KOHLER Portable Generators and Pumps Owner’s Manual

PRO 6.4, PRO 6.4E, PRO 9.0, PRO 9.0E FRC
Generator Owner’s Manual

IMPORTANT:

Read all safety precautions and instructions carefully before operating equipment.
Ensure engine is stopped and level before performing any maintenance or service.

Record product information to reference when ordering parts or obtaining warranty coverage.

WARNING: This product can expose you to chemicals, including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects, or other reproductive harm.
For more information go to www.P65warnings.ca.gov

Important Labels on Generator

DANGER

Using a generator indoors CAN KILL YOU IN MINUTES. The generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home or garage, EVEN IF doors and windows are open.

|

Only use OUTSIDE and far away from windows, doors, and vents.

Avoid other generator hazards. READ THE MANUAL BEFORE USE.

CAUTION: HOT EXHAUST

WARNING

● Do not touch the generator while operating or just after stopping.
● Hot parts can cause severe burns.
● Explosive Fuel can cause fires and severe burns.
● Do not fill the fuel tank while the generator is hot or running.
● Electrical shock can cause injury.
● Do not touch wires while the generator is running.
● Do not connect a generator to a building’s electrical system unless using an isolation (transfer) switch installed by a certified, licensed electrician.

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: This is used to notify people of important installation, operation, or maintenance information.

Read this manual carefully before operating this machine. This manual should stay with this machine if it is sold.

| WARNING
---|---
Explosive Fuel can cause fires and severe burns.

Do not fill the fuel tank while the engine is hot or running.

Gasoline is extremely flammable and its vapors can explode if ignited. Never refuel while smoking or in the vicinity of an open flame. Store gasoline only in approved containers; in well-ventilated, unoccupied buildings; away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or
sparks from the ignition. Never use gasoline as a cleaning agent.
|

WARNING

---|---
Rotating Parts can cause severe injury.

Always maintain a safe distance while a generator is in operation.

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the generator with covers, shrouds, or guards removed.
|

WARNING

---|---
Electrical Shock can cause injury.

Do not touch wires while the generator is running.

Never operate a generator in rain or snow. Never touch the generator with wet hands or electrical shock may occur.
|

WARNING

---|---
Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug lead(s) before servicing.

Before working on the generator or equipment, disable the engine as follows:

1. Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. Do not allow children to operate generators.
   |

WARNING

---|---
Hot Parts can cause severe burns.

Do not touch the generator while operating or just after stopping.

Never operate a generator with heat shields or guards removed. Do not modify the generator.

Place generator in a place where pedestrians or children will not touch generator.

Be sure to carry the generator only by its carrying handles.

|

WARNING

---|---
Hazardous Voltage.

Backfeed to the utility system can cause property damage, severe injury, or death.

Never plug a portable generator directly into a building outlet.

If the generator is used for standby power, have a certified, licensed electrician install an automatic transfer switch to prevent the inadvertent interconnection of standby and normal sources of supply.

There is a permanent conductor between the generator (stator winding) and the frame.

A| Circuit Breaker| B| Maintenance Minder| C| 240/120V/30A Electrical Socket| D| 120V/30A Electrical Socket
---|---|---|---|---|---|---|---
E| Circuit Protector| F| 12V DC Receptacle 2| G| GFCI Receptacle| H| Ground Terminal
I| Auto Idle’| J| On/Off/Start Switch| K| Fuel Tank Cap| L| Fuel Level Indicator
M| Oil Drain Plug| N| Oil Fill Plug/ Dipstick| 0| Starter Battery-| P| Choke Lever
Q| Spark Plug| R| Carbon Canister| S| Starter Handle| T| Screw
U| Air Cleaner Cover| V| Foam Element| W| Base| X| Fuel Valve
Y| Change Oil Light| Z| Replace Spark Plug Light| AA| Replace Air Cleaner Light| AB| Low Oil Indicator Light
AC| Reset| AD| Fuel Filter| AE| Voltage  elector1|

Pre-Start Checklist¹PRO 6.4 and PRO 6.4E only.²Electric start models only.

