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Kohler 11RMY

Kohler 11RMY
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Industrial Generator Sets
Models:
8.5RMY
11RMY
Controllers:
Relay
TP-5867 11/02d
Service

Table of Contents

Other manuals for Kohler 11RMY

Preview: Operation And Installation Guide
Operation And Installation Guide52 pages

Questions and Answers:

Kohler 11RMY Specifications

General IconGeneral
Model11RMY
TypePortable Generator
Fuel TypeGasoline
AC Output120/240 V
Voltage120/240 V
Frequency60 Hz
Power Output11000 Watts
Rated Output (Watts)11, 000 Watts
Starting SystemElectric Start
Starting MethodElectric/Manual

Summary

Service

Industrial Generator Sets

Specifies that the manual covers industrial generator sets.

Product Identification Information

Generator Set Identification Numbers

Guides on recording identification numbers from the generator set nameplate.

Controller Identification

Instructions for recording controller description from operation manual or sales invoice.

Engine Identification

Details for recording product identification information from the engine nameplate.

Safety Precautions and Instructions

Accidental Starting

Warnings and procedures to prevent accidental generator set starting.

Battery

Safety precautions related to battery handling, acid, and explosion risks.

Engine BackfireFlash Fire

Exhaust System

Carbon monoxide

Information on carbon monoxide hazards and symptoms from exhaust gases.

Fuel System

Explosive fuel vapors

Precautions regarding explosive fuel vapors and handling, storage, and usage of fuels.

Hazardous Noise

Hazardous Voltage Electrical Shock

Hazardous voltage. Moving rotor.

Warning about severe injury or death from moving rotor and hazardous voltage.

Hazardous voltage. Backfeed to the utility system

Warning about property damage, severe injury, or death from backfeed to the utility system.

Grounding electrical equipment.

Importance of grounding electrical equipment to prevent electrocution.

Heavy Equipment

Unbalanced weight.

Warning about severe injury or death from improper lifting.

Hot Parts

Hot engine and exhaust system.

Caution regarding severe injury or death from hot engine and exhaust system parts.

Moving Parts

Hazardous voltage. Moving rotor.

Warning about severe injury or death from moving rotor and hazardous voltage.

Rotating parts.

Warning about severe injury or death from rotating parts.

Tightening the hardware.

Caution about flying projectiles and personal injury from loose hardware.

Notice

Hardware damage.

Note on using correct tools to prevent rounding of bolt heads and nuts.

Canadian installations only.

Guidance for Canadian installations regarding transfer switch connection.

Introduction

Routine Service Parts

Information on recommended spare parts and how to obtain a complete list.

Service Assistance

Contact Information

Provides contact details for regional offices and Kohler Power Systems website for service assistance.

Section 1 Specifications

1.1 Introduction

Overview of the manual's purpose and scope for generator set specifications.

1.2 Controller Features

Lists features of the generator set's relay controller, including fault shutdowns and standard features.

1.3 Alternator

Details the PowerBoost™ IIIE voltage regulation system and provides alternator specifications.

Section 1 Specifications

1.4 Generator Set Specifications

Provides generator set specifications and refers to the nameplate for ratings.

1.5 Engine

Describes features of the 8.5/11RMY generator set engines, including multi-fuel capabilities.

1.6 Service Views

Explains how to identify single-fuel and multi-fuel generator sets using service views.

Section 1 Specifications

Engine Specification

Details engine specifications for 8.5RMY (60 Hz) and 11RMY (60 Hz) models.

1.6 Service Views

Guides on identifying single-fuel and multi-fuel generator sets based on spec numbers and fuel valve/block.

Section 1 Specifications

Figure 1-5 Generator Set Service View, Single-Fuel Systems

Diagram showing service view of single-fuel generator sets with component labels.

Section 1 Specifications

Figure 1-6 Generator Set Service View, Multi-Fuel Systems

Diagram showing service view of multi-fuel generator sets with component labels.

Section 2 Scheduled Maintenance

Accidental starting.

Safety warning and procedure for disabling the generator set to prevent accidental starting.

Hot engine and exhaust system.

Safety warning about severe injury or death from hot engine and exhaust components.

Servicing the exhaust system.

