Koehler K19201 Guide

Operation and Instruction Manual
REV C
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
K19201
Water Washout Tester

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CERTIFICATE OF CONFORMANCE
Water Washout Tester
K19201
This certificate verifies that part number K19201, Water Washout Tester, was
manufactured in conformance with the applicable standards set forth in this
certification.
Specifications: ASTM D1264
ASTM D4950
IP 215
FTM 791-3252
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.
Vincent Colantuoni
Product Manager
Koehler Instrument Company

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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.

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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).

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Table of Contents
1Introduction............................................................................................................10
1.1 Koehler’s Commitment to Our Customers .....................................................................................10
1.2 Recommended Publications..........................................................................................................10
1.3 Instrument Specifications...............................................................................................................10
2Safety Information and Warnings.........................................................................10
3Getting Started....................................................................................................... 11
3.1 Packing List....................................................................................................................................11
3.2 Installation Instructions...................................................................................................................12
3.3 Set Up ............................................................................................................................................12
4Descriptions...........................................................................................................13
4.1 Instrument Controls........................................................................................................................13
4.2 Temperature Controller Operation.................................................................................................14
4.3 Timer Controller Operation.............................................................................................................15
5Operation................................................................................................................15
5.1 Verification of Flow Rate................................................................................................................15
5.2 Instrument Operation .....................................................................................................................16
6Maintenance...........................................................................................................17
6.1 Routine Maintenance.....................................................................................................................17
6.2 Bath Cleaning.................................................................................................................................17
6.3 Inner Ball Bearing Replacement....................................................................................................18
7Calibration..............................................................................................................18
7.1 Nozzle Position Calibration............................................................................................................18
7.2 Temperature Calibration ................................................................................................................19
7.3 Rotation Calibration........................................................................................................................19
8Service....................................................................................................................20
9Replacement Parts ................................................................................................20
10 Storage ...................................................................................................................20
11 Warranty.................................................................................................................20
12 Returned Goods Policy.........................................................................................20
Notes............................................................................................................................22

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1 Introduction
The Koehler Water Washout Tester K19201
rotates a lubricated ASTM ball bearing at 600 rpm
while impinging the bearing with a stream of
water at the specified flow rate and temperature.
This manual provides operating instructions for
the K19201 Water Washout Tester, and should
be used in conjunction with applicable standard
test methods.
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: [email protected]m
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: [email protected]
ASTM Publication:
•ASTM D1264: Standard Test Method for
Determining the Water Washout
Characteristics of Lubricating Greases
•ASTM D4950: Standard Classification
and Specification for Automotive Service
Greases
2. Energy Institute (IP)
61 New Cavendish Street
London, WIM 8AR, United Kingdom
Tel: [phone]
Fax: [phone]
http://www.energyinstpubs.org.uk/
IP Publication:
•IP 215: Determination of Water Washout
Characteristics of Lubricating Grease
3. Federal Test Method (FTM)
FTM Publication:
•FTM 791-3252
1.3 Instrument Specifications
Model:
K19201
Electrical
Requirements:
115-230V, 50/60Hz
Test Temperature:
38°C and 79°C
Temperature Control
Stability:
± 1°F (±0.5°C)
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 safetyproblems 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 theapplicability 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.