1. Ensure the generator is at least 3.3 ft. (1 m) from building or other equipment and not covered with any material.
2. Refer to all warning labels prior to starting.
3. Check the oil level using an oil fill plug (N). Add oil if low. Do not overfill.
4. Check fuel level indicator (L). Add fuel if low. Stop refueling when the indicator reaches F (full) level. Check fuel system components and lines for leaks. Never refuel while the unit is running.
5. Test GFCI receptacle (G).
6. Check that the air cleaner component and all air inlets are unobstructed equipment covers, and guards are in place and securely fastened.
7. Ensure electrical devices (load) are not connected to a generator.

Starting

DANGER

Using a generator indoors CAN KILL YOU IN MINUTES. The generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home or garage, EVEN IF doors and windows are open.

|

Only use OUTSIDE and far away from windows, doors, and vents

|

WARNING

---|---
Rotating Parts can cause severe injury.

Stay away while the engine is in operation.

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed.

NOTE: Auto Idle (I) switch must be in OFF position when using electric devices that require a large starting current, such as a compressor or a submersible pump. Auto Idle (I) controls the engine speed according to the connected load. Results are better fuel consumption and less noise.

NOTE: Choke is not required to start a warm engine. Push choke lever (P) into original position.

1. Turn main AC circuit breaker (A) OFF.
2. Turn Auto Idle (I) OFF (if equipped).
3. Turn Fuel (X) ON.
4. Turn the engine to ON (J) and pull rope (or push the start button (J) for an electric start).
5. Turn choke lever (P) OFF after engine is warm.

If the engine does not start, repeat the operation until the engine starts by gradually opening the choke.

Cold Weather Starting

1. Use proper oil for the temperature expected.
2. Disengage all possible external loads.
3. Use fresh winter-grade fuel. Winter grade fuel has higher volatility to improve starting.

Operation

|

WARNING

---|---
Hazardous Voltage.

Backfeed to the utility system can cause property damage, severe injury, or death.

Never plug a portable generator directly into a building outlet.

If the generator is used for standby power, have a certified, licensed electrician install an automatic transfer switch to prevent the inadvertent interconnection of standby and normal sources of supply.

There is a permanent conductor between the generator (stator winding) and the frame.

When running speed of generating set has stabilized (approximately 3 minutes):

1. Check that circuit protectors (E) are pushed in. Press if necessary.
2. Connect appliances to electrical sockets (C, D & G) of a generator.
3. Maintenance Minder (B) shows the number of hours that generator has worked.

Angle of Operation
Do not operate this engine exceeding maximum angle of operation; see specification table. Engine damage could result from insufficient lubrication.

Cable Selection

Recommended
Cable Cross
Section| mm²| AWG| mm²| AWG| mm²| AWG
Length
of
Cable
Used| 0 to 50 m| 4| 10| 6| 9| 10| 7
51 to 100 m| 10| 7| 10| 7| 25| 3
101 to 150m¹| 10| 7| 16| 5| 35| 2
¹This cable length is the maximum permitted length, and must not be exceeded.
Installation method=cables on raceway or non-drilled tablet/Permitted drop in voltage=5%/Multi-core conductors/Cable type PVC 70°C (e.g. H07RNF)/Ambient temperature=86° F (30° C).

ON/OFF/START Switch
ON/OFF/START switch (J) controls ignition system.

ON Position:
The ignition circuit is switched on. The engine can be started.

OFF Position:
The ignition circuit is switched off. The engine will not run.

START Position:
Pressing and holding the switch in START position will start the engine with an electric start (if equipped).

Auto Idle
When Auto Idle (I) switch is in ON position, Auto Idle (I) controls engine speed according to the connected load. Results are better fuel consumption and less noise.

