Koehler K185 Series Guide

Operation and Instruction Manual
REV B
Koehler Instrument Company, Inc.
1595 Sycamore Avenue • Bohemia, New York 11716-1796 • USA
Toll Free: 1-800-878-9070 (US only) • Tel: [phone] • Fax: [phone]
http://www.koehlerinstrument.com • e-mail: [e-mail]
Petroleum Testing & Analysis Instrumentation • Custom Design & Manufacturing
K185XX
High Temperature Wheel Bearing Grease
Tester

K185XX High Temp Wheel Bearing Grease Tester
Operation and Instruction Manual
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CERTIFICATE OF CONFORMANCE
High Temperature Wheel Bearing Grease Tester
K185XX
This certificate verifies that part number K185XX, High Temperature Wheel
Bearing Grease Tester, was manufactured in conformance with the applicable
standards set forth in this certification.
Specifications: ASTM D3527
ASTM D4290
ASTM D4950
This unit is tested before it leaves the factory, to ensure total functionality and
compliance to the above specifications and ASTM standards. Test and inspection
records are on file for verification.
Jesse Kelly
Application Engineer
Koehler Instrument Company

K185XX High Temp Wheel Bearing Grease Tester
Operation and Instruction Manual
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K185XX High Temp Wheel Bearing Grease Tester
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WEEE Directive Compliance Statement
Background
The goal of the WEEE Directive is to encourage design of environment-friendly products that increase reuse,
recycling and other forms of recovery to reduce waste streams and applies to listed Electronic and Electrical
Equipment (EEE) and Koehler's equipment falls broadly into Appendix 1A; Section 9 Monitoring and Control
Equipment: Measuring, weighing or adjusting appliances for household or as laboratory equipment.
Any associated non-embedded equipment such as Lighting (Saybolt Color) and PCs/Printers also fall under
WEEE. If provided with an order these ancillary items must be WEEE compliant. For these and other reasons
(printer cartridges are regionalized) the equipment must be supplied through a third party supplier in Europe.
The WEEE Directive applies to electrical and electronic equipment falling under the categories set out in Annex
IA provided that the equipment concerned is not part of another type of equipment that does not fall within the
scope of this Directive. Annex IB contains a list of products which fall under the categories set out in Annex IA.
http://eur-lex.europa.eu/LexUriServ/LexUriServ.do?uri=OJ:L:2003:037:0024:0038:en:PDF
We do not qualify for any of the 10 exemption categories.
http://www.dpa-system.dk/en/WEEE/Products/Exemptions
Professional use
For equipment defined for ’professional use’ local authorities have no role to play. Producers and importers are
basically responsible for collection of WEEE recyclables from the professional user and for subsequent
management. A separate statement is given cataloging the items that require separation from the equipment
along with basic information on subsequent processing or recycling prior to disposal of the equipment.
http://www.dpa-system.dk/en/WEEE/Products/Private-or-professional-use
Responsibility for Registration and Annual Reporting:
Koehler will not sell directly to end users in the EU and so has no responsibility to register within each EU state
and to make annual reports. Koehler declares that this responsibility is born by the importer who is the first
level of the distribution chain and is subject to producer responsibility. We will communicate this in writing to
our distributor/importers in the EU stating they are responsible to satisfy WEEE registration and reporting
requirements in the EU states where they conduct sales activities.
It is illegal to market electrical and electronic equipment covered by producer responsibility without being
registered.
http://www.dpa-system.dk/en/WEEE/Producers/Whoissubjecttoproducerresponsibility
Product Design
Koehler's designs allow for complete disassembly to a modular level which usually allows for standard
recycling. A qualified refrigeration system technician must be consulted when disassembling and de-
commissioning any equipment with refrigeration systems.
Koehler's scientific testing equipment is robustly designed to function over a long service life and are typically
repaired many times over the course of years rather than being replaced. We believe that re-use and
refurbishment is the very best form of re-cycling.
All batteries must be readily removable not soldered in place.
Recycling instructions
In the event that replacement becomes necessary, we will include instructions, particularized to each
instrument that informs the customer of their recycling responsibilities and giving them guidance in doing this.
All Koehler equipment has been placed on the market since 13th August 2005 and so Koehler is defined as a
"new WEEE producer". As such we must provide information on refurbishment, treatment, and re-use.

