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Kohler MPAC 1200 Generator Set

Kohler MPAC 1200 generator set: . Specifications, engine details, filters, oil capacity and 3 document types.

3
Document types

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Specifications

Ratings spec sheet not in our library yet — see the documents below.

Service intervals

40
ItemActionHoursMonthsNotes
Automatic control systemTest1 moMonthly (M).
Automatic control system (automatic operation test)Test1 moTest the transfer switch automatic control system monthly.
Contactor external operating mechanismClean12 moYearly (Y); clean and relubricate if dirty; service more frequently in dusty/dirty areas
Contacts de commutation d'alimentation principauxInspect12 moA = Annuel; nettoyer ou changer les contacts principaux ou changer le contacteur
Control and power wiring connectionsAdjust12 moYearly (Y); tighten to specifications
Détérioration, coupures ou abrasion des gaines de câblageInspect12 moA = Annuel; réparer ou remplacer les câblages endommagés
Electrical system — signs of overheating or loose connections (discoloration of metal, melted plastic, burning odor)Inspect12 moYearly (Y); operator may perform
Exterior of transfer switch (vibration, leakage, high temperature, contamination, deterioration)Inspect1 moMonthly (M); service more frequently in dusty/dirty areas
External hardwareCheck1 moMonthly (M); in place, tightened, not badly worn
External hardware (in place, tightened, not badly worn)Check1 moMonthly (M).
External operating mechanism cleanlinessClean12 moClean and relubricate if dirty. Yearly (Y). Service more frequently in extremely dusty or dirty areas.
Extérieur du commutateur de transfert (vibration excessive, fuites, température élevée, contamination, détérioration)Inspect1 moM = Mensuel
Indicators (LEDs) and all remote control systemsTest12 moYearly (Y)
Inside of the transfer switch (vibration, leakage, noise, high temperature, contamination, deterioration)Inspect1 moMonthly (M).
Inside of transfer switch (vibration, leakage, high temperature, contamination, deterioration)Inspect12 moYearly (Y)
Internal hardwareCheck12 moYearly (Y); in place, tightened, not badly worn
Internal hardware (in place, tightened, not badly worn)Check1 moMonthly (M).
Intérieur du commutateur de transfertInspect12 moA = Annuel
LED indicators, time delays, and remote control systemsTest12 moYearly (Y).
Main power switching contactsInspect12 moYearly (Y); clean or replace contacts or contactor assembly as necessary; service manual task
Main power switching contacts conditionInspect12 moClean or replace main contacts or transfer switch assembly as necessary. Yearly (Y).
Main power switching mechanisms mechanical operation and integrityCheck12 moYearly (Y).
Millivolt drop test for high contact resistanceTest12 moYearly (Y).
Modules limiteurs de surtension - indicateurs d'étatInspect2 moTous les 2 mois (le cas échéant)
Modules limiteurs de surtension - état des fils de raccordementInspect2 moTous les 2 mois (le cas échéant)
Movable finger assemblies (Models KGS/KGP)Lubricate12 moApply dielectric grease, if possible. Models KGS/KGP, yearly.
Outside of the transfer switch (vibration, leakage, high temperature, contamination, deterioration)Inspect1 moMonthly (M).
Power connector pin/socket retaining bolt torque (Models KGS/KGP)Check12 moVerify bolts are properly torqued. Models KGS/KGP, yearly.
Power connector socket thermal reading (Models KGS/KGP)Test12 moTake thermal readings of each socket after it has been energized for at least 3 hours; readings exceeding 65 C (149 F) indicate a need to replace the socket. Models KGS/KGP, yearly.
Propreté du mécanisme externe du contacteurClean12 moA = Annuel; nettoyer et lubrifier s'il est sale
Raccordements de câblages de commande et d'alimentationAdjust12 moA = Annuel; serrer aux couples indiqués
SPD connecting leadsInspect2 moEvery 2 months (SPD modules, if equipped)
SPD status indicatorsCheck2 moEvery 2 months (SPD modules, if equipped)
Signes de surchauffe ou de mauvais contacts (altération de couleur du métal, plastique fondu, odeur de brûlé)Inspect12 moA = Annuel; système électrique
Signs of overheating or loose connections (discoloration of metal, melted plastic, burning odor)Check12 moVisually inspect and check; Yearly (Y). Section 2.2.2.
Système de commande automatique du commutateur de transfertTest1 moM = Mensuel
Transfer switch automatic control systemTest1 moMonthly (M) (Section 6.2.2)
Visserie externe (en place, serrée et pas excessivement usée)Inspect1 moM = Mensuel
Visserie interne (en place, serrée et pas excessivement usée)Inspect12 moA = Annuel
Voltage-sensing circuitry and setpoint calibrationAdjust60 moCheck calibration and recalibrate as necessary. Every 5 Years.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Service specifications