When Auto Idle (I) switch is in the OFF position, the engine runs at rated rpm (3,600 rpm) regardless of whether there is a load connected or not.

Stopping

1. Disconnect plugs from electrical sockets (C, D, F & G) to let the engine run under no load for 1 or 2 minutes.
2. Set ON/OFF/START switch (J) to OFF position: generator stops.
3. Close the fuel valve (X).

High Altitude Operation

If this engine is operated at an altitude of 4000 ft. (1219 meters) or above, a high-altitude carburetor kit is required. To obtain high-altitude carburetor kit information or to find a Kohler authorized dealer, visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

This engine should be operated in its original configuration below 4000 ft. (1219 meters).

Operating this engine with the wrong engine configuration at a given altitude may increase its emissions, decrease fuel efficiency and performance, and result in damage to the engine.

Engine Speed

NOTE: Do not tamper with the governor set to increase maximum engine speed. Overspeed is hazardous and will void the warranty.

Maintenance Instructions

|

WARNING

| Before working on engine or equipment, disable
engine as follows: 1) Disconnect the spark plug
lead(s). 2) Disconnect negative (–) battery cable
from battery.
---|---|---
Accidental Starts can cause
severe injury or death.
Disconnect and ground spark
plug lead(s) before servicing.

Safety is an obligation of the owner. Periodic inspection, adjustment, and lubrication will keep your generator in the safest and most efficient condition possible. The most important points of generator inspection, adjustment, and lubrication are explained on the following pages.

Maintenance Schedule

fter first 5 Hours

•  Change oil.

Every 25 Hours or Annually

•  Check starter battery (O).

Every 100 Hours or Annually¹

• Clean low-profile air cleaner element (V).
•  Change oil.
• Clean cooling areas.

Every 200 Hours²

•  Check and adjust valve clearance when the engine is cold.

Every 300 Hours

• Replace low-profile air cleaner element (V).
• Check fuel filter (AD) and clean or replace if needed.

Every 500 Hours or Annually¹

• Replace the spark plug and set the gap.
  ¹Perform these procedures more frequently under severe, dusty, dirty conditions.
  ²Have a Kohler portable dealer perform this service.

Oil Recommendations

We recommend the use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ or higher are acceptable. Select viscosity based on air temperature at the time of operation as shown in the table below.

Check Oil Level

NOTE: To prevent extensive engine wear or damage, never run the engine with the oil level below or above the operating range of the indicator on the dipstick (N).

Ensure the engine is cool. Clean oil fill/dipstick (N) areas of any debris.

1. Remove oil fill/dipstick (N); wipe the oil off.

2. Remove oil fill/dipstick (N); check the oil level.
   The level should be at top of the indicator on the dipstick (N).

3. If oil is low, add oil up to point of overflowing filler neck.

4. Reinstall oil fill/dipstick (N) and tighten securely.

Change Oil

When the change oil light (Y) goes on, press reset (AC) and follow maintenance instructions.
Change oil while the engine is warm.

1.  Clean area around oil fill cap/dipstick (N) and oil drain plug (M).
2. Remove oil drain plug (M) and oil fill cap/ dipstick (N). Drain oil completely.
3. Reinstall oil drain plug (M). Torque to 13 ft. lb. (17.6 N·m).
4. Fill crankcase with new oil, up to point of overflowing filler neck.
5. Reinstall oil fill cap/dipstick (N) and tighten securely.
6. Dispose of used oil in accordance with local ordinances.

Oil Sentry™ (if equipped)

This switch is designed to prevent the engine from starting in a low oil or no oil condition. Oil Sentry™ may not shut down a running engine before damage occurs.

Fuel Recommendations

|

WARNING

---|---
Explosive Fuel can cause fires and severe burns.

Do not fill the fuel tank while the engine is hot or running.

Gasoline is extremely flammable and its vapors can explode if ignited. Never refuel while smoking or in the vicinity of an open flame. Store gasoline only in approved containers, in well-ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from the ignition. Never use gasoline as a cleaning agent.

