K162XX

Pensky-Martens Closed Cup Flash Tester

Operation and Instruction Manual

REV A

Koehler Instrument Company, Inc.

1595 Sycamore Avenue • Bohemia, New York 11716-1796 • USA
Toll Free: 1-800-878-9070 (US only) • Tel: +1 631 589 3800 • Fax: +1 631 589 3815
http://www.koehlerinstrument.com • e-mail: [email protected]
Petroleum Testing & Analysis Instrumentation • Custom Design & Manufacturing
 Table of Contents

1 Introduction .............................................................................................................. 1
1.1 Koehler’s Commitment to Our Customers ....................................................................................... 1
1.2 Recommended Publications ............................................................................................................ 1
1.3 Electrical Requirements ................................................................................................................... 1
2 Safety Information and Warnings ........................................................................... 2
3 Getting Started ......................................................................................................... 2
3.1 Packing List ...................................................................................................................................... 2
3.2 Recommended Accessories ............................................................................................................ 2
4 Installation ................................................................................................................ 3
4.1 Instrument Description ..................................................................................................................... 3
5 Operation .................................................................................................................. 4
6 Troubleshooting ...................................................................................................... 5
6.1 Test Cover (Shutter) Jams ............................................................................................................... 5
6.2 Gas Lines on Test Cover Break ....................................................................................................... 5
6.3 Stirrer Shaft in the Cover Assembly Does Not Rotate ..................................................................... 5
6.4 Gas Leaks and Shooting Flames ..................................................................................................... 5
6.5 Heater Does Not Operate ................................................................................................................ 5
6.6 Stirrer Motor Does Not Operate ....................................................................................................... 6
6.7 Stirrer Motor Runs Hot ..................................................................................................................... 6
6.8 Flexible Motor Coupling Breaks ....................................................................................................... 6
7 Replacement Parts................................................................................................... 7
8 Assembly Diagrams................................................................................................. 8
8.1 K16200 (115V) and K16270 (220-240V) Flash Point Tester Assembly .......................................... 8
8.2 K16010 Cover Assembly................................................................................................................ 11
8.3 Wiring Diagrams ............................................................................................................................. 13
9 Service .................................................................................................................... 15
10 Storage ................................................................................................................... 15
11 Warranty ................................................................................................................. 15
12 Returned Goods Policy ......................................................................................... 15
Notes ............................................................................................................................ 16
 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

1 Introduction ASTM Publication:

 ASTM D93: Flash Point by Pensky-
Koehler Model K162XX Pensky-Martens Martens Closed-Cup Tester
Closed Cup Flash Point Tester determines the
flash points of fuels, lubricating oils, liquid 2. International Organization for
containing suspended solids and liquids that Standardization (ISO)
tend to form a surface film during testing. It 1, rue de Varembé
determines the flash points of a wide range of Case postale 56
products by a closed cup method with a flow CH-1211 Geneva 20, Switzerland
speed stirring of the sample. Tel: 41 22 749 01 11
This manual provides operating instructions Fax: 41 22 733 34 30
for the K162XX Pensky-Martens Closed Cup http://www.iso.org
Flash Point Testers, and should be used in
conjunction with applicable standard test ISO Publication:
methods. The following sources are  ISO 2719
recommended:
3. Energy Institute (IP)
1.1 Koehler’s Commitment to Our 61 New Cavendish Street
Customers London, WIM 8AR, United Kingdom
Tel: 44 (0)20 7467 7100
Providing quality testing instrumentation and Fax: 44 (0)20 7255 1472
technical support services for research and http://www.energyinstpubs.org.uk/
testing laboratories has been our specialty for
more than 50 years. At Koehler, the primary IP Publication:
focus of our business is providing you with the  IP 34: Closed Flash Point: Pensky-
full support of your laboratory testing needs. Our Martens Method
products are backed by our staff of technically
knowledgeable, trained specialists who are 4. Deutsche International Norm (DIN)
experienced in both petroleum products testing http://www.din.de
and instrument service to better understand your
requirements and provide you with the best DIN Publication:
solutions. You can depend on Koehler for a full  DIN 51758:
range of accurate and reliable instrumentation
as well as support for your laboratory testing 5. Federal Test Method (FTM)
programs. Please do not hesitate to contact us
at any time with your inquiries about equipment, FTM Publication:
tests, or technical support.  FTM 791-1102
Toll Free: 1-800-878-9070 (US only) 6. American Association of State Highway and
Tel: +1 631 589 3800 Transportation Officials (AASHTO)
Fax: +1 631 589 3815
AASHTO Publication:
Email: [email protected]  AASHTO T73-811
http://www.koehlerinstrument.com
1.3 Electrical Requirements
1.2 Recommended Publications
Model No Voltage Frequency Amps Nema Plug
1. American Society for Testing and Materials K16200 115V 60 Hz 6.5 A 5-15
(ASTM) K16270 220-240V 50/60 HZ 3.4 A 6-15
100 Barr Harbor Drive
West Conshohocken, Pennsylvania 19428-
2959, USA
Tel: +1 610 832 9500
Fax: +1 610 832 9555
http://www.astm.org
email: [email protected]