45
TypeItemValueUnitCondition
ClearanceAuxiliary switch trip distance before fully seated position1.59mm1/16 in.
ClearanceContact pressure spacer0.5mm0.02 in.
ClearanceSpring gap (800-1200 A)3.175 maximum to 1.59 minimummm1/8 in. max to 1/16 in. min deflection on mains less than prespring gap
GapArcing contact minimum gap0.0762mm0.003 in.; feeler gauge must enter 1.59 mm (1/16 in.) past edge of silver
GapMain contact minimum gap (1600-2000 A and 3000 A)6.35mm1/4 in.
GapMain contact minimum gap (800-1200 A)1.59mm1/16 in.
OtherController K1 (NR) and K2 (ER) relays energized time250millisecondsto initiate transfer
OtherExtended transfer time relay recommended setting1% = 0.1seconds (100 ms)adjustable 100 ms to 10 seconds; closed-transition models
OtherIn-phase monitor synchronism window (default)5degreesadjustable 15 to 5 degrees before synchronism only
OtherOvervoltage dropout default115% of nominal (276 V for 240 V system); maximum 690 volts%110% for 600 volt applications
OtherRelais de durée de transfert étendue - temps d'excitation réglable100 ms à 10 sréglage recommandé 1 % = 0,1 s (100 ms)
OtherShaft adjustment (600 A KSP)1.5 rotations back from limit of switching rangeafter mechanism just latches with manual handle
OtherSynchronization angle differential (default, closed transition)10degreesadjustment range 0–10 degrees
OtherSynchronization frequency differential (default, closed transition)0.1Hzadjustment range 0–0.3 Hz
OtherSynchronization voltage differential (default, closed transition)5%adjustment range 0–5%
PressureArc finger contact pressure (1600-2000 A and 3000 A)4-6.4kg9-14 lb.
PressureMain contact pressure (1600-2000 A and 3000 A)1.7-2kg3.75-4.5 lb.
ResistanceMaximum contact resistance, 1000-1200 A0.085milliohms
ResistanceMaximum contact resistance, 1600-3000 A0.050milliohms
ResistanceMaximum contact resistance, 225-400 A0.200milliohms
ResistanceMaximum contact resistance, 30-200 A0.250milliohms
ResistanceMaximum contact resistance, 600-800 A0.175milliohms
ResistanceMinimum wire insulation resistance1.24megohmshi-pot maximum 500 VAC, 1 second
ResistanceRectifier diode reverse resistanceat least 100 times the forward resistanceohmmeter R x 1 scale or diode checker
SpeedUndervoltage pickup default90% of nominal (216 V for 240 V system)%
TemperaturePower connector socket surface temperature limit65C149 F; reading indicates a need to replace socket
TorqueAnchor bar 1/4-20 socket head cap screws (3000 A)10.2Nm90 in. lb.
TorqueArc chute holding screws2.8Nm25 in. lb.
TorqueAuxiliary switch mounting screws0.14Nmmaximum (1 in. lb.)
TorqueBraid lug bolts (1600-2000 A)31.2Nm23 ft. lb.
TorqueBraid lug nuts (3000 A)19Nm14 ft. lb.
TorqueControl switch connections0.14Nmmaximum (1 in. lb.)
TorqueController assembly four corner nuts6.8Nmmaximum (5 ft. lbs. or 60 in lbs.)
TorqueEntrée de connexion de transfert forcé à off (câble AWG 12-24)0,5Nm
TorqueForced Transfer to OFF input connection (TB1) terminal0.5Nm (4.4 in. lb.)
TorqueMicroswitch holding screws0.3Nm3 in. lb.
TorqueMovable contact bus stud bolt (800-1200 A)31.2Nm23 ft. lb.
TorquePivot locknuts (1600-2000 A)13.6Nm10 ft. lb.
TorquePivot locknuts (3000 A)13.6Nm10 ft. lb.
TorquePower panel load/normal/emergency connecting bolts16.3Nm12 ft. lb.
TorquePower panel mounting nuts7.3Nm65 in. lb.
TorqueSolenoid assembly four mounting bolts (400-600 A)10.8Nm96 in. lb.
TorqueStationary contact hex head cap screws (800-1200 A)31.2Nm23 ft. lb.
TorqueStationary contact machine screws (800-1200 A)13.6Nm10 ft. lb.
VoltagePrécision de mesure de tension du contrôleur±0,5%

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Recommended fluids

FluidGradeStandardAmbientCapacityNotes
Greasedielectric greaseApply to movable finger assemblies (Models KGS/KGP) yearly, if possible. Do not use oil; order the lubrication kit shown in the Parts Catalog.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Procedures

12
Calibration (Voltage/Current) adjustment

⚠ Testing live electrical circuits. Have trained and qualified personnel take diagnostic measurements of live circuits.

