Kohler — Solenoid and Rectifier Test and Replacement (100-200 Amp 3-Phase)

Repair & overhaul

From a Kohler service manual — check it applies to your exact model before use.

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Procedure

1. Open the ATS enclosure and prevent all connected generator sets from starting.
2. Disconnect main power and verify zero volts across each phase.
3. Remove DC fast-on connections from the rectifier terminals.
4. Check the coil resistance; if infinite or shorted, replace the coil.
5. Remove the AC fast-on connections from the AC terminals of the rectifier.
6. Check the diode operation of the rectifier; if bad, remove and install the new rectifier so the red dot is in the upper right corner.
7. Connect the AC fast-on connections to the AC terminals (upper left and lower right corners).
8. Remove tie wraps as necessary without cutting wiring insulation.
9. Remove the front bolt of the coil securing strap and loosen the rear bolt, then remove the coil.
10. Lubricate the spring and plunger assembly and insert the spring into the new coil.
11. Install the plunger into the new coil and install the coil into the coil slot.
12. Install the coil holding strap and tighten the bolts.
13. Connect the DC fast-on connections to the DC terminals (lower left and upper right corners).
14. Close the enclosure, reconnect power, enable the generator set, move master switch to AUTO, and test operation.

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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