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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.
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.
n-Heptane:
WARNING: Flammable. Harmful if
inhaled.
•Keep away from heat, sparks, open
flames and any other source of ignition.
•Keep container closed.
•Use with adequate ventilation.
•Avoid prolonged breathing of vapor or
spray mist.
•Avoid prolonged or repeated skin
contact.
•Wash thoroughly after each use.
Stoddard Solvent:
WARNING: Combustible.
•Keep away from heat, sparks, open
flames and any other source of ignition.
•Keep container closed.
•Use with adequate ventilation.
•Avoid prolonged breathing of vapor or
spray mist.
•Avoid prolonged or repeated skin
contact.
•Wash thoroughly after each use.
3 Getting Started
3.1 Packing List
•K19201 Water Washout Tester
•289-001-006 Test Bearing
•22G-100-04S Additional Thumb Screws for
Test Bearing Housing (2)
•22J-304-16S Additional Thumb Screw for
Test Bearing Housing
•020-304-00P Additional Shaft Connector
•332-002-020 50 mL Graduated Cylinder
•AS568-130 O-Ring for Secondary Bearing
Assembly (2)
•414-104-3108 Tool to Disassemble the
Secondary Bearing Assembly
•463-964-001 Tool to Disassemble the
Secondary Bearing Assembly
•K19201-Manual Operation and Instruction
Manual
Accessories (purchased separately):
•289-001-006 Test Bearing
•K19201-23004 Test Bearing Assembly
•K19201-T-CAL-KIT Temp. Calibration Kit
•K19201-RPM-CAL-KIT Testing Bearing
Rotating Speed Calibration Kit
•K19201-03006 Special Gauge to Locate the
Spray Target
NOTE: The difference between the test
bearing and the secondary bearing is thatthe test
bearing contains the grease to be tested and the
secondary bearing allows the entire bearing shaft
to rotate. Do not interchange these bearings.

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3.2 Installation Instructions
1. Check Shock Watch Label on CardboardBox
for indication of rough handling and possible
damage.
2. Check labeling for correct orientation of
instrument. (e.g. This Side Up)
3. Carefully open top of box with box cutter and
remove packing foam.
4. Make two additional vertical cuts, using box
cutter, along length of two sides of the box
and remove packing foam.
5. Extract instrument and place on suitable cart
for transportation to work area / lab bench.
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.
6. Lift instrument from cart and place on bench.
Ensure that all parts listed on the packing list are
present. Inspect the unit and all accessories for
damage. If any damage is found, 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.
3.3 Set Up
Equipment Placement: Make sure the
instrument in placed on a firm, level table in an
area with adequate ventilation or in a hood.
Fill Reservoir: Close the drain valve and fill the
reservoir with water. A pan rests in the reservoir
with markings for minimum and maximum water
level limits. Then connect the drain valve to a
suitable waste receptacle.
Power: The instrument can operate at both 115V
and 230V, and can switch between the two
voltages with a switch located on the back of the
instrument, along the right side. This voltage
switch is shown in Figure 1. When unpacking the
instrument, the voltage switch will be covered
with a warning sign label, which is also shown in
Figure 1. Ensure that the voltage shown on the
voltage switch matches the input voltage of the
power supply. Connect the line cords to properly
fused and grounded receptacles with the correct
voltage as indicated on the back of the unit.
Figure 1. Voltage Switch and Warning Label
WARNING: Ensure that the voltage switch
is in the correct position that correlates to the
input voltage of the power supply BEFORE
connecting the power supply and powering on the
instrument. If the input voltage does not match
the voltage on the switch, significant damage may
be done to the instrument.
WARNING: For safety, disconnect the
power when performing any maintenance and/or
cleaning. Do NOT turn the power on unless the
bath is filled with the proper medium; otherwise,
damage may occur to the unit and the warranty
will be void.
NOTE: Before plugging in this unit, be sure
all switches are in the off position.