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

2 Safety Information and Warnings

 At all times refrain from bending over the cup
Safety Considerations. The use of this when the test is being carried out. Unexpected
equipment may involve hazardous materials and flash can cause serious injury to exposed
operations. This manual does not purport to body parts in close proximity to the cup.
address all of the safety problems associated
with the use of this equipment. It is the  Exercise caution in removing and replacing
responsibility of any user of this equipment to the cup in the furnace. Hot surfaces and
investigate, research, and establish appropriate substances may cause injury if they come in
safety and health practices and determine the contact with the operator.
applicability of regulatory limitations prior to use.
 All hose connections should be properly
Equipment Modifications and Replacement clamped and tested for leaks prior to carrying
Parts. Any modification or alteration of this out the tests.
equipment from that of factory specifications is
not recommended and voids the manufacturer  The gas source should be equipped with a
warranty, product safety, performance proper safety regulator capable of delivering 1
specifications, and/or certifications whether psi of pressure to the test flame assembly.
specified or implied, and may result in personal
injury and/or property loss. Replacement parts 3 Getting Started
must be O.E.M. exact replacement equipment.
3.1 Packing List
Unit Design. This equipment is specifically
designed for use in accordance with the  K162XX Pensky-Martens Closed Cup Flash
applicable standard test methods listed in Point Tester
section 1.2 of this manual. The use of this
equipment in accordance with any other test  K16020 PM Test Cup with Handle
procedures, or for any other purpose, is not
recommended and may be extremely
 K145-8 Thermometer Holder
hazardous.
 K162XX-Manual Pensky-Martens Closed Cup
Chemical Reagents Information. Chemicals
Flash Point Tester Operation and Instruction
and reagents used in performing the test may
Manual
exhibit potential hazards. Any user must be
familiarized with the possible dangers before
use. We also recommend consulting the 3.2 Required Accessories
Material Data and Safety Sheet (MSDS) on each
chemical reagent for additional information. Catalog No. Accessory
MSDS information can be easily located on the
internet at http://siri.uvm.edu or K16220 Stirrer Motor, 115V 60Hz
http://www.sigma-aldrich.com.

IMPORTANT SAFETY INFORMATION: K16228 Stirrer Motor, 220-240V, 60Hz

 As an important safety precaution, NEVER

use unregulated gas with the Pensky-Martens K16229 Stirrer Motor, 220-240V, 50Hz
Closed Cup Flash Point Tester!
ASTM 9F Thermometer
 Use in an area that is adequately ventilated, 250-000-09F
Range 20 to 230°F
preferably with an exhaust hood to remove
any fumes that may be emitted during the test.
ASTM 9C Thermometer
250-000-09C
 Conduct tests behind a safety shield Range: -5 to +110°C
especially if you are not sure of the flash point
or the ignition temperature. Also wear safety
glasses during tests.

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

3. Gas Pipe Coarse Adjustment Screw. Turn

ASTM 10F Thermometer
250-000-10F to adjust the gas flow prior to testing.
Range: 200 to 700°F
4. Latex Tubing. Gas connection from Main
ASTM 10C Thermometer Gas Pipe Assembly to Cover Assembly
250-000-10C
Range: 90 to 370°C
5. Cup Holder. For holding test cup after
completion of test to cool.
4 Installation
This unit comes packed partially disassembled 6. Gas Pipe Assembly. For connection of the
to fit into a pre-formed carton for shipping. unit to an external gas source
Remove the partially disassembled unit and
place on a firm, level table in a room free from 7. Stirrer Motor Switch. Powers on and off
excessive drafts where there are no corrosive the Stirrer Motor.
fumes, excessive moisture, high room
temperatures or excessive heat. 8. Power On/Off / Heat Control Dial. The
analog dial is used to control the heating
4.1 Instrument Description rate of the unit during the test procedure.
Please note the numbers indicated on the
dial plate DO NOT refer to specific
temperatures or heating rates and are only
to be used as a reference. The control dial
can be switched to the OFF position.
Turning the dial counter-clockwise past the
zero (0) to the OFF position will result in a
click and power off the unit.