NOTE: E15, E20, and E85 are NOT approved and should NOT be used; effects of old, stale, or contaminated fuel are not warrantable.

Fuel must meet these requirements:

• Clean, fresh, unleaded gasoline.
• The octane rating of 87(R+M)/2 or higher.
• Research Octane Number (RON) 90 octane minimum.
• Gasoline up to 10% ethyl alcohol, 90% unleaded is acceptable.
• Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved.
• Oil has not been added to gasoline.
• Not overfilled in the tank.
• Not older than 30 days.

Fuel Level

|

WARNING

---|---
Explosive Fuel can cause fires and severe burns.

Do not fill the fuel tank while the generator is hot or running.

Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well-ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from the ignition. Never use gasoline as a cleaning agent.

Visually check the level of fuel. If necessary, fill it up.

1. Unscrew fuel tank cap (K).
2. Fill tank until fuel gauge shows F, using a funnel and taking care not to spill any fuel.
3. Screw down fuel tank cap (K) tightly.

Fuel Line

A low permeation fuel line must be installed on carbureted Kohler Co. engines to maintain EPA and CARB regulatory compliance.

Fuel Filter

1. Open fuel tank cap (K).
2. Remove fuel filter (AD) from tank neck.
3. Clean fuel filter (AD) with a non-flammable solvent or solvent with a high flash point. Dry it fully. Replace as necessary.
4. Reinstall fuel filter (AD).
5. Reinstall fuel tank cap (K).

Sediment Bowl

1. Close the fuel valve (X) and remove cover screws and nuts.

2. Remove cover.

3. Remove sediment bowl.

4. Clean the sediment bowl with a non-flammable solvent or solvent with a high flash point. Dry it fully.

5. Check sediment bowl cover and gasket.
   Replace them if they are damaged.

6. Reinstall sediment bowl.

7. Open tank fuel valve (X).

8. Wipe off any trace of fuel with a clean cloth and check for any leakage.

Spark Plugs

|

WARNING

---|---
Electrical Shock can cause injury.

Do not touch wires while the generator is running.

Never operate a generator in rain or snow.

Never touch the generator with wet hands or electrical shock may occur.

When replacing spark plug light (Z) goes on, press reset (AC) and follow maintenance instructions.

Clean out spark plug recess. Remove spark plug (Q) and replace.

1. Check gap using a wire feeler gauge. Adjust gap, see specification table for adjustment.
2. Install spark plug (Q) into the cylinder head.
3. Torque spark plug (Q) to 20 ft. lb. (27 N·m).

Air Cleaner

NOTE: Operating an engine with loose or damaged air cleaner components could cause premature wear and failure. Replace all bent or damaged components.

When replacing air cleaner light (AA) goes on, press reset (AC) and follow maintenance instructions.

1. Remove screw (T) and air cleaner cover (U).
2. Remove foam element (V) from the air cleaner base (W).
3. Wash foam element (V) in warm water with detergent. Rinse and allow to air dry.
4. Lightly oil foam element (V) with new engine oil; squeeze out excess oil.
5. Reinstall foam element (V) into air cleaner base (W).
6. Reinstall the cover and secure it with a screw (T).

Breather Tube

Ensure both ends of the breather tube are properly connected.

Air Cooling

|

WARNING

---|---
Hot Parts can cause severe burns.

Do not touch the generator while operating or just after stopping.

Never operate a generator with heat shields or guards removed. Do not modify the generator.

Place generator in a place where pedestrians or children are not likely to touch generator.

Be sure to carry the generator only by its carrying handles.

Proper cooling is essential. To prevent overheating, ensure air cooling inlet and outlet areas are clean and unobstructed. Avoid spraying water at the wiring harness or any
electrical components. Refer to Maintenance Schedule.

Ground Terminal

Ground terminal (H) connects the earth line for the prevention of electric shock. When the electric device is grounded, be sure to ground the generator also.