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4 Descriptions
4.1 Instrument Controls
Figure 2. Instrument Descriptions - Front
1. Line Switch. For powering On and Off the
apparatus.
2. Spray Switch. This is a three-position
switch. The middle position is the OFF or
standby position. Pressing the switch down to
the Water Spray position activate the water
spray function. The switch should be in this
position when the water jet is needed without
the integrated timer. Pressing the switch up
to the Start Test position will direct the pump
flow to the spray nozzle and will start the
timer and motor, performing a test.
3. Timer Controller. For controlling and
displaying the test time.
4. Temperature Controller. For controlling the
bath reservoir temperature.
5. Flow Rate Control. The flow rate is
controlled by an analog dial. As per ASTM
D1264, the water speed at the time it leaves
the nozzle must be 5 ± 0.5 mL/s. See Section
5.1 to adjust the flow rate.
6. Reservoir Cover / Thermometer Port. Pull
open the cover to expose the test bearing /
motor assembly. The cover is designed to
provide protection to the user from heated
water while allowing one to visually see
inside the test chamber during testing. The
cover is also equipped with a small hole for
insertion of an ASTM certified thermometer
or other direct contact thermometer.
Figure 3. Instrument Descriptions - Inside
7. Motor Switch. When turned on, the motor
will rotate the test bearing assembly. This
switch should be used if rotation needs to be
supplied to the bearing without using the
integrated timer during a test.
8. Test Bearing Housing Assembly. The test
bearing housing assembly holds the test
bearing. It is easily removed by loosening the
five thumb screws that hold it in place. See
Section 5.2 for instructions to assemble and
disassembly the bearing housing.
9. Secondary Bearing Housing Assembly.
The secondary bearing housing assembly
holds the secondary bearing. It can be
removed and replaced as per Section 6.3.
10. Emergency Stop Switch. Prevents the test
from running (or terminates a currently
running test) while the cover is open. This
switch will not stop the motor if the motor
switch is turned on.
11. Water Level Pan. The pan is marked with
maximum and minimum water level limits
when filling the bath. The pan will also catch
any grease that falls off during the test
12. Overflow Drain. Water will flow out to the
back of the instrument if the water level rises
above this.
13. Water Jet Nozzle. When the spray switch is
turned to the Start Test or Water Spray
position, water will flow out of the nozzle and
will strike the test bearing. See Section 7.1 to
adjust the angle of the water jet.
1
2
3
4
5
6
7
8
9
10
11
12
13

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Figure 4. Instrument Descriptions - Back
14. Power Input. For connecting the power cord.
15. Voltage Switch. Used to switch between
115V and 230V operation. Ensure that the
voltage shown on the voltage switch matches
the input voltage of the power supply. See
Section 3.3 for further information.
16. RPM Calibration Port. Used when adjusting
the motor rpm speed. This does not need to
be adjusted under normal circumstances,
since the motor is factory calibrated.
17. Overflow and Drain Outlet. Water will flow
outof thisadaptor ifthe water levelin thebath
is too high. To prevent spillage, connect
tubing from this outlet to a water drain. This
drain outlet is also used to empty the water
out of the instrument after testing is
completed.
4.2 Temperature Controller Operation
Figure 5. Temperature Controller
1. Process Temperature Display. The upper red
LED display shows the process temperature as
read from the RTD probe.
2. Set Point Temperature Display. The lower
green LED display shows the set point
temperature of the controller.
3. Programming Key. Permits scrolling through
controller menu parameters. One Level Forward
4. Down Key. Used to decrease the set point
temperature and to decrease or change
parameter values when programming the
temperature controller.
5. Up Key. Used to increase the set point
temperature and to increase or change
parameter values when programming the
temperature controller.
6. Exit / Function Key. This key is used to exit or
leave a level. One level backward
IMPORTANT NOTE: The digital temperature
controller for the unit comes pre-programmed
from the Koehler factory. Please do NOT attempt
to re-program the digital temperature controller as
this will void the product warranty. If assistance is
required, please do not hesitate to contact the
Koehler technical service department.
Setting the Temperature. Set the desired operating
temperature by adjusting the set point with the up
and down keys. The set point will be displayed in
the lower green Set Point LED display and the
actual temperature will be displayed in the upper
red Process LED display. Please allow the
instrument to fully equilibrate before proceeding
with any testing.
Temperature Calibration. This routine allows the
digital temperature controller to be calibrated to a
certified thermometer.
a. Use a certified calibrated measuring device to
acquire the temperature. Calculate the difference
between the measuring device and the Process
value displayed on the controller.
b. Press the program key two times until PCt is
displayed in the lower green LED display. Press
the DOWN key. CAL will display on the lower
green display. If there is a value observed in the
upper red LED display, add it to the calculated
7
15
16
17
14