Tools: Personal computer with Kohler SiteTech software, Digital voltmeter, Clamp-on current sensing meter (current calibration)

  1. Measure the source voltages as instructed in Section 4.4.3 and record the measured values.
  2. Connect a computer to the MPAC controller and start the SiteTech program.
  3. Click on Parameters and scroll to MPAC Source 1 Calibration or MPAC Source 2 Calibration.
  4. Enter the measured voltage into the corresponding calibration line.
  5. Click on Apply Changes to save the new calibration settings.
  6. For current calibration, enter the measured current (amps) into the corresponding Calibration Factor Load Current L1, L2, or L3 setting.
Shaft Adjustment, 600 Amp Model KSP adjustment

Tools: Manual operating handle

  1. Turn the large round shaft in (clockwise) until the mechanism just latches when operated with the manual handle.
  2. Turn the shaft back 1.5 rotations from the limit of the switching range.
  3. Hold the shaft and tighten the nut.
  4. Replace the cover on the mechanical unit.
Engine Start Test Procedure diagnostic

⚠ Accidental starting. Disconnect the battery cables before working on the generator set; remove negative lead first.

Tools: Ohmmeter or test lamp

  1. Start with the transfer switch in the Source N position. Connect an ohmmeter or test lamp across the engine start contacts.
  2. Models KSS/KSP: Pins 8 and 9 of connector P1. Models KGS/KGP: Pins 5 and 10 of connector P1.
  3. Disconnect Normal power from the transfer switch and verify the engine start contacts close.
  4. Reconnect Normal power and verify the engine start contacts open after applicable time delays.
  5. If contacts do not operate, replace the ATS controller.
  6. Press the Test button to initiate a test sequence and verify the engine start contacts close.
  7. Press the End button; verify the contacts open after the engine cooldown time delay.
Procedure to Clear a Module Status Conflict diagnostic
  1. Disconnect power to the transfer switch.
  2. Disconnect the module.
  3. Close the enclosure door and reconnect power to the ATS; display shows Module Status Change.
  4. Press the button labeled Reset; display shows Check Module Setup to Clear Fault.
  5. Uninstall the module through the ATS controller keypad (Section 1.11.1).
  6. Disconnect power to the ATS.
  7. Connect the new module.
  8. Close the enclosure door and reconnect power; display shows Module Status Change.
  9. Press Reset to display Reset New Module; press reset from that menu.
  10. Navigate to the Set Auxiliary I/O menu to check the status and settings for the new module.
Voltage, Frequency, and Phase Rotation Measurement Procedure diagnostic

⚠ Perform voltage checks in the order given to avoid damaging the transfer switch.

⚠ Do not connect or disconnect the controller wiring harness when power is connected.