Connect generator to the ground: Attach a 6 AWG (10 mm²) copper wire to the generator’s ground connection and to a galvanized steel grounding rod (not provided) driven 3.3 ft. (1 m) into the ground.

Connecting Alternating Current (AC)

NOTE: Ensure all electric devices including lines and plug connection are in good condition before connection to the generator.

NOTE: Ensure total load is within the generator rated output.

NOTE: Ensure receptacle load current is within a receptacle rated current.

1. Start engine.
2. Plug into AC receptacle (C, D, or G).
3. Turn on any electric devices.

AC Rated Power

AC rated power is the maximum amount of power the generator can support.

AC Maximum Power

AC maximum power is an additional power generator momentarily produces to aid in starting electrical devices requiring power above the generator’s rated power requirements.

GFCI Receptacle

|

WARNING

---|---
Electrical Shock can cause injury.

Do not touch wires while the generator is running.

Never operate a generator in rain or snow.

Never touch the generator with wet hands or electrical shock may occur.

To reduce the chance of electrical shock:

1. Do not attempt to operate the equipment if the ground fault circuit interrupter (GFCI) RESET button pops out repeatedly during use.
2. Remember that only receptacles labeled GFCI has ground fault circuit interrupter protection.

Ground Fault Circuit Interrupter (GFCI) stops power to protected receptacles (G) if a ground fault (electrical leak) is detected. If the RESET button pops out, equipment plugged into a receptacle (G) may be faulty. If this happens, check equipment carefully. If equipment appears to be in good condition, press the RESET button firmly until a click is heard. This will restore power. If the RESET button pops out again, unplug equipment immediately. Contact a Kohler portable dealer before attempting to use it again.

GFCI Receptacle Test

1.  Start engine.
2. Press the TEST button, if functioning properly RESET button should pop out, stopping power to the outlet.
3. If the GFCI operation is correct, push the RESET button in. If GFCI operates incorrectly, contact a Kohler portable dealer.

Overload (Capacity of Generator)

Never exceed the rated load of the generator (in Amps and/or Watts) when it is running continuously. See specifications table for rated outputs.

Before connecting and operating a generator, calculate the electrical power required by electric appliances (in Watts). This electrical power rating is usually found on the manufacturer’s plate on bulbs, electrical appliances, motors, etc. Sum total of power required by these appliances should not exceed the nominal power rating of the generator.

Circuit protectors (E) and circuit breaker (A) will stop power to protected receptacles (C, D, F or G) when an overload of a connected electrical device is detected or AC output voltage rises to protect the generator and any connected electric devices.

When overload occurs and power generation stops, proceed as follows:

1. Turn off any connected electric devices and stop the generator.
2. Reduce total wattage of connected electric devices within application range.
3. Check for blockages in cooling air inlet and outlet areas and around the control unit. If any blockages are found, remove them.
4. After checking, restart the generator.

Voltage Selector (if equipped)

When the voltage selector (AE) switch is in 120V/240V position, 120V is supplied to all electrical sockets (C, D & G) and 240V is supplied to 240/120V/30A electrical socket (C). When the voltage selector (AE) switch is in the 120V position, only 120V is supplied to electrical sockets (D & G).

Ensure to turn main circuit breaker (A) to OFF position before using voltage selector (AE) switch to avoid accidentally damaging generator because of any connected load that
maybe drawing power from the unit.

Voltage Selector Receptacle Power

PRO 6.4/
PRO 6.4E| PRO 9.0/
PRO 9.0E
120V Only| 240V/120V/ 30A| 30A @ 120V| N/A
120V/30A| 30A @ 120V| N/A
GFCI| 20A @ 120V| N/A
120V/ 240V| 240V/120V/ 30A| 21.7A @ 240V| N/A
120V/30A| 30A @ 120V| N/A
GFCI| 20A @ 120V| N/A

Battery Charging Using DC Receptacle (if equipped)

|

WARNING

---|---
Electrical Shock can cause injury.

