Kohler KGP, Manual

Page: 84 / 126

TP-6461 1/08 84 Section 5 Component Replacement, Model KGS/KGP
Replacing Contact Assembly, 3000 Amp
Model
Refer to Figure 5-7, Figure 5-8, and Figure 5-9 for the
following procedure:
1. Arc finger, adjustment nut
2. Contact assembly
3. Braid lug
4. B-Phase braid lug studs 5. C-Phase braid lug bolts
6. Braid lug nuts and washers
7. Pivot stud
8.
566864
6
5
4
3
7
2
1
Figure 5-9 Movable Contact B Phase, 3000 Amp
1. Secure the new movable contact assembly with
the pivot studs, locknuts, and lock washers.
Torque the locknuts to 13.6 Nm (10 ft. lb.).
2. To replace an A-phase, C-phase, or neutral contact
assembly secure the braid lugs to the bus bars with
the bolts, nuts and compression washers. Torque
the nuts to 19 Nm (14 ft. lb.). To replace a B-phase
contact assembly, follow the procedure described
in step 3b.
OR
3. To replace a B-phase contact assembly:
a. Use a bent wire to align the bus bar holes with
the braid lug holes.
b. Use the braid lug bolts that were removed from
the C-phase assembly to push the B-phase
braid lug studs back into position in the B-phase
assembly. Tap the bolts lightly with a hammer, if
necessary.
c. Secure the B-phase studs and C-phase bolts
with compression washers and nuts. Torque
the nuts to 19 Nm (14 ft. lb.).
4. Install the anchor bars on the load bus assembly
with twelve 1/4-20 socket head cap screws. The
longer cap screws are used on the sides. Torque
the cap screws to 10.2 Nm (90 in. lb.).
5. Connect the actuator arms to the contact posts and
secure with two retaining rings.
6. Close the contacts slowly until the arcing contacts
touch. The main contacts should have a 6.35 mm
(1/4 in.) minimum gap. If they do not, adjust the arc
finger adjustment nut as required. If the contacts
cannot be brought within specifications, reject the
contact assembly.
7. Measure and record the prespring gap.
8. Close the contacts fully.
9. Rock the arcing contact from toe to heel and verify
that there is an 0.0762 mm (0.003 in.) minimum
gap at the arcing contact. A feeler gauge must
enter 1.59 mm (1/16 in.) past the edge of the silver.
10. The spring gap dimension must be 1.59 mm
(1/16 in.) less than the prespring gap dimension
measured in step 7. If the contacts are not within
specifications, reject the contact assembly.
11. Check that the contact pressure of each of the
three outside main contacts is between 1.7--2 kg
(3.75--4.5 lb.). Check that the contact pressure of
the arc finger, is between 4--6.4 kg (9--14 lb.).
12. Check that both main and arc contact fingers are
not bottomed out when closed.
13. Secure the arc chute and arc chute pad with two
machine screws.
14. Check the operation of the transfer switch by
manually opening and closing the switch
assemblies.
15. Reinstall and secure the blue plastic cover.
16. Close the cabinet door.
17. Reconnect the normal power source and the
emergency power source. If a generator set is the
emergency power source, connect the negative (--)
battery cable to the starting battery and place the
generator set master switch in the Auto (or
Remote) position.
18. Test the switch for proper operation.