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difference obtained in the previous step. This is
the offset value.
c. Press the Program Key. The lower green display
will flash. Use the up or down keys to adjust to the
new calibration offset value on the upper red
display calculated in the previous step. When the
value has been entered, the controller will
automatically store the value. The lower green
display will stop flashing. If further adjustments
are necessary, press the Program Key again.
Resume regular operations by pressing the Exit /
Function key two times. Verify if the new
calibration is correct by observing the upper red
display and comparing the value with the
calibrated reference device.
Auto Tune. This routine allows the digital
temperature control to learn the heating
parameters needed for any particular set point
temperature. This operation should be done
when installing a new unit, after replacing or
changing the bath medium type, or utilizing a
different temperature set point 20% different from
the previously used set point temperature.
a. Set the operating temperature to the desired
setting.
b. Press the up and down arrow buttons
simultaneously for about 5 seconds. When Auto
Tune is active, the lower green LED display will
blink TUNE. Auto Tune will automatically toggle
off when the set point temperature is reached.
Auto tune can be terminated by pressing the up
& down buttons simultaneously again.
4.3 Timer Controller Operation
Figure 6. Temperature Controller
1. Timer Countdown Display. The upper red LED
display shows the time remaining for the test.
2. Set Point Timer Display. The lower orange LED
display shows the set point time of the controller.
3. Reset Key. Resets the elapsed time on the
countdown timer.
4. Lock Key. Locks all other buttons on the timer
unit.
5. Down Keys. Decreases each corresponding digit
of the set point timer.
6. Up Keys. Increases each corresponding digit of
the set point timer.
5 Operation
WARNING: Ensure that the voltage switch
is in the correct position that matches the input
voltage of the power supply BEFORE connecting
the power supply and powering on the
instrument. If the input voltage does not match
the voltage on the switch, significant damage may
be done to the instrument. See Section 3.3 for
more information on the voltage switch.
5.1 Verification of Flow Rate
The pump speed is controlled by an analog
dial. As per ASTM D1264, the water speed at the
time it leaves the nozzle must be 5 ± 0.5 mL/s. It
is required for the operator to verify the water flow
rate as per Section 8.3 of ASTM D1264 and
requires the use of the supplied piece of Tygon
tubing and borosilicate glass graduated cylinder.
This procedure is illustrated in Figure 7 and is
described below:
Figure 7. Water Flow Rate Verification Setup
1
2
3
4
5
6

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1. Connect the Tygon tubing to the nozzle
outlet. Place the other end of the Tygon
tubing into the graduated cylinder. This setup
is shown in Figure 7.
2. Turn the spray switch to the “Water Spray”
position. Water will then begin to spray out of
the nozzle and through the Tygon tubing, into
the graduated cylinder.
3. Start a timer or stop watch as soon as the
water enters the graduated cylinder. After 5 –
10 seconds pass, turn the spray switch back
to the off position. Stop the timer or stop
watch once the water no longer enters the
graduated cylinder
4. Measure the volume of water in the
graduated cylinder.
5. To determine the flow rate, divide the volume
of water (in mL) by the measured time on the
timer or stop watch (in seconds).
6. The calculated flow rate should be 5 ± 0.5
mL/s as per ASTM D1264. If the flow rate falls
outside of this range, adjust the Flow Rate
Control (Section 4.1, Item 5) accordingly.
7. Repeat the flow rate verification process until
the flow rate is within the ASTM D1264 5 ±
0.5 mL/s range.
5.2 Instrument Operation
NOTE: Be sure to read the safety and hazard
warnings, the installation procedure and any of
the standard test methods mentioned in the
Introduction of this manual before operating this
instrument.
1. Remove the bearing housing by removing the
five thumb screws holding the bearing
housing to the bath. See Figure 8 below:
Figure 8. Remove Thumb Screws
2. The central, larger thumbscrew secures the
bearing shaft and small bearing plate in place
through the center of the bearing housing.
Once the five thumb screws are removed,
pull the bearing housing and bearing shaft
out of the instrument.
3. Disassemble the bearing housing and
bearing shaft by removing the thumb screws
from the bearing housing, and by taking out
the thumb screw in the middle of the housing.
Figure 9 shows the components of the test
bearing housing and Figure 10 shows the
components of the bearing shaft.
Figure 9. Left to Right: Bearing Plate, Test Bearing
(packed), Bearing Shield
Figure 10. Left to Right: Shaft Connector, Bearing
Shaft, Small Bearing Plat w/ Large Thumb Screw
4. Clean the bearing housing. If the housing
holds a used test bearing, replace it with a
new test bearing. Pack the new test bearing
with grease as per the standard test method.
5. Reassemble the test bearing housing. To do
so, place the grease packed test bearing into
the bearing shield. Then place the bearing
plate over the open end of the bearing shield.
Insert the four smaller thumb screws into the
bearing housing from the side of the bearing
shield. See Figure 11 for an assembled
bearing housing:
Figure 11. Assembled Bearing Housing
remove
these
screws