Caution about touching hot engine parts during exhaust system servicing.

Hazardous voltage. Moving rotor.

Warning about severe injury or death from moving rotors and hazardous voltage.

Section 2 Scheduled Maintenance

2.1 Service Schedule

Instructions to perform maintenance items at designated intervals for the generator set's life.

2.2 Lubrication System

Details on the lubrication system, including low oil pressure shutdown and oil level checks.

2.2.1 Low Oil Pressure Shutdown

Explanation of the low oil pressure shutdown feature protecting the engine from internal damage.

2.2.2 Oil Level Check

Procedure for checking the engine oil level regularly to prevent running out of oil.

2.2.3 Engine Oil Recommendation

Guidance on selecting synthetic or nonsynthetic engine oil based on API service class and viscosity.

Section 2 Scheduled Maintenance

Figure 2-4 Service Schedule

Table detailing maintenance actions, intervals, and system components for the generator set.

Section 2 Scheduled Maintenance

2.2.4 Oil Change Procedure

Step-by-step instructions for draining oil, replacing the oil filter, and filling with new oil.

Section 2 Scheduled Maintenance

2.3 Spark Plugs

Procedure for checking, adjusting, or replacing spark plugs as necessary.

2.4 Air Cleaner Element and Precleaner

Instructions for washing and oiling the precleaner and replacing the paper element.

Section 2 Scheduled Maintenance

3. Wash and oil the foam precleaner.

Procedure for washing, drying, and oiling the foam precleaner.

2.5 Cooling System

Information on the cooling system, air intake, and exhaust, emphasizing keeping inlets clean.

Section 2 Scheduled Maintenance

2.6 Exhaust System

Instructions for inspecting the exhaust system for cracks, corrosion, and obstructions.

2.7 Battery

Detailed safety warnings and procedures for handling batteries, including acid cleanup and short circuits.

Section 2 Scheduled Maintenance

2.7.1 Cleaning the Battery

Procedure for cleaning battery terminals and cables to prevent corrosion.

2.7.2 Checking Battery Electrolyte Level

Instructions for checking the battery electrolyte level before each startup and refilling if necessary.

2.7.3 Checking Electrolyte Specific Gravity

Procedure for checking battery electrolyte specific gravity using a hydrometer and interpreting results.

Section 2 Scheduled Maintenance

2.8 Storage Procedure

Steps for preparing the generator set for storage for three months or longer.

2.8.1 Lubricating System

Procedure for preparing the engine lubricating system for storage, including oil change.

2.8.2 Fuel System

Procedure for preparing the fuel system for storage by running the engine until it stops.

Section 2 Scheduled Maintenance

2.8.3 Internal Engine Components

Procedure for preparing internal engine components for storage using fogging agent or engine oil.

2.8.4 Exterior

Steps for preparing the generator set exterior for storage, including cleaning and sealing openings.

2.8.5 Battery

Procedure for storing the battery after other storage steps are completed.

Section 3 Troubleshooting

General Troubleshooting Chart

A quick reference table for troubleshooting common generator set problems, causes, and corrective actions.

Section 3 Troubleshooting

General Troubleshooting Chart, continued

Continued table for troubleshooting generator set issues such as starting, stopping, and running problems.

Section 3 Troubleshooting

General Troubleshooting Chart, continued

Continued troubleshooting chart covering issues like erratic operation, lack of power, and noise.

Section 3 Troubleshooting

General Troubleshooting Chart, continued

Troubleshooting chart addressing smoke, high oil consumption, engine knocks, and voltage output issues.

Section 3 Troubleshooting

General Troubleshooting Chart, continued

Troubleshooting chart for no generator output voltage and no AC output issues.

Section 4 Controller Troubleshooting

4.1 Relay Controller

Covers troubleshooting procedures for generator sets equipped with relay controllers and related engine components.

Figure 4-1 Generator Set Controllers

Table cross-referencing generator set models and spec numbers with controller types.

Figure 4-2 Basic Relay Controller 358076

Diagram and component identification for the basic relay controller with separate cyclic crank board.

Section 4 Controller Troubleshooting

Figure 4-3 Integrated Relay Controller GM10615

Diagram and component identification for integrated relay controller with fault lamp and cyclic crank control.

