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Maintenance

2

TP-7088    6/17

KohlerPower.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 fi res and severe 
burns.

Do not 

fi

 ll fuel tank while 

engine is hot or running.

Gasoline is extremely 

fl

 ammable 

and its vapors can explode 

if ignited. Never refuel while 

smoking or in vicinity of an open 

fl

 ame. Store gasoline only in 

approved containers, in well 

ventilated, unoccupied buildings, 

away from sparks or 

fl

 ames. 

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 certi

fi

 ed, 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 

fl

 ammable. 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.

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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