Kohler — Solenoid Assembly Removal and Disassembly (100-200 Amp Single-Phase)
Repair & overhaul
From a Kohler service manual — check it applies to your exact model before use.
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Before you start
- Spring-loaded parts can cause severe personal injury or property damage. The spring in the solenoid assembly exerts substantial force on the coil. Hold the coil assembly securely when removing the screws.
- Wear protective goggles when servicing spring-loaded parts.
Procedure
- Disable the generator set and disconnect all power sources before opening the enclosure.
- To replace the Normal source coil, first move the contactor to the Emergency source position (and vice versa).
- Remove the two mounting screws that hold the solenoid assembly to the current-carrying unit; save the two square nuts.
- Remove two screws from the core plate.
- Remove the core plate and the steel core with washer.
- Remove the coil from the coil bracket.
Tools required
- Basic electrician's hand tools
- Pliers Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
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.