Tools: Digital voltmeter with insulated probes, Phase rotation meter

  1. Verify the generator set master switch is OFF and both power sources are disconnected.
  2. Disconnect the power switching device and controller wiring harnesses at the inline disconnect plug.
  3. Manually operate the transfer switch to position E.
  4. If Source N is a generator set, start the generator.
  5. Close the Source N circuit breaker or switch.
  6. Check Source N phase-to-phase and phase-to-neutral voltages and frequency.
  7. Use a phase rotation meter to check Source N phase rotation; rewire terminals if necessary.
  8. Stop the generator set and disconnect Source N.
  9. Manually operate the transfer switch to position N and repeat steps 4 through 8 for Source E.
  10. Disconnect both sources to the transfer switch.
  11. Connect the power switching device and controller wiring harnesses at the inline disconnect plug.
  12. Close and lock the transfer switch enclosure door.
  13. Reconnect both power sources.
  14. Move the generator set master switch to the AUTO position.
Complete the RSA III final installation installation
  1. Mount the RSA III box to the wall or to the electrical box in the wall if not already done; check that the box is square.
  2. Position the RSA III front panel assembly to the box and install four self-tapping screws X-67-154; do not tighten.
  3. Center the remote annunciator in the box and square with the wall; tighten the screws.
  4. Flush mount: place wall-mounting plate GM85126 behind the RSA III front panel assembly flange.
Configuration de la commande de charge basée sur la durée installation
  1. Raccorder chaque circuit de charge à une borne de sortie de la carte principale ou d'un module E/S.
  2. Utiliser le menu Set Inputs/Outputs pour affecter la sortie à une sortie de commande de charge 1 à 9.
  3. Aller au menu Set S1 Time Delays ou Set S2 Time Delays.
  4. Sélectionner le mode de commande de charge Time.
  5. Entrer le nombre de charges à contrôler, égal au nombre de circuits raccordés.
  6. Définir Load # Disc N>E : temporisation avant transfert (min:s, max 60 min).
  7. Définir Load # Reconn E>N : temporisation après transfert (min:s, max 60 min).
  8. Entrer Loads to Add : nombre de circuits de charge (1 à 9).
  9. Pour la source 2, répéter les étapes 3 à 6 dans Set S2 Time Delays.
Configure the APM402 controllers for the remote serial annunciator installation
  1. Verify the controller defaults to a 19200 baud rate and Modbus address #1.
  2. If Modbus settings need altering, use SiteTech software to make the configuration changes.
  3. Verify the RS-485 address on the controller matches the address on the RSA III master.
Configure the APM603 controllers for the remote serial annunciator installation
  1. Verify the controller is factory configured with RSA Baud Rate 19200, RSA Comm Protocol Modbus, and RSA Modbus Address 1.
  2. Verify the RS-485 address on the controller matches the address on the RSA III master.
Configure the APM802 controllers for the remote serial annunciator installation
  1. Verify the controller is factory configured with speed 19200 baud, stop bit 1, parity without, function Modbus slave, slave number 1.
  2. Verify the RS-485 address on the controller matches the address on the RSA III master.
Configure the DEC 3+ controller for the remote serial annunciator installation

⚠ After setting DIP switches, power down and then power up the controller for the change to be acknowledged.

  1. Set the controller Modbus address to #1 by placing DIP switches 6, 7, and 8 to the open position.
  2. The DEC 3+ controller baud rate is fixed at 19200; no change is required.
  3. If a communication module board was installed, download firmware version 1.23 or higher (red board) or 2.03 or higher (blue board).
  4. Replace the controller cover and hardware.
Configure the DEC 550 and DEC 6000 Controllers for the Remote Serial Annunciator installation
  1. Replace the controller cover and hardware.
  2. Press the Reset Menu key on the controller keypad.
  3. Go to Menu 14, Programming Mode, and press the down arrow key to Programming Mode.
  4. Enter the access code (factory default is 0) and press Enter.
  5. Go to Menu 13, Communications, and press the right arrow key to Protocol - Modbus.
  6. Set the controller Modbus address to #1 and press Enter.
  7. Set the Baud Rate to 19200 if not already shown.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Voltage reconnection

