Kohler 100-1000 Amp Single Coil Contactor Solid-State Automatic Transfer and Bypass, Isolation Switch Operation and Service Manual (tp5090)

These Kohler automatic transfer and bypass/isolation switches sit in electrical rooms or generator rooms, quietly handling the swap between utility and generator power. This manual is what I keep handy when the switch doesn’t transfer, transfers late, or refuses to retransfer after the utility comes back. It walks you through how to test the solid-state controls, verify the single-coil contactor is doing its job, and confirm a real failure before you order expensive parts. For example, when a switch sticks on generator, I use this book to trace the control signals, isolate whether it’s the coil, sensing board, or mechanical interlock, and then disassemble only what’s needed.

Applications & Use Cases

• Trace transfer faults step by step so you don’t guess at bad boards or coils.
• Verify timer and sensing logic before adjusting or replacing components.
• Follow a logical sequence to disassemble, inspect, and reassemble the contactor and mechanism.
• Use wiring and terminal callouts to route and label conductors during repairs or upgrades.
• Confirm bypass and isolation functions after maintenance with proper test procedures.

FAQ

Q: Can I keep this manual on a tablet in the electrical room?

A: Yes, it’s practical to use digitally; you can zoom wiring details and search terms while you work.

Q: Is it worth printing parts of it for field service calls?

A: Many techs print the key diagrams and procedures, laminate them, and keep them in the switch cabinet.

Safety Note

Always de-energize and verify absence of voltage on all sources before opening, removing, or adjusting any switch components.

Kohler 100-1000 Amp Single Coil Contactor Solid-State Automatic Transfer and Bypass, Isolation Switch Index:

Introduction
Installation
Functional Test
Bypass
Isolation
General Maintenance
Sequence of Operation
Troubleshooting
Accessories
Battery Charger
Generator Set Exercise Timer
Auxiliary Contacts
In-phase Monitor
Transfer Switch Removal
Transfer Switch Installation …..
Manual Load Transfer .. j… ….. ….
Disconnecting the Control Panel .
Sensor Adjustments
Time Delay Adjustments
Wiring Diagrams
Outline and Mounting
Enclosure Outline. .

Kohler