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TP-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 speci

fi

 cation. See Figure 1.

With engine stopped, check exciting coil 

stator winding resistance between wires 

with ohmmeter or circuit tester. Replace if 

out of speci

fi

 cation. See Figure 1.

Brush resistance

With engine stopped, remove brush. 

Check brush and slip ring of rotor for 

resistance. Replace if out of speci

fi

 cation. 

See Figure 1.

Flashing Field

With engine stopped, momentarily touch 

brush terminals with leads from a good 12 

volt battery. See Figure 1.

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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