Katolight — Assembly Instructions 15kW Unit
Repair & overhaul · genset
From a Katolight service manual covering: 15kW Lighthouse, 9kW Lighthouse, PM0621512, PM0639011. Check it applies to your exact model before use.
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Procedure
- Attach the 2 mounting brackets to the engine with 4 bolts, torque 7 - 10ft./lb.
- Attach antifreeze overflow bracket to mounting bracket on front side of engine.
- Attach black ground wire to engine block on back side.
- Remove governor from old engine and attach to new engine.
- Remove the 4 screws holding the protective screen on the front of the generator.
- Align generator and engine, start 2 bolts through generator into engine housing on each side, do not tighten; attach lift bracket with 2 bolts finger tight.
- Align rotor plate with engine plate; start 6 hex drive bolts through generator flange into engine plate, finger tight.
- Raise unit, install 2 bottom bolts through generator head; tighten all 8 bolts, torque 30 - 50 ft/lb.
- Ensure generator flange fits snug into engine plate (~1/32" inside); tighten 6 hex drive bolts, torque 10 - 17 ft./lb.
- Replace protective screen; place unit on metal frame and attach with 4 bolts; follow disassembly in reverse to complete cabinet.
Tools required
- torque wrench Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Mounting brackets 7 - 10ft./lb.
- Generator to engine 30 - 50 ft/lb
- Hex drive bolts 10 - 17 ft./lb.
- Generator flange approximately 1/32" inside engine plate
Source: Katolight service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.