Kohler K Series Automatic Transfer Switches Service Parts Manual (tp5645)

These Kohler K Series automatic transfer switches sit between your utility feed and generator, usually in plant rooms, data centers, or commercial buildings where power can’t go down. This parts manual is what I’d use at the bench or desk to match every relay, contact kit, coil, and enclosure piece to the correct Kohler part number before I touch a wrench. If a switch is chattering, won’t transfer, or has heat-damaged contacts, this book lets me identify exactly which internal assemblies and hardware I’ll need so the unit goes back together once, the right way.

Applications & Use Cases

• Planning a shutdown: Lay out all contact kits, coils, and hardware to order before you schedule the outage.
• Tear-down tracking: Match what you pull out of the cabinet to the correct exploded view so no small bracket or insulator gets mis-ordered.
• Model/version differences: Verify you’re looking at the right K Series variant so mounting plates and wiring components actually fit.
• Stockroom control: Build a shelf list of high-failure items to keep on hand and cut emergency lead time.
• Post-fault repair: After a fault or overheating event, trace damaged pieces and confirm every affected part number in one place.

FAQ

Q: Can I use this on a tablet or laptop at the switchgear line-up?

A: Yes, it’s practical to keep it as a digital file so you can zoom in on diagrams and part callouts right beside the equipment.

Q: Is it worth printing sections of this manual?

A: Printing the views for the exact switch model you’re working on is handy; you can mark parts, note quantities, and carry it into tight rooms without risking a device.

Safety Note

Always isolate all power sources and verify zero energy before opening or servicing any automatic transfer switch.

Kohler K Series Automatic Transfer Switches Index:

Description Page
Introduction 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Other Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Standard Hardware and Leads . . . . . . . . . . . . . . . . . . . 2
How to find Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . 2
Consult Factory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Interpreting a Transfer Switch Part Number . . . . . . . . . 3
Automatic Transfer Switch Contactors 4
30-104 Amps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
150 Amp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
225-400 Amp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
600/800 Amp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1000/1200 Amp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1600/2000 Amp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3000/4000 Amp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Description Page
Automatic Transfer and Bypass-Isolation Swith
Contactors 32
150-400 Amp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
600-800 Amp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1000-2000 Amp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Coils, Rectifiers, Resistors, Springs, and Service
Contactors 38

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