Kohler — Installing Generator Terminal Block
Installation
From a Kohler service manual — check it applies to your exact model before use.
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Before you start
- Connections are polarity-sensitive. The transfer mechanism will not operate if the connections are reversed.
Procedure
- Bend the insulating cover to fit around the terminal block before installing it.
- Orient the terminal block so the two studs are at the top and install it in the enclosure.
- Secure with two 10-32 x 1/2 in. hex head screws; torque to 3.4 Nm (30 in. lb.).
- Connect leads AL1-A and AL2-A (power) to terminals L1 and L2 on the generator circuit breaker.
- Torque 35-70 A circuit breakers to 5.1 Nm (45 in. lb.); 80-125 A breakers to 5.7 Nm (50 in. lb.).
- Connect leads AL1-A and AL2-A to terminals L1 and L2 on the generator terminal block.
- Install control leads AL1-A and AL2-A on top of the power leads on the terminal block.
- Secure with a 1/4 x 5/8 in. plain washer and 1/4-20 x 7/16 in. hex nut washer assembly.
- Torque the nuts to 6.8 Nm (60 in. lb.).
Tools required
- 5/16 in. nut driver Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- 3.4 Nm (30 in. lb.)
- 5.1 Nm (45 in. lb.)
- 5.7 Nm (50 in. lb.)
- 6.8 Nm (60 in. lb.)
Source: Kohler 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.