4.2 Sequence of Operation

Describes controller operation sequences for start, run, stop, and fault shutdown modes.

Figure 4-4 Controller Circuit Board Relays

Table listing relay descriptions and their corresponding part numbers for basic and integrated controllers.

Section 4 Controller Troubleshooting

Figure 4-5 System Relays

List of system relays not located on the controller circuit board with their respective labels.

Figure 4-6 Basic Controller Circuit Board 358095

Diagram of the basic controller circuit board with component identification.

Figure 4-7 Integrated Controller Circuit Board GM10064

Diagram of the integrated controller circuit board with component identification.

Section 4 Controller Troubleshooting

4.2.1 Starting Sequence

Details the sequence of operations for starting the generator set locally or remotely.

4.2.2 Running Sequence

Describes the generator set's running sequence, including AC output and crank disconnect relay operation.

4.2.3 Stopping Sequence

Explains the procedure for stopping the generator set by placing the master switch in the OFF/RESET position.

4.2.4 Fault Shutdown

Outlines fault conditions that cause the generator set to shut down and how to restart it.

Section 4 Controller Troubleshooting

Grounding electrical equipment.

Safety instructions regarding grounding to prevent electrocution.

Short circuits.

Warnings about bodily injury and equipment damage from short circuits.

Overspeed Setting

Information on adjusting the overspeed setting using potentiometers on the controller circuit board.

Figure 4-8 Overspeed Potentiometer Identification

Table identifying overspeed potentiometers for different controller circuit boards.

Section 4 Controller Troubleshooting

4.4 Cyclic Cranking

Details on adjusting cyclic cranking potentiometers for improved starter motor engagement.

4.4.1 Adjustment

Procedure for adjusting the ON and OFF potentiometers for cyclic cranking time.

4.4.2 Testing

Instructions for testing the cyclic cranking board using specific test equipment.

Section 4 Controller Troubleshooting

Cyclic Cranking Board Test Procedure

Step-by-step procedure for testing the cyclic cranking board using a voltmeter and battery.

Section 5 GeneratorRelay Controller Troubleshooting

Figure 5-1 Troubleshooting the Relay Controller Circuit Board (1 of 3)

Flowchart for troubleshooting the relay controller circuit board, starting with engine crank status.

Section 5 GeneratorRelay Controller Troubleshooting

Figure 5-2 Troubleshooting the Relay Controller Circuit Board (2 of 3)

Flowchart continuation for troubleshooting, covering engine start and fault shutdown conditions.

Section 5 GeneratorRelay Controller Troubleshooting

Figure 5-3 Troubleshooting the Relay Controller Circuit Board (3 of 3)

Final part of the flowchart, addressing engine shutdown after 30 seconds and stopping issues.

Section 6 Component Testing and Adjustment

6.1 Theory of Operation, 1-Phase Generator Sets with Power Boost IIIE Voltage Regulator

Explains the theory of operation for single-phase generator sets using the PowerBoost IIIE voltage regulator.

6.2 Generator Troubleshooting

Guides on troubleshooting no or low AC output, including separate excitation procedures.

Figure 6-1 Single-Phase Generator Schematic

Schematic diagram illustrating the components of a single-phase generator.

Figure 6-2 Generator Troubleshooting

Flowchart for diagnosing generator output issues, guiding through rotor and stator checks.

Section 6 Component Testing and Adjustment

6.3 Voltage Regulator

Details the Power-Boost IIIE voltage regulator's function in monitoring and maintaining generator output voltage.

Figure 6-3 Separate Excitation Connections

Diagram showing the connections for separately exciting the generator's main field using an external battery.

Figure 6-4 PowerBoost IIIE Voltage Regulator

Illustration of the PowerBoost IIIE voltage regulator with labeled components.

Section 6 Component Testing and Adjustment

6.3.1 Voltage Regulator Test

Procedure for testing the voltage regulator using a variable transformer, lamp, and voltmeter.

Figure 6-5 Voltage Regulator Test Connections

Diagram showing the setup for testing the voltage regulator with necessary components.