K185XX High Temp Wheel Bearing Grease Tester
Operation and Instruction Manual
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Our instrument manual will include this compliance statement and indicate that any collection of materials will
be handled by their authorized distributor. In the event that the distributor is unreachable or is no longer a
distributor for Koehler Instrument, Co., other arrangements may be made including accepting the materials
directly.
Recycling is free of charge. Shipping is the responsibility of the end users. Whether shipping to a distributor or
to Koehler directly, safe, properly declared, and labeled packaging and shipping expenses are the sole
responsibility of the end user.
WEEE Marking
Since Koehler products are subject to the WEEE Directive we must display the WEEE symbol shown above in
accordance with European Standard EN 50419 on the equipment. It must be indelible, at least 5mm in height,
and clearly legible. If the equipment is too small the mark must be in the product literature, guarantee
certificate, or on the packaging. Rules on marking are established in section 49 of the WEEE Order.
Koehler Instrument Company, Inc.
c/o RECYCLING
1595 Sycamore, Ave.
Bohemia, NY 11716
As a minimum the following substances, preparations and components have to be removed from any
separately collected WEEE:
- Mercury containing components, such as switches or backlighting lamps (compact fluorescent lamps, CFL),
- Batteries
- Printed circuit boards if the surface of the printed circuit board is greater than 10 square centimeters (about 4
sq in.),
- Toner cartridges, liquid and pasty, as well as color toner,
- Chlorofluorocarbons (CFC), hydrochlorofluorocarbons (HCFC) or hydrofluorocarbons (HFC), hydrocarbons
(HC)
- Liquid crystal displays (together with their casing where appropriate) of a surface greater than 100 square
centimeters and all those back-lighted with gas discharge lamps,
- External electric cables
- Components containing refractory ceramic fibers as described in Commission Directive 97/69/EC of 5
December 1997 adapting to technical progress Council Directive 67/548/EEC relating to the classification,
packaging and labeling of dangerous substances (2),
- Electrolyte capacitors containing substances of concern (height > 25 mm, diameter > 25 mm or
proportionately similar volume)
2. The following components of WEEE that is separately collected have to be treated as indicated:
- Equipment containing gases that are ozone depleting or have a global warming potential (GWP) above 15,
such as those contained in foams and refrigeration circuits: the gases must be properly extracted and properly
treated. Ozone-depleting gases must be treated in accordance with Regulation (EC) No 2037/2000 of the
European Parliament and of the Council of 29 June 2000 on substances that deplete the ozone layer (4).

K185XX High Temp Wheel Bearing Grease Tester
Operation and Instruction Manual
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Table of Contents
1Introduction..............................................................................................................8
1.1 Koehler’s Commitment to Our Customers .......................................................................................8
1.2 Recommended Publications ............................................................................................................8
1.3 Instrument Specifications.................................................................................................................8
2Safety Information and Warnings...........................................................................9
3Getting Started.........................................................................................................9
3.1 Packing List......................................................................................................................................9
3.2 Unpacking ........................................................................................................................................9
4Operation................................................................................................................10
4.1 Description of Instrument Controls.................................................................................................10
4.2 Temperature Controller Operation.................................................................................................11
4.3 Spindle Temperature Display Operation........................................................................................12
4.4 Bearing Assembly Procedure ........................................................................................................13
4.5 Control Panel Setup.......................................................................................................................14
4.6 Operating the Torque or Current Meter Alarm Limit ......................................................................14
5Service....................................................................................................................15
5.1 Over-Temperature Protection ........................................................................................................15
5.2 Over-Power Protection...................................................................................................................15
6Service....................................................................................................................15
7Maintenance...........................................................................................................15
7.1 Routine Maintenance.....................................................................................................................15
7.2 Troubleshooting .............................................................................................................................15
8Replacement Parts................................................................................................. 16
9Storage ...................................................................................................................17
10 Warranty.................................................................................................................17
11 Returned Goods Policy.........................................................................................17
Notes............................................................................................................................ 18
Notes............................................................................................................................ 19
Notes............................................................................................................................ 20