9. Powertrol Heater. For heating of the test

cup.

10. Cup and Cover Assembly. Comprised of

Gas and Pilot Flame tubes, Flame Indicator
bead, Stirrer Blade and coupling, Shutter
and Shutter Arm, and thermometer holder.
The brass test cup contains the test
specimen and is built with a heat resistant
handle. An indicator line is engraved inside
the test cup for proper sample level.

11. Thermometer Port. Designed to

accommodate ASTM 9C and 10C
thermometer and hold a desired height in
test cup.

12. Motor. Mount Motor on Vertical motor rod.

Motor is designed to rotate flexible stirrer
shaft at two prescribed speeds as per ASTM
1. Motor Support Rod. Installed in the base of D93.
the unit and allows for the stirrer motor to
clamp on mount on the unit at the To Reassemble:
appropriate test height. See diagram K16200 Flash Point Tester
Assembly. The following components have been
2. Fiber Knob. Rotate knob to open and close disassembled for shipping:
cover assembly at prescribed intervals
during testing.  K16010 Cover Assembly

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

 K16020 Cup 6. Connect the gas inlet to a regulated low

pressure gas supply (0.5 to 1.0 psi). Use
 K160-3-11 Cup Holder only propane, LPG, or natural gas. Do not
use direct unregulated pressure from an
 K160-1- Latex Tubing LPG tank. Connect two rubber hoses from
21A the cover assembly to main gas pipe outlets.
 K160-4-6 Gas Pipe Assembly
7. With the unit on a firm, level table, connect
1. Place the Cover Assembly into the Cup and the line cord to a properly fused and
place inside the air bath. Align the cup into grounded receptacle of the correct voltage
the screw holes on top of the brass bell. as indicated in Section 1.3. Be sure the
Power switch is off before connecting the
2. Wrap the threads of the main gas pipe with line cord. To double check the electrical
Teflon thread sealant tape. Install the main requirements, refer to the information plate
gas pipe into the ¼ pipe tee using an open on the side of the instrument. The unit is
end or adjustable wrench only and tighten now ready for operation. Proceed to
securely. Do not use pipe wrench. Operating Instruction.

5 Operation
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. Thoroughly clean and dry all parts of the cup

3. Place the Cup Holder on the main gas pipe and its accessories before starting the test.
at a convenient height and tighten the thumb Particular care should be taken to avoid the
screw. presence of any flammable products used to
clean the apparatus.
4. Install the motor support rod into the base
and tighten the set screw into the base to 2. Fill the cup with the sample being tested up
secure the rod. to the level indicated by the filling mark.

5. Install the stirrer motor on the support rod. 3. Place the lid on the cup and set the cup
Only position the stirrer motor as shown: inside the stove. Be sure to have the
locating grooves properly aligned.

4. Insert the thermometer into the thermometer

port. If it is known that the sample will flash
above 220°F or 122°C, the ASTM 10F or
10C Thermometer may be used. Otherwise,
it is preferable to begin testing with either
the ASTM 9F or 9C Thermometer.

5. Light the test flame with an external ignition

source. Adjust the flame using the coarse
adjustment screw. Use the valve screw
After approximately 100 hours of use, (shown in the picture, top right) to adjust the
remove the motor cover and locate the two flame so that it is 5/32” diameter, the same
drive shafts. Place a few drops of light size as the bead provided for comparison
lubricating oil such as 3 in 1 into the bottom (indicated by white arrow). The pilot flame
of each shaft and re-install the motor cover. (indicated by black arrow) is provided in
case the test flame extinguishes upon
dipping.

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

220°F, apply the test flame at each

temperature reading of 5°F.

9. Record the temperature when the flash point

occurs.

10. For full details on the testing procedure,

refer to standard test methods listed in
section 1.2.

6 Troubleshooting
6. Adjust the dial on the variable heat control
until the temperature reading on the 6.1 Test Cover (Shutter) Jams
thermometer increases to no less than 9°F,
or more than 11°F per minute. Turn the dial Solution:
fully clockwise and back counterclockwise to
set the temperature. The dial is non-linear.  Disassemble cover assembly and clean parts
with appropriate solvent.
7. Connect the stirrer to the stirrer motor by  Check for smooth operation
turning the placement screw (shown below)
counterclockwise and inserting the flexible 6.2 Gas Lines on Test Cover Break
stirrer. Turn the placement screw clockwise
to tighten. Make sure the flexible stirrer has Solution:
a smooth curve when inserting into the
motor. If it is too tight or too loose, the shear  Pilot flame gas line: Replace by loosening
stress will break it. the set screw and inserting a new ignitor tube
and nozzle assembly.
NOTE: The motor coupling on the right side  Test flame gas line: Replace the entire pivot
of the motor (closest to the mounting rod) block and jet tube assembly (K160-1-8A)
rotates at a higher RPM in accordance to which is held in place by two screws.
ASTM D93 Procedure B. The motor
coupling on the opposite side rotates at a 6.3 Stirrer Shaft in the Cover Assembly
lower RPM in accordance to ASTM D93 Does Not Rotate
Procedure A.
Solution:

 Remove the propellers from shaft (screws)

 Remove shaft from cover assembly and clean.
Replace if needed.
 Return shaft to the cover assembly and check
for smooth operation.
 Replace propellers in proper order.

6.4 Gas Leaks and Shooting Flames

8. Shut off the stirrer motor during the Solution:
application of the test flame. Apply the
test flame at each temperature reading by  Check for delivery pressure of the supply gas
turning the fiber knob clockwise. The cover (1 psi max)
assembly will open and the test flame will  Close valve all the way and check for leakage.
dip into the sample cup. Apply the test flame Replace valve and/or latex tubing if need be.
burner so that the test flame is lowered in
one-half second, left in its lowered position 6.5 Heater Does Not Operate
for one second, and quickly raised to it’s
high position. Dip the test flame every 2°F, Solution:
up to 220°F. For temperature ranges above

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

 Access heater by loosening the screws in the 6.7 Stirrer Motor Runs Hot
back support and swing bell assembly out of
the way. Solution:
 Check heater for continuity. If open, replace
heater.  Check electrical service for compatibility.
 Replace variable control. Access via bottom of  It is normal for the stirrer housing to be warm.
heater unit housing.
6.8 Flexible Motor Coupling Breaks
6.6 Stirrer Motor Does Not Operate
Solution
Solution:
 Replace the flexible stirrer coupling assembly
 Ensure the power cord is plugged into the (K160-9) by inserting the end receptacle into
receptacle. the drive motor and cover assembly.
 While unplugged, remove cover from motor  To prevent premature breakage of the motor
housing and check drive belt. Replace if spring:
needed. - Check the stirrer shaft in cover assembly for
 Remove back cover of housing and check for unrestricted motion.
clearance between the cover and the fan. - Position the drive motor as high as possible on
the support rod and ensure that the coupling is
a gentle arc between the drive motor and
cover assembly.

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

7 Replacement Parts

Part Number Replacement Part

K16010 Cover Assembly

K16020 Pensky-Martens Test Cup

K160-3-3 Brass Bell

K160-3-2 Cast Iron Bell

K160-1-14 Thermometer Ferrule Adapter

K145-8 Thermometer Ferrule

K160-9 Flexible Shaft and Coupling

K162-0-1 Cast Iron Base

K16220 Stirrer Motor, 115V, 60 Hz

010-115-005 Wattstat, 115V †

225-115-002 Brick Heater, 115V, 1000W †

K16229 Stirrer Motor, 220-240V, 50 Hz

010-230-004 Wattstat, 220-240V ‡

225-230-002 Heater, 220-240V, 1000W ‡

K160-1-8A Pivot, Block and Jet Tube Assembly

K160-3-12 Main Gas Pipe Assembly

Note:
† For 115V Unit (K16200) ONLY
‡ For 220-240V Unit (K16270) ONLY

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

8 Assembly Diagrams
8.1 K16200 (115V) and K16270 (220-240V) Flash Point Tester Assembly
Parts List:

Item No. Description Part Number

1 Cast Iron Base K160-0-1

2 Upright K160-3-4

3 Case Iron Bell K160-3-2

4 Spacer K160-3-10

5 Brass Bell K160-3-3

6 Gas Pipe Assembly K160-4-6

7 Feeder Nipple K160-3-7

8 Valve Stem & “O” Ring Assembly K160-3-9

9 Cup Holder K160-3-11

10 1’’ OD Rubber Feet 160-100-001

11 ¼ MPT x ¼ Brass Hose Barb 030-104-00N

12 ¼ Brass Tee Connector 020-104-10N

13 Stand-Off K162-0-3

14 10-32 x ½ Phillips Head Screw 22I-102-10N

15 10-32 x ½ Fil Hd Screw, Brass NP 22I-102-09N

16 ¼ - 20 x ½ Socket Setscrew 22J-102-04T

17 ¼ - 20 x ¾ Thumbscrew, Steel Cad Place 22J-304-17C

Powetrol Heater Assembly 115 V (for K16200) K162-0-4

18
Powetrol Heater Assembly 230 V (for K16270) K162C-0-4

19 Cup K16020

20 Cover Assembly K16010

21 Latex Tubing K160-1-21A

22 1/8 Hex Kay 310-108-000

Note: Item Numbers correspond to the following drawings on page 8 and 9:

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

K16200 Flash Point Tester Assembly (115V Model)

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

K16270 Flash Point Tester Assembly (230V Model)

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

8.2 K16010 Cover Assembly

Parts List:
Item No Description Part Number
1 Thermometer Ferrule K145-8-4
2 Operating Tube & Spring Anchor K160-1-1E
3 Shutter K160-1-2
4 Flame Guide K160-1-2A
5 Shutter Base Plate K160-1-3
6 Pivot & Tube Assembly K160-1-4
7 Cam K160-1-5A
8 Thermometer Tube Assembly K160-1-6
9 Fiber Knob K160-1-7
10 Pivot Block K160-1-8
11 Operating Tube Upper Spring anchor K160-1-10
12 Pivot, Shutter K160-1-11
13 Stirrer Shaft Column K160-1-12
14 Stirrer Column Nut K160-1-13
15 Ferrule Adapter K160-1-14
16 Large Propeller K160-1-16
17 Small Propeller K160-1-17
18 Shutter Tube Support Assembly K160-1-18
19 Jet Tube K160-1-19
20 Jet Tube Collar K160-1-20
21 Igniter Tube and Nozzle Assembly K16010-01000
22 Set, Tubing, Latex K160-1-21A
23 Jet K160-1-22
24 Pivot K160-1-23
25 Torsion Spring K160-1-25
26 Jet Needle K160-1-27
27 Stirrer Shaft Assembly K160-9
28 Screw, R.H., B.N.P., #2-56 x 1/8 Long 22B-108-00N
29 Screw, Fil Hd., B.N.P., #2-56 x 7/16 Long 22B-716-09X
30 Nut, Hex, Brass #2-56 22B-000-05X
31 Screw, R/H/. Brass #2-56 x 3/16 Long 22B-316-00X
32 Screw, Socket Set, #8-32 x ¼ Long 22G-104-104S
33 Screw, R.H. B.N.P, #2-56 x 5/16 Long 22B-516-00X

Item numbers correspond to the following drawing:

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

Cover Assembly Diagram:

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

8.3 Wiring Diagrams

K16200 115V Model:

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

K16270 220-240V Model:

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 K162XX Pensky-Martens Closed Cup Flash Point Tester
Operation and Instruction Manual

9 Service IMPLIED WARRANTIES OF FITNESS FOR A

PARTICULAR PURPOSE. Please save the
Under normal operating conditions and with shipping carton in the event the equipment needs
routine maintenance, the K162XX Manual Pensky- to be returned to the factory for warranty repair. If
Martens Flash Point Tester should not require the carton is discarded, it will be the purchaser’s
service. Any service problem can be quickly responsibility to provide an appropriate shipping
resolved by contacting Koehler’s technical service carton.
department either by letter, phone, fax, or email. In
order to assure the fastest possible service,
please provide us with the following information.
12 Returned Goods Policy
To return products for credit or replacement,
Model Number: please contact Koehler Customer Service with
Serial Number: your purchase order number, our packing
list/invoice number, the item(s) to be returned and
Date of Shipment: the reason for the return. You will be issued a
Returned Authorization (RA) number, which must
10 Storage be prominently displayed on the shipping
container when you return the material to our
This laboratory test instrument is equipped with plant. Shipping containers without an RA number
electrical components. Storage facilities should be prominently displayed with will be returned to the
consistent with an indoor laboratory environment. sender. Goods must be returned freight prepaid.
This testing equipment should not be subjected to Returns will be subject to a restocking charge, the
extremes of temperature and/or moisture. application of which will depend upon the
This equipment was shipped from the factory in circumstances necessitating the return. Some
a corrugated cardboard container. If long term returns cannot be authorized, including certain
storage is anticipated, re-packing the instrument in products purchased from outside vendors for the
a water-resistant container is recommended to convenience of the customer, products
ensure equipment safety and longevity. manufactured on special order, products shipped
from the factory past ninety (90) days, and
11 Warranty products which have been used or modified in
such a way that they cannot be returned to stock
We, at Koehler, would like to thank you for your for future sale.
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

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Operation and Instruction Manual

Notes

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Operation and Instruction Manual

Notes

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