Do not touch wires while the generator is running.

Never operate the generator in rain or snow.

Never touch the generator with wet hands or electrical shock may occur.

NOTE: This section refers to charging 12V batteries in other equipment like motor vehicles or off-road vehicles. No jump-starting is possible.

NOTE: Follow safety procedures when handling batteries to avoid damage to electrical components and battery explosions. Refer to battery manufacturers’ safety data sheet on
safety risks of working with batteries. Refer to battery manufacturer’s instructions on battery charging/ maintaining procedures.

NOTE: Generator DC rated voltage is 12V. DC circuit protector (E) will turn off automatically if the current above-rated flows during battery charging. Start generator first, then connect a generator to battery for charging. Before starting to charge the battery, ensure the DC circuit protector (E) is in the RESET position. If DC circuit protector (E) turns off again, stop charging the battery immediately and contact a Kohler portable dealer.

NOTE: Do not connect a VRLA (valve regulated lead acid) battery. To charge a VRLA battery, a special (constant-voltage) battery charger is required.

NOTE: Do not connect any load to the battery or use the engine starter motor while charging. This causes a high current to flow through the generator which will burn out the coil.

NOTE: Prior to charging the battery, remove positive and negative cables to the battery.

1. Start generator.
2. Press DC circuit protector (E) in.
3. Connect red battery charger lead to the positive battery terminal. Connect black battery charger leads to the negative battery terminal. Do not reverse these positions. Connect cord to DC receptacle (F).

Operating Range of DC Power Supply (Charging 12V battery only):

This power source is designed to charge batteries up to 40Ah that are half- discharged. Do not charge batteries of a higher capacity than 40Ah.

12V Battery:

The time required for recharging a battery varies depending on the discharge level of the battery. When the specific gravity of the battery reaches 1.26 to 1.28, charging is complete. When charging, check the battery’s specific gravity once an hour. The average time for charging a half-discharged 40Ah battery is approximately 5 hours. Be sure to check the battery fluid level before charging.

DC Circuit Protector

NOTE: Reduce a load of the connected electric device below the specified rated output of the generator if the DC circuit protector (E) turns off. If DC circuit protector (E) turns off again, stop using device immediately and contact a Kohler portable dealer.

DC circuit protector (E) button will pop out, stopping power to DC receptacle (F) when the electric device is connected to generator is operating at a current above-rated flows. To use this equipment again, press the DC circuit protector (E) button.

Starter Battery (if equipped)

As starter battery (O) is maintenance-free, just check the condition and tightness of connections and its general cleanliness.

Circuit Breaker

Generating set’s electrical circuit is protected by one or more magnetothermal, differential, or thermal cut-out switches. If an overload and/or short circuit occurs, the supply of electrical energy may be cut.

If necessary, replace circuit breaker (A) in generating set with circuit breakers with identical nominal ratings and specifications.

Clean Generating Set

1. Remove all dust and debris from around the exhaust.
2. Clean generating set, particularly alternator and engine air inlets and outlets, using a cloth and brush.
3. Check the general condition of generating the set and replace any faulty parts.

Transporting Generator

Before transporting the generator, check that bolts are correctly tightened, close the fuel valve (X), and disconnect the starter battery (O). The generator should be transported in its normal operating position; never lay it on its side. Ensure where the generator is to be stored or used is carefully prepared beforehand.

Repairs/Service Parts

We recommend that you use a Kohler portable dealer for all maintenance, service, and replacement parts for the engine. To find a Kohler portable dealer visit KohlerPower.com or call 1-800-544-2444 (U.S. and Canada).

Storage

Long-term storage of your generator will require some preventative procedures to guard against deterioration.

NOTE: Do not connect with any electrical devices (unloaded operation).

If the engine will be out of service for 2 months or more follow the procedure below.