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6. Screw the bearing housing into the assembly
in the instrument.
7. Insert the bearing shaft assembly into the
bearing assembly. The shaft connector
attaches the motor shaft to the bearing shaft.
The bearing shaft is inserted through the
center of the bearing assembly. The bearing
shaft is secured in place with the small
bearing plate, which is screwed into the
bearing assembly with the one large thumb
screw. After screwing the shaft assembly into
the instrument, ensure that the four smaller
thumb screws are properly secured.
NOTE: Do not run the test bearing
without greasing it first.
The ball bearing located in the secondary
bearing housing on the motor side is greased
prior to shipment. Under normal operating
conditions, the ball bearing should be
replaced and greased every two years or as
needed. Refer to the Maintenance Procedure
for these instructions.
8. Fill the water bath distilled water. The pan in
the bath has markings to indicate the
minimum and maximum water level. Be sure
the drain valve (located on the side of the
instrument) is closed before adding water to
the bath. This water level must be maintained
to avoid the heater burning out.
NOTE: Always double check the water
level before beginning a test
9. Turn on the instrument and adjust the
temperature controller (Figure 5) to the
desired temperature as stated in the
standardized test method.
10. When the water has reached the specified
temperature, adjust the Flow Rate Control
Knob to the prescribed speed and verify
using the procedure outlined in Section 5.1.
11. To start a test, turn the spray switch to the
Start Test position to start the timer and the
motor.
NOTE: Make sure the cover is closed
before running a test. The test will not run if the
cover is open.
12. Proceed in accordance with the test
methods listed in Section 1.2.
13. Remove the water from the water bath by
placing a waste container under the drain
valve. Open the valve. Allow the water tofully
drain before closing. Be sure the drain valve
is closed before adding more water to the
bath. The drain valve is closed when the knob
is perpendicular to the spout.
6 Maintenance
WARNING: Disconnect power to the unit
before servicing and accessing any internal
portion of the instrument to avoid exposure to
high voltages and/or temperatures which may
result in personal injury or death. If you have any
questions about maintaining your equipment,
then please do not hesitate to contact the Koehler
technical service department.
6.1 Routine Maintenance
The K19201 Water Washout Tester requires
little routine maintenance to provide many years
of continuous service. However, over the course
of time, some instrument parts may need to be
replaced. When ordering replacement part(s),
please provide the model number, serial number,
and product shipment date of your equipment so
that we can ensure you will receive the proper
replacement part(s).
6.2 Bath Cleaning
•To clean the instrument’s exterior, which
includes all painted surfaces and glass, either
a solution of soap and water or laboratory
grade detergent may be used.
•Apply cleaner to clean wipe or cloth, not to
the instrument directly. Wipe surface clean.
•Do Not clean bath exterior with organic
chemicals such as Acetone, Toluene,
Hexane, etc.
•For more difficult cleaning of finished
surfaces, a dilute solution or isopropanol in
water may be used.
•It is not recommended that more aggressive
solvents be used on painted surfaces since
paint color will tarnish or be stripped from the
instrument.

