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Kohler PRO 5.4 DES Service Manual
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Kohler PRO 5.4 DES Service Manual

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PRO 5.4 DES
Generator Service Manual
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.
2
Safety
3
Specifi cations
6
Troubleshooting
9
Electrical System
13
Disassembly/Inspection and Service
19
Reassembly
38 690 01 Rev. --
KohlerPower.com
1

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Summary of Contents for Kohler PRO 5.4 DES

  • Page 1 PRO 5.4 DES Generator Service Manual 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.

  • Page 2: Safety Precautions

    Safety 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.

  • Page 3: Identification Numbers

    Specifi cations IDENTIFICATION NUMBERS Kohler identifi cation numbers (model, specifi cation and serial) should be referenced for effi cient repair, ordering correct parts, and engine replacement. Model .....
  • Page 4 Specifi cations TORQUE SPECIFICATIONS PRO 5.4 DES Door Panel 9.0 N·m (79 in. lb.) Fastener End Cover 4.0 N·m (35 in. lb.) Fastener Engine Adapter 27.1 N·m (240 in. lb.) Fastener Engine Baffl e 9.0 N·m (79 in. lb.) Fastener Engine Mount 13.6 N·m (120 in.

  • Page 5: General Torque Values

    Specifi cations GENERAL TORQUE VALUES 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)

  • Page 6: Troubleshooting Guide

    Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at fi rst, 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. Use these to locate causing factors. Condition Possible Cause Solution...
  • Page 7 Troubleshooting No or Low Output Voltage Alternator Specifi cations 1. Engine speed set too low. Needs to be set for 3600 Unit Ohms RPM at no load. Adjust if necessary. If speed is correct proceed to next step. Stator Winding 0.280 2.
  • Page 8 Troubleshooting 5. Isolate all main stator leads and measure resistance 2. Use a meter set to diode test and check each across each winding and check each main stator diode. lead to ground. Compare readings to values in d. Resistance from rotor leads to rotor shaft. Alternator Specifi...

  • Page 9: Electrical System

    Electrical System 38 690 01 Rev. -- KohlerPower.com...
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  • Page 12 Electrical System WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) Do not allow children to operate generator.
  • Page 13 Disassembly/Inspection and Service PRO 5.4 DES Components Lifting Ring Cotter Pin Washer Jam Nut Cover Battery Lifting Ring Frame Battery Tray Battery Clamp Door Door Panel Control Panel Control Panel Frame Fuel Tank Shroud Front Panel Side Panel Fuel Tank...
  • Page 14 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) Do not allow children to operate generator.
  • Page 15 Disassembly/Inspection and Service Remove Front Panel Remove Fuel Tank CAUTION WARNING Electrical Shock can cause injury. Fuel can cause fi res and severe burns. Do not touch wires while engine is running. Do not fi ll fuel tank while engine is hot or running.
  • Page 16 Disassembly/Inspection and Service PRO 5.4 DES Components Lower Alternator Engine Baffl e Muffl er Shield Engine Mount Baffl e Isolator Mount Exhaust Pipe Muffl er Clamp Muffl er Retention Container Alternator Mount Fuel Hose Remove Muffl er and Muffl er Shield Remove Engine and Alternator 1.
  • Page 17 Remove Isolator Mounts (if required) NOTE: Removal of isolator mounts is not necessary for servicing engine or alternator. Remove nuts and washers securing isolator mounts, and remove isolator mounts. PRO 5.4 DES Alternator End Cover Rear Cover Stator Front Cover...
  • Page 18 Disassembly/Inspection and Service Remove Engine Adapter (if required) 1. Remove screws securing engine adapter, and remove engine adapter. 2. Inspect engine adapter for cracks. Replace if cracked. Remove Engine Baffl e 1. Remove screws securing engine baffl e and pull fuel hose through engine baffl...
  • Page 19 Reassembly PRO 5.4 DES Alternator End Cover Rear Cover Stator Front Cover Front Cover Shield Engine Adapter Stator Cover Rotor Bearing Through Bolt Stator Assembly If alternator was removed from engine, and engine was 2. Place stator on front cover with wires up.
  • Page 20 Reassembly PRO 5.4 DES Components Lower Alternator Engine Baffl e Muffl er Shield Engine Mount Baffl e Isolator Mount Exhaust Pipe Muffl er Clamp Muffl er Retention Container Alternator Mount Fuel Hose KohlerPower.com 38 690 01 Rev. --...
  • Page 21 Reassembly Install Isolator Mounts (if required) Install isolator mounts to retention container with washers and nuts. Torque to 47.5 N·m (35 ft. lb.). Install Lower Alternator Baffl e 1. Position lower alternator baffl e in retention container. 2. Push fuel hose through lower alternator baffl e. 3.
  • Page 22 Reassembly PRO 5.4 DES Components Lifting Ring Cotter Pin Washer Jam Nut Cover Battery Lifting Ring Frame Battery Tray Battery Clamp Door Door Panel Control Panel Control Panel Frame Fuel Tank Shroud Front Panel Side Panel Fuel Tank Fuel Tank Cap...
  • Page 23 Reassembly Install Fuel Tank Install Intake Air Tube Position intake air tube onto air cleaner and secure with hose clamp. WARNING Fuel can cause fi res and severe burns. Install Lifting Ring (if required) Do not fi ll fuel tank while engine is hot or 1.
  • Page 24 Reassembly Install Cover 1. Position cover on generator and secure to side panel with screws and torque to 9.0 N·m (79 in. lb.). 2. Install ground cable to cover and generator and tighten securely with screws. Generator is now completely reassembled. Before starting or operating engine, be sure to follow steps below.
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  • Page 28 © 2014 by Kohler Co. All rights reserved. KohlerPower.com 38 690 01 Rev. --...