VoltagePhaseConnectionLeadsNotes
APM402 and Decision-Maker 3000 P21P21-1 GND Shield; P21-2 (+) White; P21-3 (-) BlackConnect shield at either end but not at both ends.
APM603 customer connection terminal block(+) White; (-) Black; Shield — do not connect at the customer connection terminal block; tape to insulate unused endConnect shield at the RSA III P27 connection but not at the APM603 customer connection terminal block.
APM802 TB10TB10-7 (-) Blue; TB10-8 (+) Green; Shield — do not connect at TB10 or base module; tape to insulate unused end120 ohm resistor located on the base module; connect shield at the RSA III P27 connection only.
Communication module board TB5 (DEC 3+)TB5-3 ATS Position Input Return; TB5-4 User 1 Input Return; TB5-5 User 2 Input Return; TB5-6 User 3 Input Return; TB5-9 ATS Position Input; TB5-10 User 1 Input; TB5-11 User 2 Input; TB5-12 User 3 InputTerminals 1, 2, 7, and 8 not used. User 3 Input reserved for high battery volts (HBV) on DEC 3+ controllers.
Decision-Maker 3+ P21P21-1 - Black; P21-2 + White; P21-3 GND ShieldConnect shield at either end but not at both ends.
Decision-Maker 3500 TB12COM (+) (+) White; COM (-) (-) Black; Shield — do not connect at TB12 or DEC 3500, tape to insulate unused endConnect shield at the RSA III P27 connection only.
Decision-Maker 550 and 6000 P20P20-1 GND Shield; P20-2 + White; P20-3 - BlackConnect shield at either end but not at both ends.
Decision-Maker 8000 RS-485A terminal: blue wire, High (H) or Positive (+); B terminal: green wire, Low (L) or Negative (-)120 ohm resistor located on the controller base box; connect shield at the RSA III P27 connection only.
P27 connector on RSA III slaveP27-1 (-) Black (from master or previous slave); P27-2 (+) White (from master or previous slave); P27-3 Shield (from master or previous slave); P27-4 (-) Black (to next slave or terminating resistor); P27-5 (+) White (to next slave or terminating resistor); P27-6 Shield (to next slave or open)RS-485 daisy chain from master to slave.
P27 connector on master RSA IIIP27-1 (-) Black (from controller); P27-2 (+) White (from controller); P27-3 Shield (from controller); P27-4 (-) Black (to slave or terminating resistor); P27-5 (+) White (to slave or terminating resistor); P27-6 Shield (to slave or open)RS-485 communication from controller to RSA III master. Connect shield at either end but not both ends.
P27-1 (Controller to RSA III master)(-) Black (from controller)RS-485 communication; use Belden #9841 or equivalent.
P27-2 (Controller to RSA III master)(+) White (from controller)RS-485 communication.
P27-3 (Controller to RSA III master)Shield (from controller)Connect the shield wire at either end but not at both ends.
P27-4 (Master to slave)(-) Black (to slave or terminating resistor)RS-485 communication.
P27-5 (Master to slave)(+) White (to slave or terminating resistor)RS-485 communication.
P27-6 (Master to slave)Shield (to slave or open)RS-485 communication.
P37 power connectionsP37-1 Ground; P37-2 12/24 VDC battery input1 (not polarity sensitive); P37-3 12/24 VDC battery input2 (not polarity sensitive)Requires 12/24-volt, 200 mA (min.) DC power source; voltage should match generator set starting system.
P37-1GroundPower/CAN connections.
P37-212/24 VDC battery input1 (not polarity sensitive)Attach battery positive (+) at the starter solenoid.
P37-312/24 VDC battery input2 (not polarity sensitive)Attach battery negative (-) at the engine ground.
P40 output connectionsP40-1 Common fault relay normally closed; P40-2 Common fault relay common; P40-3 Common fault relay normally open; P40-4 Horn relay normally closed; P40-5 Horn relay common; P40-6 Horn relay normally openDry contacts rated at 220 VAC @ 0.8 amps and 30 VDC @ 2 amps.
P41 input connectionsP41-1 Local ATS emergency on input (EPS); P41-2 Local ATS emergency on input return (EPS); P41-3 User-Defined Digital input 1; P41-4 User-Defined Digital input 1 return; P41-5 User-Defined Digital Input 2; P41-6 User-Defined Digital Input 2 return; P41-7 User-Defined Digital Input 3; P41-8 User-Defined Digital Input 3 returnEPS and user-defined digital inputs typically supplied via remote Modbus RS-485 but may be hardwired locally.
P42 connectionsP42-1 User-defined digital input 4; P42-2 User-defined digital input 4 return; P42-3 User-defined digital input 5; P42-4 User-defined digital input 5 returnLocal user-defined digital inputs 4 and 5.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Parts

13model family
Part #DescriptionQtySystem
APM402APM402 Controller1Controller Amazon eBay $875.00
APM603APM603 controller uses a CR1220 internal battery to preserve the time, date, and generator set events.1Controller Amazon eBay $1500.00
APM802APM802 controller uses two BR2032 internal batteries in the controller base module and HMI to preserve the time, date, and generator set events.1Controller Amazon eBay $6999.00
DEC3500Controller Assembly1Controller Amazon eBay
DEC8000DECISION-MAKER® Model DEC80001Controller Amazon eBay
GM49791-1Communication module board1Communication board Amazon
295010Retainer1Service part / kit Amazon eBay
G12-520Remote Serial Annunciator (RSA III)Service part / kit Amazon eBay
GM32644-KA1Communication moduleService part / kit buy
GM32644-KP1Communication moduleService part / kit buy
GM41143-KP2Modbus/Ethernet converter for serial to Ethernet communicationService part / kit buy
GM60407Supply, power1Service part / kit buy
GM86125Board, main logic (RSA III circuit board)1Service part / kit buy

Compiled from this model's family documentation — may include parts for closely-related variants. Confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.

Available documents

Reference (Kohler)Parts manual — Kohler-Controller Brochure (Kohler)Service manual — Annunciators tt1625 (Kohler)Service manual — tp6866 (Kohler)Service manual — tp6866fr (Kohler)Service manual — tp6921 (Kohler)Service manual — tt1625 (Kohler)

This page was generated from the 7 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.