spiralock M--0 M-.7 Elastic Stop M--0 M-.00 Elastic Stop M--0 M-.00 Spiralock M--0 M-.00 Elastic Stop M--0 M-.0 Elastic Stop M-0-0 M0-.0 Standard M-0-0 M0-.0 Elastic Stop M--0 M-.0 Standard M--0 M-.0 Elastic Stop M--0 M-.00 Standard M--0 M-.00 Elastic Stop Washers Bolt/ Part No. ID OD Thick. Screw MA M MA M MA M MA M MA M MA M0 MA M MA M MA M MA M MA M0 MA M * This metric hex bolt s hardness is grade 0.. TP-0 / Appendix A-7

34 TP-0 / Kohler Co.,. All rights reserved. KOHLER CO. Kohler, Wisconsin 0 Phone 0--, Web site Fax 0-- (U.S.A. Sales), Fax 0-- (International) For the nearest sales and service outlet in U.S.A. and Canada Phone -00--