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TP-7088    6/17

KohlerPower.com

Electrical System

 

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.

Check Control Panel

Remove control panel from frame. Remove control box 

from control panel and check each components and 

wiring.

Disassembly

1.  Remove the end cover and disconnect wire 

terminals from wiring board.

2.  Remove control panel.
3.  After disconnecting individual wires, remove control 

panel components.

Reassembly

NOTE:  Circuit diagrams provide colored wires used for 

easy identi

fi

 cation. To replace wires, use heat-

resistant type wires (permissible temperature 

range 75°C (167°F) or over) and same gauge of 

wire that is removed.

1.  Install receptacles, circuit breakers, sockets, 

switches, etc. on control panel.

2.  Connect wires to control panel components.
3.  Assemble wire terminals to wiring board.
4.  Assemble end cover to rear cover. Torque screws to 

4 N·m (35 in. lb.).

5.  Attach control panel and control box to frame. 

Torque screws to 9.9 N·m (87 in. lb.).

 

WARNING

Before working on engine or equipment, disable engine as 

follows: 1) Disconnect spark plug lead(s). 2) Disconnect 

negative (–) battery cable from battery.
Do not allow children to operate generator.

Accidental Starts can cause severe injury 
or death.

Disconnect and ground spark plug lead(s) 

before servicing.

Summary of Contents for PRO6.4

Page 1: ...m 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 performin...

Page 2: ...re 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 whil...

Page 3: ...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...

Page 4: ...ol 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...

Page 5: ...ish 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 Tighte...

Page 6: ...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 s...

Page 7: ...th 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 b...

Page 8: ...heck circuit breakers and receptacles Unit Item Generator Spec REMARK PRO6 4 6 4E PRO9 0 9 0E Main Winding Red Blue 0 27 10 0 13 10 Red White PRO9 0E White Black 0 27 10 0 13 10 Field Winding Between...

Page 9: ...Main Winding 2 C Exciter Field Coil D Sub Coil E Circuit Breaker 18 5A F 240 120V 30A Electrical Socket G Circuit Breaker 30A H 120V 30A Electrical Socket I Circuit Breaker 20A J GFCI Receptacle K Gr...

Page 10: ...0V 30A Electrical Socket J 120V 30A Electrical Socket K GFCI Receptacle L Circuit Protector 20A M Circuit Protector 30A N Ground Terminal O Auto Throttle Switch P 12V DC Receptacle Q On Off Start Swit...

Page 11: ...ding 1 B Main Winding 2 C Exciter Field Coil D Sub Coil E Circuit Breaker F 240 120V 30A Electrical Socket G 120V 30A Electrical Socket H GFCI Receptacle I Circuit Protector 20A J Ground Terminal K En...

Page 12: ...H 240 120V 30A Electrical Socket I 120V 30A Electrical Socket J GFCI Receptacle K Circuit Protector 20A L Ground Terminal M Auto Throttle Switch N 12V DC Receptacle O On Off Start Switch P Auto Idle M...

Page 13: ...olored wires used for easy identification To replace wires use heat resistant type wires permissible temperature range 75 C 167 F or over and same gauge of wire that is removed 1 Install receptacles c...

Page 14: ...l Box C Rotor D Through Bolt E Stator F Stator Cover G Rear Cover H AVR I End Cover J Wiring Board K Brush Holder L Front Cover M Muffler Bracket N Muffler Cover O Muffler P Exhaust Pipe Q Fuel Valve...

Page 15: ...ws 1 Disconnect spark plug lead s 2 Disconnect negative battery cable from battery Do not allow children to operate generator Accidental Starts can cause severe injury or death Disconnect and ground s...

Page 16: ...F G H B I K J Q N O P A R L M A Control Panel B Control Box C Rotor D Through Bolt E Stator F Stator Cover G Rear Cover H AVR I End Cover J Wiring Board K Brush Holder L Front Cover M Muffler Bracket...

Page 17: ...or when generator is started 1 Install brush holder Torque screw to 4 N m 35 in lb Install AVR 1 Attach connectors to brush holder AVR unit Torque screws to 4 N m 35 in lb Install End Cover 1 Tighten...

Page 18: ...NOTES 18 KohlerPower com TP 7088 6 17...

Page 19: ...NOTES 19 TP 7088 6 17 KohlerPower com...

Page 20: ...2017 by Kohler Co All rights reserved 20 KohlerPower com TP 7088 6 17...

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