Kohler PRO6.4 User Manual

PRO6.4, PRO6.4E, PRO9.0, PRO9.0E
Generator Service Manual
KohlerPower.comTP-7088 6/17
1
2 Safety
3 Specifi cations
6 Troubleshooting
9 Electrical System
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 performing any maintenance or service.
For all engine related maintenance, disassembly and reassembly, refer to service manual of engine
powering this equipment.

Kohler PRO6.4 Specifications

General

Rated Output (Watts)	6400
Engine Displacement	429 cc
Fuel Tank Capacity	7.9 gallons
Run Time at 50% Load	14 hours
Weight	229 lbs
Displacement	429 cc
AC Output	120/240V
Voltage	120/240V
Starting Method	Electric/Recoil
Engine Type	4-Cycle, OHV, Air-Cooled
Starting System	Electric/Recoil
Noise Level	74 dB
Outlets	(1) 120/240V 30A
Engine	Kohler Command PRO CH440

Summary

Safety Precautions

Explosive Fuel Safety

Warning about handling explosive fuel and potential fire/burn hazards.

Hot Surface Safety

Warning about touching hot generator parts, risk of severe burns.

Rotating Parts Safety

Warning about rotating parts causing severe injury; keep clear.

Hazardous Voltage and Backfeed

Warning about hazardous voltage and backfeed to utility system causing damage or death.

Cleaning Solvents Safety

Warning about cleaning solvents; use in ventilated areas, avoid ignition sources.

Electrical Shock Prevention

Warning about electrical shock; avoid touching wires, wet hands, rain/snow.

Carbon Monoxide Danger

Danger of carbon monoxide poisoning from indoor generator use; use only outdoors.

Specifications

Identification Numbers

Kohler identification numbers for repair, ordering parts, and engine replacement.

General Specifications

General specifications including dimensions, weight, power ratings, and fuel tank capacity.

Torque Specifications

Torque specifications for various generator components and fasteners.

General Torque Values

General torque values for English and metric fasteners based on grade and size.

Troubleshooting

Troubleshooting Guide

Guide to identify and resolve common generator issues with possible causes and solutions.

Diagnostic Tests and Procedures

Procedures for testing stator voltage, AVR, and brush resistance.

AVR Replacement Procedure

Procedure for replacing the Automatic Voltage Regulator (AVR) and checking voltage output.

Electrical System

Wiring Diagrams

Wiring diagrams for PRO6.4, PRO6.4E, PRO9.0, and PRO9.0E models.

Electrical System Safety

Safety warnings regarding accidental starts and electrical shock when working on the electrical system.

Control Panel Diagnostics

Instructions to check the control panel components and wiring.

Disassembly/Inspection and Service

Component Identification

Illustrated overview of generator components for disassembly and service.

Disassembly Safety

Safety warnings regarding accidental starts and electrical shock during disassembly.

Component Removal and Brush Inspection

Procedures for removing components and inspecting brushes.

Reassembly

Component Reassembly Steps

Step-by-step instructions for reassembling generator components.