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Operation and Instruction Manual
K19201-Manual -18-
•Glass surfaces may be cleaned using a more
aggressive solvent such as acetone, if
necessary.
SHOCK AND BURN HAZARD: Only
clean inside the bath when equipment is de-
energized and unplugged from the mains power
supply. Allow adequate time for heating coils to
completely cool before cleaning.
6.3 Inner Ball Bearing Replacement
K19201 has two ball bearing assemblies. The
test bearing is replaced after every test, since
grease sample must be packed into it, as
described in Section 5.2. The secondary ball
bearing does not need to be replaced after every
test. The secondary ball bearing is located next
to the motor (see Section 4.1, Item 9). The
secondary ball bearing is recommended to be
replaced after 1 - 2 years of operation. To replace
the secondary ball bearing:
1. Remove the test bearing assembly as per
Section 5.2 by removing the 5 thumbscrews.
2. Using the supplied tool to remove the
secondary bearing assembly (part numbers
414-104-3108 and 463-964-001), unscrew
the four screws that hold the secondary
bearing assembly in place. The screws are
located on the side of the assembly that faces
the motor shaft.
3. Once the screws are removed, carefully
remove the secondary ball bearing assembly
out of the instrument.
4. Disassemble the bearing assembly. Figure
12 shows each component of the assembly.
Figure 12. Secondary Ball Bearing Assembly
5. Replace the secondary ball bearing with a
new, unused secondary bearing. Do not use
a test bearing in this assembly.
6. Replace the O-ring of the secondary bearing
assembly with a new, unused O-ring.
7. Reassemble the secondary bearing
assembly.
8. Insert the secondary bearing assembly into
the instrument, in the same position and
orientation in which it was removed.
9. Screw the four screws into the secondary
bearing assembly using the supplied tool to
hold the assembly in place.
7 Calibration
7.1 Nozzle Position Calibration
The angle of the water jet can be adjusted and
locked in place so that it strikes the same position
of the test bearing for each test. The K19201-
03006 special gauge is used to adjust the angle
of the water jet, which is purchased separately
from the instrument. This proper position of the
water jet is shown in Figure 13, and the procedure
to adjust this position is described below.
Figure 13. Calibration of Water Jet Position
1. Attach the test bearing assembly to the test
position using the thumbscrews.
2. Place the K19201-03006 gauge on the
bearing assembly. The gauge should rest
with the two upper thumb screws of the
bearing assembly inside the two outer
grooves of the gauge tool. See Figure 13 for
reference.
3. Turn the spray switch to the “Water Spray”
position. Water will then begin to spray out of
the nozzle.
4. The water jet should strike the bearing
assembly directly in the corner of the middle
groove of the gauge tool. This is shown in
Figure 13.

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Operation and Instruction Manual
K19201-Manual -19-
5. If the water jet does not strike this position,
the angle of the nozzle can be adjusted. To
adjust the nozzle, loosen the brass coupling
that holds the nozzle in place. Once the
coupling is loosened, the direction of the
nozzle can be adjusted by hand, so that it
strikes the correct position of the bearing, as
shown in Figure 13. Hold the nozzle in the
correct position, then hand-tighten the brass
coupling to lock the nozzle’s position in place.
WARNING: DO NOT use any tools to
tighten the brass coupling. Overtightening can
severely damage the equipment on this
instrument.
7.2 Temperature Calibration
See Section 4.2 for information regarding
calibration of the temperature controller.
Temperature calibration requires use of a
calibrated temperature measuring device. This
device is a part of the K19201-T-CAL-KIT
Temperature Calibration Kit that can be
purchased separately with the instrument. The
procedure to measure the bath temperature with
this device is as follows:
1. Fill the bath, as described in Section 5.2.
2. Turn the spray switch to the “Water Spray”
position. Water will then begin to spray out of
the nozzle and will circulate through the bath.
3. With the lid of the instrument closed, place
the probe of the temperature measuring
device in the small hole in the instrument’s lid
next to the viewing window (as shown in
Figure 14).
Figure 14. Temperature Calibration Hole
4. Push the probe into the hole, until the end of
the probe reaches the bottom of the bath.
5. Raise the probe by an inch, so the end of the
probe is in the ideal position for temperature
measurement of the bath.
6. Read the measured temperature on the
display of the calibrated temperature
measuring device.
7.3 Rotation Calibration
As per ASTM D1264, the test bearing must
rotate at 600 ± 30 rpm during the test. The motor
is factory calibrated, so that the bearing rotates at
600 rpm as per ASTM D1264. To check the rpm
speed of the motor and to adjust it if necessary,
the K19201-RPM-CAL-KIT Rotation Calibration
Kit is used, which is purchased separately with
the instrument. The procedure to measure and
adjust the rpm of the bearing with this calibration
device is as follows:
1. Attach the shaft with the shaft connector to
the motor.
2. Turn the motor switch (Section 4.1, Item 7) to
the on position. The motor will then rotate the
bearing assembly.
3. Point the calibration rpm meter at the end of
the motor that connects to the shaft
connector. The end of the motor is black, and
has a portion that is painted white. Ensure the
laser of the rpm meter is pointed at the end of
the motor, so it can detect the white portion
to measure the rpm.
4. The meter should read 600 ± 30 rpm.
5. If the rpm does not fall in this range, the motor
speed can be adjusted. To do so, a second
operator may be needed. There is a small
hole located on the back of the instrument
(Section 4.1, Item 16). Insert the screwdriver
into this hole, and slowly turn the screw to
adjust the motor speed. Monitor the rpm as
the screw is adjusted until the rpm is properly
calibrated.
6. Once the calibration meter reads 600 ± 30
rpm, turn off the motor witch.
7. Calibrate the temperature controller as per
Section 4.2 if needed.