1.  Add Kohler PRO Series fuel treatment or equivalent to the fuel tank. Run engine 2-3 minutes to get stabilized fuel into the fuel system (failures due to untreated fuel are not warrantable).
2. Change oil while the engine is still warm from operation. Remove spark plug (Q) and pour about 1 oz. of engine oil into the cylinder(s). Replace spark plug (Q) and crank engine slowly to distribute oil.
3. Clean generator.
4. Store generator in a dry, well-ventilated place, with a cover, placed over it. When covering the generator, be sure to do so only after the engine and muffler/shield have
   completely cooled down. The generator must remain in the same position as normal operation.

Troubleshooting

Do not attempt to service or replace major engine components, or any items that require special timing or adjustment procedures. This work should be performed by a Kohler portable dealer.

Engine Not Starting/
Running Abnormally| Engine Stopped| No Electric Current| Tripping of Circuit
Breaker
Load connected to generating set during start-up| •| | |
Start and Stop control ON or OFF| •| | |
Oil level too low| •| •| |
Unsuitable fuel| •| | |
Fuel level too low| •| •| |
Fuel valve closed| •| | |
Clogged fuel filter| •| | |
Clogged fuel strainer| •| | |
Clogged air filter| •| | |
Faulty spark plug| •| | |
Fuel supply blocked or leaking| •| | |
Faulty starter battery| •| | |
Blocked ventilation inlets| | •| |
Circuit protectors not actuated| | | •|
Faulty appliance supply cord| | | •|
Faulty electrical sockets| | | •|
Faulty alternator| | | •|
Device connected or faulty cord| | | | •
Overload| | | | •
Battery Incorrectly Connected| •| | |
Specifications

Model| PRO 6.4/
PRO 6.4E| PRO 9.0/
PRO 9.0E
Overall Dimensions: (L x W x H)| 29.4 in. (747 mm)
21.4 in. (544 mm)
22.3 in. (566 mm)| 29.4 in. (747 mm)
21.4 in. (544 mm)
22.3 in. (566 mm)
Dry Weight| 178 lbs. (81 kg) / 201 lbs. (91 kg)| 206 lbs. (93 kg) / 222 lbs. (101 kg)
AC Rated Power| (120 Volts x 43.3 **Amps)
5200 Watt
 ( 240 Volts x 21.7 Amps)| (120 Volts x 60 Amps)**

7200 Watt
(240 Volts x 30 Amps)

AC Maximum Power| (120 Volts x 53.3Amps)

6400 Watt

(240 Volts x 26.7 Amps)

| (120 Volts x 75Amps)

9000 Watt

(240 Volts x 37.5 Amps)

DC Rated Power| 100 watt (12 Volts x 8.3 Amps)
Engine Specifications

Bore| 3.1 in. (78 mm)| 3.5 in. (89 mm)
Stroke| 2.3 in. (58 mm)| 2.7 in. (69 mm)
Displacement| 16.9 cu. in. (277 cc)| 26.2 cu. in. (429 cc)
Oil Capacity (Re fi ll)| 0.63 U.S. qt.
(0.60 L)| 1.16 U.S. qt. (1.1 L)
Maximum Angle of Operation **(@ full oil level)*| 25°
Run Time| 15 hours| 11 hours
Fuel| See fuel section
Fuel Tank Capacity| 8 gal. (30.2 L)
Spark Plug Gap| 0.03 in. (0.76 mm)**

*Exceeding maximum angle of operation may cause engine damage from insufficient lubrication.

Additional specification information can be found at KohlerPower.com.

Exhaust Emission Control System for models PRO 6.4, PRO 6.4E, PRO 9.0, and PRO 9.0E is EM for U.S. EPA, California, and Europe.

Accessory System

Accessory kits are available for models in the table below which includes custom kits consisting of legs, handles, wheels, lifting kits — whatever you want, any way you want it.

