Kohler PRO6.4 Bedienungsanleitung

PRO6.4, PRO6.4E, PRO9.0, PRO9.0E

Generator Service Manual

KohlerPower.comTP-7088 6/17 1

2 Safety

3 Speciﬁcations

6 Troubleshooting

9 Electrical System

14 Disassembly/Inspection and Service

16 Reassembly

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment.

Ensure equipment is stopped and level before performing any maintenance or service.

For all engine related maintenance, disassembly and reassembly, refer to service manual of engine

powering this equipment.

Maintenance

2 TP-7088 6/17KohlerPower.com

SAFETY PRECAUTIONS

DANGER: A hazard that will result in death, serious injury, or substantial property damage.

WARNING: A hazard that could result in death, serious injury, or substantial property damage.

CAUTION: A hazard that could result in minor personal injury or property damage.

NOTE: is used to notify people of important installation, operation, or maintenance information.

WARNING

Explosive Fuel can

cause ﬁres and severe

burns.

Do not ﬁll fuel tank while

engine is hot or running.

Gasoline is extremely ﬂammable

and its vapors can explode

if ignited. Never refuel while

smoking or in vicinity of an open

ﬂame. Store gasoline only in

approved containers, in well

ventilated, unoccupied buildings,

away from sparks or ﬂames.

Spilled fuel could ignite if it comes

in contact with hot parts or sparks

from ignition. Never use gasoline

as a cleaning agent.

WARNING

Hot Parts can cause

severe burns.

Do not touch generator

while operating or just

after stopping.

Never operate generator with heat

shields or guards removed. Do not

modify generator.

Place generator in a place where

pedestrians or children are not

likely to touch generator.

Be sure to carry generator only by

its carrying handles.

WARNING

Rotating Parts can

cause severe injury.

Always maintain a safe

distance while generator

is in operation.

Keep hands, feet, hair, and

clothing away from all moving

parts to prevent injury. Never

operate generator with covers,

shrouds, or guards removed.

WARNING

Hazardous Voltage.

Backfeed to utility system

can cause property

damage, severe injury, or

death.

Never plug a portable generator

directly into a building outlet.

If generator is used for standby

power, have a certiﬁed, licensed

electrician install an automatic

transfer switch to prevent

inadvertent interconnection of

standby and normal sources of

supply.

There is a permanent conductor

between the generator (stator

winding) and the frame.

WARNING

Cleaning Solvents can

cause severe injury or

death.

Use only in well

ventilated areas away

from ignition sources.

Carburetor cleaners and solvents

are extremely ﬂammable. Follow

cleaner manufacturer’s warnings

and instructions on its proper and

safe use. Never use gasoline as a

cleaning agent.

WARNING

Electrical Shock can

cause injury.

Do not touch wires while

generator is running.

Never operate generator in rain or

snow.

Never touch generator with wet

hands or electrical shock may

occur.

Maintenance

3TP-7088 6/17 KohlerPower.com

IDENTIFICATION NUMBERS

Kohler identiﬁcation numbers (model, speciﬁcation and serial) should be referenced for efﬁcient repair, ordering

correct parts, and engine replacement.

Model. . . . . . . . . . . . . . . . . . . . . PRO6.4E

PRO

Numerical Designation

Optional

Speciﬁcation . . . . . . . . . . . . . . . PRO64-3001

Serial . . . . . . . . . . . . . . . . . . . . . 4723500328

Year Manufactured Code Factory Code

Code Year

47 2017

48 2018

49 2019

GENERAL SPECIFICATIONS1PRO6.4 / PRO6.4E PRO9.0 / PRO9.0E

Overall Dimensions (L x W x H)

747 mm (29.4 in.)

544 mm (21.4 in.)

566 mm (22.3 in.)

Dry Weight 81 kg (178 lbs.) / 91 kg

(201 lbs.)

93 kg (206 lbs.) / 101 kg

(222 lbs.)

AC Rated Power 5200 Watt (120 Volts x 43.3 Amps)

(240 Volts x 21.7 Amps) 7200 Watt (120 Volts x 60 Amps)

(240 Volts x 30 Amps)

AC Maximum Power 6400 Watt (120 Volts x 53.3 Amps)

(240 Volts x 26.7 Amps) 9000 Watt (120 Volts x 75 Amps)

(240 Volts x 37.5 Amps)

DC Rated Power 100 Watt (12 Volts x 8.3 Amps)

Fuel Tank 30.2 L (8 gal.)