Section 6 Component Testing and Adjustment

6.3.2 Voltage Regulator Adjustment

Procedure for adjusting the voltage regulator using potentiometers for voltage, stabilizer, and Volts/Hz settings.

Figure 6-6 PowerBoost IIIE Voltage Regulator Test and Adjustment Setup

Diagram illustrating the setup for testing and adjusting the PowerBoost IIIE voltage regulator.

Figure 6-7 Controller Top View, Typical

Diagram showing the top view of a typical controller with labeled potentiometers and circuit breakers.

Section 6 Component Testing and Adjustment

Voltage Regulator Adjustment Procedure

Step-by-step guide for adjusting voltage regulator settings, including frequency and voltage levels.

Figure 6-8 Cut-In Frequencies

Table listing cut-in frequencies for 50 Hz and 60 Hz generator models.

6.4 Main Field (Rotor)

Information on the generator's rotor, including visual inspection and testing procedures.

Section 6 Component Testing and Adjustment

Rotor Test Procedure

Step-by-step procedure for testing the rotor's continuity, resistance, and ground shorts using an ohmmeter and megohmmeter.

6.4.2 Slip Rings

Guidance on cleaning and inspecting slip rings, noting their normal appearance and cleaning methods.

6.5 Stator

Information on the generator stator, including visual inspection and testing procedures for continuity and shorts.

Section 6 Component Testing and Adjustment

Stator Continuity and Resistance Tests

Procedure for testing stator continuity, resistance, and insulation to ground.

Figure 6-10 Testing Stator Windings

Illustration showing how to test stator windings with an ohmmeter.

Figure 6-11 Alternator Stator Leads

Diagram showing generator stator lead connections and their corresponding numbers.

Section 6 Component Testing and Adjustment

Figure 6-12 Continuity Test Results on a Good Stator

Table showing continuity test results for a good stator's leads.

6.6 Brushes

Information about generator brushes, their function, and causes of arcing.

Figure 6-13 Brush Assembly

Diagram illustrating brush assembly and correct positioning for contact with slip rings.

Section 6 Component Testing and Adjustment

6.7 EngineGenerator Components

General safety warnings for working with engine/generator components and hazardous voltage.

6.7.1 Gas Valve Operation Check

Procedure to check the operation of the gas valve by applying 12 VDC.

6.7.2 Voltage Checks

Procedure for checking voltage at various engine/generator components using a voltmeter.

6.7.3 Continuity Checks

Instructions for checking component continuity using an ohmmeter after disconnecting the battery.

Figure 6-14 Voltage Checks

Table detailing voltage checks for hourmeter and stator winding connections.

Section 6 Component Testing and Adjustment

Figure 6-15 Continuity Checks

Table listing components, ohmmeter connections, scales, switch positions, and expected readings for continuity checks.

Section 6 Component Testing and Adjustment

6.8 Fault Shutdown Test Procedure

Procedure for verifying generator set shutdowns for overspeed, overcrank, and low oil pressure.

6.8.1 Controller Fault Shutdown Functions

Details how the controller handles overspeed, low oil pressure, and overcrank shutdowns.

Overspeed

Procedure for testing the overspeed shutdown function by manually increasing engine speed.

Low Oil Pressure (LOP) Shutdown

Procedure for testing the low oil pressure shutdown by simulating low oil pressure conditions.

Section 6 Component Testing and Adjustment

Overcrank Shutdown

Procedure for testing the overcrank shutdown by simulating engine cranking cycles.

6.8.2 Fault Shutdown Switches

Tests for low oil pressure and high engine temperature shutdown switches.

Low Oil Pressure (LOP) Switch

Procedure for testing the LOP switch by simulating low oil pressure conditions.

High Engine Temperature (HET) Switch

Procedure for checking the continuity of the high engine temperature switch.

Section 6 Component Testing and Adjustment

6.9 Electronic Governor

Overview of the electronic governor system, including its components and operation.

6.9.1 Operation

Explanation of how the electronic governor maintains engine speed and generator output frequency.

6.9.2 Initial Checks and Operation Test

Steps for initial checks and operation tests of the electronic governor system before adjustment.

Section 6 Component Testing and Adjustment

Figure 6-16 Stepper Motor and Carburetor

Diagram showing the electronic governor stepper motor and its connection to the carburetor throttle linkage.