Accessory System| PRO 3.7 /PRO 3.7 E| 6.4E| 6.4 /PRO 9.0 / 9.0E| GEN 5.0| WP 2.0 WP 3.0 TP 3.0
---|---|---|---|---|---
Wheel Kit| •| •| •| •| •| •| •
Leg Kit| •| •| •| •| •| •| •
Lifting Kit| •| •| •| •| | |
Wheelbarrow Handle Kit| •| •| •| •| •| •| •
Cord Management Kit| •| •| •| •| •| •| •
Hand Truck Handle Kit| •| •| •| •| | |
Isolator Kit| •| •| •| •| •| •| •
Tri-fuel Regulator Kits| | •| •| | | |

Install Wheel Kit

NOTE: Tilt unit so fuel tank cap is upward to ensure no fuel leakage.

NOTE: A clamping device or an assistant to hold assembly while installing the kit will make the process easier.

Wheel kit includes 2 wheels and mounting hardware to be installed opposite of engine side. Wheel kit and leg kit are designed to be installed together. 2 wheel kits can be
combined for a 4 wheel configuration.

1. Place 4 screws into holes of the frame.
2. Bring bracket of wheel underframe and align screws with bracket holes.
3. Thread nuts to screws. Torque to 221 in. lb. (25 N·m).

Install Leg Kit

NOTE: Tilt unit so fuel tank cap is upward to ensure no fuel leakage.

NOTE: A clamping device or an assistant to hold assembly while installing the kit will make the process easier.

Leg kit includes 2 legs and mounting hardware.

Leg kit and wheel kit are designed to be installed together. 2 leg kits can be combined for a 4 legged configuration.

1. Place 4 screws into holes of the frame.
2. Bring leg underframe and align screws with leg holes.
3. Thread nuts to screws. Torque to 221 in. lb.(25 N·m).

Install Wheelbarrow Handle Kit

Wheelbarrow Handle Kit

The wheelbarrow handle kit includes two wheelbarrow handles and mounting hardware.

1. Align the handle with holes on the frame.
2. Place washers between handle and frame while installing the screw.
3. Thread nut to screw. Torque to 4 in. lb. (0.5 N·m).

Install Cord Management Kit

Cord Kit

The cord management kit includes 2 posts and mounting hardware. The cord management kit can be installed anywhere on the unit on the same side, not across the unit.

1. Place post sides together onto the frame.
2. Place 3 nuts into holes in 1 side.
3. While holding together, insert screws into the other side and thread into nuts. Torque to 221 in. lb. (25 N·m).

Install Lift Kit

Lifting Kit

NOTE: A clamping device or an assistant to hold assembly while installing the kit will make the process easier.

The lift kit includes a lift bar and mounting hardware.

1. Align lift bar holes under holes of the frame.
2. While holding in this position, install screws.
3. Thread nuts to screws. Torque to 221 in. lb. (25 N·m).

Install Hand Truck Handle Kit

Hand Truck Handle Kit

NOTE: A clamping device or an assistant to hold assembly while installing the kit will make the process easier.

The hand truck handle kit includes a hand truck handle and mounting hardware.

1. Position hand truck handles on unit aligning frame holes and handle holes.
2. Place washer between handle and frame.
3. While holding in this position, install screws.
4. Thread nuts to screws. Torque to 4 in. lb. (0.5 N·m).
5. Install release knob through the frame. Place washer and hitch pin on the inside of the assembly.

Install Isolator Kit

Isolator Kit

Isolator Kit includes 4 isolators and mounting hardware.

1. Align isolator holes under holes of the frame.
2. While holding in this position, install screws.
3. Thread nuts to screws. Torque to 221 in. lb. (25 N·m).

© 2017, 2018 by Kohler Co. All rights reserved.
KohlerPower.com
TP-7087 8/18a

References

• 18aKohlerPower.com
• Kohler Energy | Cleaner Energy Solutions for individuals, businesses and communities
• P65warnings.ca.gov

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>