1 Values are in Metric units. Values in parentheses are English equivalents.

California Proposition 65 Warning

Engine exhaust from this product contains

chemicals known to State of California to cause

cancer, birth defects, or other reproductive harm.

California Proposition 65 Warning

This product contains chemicals known to State

of California to cause cancer, birth defects, or

other reproductive harm.

Maintenance

4 TP-7088 6/17KohlerPower.com

TORQUE SPECIFICATIONS1PRO6.4, PRO6.4E, PRO9.0, PRO9.0E

Alternator Front Cover 53.5 N·m (474 in. lb.)

Alternator Rear Cover 4.5 N·m (40 in. lb.)

AVR and Brush Assembly 4.0 N·m (35 in. lb.)

Battery Mounting Bracket

M6 Screws

M8 Screws

9.9 N·m (87 in. lb.)

25.0 N·m (221 in. lb.)

Carbon Canister Mounting Bracket 9.9 N·m (87 in. lb.)

Control Panel Back Cover 5.8 N·m (51 in. lb.)

Control Panel Electrical Components

M3 Screws

M4 Screws

1.3 N·m (11 in. lb.)

2.9 N·m (26 in. lb.)

Control Panel 9.9 N·m (87 in. lb.)

End Cover 4.0 N·m (35 in. lb.)

Engine/Alternator Rubber Mounts 18.3 N·m (162 in. lb.)

Frame Assembly

M6 Screws

M10 Screws

11.5 N·m (102 in. lb.)

30.0 N·m (266 in. lb.)

Fuel Tank Mounting 9.9 N·m (87 in. lb.)

Mufﬂer Assembly

M8 Screws

M10 Screws

25.0 N·m (221 in. lb.)

32.5 N·m (288 in. lb.)

Mufﬂer Cover Assembly 9.9 N·m (87 in. lb.)

Rotor Assembly 22.0 N·m (195 in. lb.)

Stator Assembly 10.4 N·m (92 in. lb.)

Wire Connector 2.5 N·m (22 in. lb.)

1 Values are in Metric units. Values in parentheses are English equivalents.

Maintenance

5TP-7088 6/17 KohlerPower.com

GENERAL TORQUE VALUES

Metric Fastener Torque Recommendations for Standard Applications

Property Class Noncritical

Fasteners

Into Aluminum

Size 4.8 5.8 8.8 10.9 12.9

Tightening Torque: N·m (in. lb.) ± 10%

M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)

M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)

M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)

M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)

Tightening Torque: N·m (ft. lb.) ± 10%

M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)

M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)

M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)

Torque Conversions

N·m = in. lb. x 0.113 in. lb. = N·m x 8.85

N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737

English Fastener Torque Recommendations for Standard Applications

Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners

Into Aluminum

Size Grade 2 Grade 5 Grade 8

Tightening Torque: N·m (in. lb.) ± 20%

8-32 2.3 (20) 2.8 (25) — 2.3 (20)

10-24 3.6 (32) 4.5 (40) — 3.6 (32)

10-32 3.6 (32) 4.5 (40) — —

1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70)

1/4-28 9.6 (85) 15.8 (140) 22.6 (200) —

5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150)

5/16-24 18.7 (165) 30.5 (270) — —

3/8-16 29.4 (260) — — —

3/8-24 33.9 (300) — — —

Tightening Torque: N·m (ft. lb.) ± 20%

5/16-24 — — 40.7 (30) —

3/8-16 — 47.5 (35) 67.8 (50) —

3/8-24 — 54.2 (40) 81.4 (60) —

7/16-14 47.5 (35) 74.6 (55) 108.5 (80) —

7/16-20 61.0 (45) 101.7 (75) 142.5 (105) —

1/2-13 67.8 (50) 108.5 (80) 155.9 (115) —

1/2-20 94.9 (70) 142.4 (105) 223.7 (165) —

9/16-12 101.7 (75) 169.5 (125) 237.3 (175) —

9/16-18 135.6 (100) 223.7 (165) 311.9 (230) —

5/8-11 149.5 (110) 244.1 (180) 352.6 (260) —

5/8-18 189.8 (140) 311.9 (230) 447.5 (330) —

3/4-10 199.3 (147) 332.2 (245) 474.6 (350) —

3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

Troubleshooting

6 TP-7088 6/17KohlerPower.com

TROUBLESHOOTING GUIDE

When troubles occur, be sure to check simple causes which, at ﬁrst, may seem too obvious to be considered. For

example, a starting problem could be caused by an empty fuel tank.