K185XX High Temp Wheel Bearing Grease Tester
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1 Introduction
The Koehler High Temperature Wheel Bearing
Grease Tester is the latest design for performing
ASTM D3527, D4290, and D4950 test
specifications. The high temperature stability of
automotive wheel bearing greases is evaluated
in a modified automotive front wheel hub-
spindle-bearings assembly. The ASTM D3527
Life Performance test employs severe conditions
(25 lbf (111N) thrust load, 1000rpm, 160°C
spindle temperature) to induce grease
deterioration and failure. The test continues in a
20/4 hour on/off cycle until grease breakdown
causes measured drive motor torque to increase
past an established end point. The number of
hours to failure is the test result. The ASTM
D4290 Accelerated Leakage Tendencies
procedure employs similar test conditions for a
20 hour period, after which leakage of grease
and oil is measured and the bearings are
washed and examined for deposits of gum and
varnish.
The unit consists of a modified front wheel
hub-spindle-bearings assembly housed in a
constant temperature oven and coupled by a 1/4
horsepower variable-speed drive motor. The
unit controls test functions automatically and
provides continuous digital display of motor
torque, RPM, chamber temperature, spindle
temperature, time and elapsed time.
This manual provides important information
regarding safety, technical reference, installation
requirements, operating condition specifications,
user facility resource requirements, and
operating instructions for the High Temperature
Wheel Bearing Grease Tester. This manual
should also be used in conjunction with
applicable published laboratory procedures.
Information on these procedures is given in
section 1.2.
1.1 Koehler’s Commitment to Our
Customers
Providing quality testing instrumentation and
technical support services for research and
testing laboratories has been our specialty for
more than 50 years. At Koehler, the primary
focus of our business is providing you with the
full support of your laboratory testing needs. Our
products are backed by our staff of technically
knowledgeable, trained specialists who are
experienced in both petroleum products testing
and instrument service to better understand your
requirements and provide you with the best
solutions. You can depend on Koehler for a full
range of accurate and reliable instrumentation
as well as support for your laboratory testing
programs. Please do not hesitate to contact us
at any time with your inquiries about equipment,
tests, or technical support.
Toll Free: 1-800-878-9070 (US only)
Tel: [phone]
Fax: [phone]
Email: [e-mail]
http://www.koehlerinstrument.com
1.2 Recommended Publications
1. American Society for Testing and Materials
(ASTM)
100 Barr Harbor Drive
West Conshohocken, Pennsylvania 19428-
2959, USA
Tel: [phone]
Fax: [phone]
http://www.astm.org
email: [e-mail]
ASTM Publication:
ASTM D3527: Life Performance of
Automotive Wheel Bearing Grease
ASTM D4290: Determining the Leakage
Tendencies of Automotive Wheel
Bearing Grease Under Accelerated
Conditions
ASTM D4950: Standard Classification
and Specification for Automotive Service
Greases
1.3 Instrument Specifications
Electrical Requirements
Model No
Voltage
Frequency
Amps
K18500
115V
60 Hz
13A
K18590
220-240V
50 Hz
7A
K18595
220-240V
60 Hz
7A