Figure 6-17 Magnetic Pickup Leads

Diagram showing magnetic pickup leads and their connection points.

6.9.3 HuntingSurging

Procedure for checking engine and carburetor for hunting/surging issues before testing the governor.

6.9.4 Governor System Operation Test

Procedure for testing the governor system operation, including stepper motor and magnetic pickup checks.

Section 6 Component Testing and Adjustment

Figure 6-18 Governor System Operation Test Procedure Summary

Flowchart summarizing the governor system operation test procedure.

Figure 6-19 Magnetic Pickup Air Gap

Diagram illustrating how to check and adjust the magnetic pickup air gap.

6.9.5 Frequency Adjustment

Procedure for adjusting the engine governor to change the generator output frequency.

Section 6 Component Testing and Adjustment

Figure 6-20 Actuator Coil Group

Diagram showing the actuator coil group and its connection points.

Figure 6-21 Governor Adjustment Potentiometers

Illustration of governor adjustment potentiometers on the electronic governor board.

6.9.6 Overspeed Verification and Adjustment

Procedure for checking and adjusting the generator set's overspeed setting.

Section 6 Component Testing and Adjustment

6.10 Speed Sensor

Procedure for verifying the correct operation of the speed sensor.

Figure 6-22 Speed Sensor Air Gap

Diagram showing the speed sensor, magnetic actuator, and air gap.

Figure 6-23 Speed Sensor Test Connections

Diagram illustrating the connections for testing the speed sensor with a voltmeter and DC power supply.

Section 6 Component Testing and Adjustment

Figure 6-24 Electronic Governor Wiring

Wiring diagram for the electronic governor system, showing connections to the controller and engine components.

Section 6 Component Testing and Adjustment

6.11 Fuel Systems

Overview of fuel systems for single-fuel and multi-fuel generator sets, and how to troubleshoot fuel supply issues.

6.11.1 Gas Piping

Guidelines for verifying gas pipe size and length to ensure adequate natural gas flow rate.

Figure 6-25 Maximum Natural Gas Pipe Length

Table providing maximum natural gas pipe lengths based on model and pipe size.

Figure 6-26 Maximum Natural Gas Flow Rate

Table listing maximum natural gas flow rates for 8.5RMY and 11RMY generator set models.

Section 6 Component Testing and Adjustment

6.11.2 Fuel Solenoid Valve

Information on the fuel solenoid valve's function and procedure for testing its operation.

6.11.3 Fuel Regulators

Details on the primary and secondary fuel regulators, their function, and checking fuel pressure.

Figure 6-27 Fuel Regulator and Valve

Diagram showing the fuel regulator and valve components, including secondary pressure regulator and fuel solenoid valve.

6.11.4 Fuel Conversion, Single-Fuel Models

Instructions regarding fuel conversion for single-fuel models, noting restrictions on emission-certified units.

Section 6 Component Testing and Adjustment

Figure 6-28 Emission-Certification Decal, Typical

Example of an emission-certification decal found on engines, providing important engine information.

6.11.5 Fuel Metering Valve Adjustment

Procedure for adjusting fuel metering valves, emphasizing safety precautions and required tools.

Figure 6-29 Fuel Metering Valve Adjustment Components, Single-Fuel Models Only

Diagram showing components used for fuel metering valve adjustment, including oxygen sensor plug and valve.

Section 6 Component Testing and Adjustment

Figure 6-30 Multi-Fuel Generator Set Fuel Block Location, Air Inlet Side

Diagram showing the location of the multi-fuel generator set fuel block and fuel inlet.

6.11.6 Fuel Conversion, Multi-Fuel Systems

Procedure for converting multi-fuel generator sets between natural gas and LP vapor fuels.

Section 6 Component Testing and Adjustment

Fuel Conversion Procedure for Multi-Fuel Systems

Step-by-step guide for converting multi-fuel systems, including hose and fitting connections and leak checks.

Figure 6-31 Fuel Block Connections, Natural Gas System Shown

Diagram illustrating fuel block connections for a natural gas system, showing fuel lines and fittings.