Some general common causes of generator troubles are listed below and vary by speciﬁcation. Use these to locate

causing factors.

Condition Possible Cause Solution

No AC output Circuit breaker in OFF position. Switch circuit breaker to ON.

Circuit protector popped out. Press circuit protectors.

Engine not operating at rated RPM. Adjust engine running at normal operating

temperature to 3750 ± 100 RPM.

Circuit breaker or receptacles faulty. Test for voltage at circuit breaker and

receptacles.

Stator is faulty. Test for voltage and resistance.

Brushes are faulty. Test for resistance between brushes and

slip ring.

AVR is faulty. Test for voltage.

Low voltage at stator Field polarity was lost. Flash rotor ﬁeld.

Alternator can't output

rated power

Engine not operating at rated RPM. Adjust engine running at normal operating

temperature to 3750 ± 100 RPM.

Overload condition. Calculate electrical power required by

electric appliances (in Watts). Reduce

total wattage of connected electric devices

within application range.

Appliance is faulty. Repair faulty appliance.

Tests

Stator voltage

Note: Make sure that auto idle feature is

turned off during the test.

Remove rear cover and start engine with

no load. Check if stator terminals have

correct voltage. The voltage from ground

to each winding is 120V and from winding

to winding is 240V. All values have ±10%

tolerance.

7TP-7088 6/17 KohlerPower.com

Troubleshooting

Stator resistance

With engine stopped, check main coil

stator winding resistance between wires

with ohmmeter or circuit tester. Replace if

out of speciﬁcation. See Figure 1.

With engine stopped, check exciting coil

stator winding resistance between wires

with ohmmeter or circuit tester. Replace if

out of speciﬁcation. See Figure 1.

Brush resistance

With engine stopped, remove brush.

Check brush and slip ring of rotor for

resistance. Replace if out of speciﬁcation.

See Figure 1.

Flashing Field

With engine stopped, momentarily touch

brush terminals with leads from a good 12

volt battery. See Figure 1.

Troubleshooting

8 TP-7088 6/17KohlerPower.com

Replace AVR

With engine stopped, replace AVR with a

new AVR. Start engine and adjust trimmer

on back of AVR. Test terminal voltage.

Voltage should be between 95-135V. If

voltage is met, original AVR is not adjusted

properly or faulty. Replace as necessary. If

voltage not met, check circuit breakers and

receptacles.

Unit Item Generator Spec. REMARK

PRO6.4/6.4E PRO9.0/9.0E

Main Winding Red-Blue 0.27Ω±10% 0.13Ω±10% Red-White

(PRO9.0E)

White-Black 0.27Ω±10% 0.13Ω±10%

Field Winding Between slip ring 46.6Ω±10% 56.4Ω±10%

Exciter Winding Blue-Blue 1.60Ω±10% 1.02Ω±10%

DC Winding Orange-Orange 0.10Ω±10% 0.08Ω±10%

Brush Length 9mm Service limit:

5mm

Figure 1 Generator Speciﬁcations

NOTE: Alternator should not be in contact with panel, AVR, etc during above resistance tests. Alternator should be

tested at room temperature.

9TP-7088 6/17 KohlerPower.com

Electrical System

PRO6.4 Wiring Diagram

AMain Winding 1 BMain Winding 2 CExciter Field Coil DSub Coil

ECircuit Breaker 18.5A F240/120V/30A

Electrical Socket GCircuit Breaker 30A H120V/30A Electrical

Socket

ICircuit Breaker 20A JGFCI Receptacle KGround Terminal LOn/Off Switch

MAVR NMaintenance Minder OOil Level Switch PSpark Plug

QIgnition Module

OPQ

Electrical System

10 TP-7088 6/17KohlerPower.com

PRO6.4E Wiring Diagram

AMain Winding 1 BMain Winding 2 CExciter Field Coil DSub Coil

EDC Winding FAuto Idle Coil GVoltage Selector HCircuit Breaker

I240/120V/30A

Electrical Socket J120V/30A

Electrical Socket KGFCI Receptacle LCircuit Protector 20A

MCircuit Protector 30A NGround Terminal OAuto Throttle Switch P12V DC Receptacle

QOn/Off/Start Switch RAuto Idle Module SMaintenance Minder TAVR

URectiﬁer VDiode WBattery Fuse XStarter Motor

Y12 Volt Battery ZStator AA Electronic Throttle

Control AB Ignition Coil

AC Spark Plug AD Oil Sentry™

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