Kohler PRO6.4 Service Manual
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Kohler PRO6.4 Service Manual

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PRO6.4, PRO6.4E, PRO9.0, PRO9.0E
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
14
Disassembly/Inspection and Service
16
Reassembly
TP-7088
6/17
KohlerPower.com
1

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Summary of Contents for Kohler PRO6.4

  • Page 1 PRO6.4, PRO6.4E, PRO9.0, PRO9.0E 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: Maintenance

    Maintenance 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

    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: Torque Specifications

    Maintenance TORQUE SPECIFICATIONS PRO6.4, 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 9.9 N·m (87 in. lb.) M8 Screws 25.0 N·m (221 in.

  • Page 5: General Torque Values

    Maintenance 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 and vary by specifi cation. Use these to locate causing factors.
  • Page 7 Troubleshooting Stator resistance With engine stopped, check main coil stator winding resistance between wires with ohmmeter or circuit tester. Replace if out of specifi cation. See Figure 1. With engine stopped, check exciting coil stator winding resistance between wires with ohmmeter or circuit tester. Replace if out of specifi...
  • Page 8 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. Generator Spec. Unit Item REMARK PRO6.4/6.4E PRO9.0/9.0E Red-Blue 0.27Ω±10% 0.13Ω±10% Red-White Main Winding (PRO9.0E) White-Black 0.27Ω±10%...

  • Page 9: Electrical System

    Electrical System PRO6.4 Wiring Diagram Main Winding 1 Main Winding 2 Exciter Field Coil Sub Coil 240/120V/30A 120V/30A Electrical Circuit Breaker 18.5A Circuit Breaker 30A Electrical Socket Socket Circuit Breaker 20A GFCI Receptacle Ground Terminal On/Off Switch Maintenance Minder Oil Level Switch...
  • Page 10 Electrical System PRO6.4E Wiring Diagram Main Winding 1 Main Winding 2 Exciter Field Coil Sub Coil DC Winding Auto Idle Coil Voltage Selector Circuit Breaker 240/120V/30A 120V/30A GFCI Receptacle Circuit Protector 20A Electrical Socket Electrical Socket Circuit Protector 30A Ground Terminal Auto Throttle Switch 12V DC Receptacle On/Off/Start Switch...
  • Page 11 Electrical System PRO9.0 Wiring Diagram Main Winding 1 Main Winding 2 Exciter Field Coil Sub Coil 240/120V/30A 120V/30A Electrical Circuit Breaker GFCI Receptacle Electrical Socket Socket Circuit Protector 20A Ground Terminal Engine Switch Maintenance Minder Oil Sentry Spark Plug Ignition Coil TP-7088 6/17 KohlerPower.com...
  • Page 12 Electrical System PRO9.0E Wiring Diagram Main Winding 1 Main Winding 2 Exciter Field Coil Sub Coil 240/120V/30A DC Winding Auto Idle Coil Circuit Breaker Electrical Socket 120V/30A Electrical GFCI Receptacle Circuit Protector 20A Ground Terminal Socket Auto Throttle Switch 12V DC Receptacle On/Off/Start Switch Auto Idle Module Maintenance Minder...
  • Page 13 Electrical System WARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect Accidental Starts can cause severe injury negative (–) battery cable from battery. or death. Disconnect and ground spark plug lead(s) Do not allow children to operate generator.
  • Page 14 Disassembly/Inspection and Service PRO6.4, PRO6.4E, PRO9.0, and PRO9.0E Components Control Panel Control Box Rotor Through Bolt Stator Stator Cover Rear Cover End Cover Wiring Board Brush Holder Front Cover Muffl er Bracket Muffl er Cover Muffl er Exhaust Pipe Fuel Valve...
  • Page 15 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect Accidental Starts can cause severe injury negative (–) battery cable from battery. or death. Disconnect and ground spark plug lead(s) Do not allow children to operate generator.
  • Page 16 Reassembly PRO6.4, PRO6.4E, PRO9.0, and PRO9.0E Components Control Panel Control Box Rotor Through Bolt Stator Stator Cover Rear Cover End Cover Wiring Board Brush Holder Front Cover Muffl er Bracket Muffl er Cover Muffl er Exhaust Pipe Fuel Valve Fuel Hose...
  • Page 17 Reassembly Install Front Cover Install Muffl er 1. Attach front cover to engine main bearing cover. 1. Assemble muffl er pipe and gasket to engine exhaust Torque to 53.5 N·m (474 in. lb.). and snug screws. 2. Assemble muffl er bracket to rear cover and snug Install Rotor screws.
  • Page 18 NOTES KohlerPower.com TP-7088 6/17...
  • Page 19 NOTES TP-7088 6/17 KohlerPower.com...
  • Page 20 © 2017 by Kohler Co. All rights reserved. KohlerPower.com TP-7088 6/17...

This manual is also suitable for:

Pro6.4ePro9.0Pro9.0e

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