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Operation and Instruction Manual
K19201-Manual -20-
8 Service
Under normal operating conditions and with
routine maintenance, the K19201 Water Washout
Tester should not require service. Any service
problem can be quickly resolved by contacting
Koehler’s technical service department either by
letter, phone, fax, or email. In order to assure the
fastest possible service, please provide us with
the following information.
Model Number:
Serial Number:
Date of Shipment:
9 Replacement Parts
Part Number
Replacement Part
289-001-033
Secondary Bearing
289-001-006
Test Bearing
K19201-23004
Test Bearing Assembly
AS568-130
O-ring for Secondary Bearing
020-304-00P
Shaft Connector
332-002-020
50 mL Graduated Cylinder
K19201-03006
Gauge to Locate Spray Target
414-104-3108
Tool for Secondary Bearing
463-964-001
Tool for Secondary Bearing
22G-100-04S
Thumb Screws for Test Bearing
22J-304-16S
Thumb Screw for Test Bearing
10 Storage
This laboratory test instrument consists of
Electrical & Mechanical Components. Storage
facilities should not be subject to extremes of high
and low temperatures or extremes of high and
low moisture conditions. Storage facilities should
be consistent with indoor laboratory environment.
NOTE: Unit is shipped in corrugated cartons
and if long term storage is anticipated, repacking
with water resistant packing is recommended to
insure a safe condition for the equipment.
11 Warranty
We, at Koehler, would like to thank you for your
equipment purchase, which is protected by the
following warranty. If within one (1) year from the
date of receipt, but no longer than fifteen (15)
months from the date of shipment, Koehler
equipment fails to perform properly because of
defects in materials or workmanship, Koehler
Instrument Company, Inc. will repair or, at its sole
discretion, replace the equipment without charge
F.O.B. its plant, provided the equipment has been
properly installed, operated, and maintained.
Koehler Instrument Company must be advised in
writing of the malfunction and authorize the return
of the product to the factory. The sole
responsibility of Koehler Instrument Company
and the purchaser’s exclusive remedy for any
claim arising out of the purchase of any product
is the repair or replacement of the product. In no
event shall the cost of the purchaser’s remedy
exceed the purchase price, nor shall Koehler
Instrument Company be liable for any special,
indirect, incidental, consequential, or exemplary
damages. KOEHLER INSTRUMENT
COMPANY, INC. DISCLAIMS ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING ANY IMPLIED WARRANTIES OF
FITNESS FOR A PARTICULAR PURPOSE.
Please save the shipping carton in the event the
equipment needs to be returned to the factory for
warranty repair. If the carton is discarded, it will
be the purchaser’s responsibility to provide an
appropriate shipping carton.
12 Returned Goods Policy
To return products for credit or replacement,
please contact Koehler Customer Service with
your purchase order number, our packing
list/invoice number, the item(s) to be returned and
the reason for the return. You will be issued a
Returned Authorization (RA) number, which must
be prominently displayed on the shipping
container when you return the material to our
plant. Shipping containers without an RA number
prominently displayed with will be returned to the
sender. Goods must be returned freight prepaid.
Returns will be subject to a restocking charge, the
application of which will depend upon the
circumstances necessitating the return. Some
returns cannot be authorized, including certain
products purchased from outside vendors for the
convenience of the customer, products
manufactured on special order, products shipped
from the factory past ninety (90) days, and