Katolight — Assembly Instructions 9kW 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

1. Install four isolators to engine, torque to 10-17 ft./lbs. (13.56 to 23.05Nm).
2. Install ground wire (star washer with lock) on starter side.
3. Attach engine to frame with four 5/16 nyloc nuts and flat washer, torque 10-17 ft./lbs.
4. Bolt engine adapter to engine, solid side up, blue loctite on adapter whiz bolts, torque 10-17 ft.lbs.
5. Install rotor on engine shaft; install 13mm nut and flat washer, loctite engine end of bolt, torque 10 to 17 ft.lbs.
6. Install stator to adapter starting lower bolt on exhaust side with J clamp and nut with flat washer.
7. Loosen screw on governor spring retainer and install manifold shield.
8. Install three remaining adapter to gen head bolts, nuts and flat washers, torque 10 to 17 ft./lbs.
9. Attach control box to top of stator housing.
10. Stator hook up: black to black, white wires to white posts, attach ground with star washer.
11. Engine wire hook up: blue wire to oil pressure sensor, connect voltage regulator lead, black wire to solenoid, red ring terminal to starter.
12. Install muffler and muffler shield; torque muffler clamp 3 to 12 ft-lbs.
13. Attach end panel, back panel and engine end panel; hook up fan and fuel line; attach battery box, front panel and lid; test unit.

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.

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