Kohler TP-6808 — Contactor Assembly Removal and Installation (Single-Phase)
Repair & overhaul
For the Kohler TP-6808, from the Kohler service manual.
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Before you start
- Disconnect all power sources before opening the enclosure.
Procedure
- Disable the generator set and disconnect all power sources.
- Loosen power terminal lugs; disconnect normal, emergency, and load conductors.
- Disconnect the contactor wiring harness from the controller at connector P13.
- Support contactor; remove screws at corners of the contactor base.
- Lift and pull the contactor assembly from the enclosure.
- Installation: align mounting holes and reinstall mounting screws.
- Tighten screws to torques: 100/150/200 Amp 2.4 Nm, 300/400 Amp 6.8 Nm.
- Reconnect conductors and harness; tighten to the specified torques.
Tools required
- basic hand tools
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- 100 Amp 2.4 Nm (21 in. lb.)
- 150/200 Amp 2.4 Nm (21 in. lb.)
- 300/400 Amp 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.