K185XX High Temp Wheel Bearing Grease Tester
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Digital Controls and Displays
Timer:
On/off cycle and real time
Chamber Temperature:
°C
Spindle Temperature:
°C
Motor RPM:
0-1725 rpm
Motor Torque:
Current Draw
Elapsed Time:
9999.9 hr
Max Temperature:
177°C (350°F)
2 Safety Information and Warnings
Safety Considerations. The use of this
equipment may involve hazardous materials and
operations. This manual does not purport to
address all of the safety problems associated
with the use of this equipment. It is the
responsibility of any user of this equipment to
investigate, research, and establish appropriate
safety and health practices and determine the
applicability of regulatory limitations prior to use.
Equipment Modifications and Replacement
Parts. Any modification or alteration of this
equipment from that of factory specifications is
not recommended and voids the manufacturer
warranty, product safety, performance
specifications, and/or certifications whether
specified or implied, and may result in personal
injury and/or property loss. Replacement parts
must be O.E.M. exact replacement equipment.
Unit Design. This equipment is specifically
designed for use in accordance with the
applicable standard test methods listed in
section 1.2 of this manual. The use of this
equipment in accordance with any other test
procedures, or for any other purpose, is not
recommended and may be extremely
hazardous.
Overtemperature Protection. This unit is
equipped with Overtemperature Protection
(OTP) circuitry to prevent overheating. The unit
will automatically interrupt power whether
equipment malfunction or operator error causes
the temperature to exceed either 20 °C above
the set point or the maximum recommended
temperature range. The power can only then be
restored by identifying and correcting the
problem, allowing the unit to return to normal
operating temperatures, and resetting the power
to the unit.
Chemical Reagents Information. Chemicals
and reagents used in performing the test may
exhibit potential hazards. Any user must be
familiarized with the possible dangers before
use. We also recommend consulting the
Material Data and Safety Sheet (MSDS) on each
chemical reagent for additional information.
MSDS information can be easily located on the
internet at http://siri.uvm.edu or
http://www.sigma-aldrich.com.
3 Getting Started
3.1 Packing List
High Temperature Wheel Bearing Grease
Tester (K18500, K18590, K18595)
Spindle Thermocouple (K185-0-42A)
Cabinet Thermocouple (K185-0-42)
Inboard Bearing Set (289-004-001)
Includes: LM67048 Cone and LM67010
Cup
Outboard Bearing Set (289-004-002)
Includes: LM11949 Cone and LM11910
Cup
Grease Packer Assembly (K185-0-47B)
Bearing Installation/Removal Tools:
Includes:
Bearing Installer (K185-0-50)
Small Bearing Cup Remover (K185-0-
51A)
Large Bearing Cup Remover (K185-0-
51B)
Bearing Cup Installer (K185-0-56)
Bearing Puller (K185-0-49)
Spindle Wrench Pins (K185-0-41)
Accessories (purchased separately):
ASTM 42C Thermometer (250-000-42C)
Range: 95 to 255°C
3.2 Unpacking
Carefully unpack and place the instrument and
accessories in a secure location. Ensure that all
parts listed in previous section are present.
Inspect the unit and all accessories for damage.
If you find any damage, keep all packing
materials and immediately report the damage to
the carrier. We will assist you with your claim, if
requested. When submitting a claim for shipping
damage, request that the carrier inspect the
shipping container and equipment. Do not return
goods to Koehler without written authorization.

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WARNING: For personal safety, do not
operate the apparatus with the chamber doors
open. There is a possibility of electrical shock
and the possibility of injuries due to moving
mechanical parts and high temperatures.
Remove the main chassis from the carton and
place on a firm, level table in an area with
adequate ventilation or in a hood.
WARNING: Be sure two or more
individuals are available for extracting and lifting
instrument from box to cart and from cart to
bench. Individuals must lift in accordance to
proper technique. See Figure below.
Environmental Conditions: The instrument
environment must comply with the following
conditions for proper setup:
No / Low Dust
No direct sunlight
Not near heating or AC ventilation ducts
No Vibrations
Clearance from other instruments
Temperature Range: 5 to 40°C
Elevation to 2000 meters
Relative Humidity: < 80%
Power: Connect the line cords to properly fused
and grounded receptacles with the correct
voltage as indicated in section 1.3 or on the
information plate at the back of the individual
units.
WARNING: For user safety, please
disconnect the line cord whenever performing
any maintenance and/or cleaning of the unit.
4 Operation
The Koehler High Temperature Wheel Bearing
Grease Tester is designed for acquiring test
data in accordance with the ASTM D3527 and
D4290 test procedures. Please be sure to read
the safety and hazard warnings, the installation
procedure, and the standard test method before
operating this instrument.
4.1 Description of Instrument Controls
1. Timer. Displays the current time. The start
and finish times for testing can be
programmed. Please refer to the K18500
Timer Manual for full details of operating the
timer. Note that when you turn on the unit
only the timer and reset switch lights will be
illuminated. In order to start a test, set the
timer to the desired on and off times and
press the reset (RST) button. After pressing
the reset button, turn on the switches for the
fan, heat, and motor. These displays will
only turn on when the start time is reached.
Once the stop time is reached then these
components will automatically turn off. The
timer has two functions: to turn on/off the
motor, fan, and heat, and to keep track of
how long the motor has been running
(elapsed time). To toggle between the Real
Time Clock and the Elapsed Timer, press
the display (DSP) key. To reset the Elapsed
Timer to zero, make sure that the Elapsed
Time is currently being displayed and then
press reset (RST) to reset to zero.
2. Spindle Temperature Display. Displays the
spindle temperature in °C.
3. Chamber Temperature Display. Displays
the chamber temperature in °C.
4. Torque Display. Displays the torque
indicated as the motor current in milliamps
(mA).
5. Motor RPM Display. Displays the
revolutions per minute (RPM) of the motor.
6. Elapsed Time. Displays the time elapsed
during the test.
7. Line Switch. Controls the power to all the
electrical components.