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Home›Repair guides›Kohler›Contact Assembly Replacement, 800-1200 Amp Models

Kohler MPAC 1200 / MPAC 1500 — Contact Assembly Replacement, 800-1200 Amp Models

Repair & overhaul

For the Kohler MPAC 1200 / MPAC 1500, from the Kohler service manual.

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Before you start

  • Hazardous voltage. Disconnect all power sources before opening the enclosure.

Procedure

  1. Remove the machine screws and flat washers securing the blue plastic switch cover; remove the cover.
  2. Manually place the movable contact assembly in the open position.
  3. Remove the screws securing the arc chute; remove the arc chute and arc chute pad.
  4. Remove the two retaining rings and slide the actuator arms from the contact posts.
  5. Remove one retaining ring from the pivot pin and slide out the pivot pin.
  6. Remove the bus stud bolt, compression washer, and clamp bracket.
  7. Remove the movable contact assembly.
  8. If replacing the stationary contact, remove the hex head cap screws, machine screws, and stationary contact.
  9. Install the new stationary contact and lug assembly; torque cap screws to 31.2 Nm (23 ft. lb.) and machine screws to 13.6 Nm (10 ft. lb.).
  10. Install the new movable contact with the bus stud bolt and clamp bracket; torque the bus stud bolt to 31.2 Nm (23 ft. lb.).
  11. Install the pivot pin and secure with the retaining ring; connect the actuator arms and secure with two retaining rings.
  12. Adjust the contacts: main contact gap 1.59 mm (1/16 in.) minimum; arcing contact gap 0.0762 mm (0.003 in.) minimum.
  13. Secure the arc chute and arc chute pad with the two machine screws; check operation.

Tools required

Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.

Specs & values

  • Cap screws 31.2 Nm (23 ft. lb.)
  • Machine screws 13.6 Nm (10 ft. lb.)
  • Main contact minimum gap 1.59 mm (1/16 in.)
  • Arcing contact minimum gap 0.0762 mm (0.003 in.)
  • Spring gap 3.175 mm (1/8 in.) max to 1.59 mm (1/16 in.) min

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.

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