Kohler APM603 Controller Generator Set Controllers Service Manual (tp7139)

This Kohler APM603 controller usually lives in a generator that’s sitting in a plant room, on a jobsite, or backing up a commercial building. When it acts up, you don’t want to be guessing at part numbers. This service parts manual lets you match what’s in your hands—boards, harnesses, display, buttons—to the exact Kohler listing before you order. For example, if the controller screen goes dead after a fault and you pull it apart, this book helps you sort out whether you need just the keypad/display, a specific PCB, or a full controller assembly.

Applications & Use Cases

• Plan a controller repair by identifying every replaceable component before you shut the set down.
• Trace wiring and match harnesses and connectors so you don’t order the wrong lead set.
• Verify revisions and superseded parts when replacing older APM603 units in the field.
• Build a spare-parts shelf for critical sites so common failures don’t cause long outages.
• Cross-check what a vendor quotes against the official listing to avoid mismatched parts.

FAQ

Q: Can I use this manual on a tablet or laptop at the generator?

A: Yes, it’s handy to zoom in on diagrams and part callouts while you’re standing at the controller.

Q: Should I still print pages from this manual?

A: Printing the relevant exploded views and lists is useful for teardown, tagging removed parts, and marking what’s been ordered.

Safety Note

Always isolate the generator and follow lockout/tagout procedures before opening or handling the APM603 controller.

Kohler APM603 Controller Generator Set Controllers Index:

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Numbering System Significance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
How to Find Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hardware References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 2: Controller Module Parts, 80–300 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 3: Controller Module Parts, 350–500 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 4: Controller Module Parts, KD800–1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section 5: Controller Module Parts, KD1250A–1350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 6: Controller Module Parts, KD1500–1750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 7: Controller Module Parts, KD2000–KD2500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Section 8: Controller Module Parts, KD2800–3250 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 9: Controller Assembly Parts, GM109412–S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 10: Controller Assembly Parts, GM105183–BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Section 11: Controller Assembly Parts, 11601006001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Appendix D Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Appendix E Common Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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