Section 7 Generator Reconnection

7.1 Voltage Reconnection

Explains voltage reconnections and governor/voltage regulator adjustments at the time of frequency adjustment.

Accidental starting.

Safety warning and procedure to prevent accidental generator set starting.

Hazardous voltage. Moving rotor.

Warning about severe injury or death from moving rotors and hazardous voltage.

Grounding electrical equipment.

Safety instructions regarding grounding electrical equipment to prevent electrocution.

Short circuits.

Warnings about bodily injury and equipment damage from short circuits.

Section 7 Generator Reconnection

7.2 Four-Lead (Single-Phase) Generator Sets

Illustrates reconnection of 4-lead generator sets, following National Electrical Code requirements.

7.2.1 Factory Connections, 110220 Volts 50 Hz or 120240 Volts 60 Hz

Shows factory connection configurations for 110/220V 50Hz and 120/240V 60Hz generator sets.

Figure 7-1 110220 and 120240 Volt, 3-Wire Configurations

Diagrams for 3-wire configurations, detailing stator lead connections for different voltages.

7.2.2 Reconnection Options

Describes reconnection options using a factory two-pole circuit breaker and voltage connection options.

Figure 7-2 Four-Lead, Single-Phase Generator Set Voltage Connection Options

Table listing voltage options for four-lead, single-phase generator sets.

Section 7 Generator Reconnection

Figure 7-3 110 and 120 Volt, 3-Wire Configurations

Diagrams for 110/120 volt, 3-wire configurations with jumper lead details.

220 and 240 Volt Configuration

Procedure for 220 and 240 volt configurations, noting no jumper lead is used.

Figure 7-5 220 and 240 Volt, 2-Wire Configurations

Diagrams for 220/240 volt, 2-wire configurations, showing stator lead connections.

Figure 7-4 110 and 120 Volt, 2-Wire Configurations

Diagrams for 110/120 volt, 2-wire configurations, including notes on ammeter usage.

Section 8 DisassemblyReassembly

8.1 Disassembly

Instructions for disassembling the generator set alternator, including safety precautions and enclosure removal.

NOTICE

Note regarding hardware damage and the use of correct tools for disassembly.

Section 8 DisassemblyReassembly

Figure 8-3 Controller Top View, Typical

Diagram showing the typical top view of the controller with labeled connectors and terminal blocks.

Figure 8-4 Exhaust Muffler Duct

Diagram illustrating the exhaust muffler duct components.

Figure 8-5 Generator Set, Right Side

Diagram showing the right side of the generator set, highlighting alternator mounting hardware.

Figure 8-6 Generator Set, Right Side

Diagram showing the right side of the generator set, indicating the engine support block.

Section 8 DisassemblyReassembly

Figure 8-7 Alternator End Bracket

Diagram showing the alternator end bracket with labeled components like brush cover and speed sensor.

Figure 8-8 Speed Sensor Assembly

Diagram illustrating the speed sensor assembly, including mounting screws and gap.

6. If the speed sensor must be tested or replaced,

Procedure for removing, testing, and reinstalling the speed sensor.

7. Check the brushes.

Instructions for removing, inspecting, and replacing generator brushes.

8. Remove the stator and rotor.

Procedure for removing the stator and rotor, including loosening the thrubolt.

Section 8 DisassemblyReassembly

Figure 8-9 Rotor, Side View

Diagram showing the rotor's side view, indicating the thrubolt and magnetic actuator.

Figure 8-10 Generator Adapter

Diagram showing the generator adapter and its mounting holes.

8.2 Reassembly

Instructions for reassembling the generator set alternator, including adapter, rotor, and stator installation.

Section 8 DisassemblyReassembly

Figure 8-12 Generator Set, Right Side

Diagram showing the right side of the generator set, illustrating overbolts and rotor thrubolt.

Figure 8-13 Brush Positioning

Diagram showing correct brush positioning relative to slip rings.

Figure 8-14 Speed Sensor Assembly

Diagram illustrating the speed sensor assembly, showing mounting screws and gap adjustment.

Section 8 DisassemblyReassembly

7. Install the exhaust system.

Procedure for installing the exhaust system, including duct, muffler, and mounting hardware.

Figure 8-15 Exhaust Muffler Duct

Diagram illustrating the exhaust muffler duct components and hardware.

