Kohler K, KN, KB Transfer Switches Service and Parts Manual (tp5257)

These Kohler K, KN, and KB transfer switches usually live in utility rooms, plant rooms, or outdoor enclosures, quietly shifting loads between normal power and generator supply. This service and parts manual is what I use to match every relay, terminal block, coil, and mechanism in the cabinet to the correct Kohler part number before I order anything. When a switch is chattering, not transferring, or has heat damage on a pole assembly, this book lets me trace what I pulled out on the bench back to the exact assembly and all its sub‑components.

Applications & Use Cases

• Confirm part numbers before ordering replacement coils, contacts, or control boards after a teardown.
• Match physical components in an older or dirty cabinet to the correct illustrated listing when tags are missing or unreadable.
• Verify compatible revisions when mixing new parts into an existing K, KN, or KB switch lineup.
• Cross-check hardware and kits so all brackets, screws, and linkages needed for a repair arrive in one trip.
• Document what was changed on a work order by referencing the exact Kohler item numbers.

FAQ

Q: Can I use this manual on a tablet at the jobsite?

A: Yes, it’s practical to zoom in on the exploded views and part callouts on a tablet while standing at the switchboard.

Q: Is it worth printing sections of this manual?

A: For frequent repairs, printing the key diagrams and keeping them in a shop binder saves time and keeps greasy hands off your device.

Safety Note

Always isolate all power sources and verify the transfer switch is de-energized before opening, inspecting, or replacing any components.

Kohler K, KN, KB Transfer Switches Index:

Introduction
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Explanation of Kohler Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transfer Switch Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Enclosures
Open, 30-4000 Amps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Automatic, NEMA Type 1, 30-800 Amps. . . . . . . . . . . . . . . . . . . . . . . . 8
Automatic, NEMA Type 1, 1000-1200 Amps. . . . . . . . . . . . . . . . . . . . . 12
Automatic, NEMA Type 1, 1600-2000 Amps. . . . . . . . . . . . . . . . . . . . . 16
Automatic, NEMA Type 1, 3000-4000 Amps. . . . . . . . . . . . . . . . . . . . . 20
Nonautomatic, NEMA Type 1, 30-800 Amps. . . . . . . . . . . . . . . . . . . . . 24
Nonautomatic, NEMA Type 1, 1000-1200 Amps. . . . . . . . . . . . . . . . . 28
Nonautomatic, NEMA Type 3R, 30-800 Amps. . . . . . . . . . . . . . . . . . . 32
Automatic, NEMA Type 3R, 30-800 Amps. . . . . . . . . . . . . . . . . . . . . . . 36
Automatic, NEMA Type 12, 30-400 Amps. . . . . . . . . . . . . . . . . . . . . . . 40
Automatic, NEMA Type 12, 600-800 Amps. . . . . . . . . . . . . . . . . . . . . . 42
Automatic, NEMA Type 12, 1000-1200 Amps. . . . . . . . . . . . . . . . . . . . 44
Automatic, NEMA Type 1, CSA 30-800 Amps. . . . . . . . . . . . . . . . . . . 46
Automatic Transfer and Bypass Isolation . . . . . . . . . . . . . . . . . . . . . . . 50
NEMA Type 1, 150-400 Amps.
Automatic Transfer and Bypass Isolation, . . . . . . . . . . . . . . . . . . . . . . 54
NEMA Type 1, 400-800 Amps.
Automatic Transfer and Bypass Isolation, . . . . . . . . . . . . . . . . . . . . . . 58
NEMA Type 1, 1000-1200 Amps.
Automatic Transfer and Bypass Isolation, . . . . . . . . . . . . . . . . . . . . . . . 62
NEMA Type 1, 1600-2000 Amps.
Inner Door Panel
Relay Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Solid State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Nonautomatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
S140 Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Neutral Lug Assembly
Neutral Lug Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
30-800 Amp., CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Transformer Assembly
Single-Phase Sensing 110-240 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Single-Phase Sensing 190-380 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Single-Phase Sensing 416-600 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Three-Phase Sensing 110-240 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Three-Phase Sensing 380-600 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Accessories
Accessories Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Accessories Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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