8. Reconnect leads to the controller.

Instructions for reconnecting various leads, including speed sensor harness and brush leads, to the controller.

Figure 8-16 Controller Top View, Typical

Diagram showing the typical top view of the controller with labeled connectors for reconnection.

Section 8 DisassemblyReassembly

9. Reinstall the enclosure panels.

Procedure for reinstalling the generator set enclosure panels, including housing roof and doors.

Figure 8-17 Generator Set Weather Housing

Diagram showing the weather housing panels and their numbering.

Figure 8-18 Generator Set Sound Enclosure

Diagram showing the sound enclosure panels and their numbering.

10. Return the generator set to operation.

Steps to return the generator set to operation after reassembly, including checking the master switch and fuel supply.

Section 9 Wiring Diagrams

9.1 General

General information regarding the manual's applicability to various model and spec numbers.

9.2 Wiring Diagram Cross-Reference

Table to determine the correct wiring diagram version number based on model and spec number.

9.3 Controller Wiring Diagrams Reference

Reference table for controller wiring diagrams, linking controller types to schematic and point-to-point diagram versions.

Section 9 Diagrams and Drawings

Relay Controller, Schematic Diagram, 1 Phase, ADV-6297-B

Schematic diagram for the relay controller, version ADV-6297-B, showing 1-phase connections.

Section 9 Diagrams and Drawings

Relay Controller, Point-to-Point Wiring Diagram, 1 Phase, GM10164-A

Point-to-point wiring diagram for the relay controller, version GM10164-A, showing 1-phase connections.

Section 9 Diagrams and Drawings

Relay Controller, Schematic Diagram, 1 Phase, ADV-6297-E

Schematic diagram for the relay controller, version ADV-6297-E, showing 1-phase connections.

Section 9 Diagrams and Drawings

Relay Controller, Schematic Diagram, ADV-6524-

Schematic diagram for the relay controller, version ADV-6524, showing 1-phase connections.

Section 9 Diagrams and Drawings

Relay Controller, Point-to-Point Wiring Diagram, GM10169-

Point-to-point wiring diagram for the relay controller, version GM10164-A, showing 1-phase connections.

Appendix A Abbreviations

A, amp

Abbreviation for ampere.

ABDC

Abbreviation for after bottom dead center.

AC

Abbreviation for alternating current.

AD

Abbreviation for analog to digital.

ADC

Abbreviation for analog to digital converter.

Appendix A Abbreviations

k

Abbreviation for kilo (1000).

K

Abbreviation for kelvin.

kA

Abbreviation for kiloampere.

KB

Abbreviation for kilobyte (2^10 bytes).

kg

Abbreviation for kilogram.

Appendix B Common Hardware Application Guidelines

BoltScrew Length:

General rule for determining minimum and maximum bolt/screw length based on nut clearance.

Washers and Nuts:

Guidelines for using split lock washers, flat washers, and nuts with specific hardware types.

Figure 1 Acceptable Bolt Lengths

Diagram illustrating acceptable and unacceptable nut/bolt clearance relative to nut depth.

Figure 2 Acceptable Hardware Combinations

Diagram showing acceptable hardware combinations based on entry and exit hole types.

Appendix C General Torque Specifications

American Standard Fasteners Torque Specifications

Table of torque specifications for American standard fasteners assembled into cast iron, steel, and aluminum.

Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Table of torque specifications for metric fasteners assembled into cast iron, steel, and aluminum.

Appendix D Common Hardware Identification

ScrewBoltsStuds Head Styles

Illustrations and names of various screw, bolt, and stud head styles.

Nuts Nut Styles

Illustrations and names of various nut styles.

Washers Washer Styles

Illustrations and names of various washer styles.

Hardness Grades American Standard

Identification of American Standard hardness grades for fasteners.

Hardness Grades Metric

Identification of metric hardness grades for fasteners.

Appendix E Common Hardware List

American Standard

List of part numbers and dimensions for common American standard hex head bolts and nuts.

Washers

List of part numbers and dimensions for common American standard washers.

Appendix E Common Hardware List

Metric

List of part numbers and dimensions for common metric hex head bolts, nuts, and washers.

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