Kohler PRO 5.2, PRO 7.5, GEN 5.0, PRO 5.2 E, PRO 7.5 E Service Manual

PRO 5.2, PRO 5.2 E, PRO 7.5, PRO 7.5 E

Generator Service Manual

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating

instruction of equipment that this engine powers.
Ensure engine 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

KohlerPower.com37 690 01 Rev. --

1

Safety

SAFETY PRECAUTIONS

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.

WARNING

WARNING

Explosive Fuel can
cause fi res and severe
burns.

Do not fi ll fuel tank while
engine is hot or running.

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

WARNING

Rotating Parts can cause
severe injury.

Stay away while
generator is in operation.

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

WARNING

Carbon Monoxide can
cause severe nausea,
fainting or death.

Avoid inhaling exhaust
fumes.

Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled.

Accidental Starts can
cause severe injury or
death.

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

Before working on engine or
equipment, disable engine as
follows: 1) Disconnect spark plug
lead(s). 2) Disconnect negative (–)
battery cable from battery.

Do not allow children to operate
generator.

Hot Parts can cause
severe burns.

Do not touch generator
while operating or just
after stopping.

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

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

Be sure to carry generator only by
its carrying handles.

Cleaning Solvents can
cause severe injury or
death.

Use only in well
ventilated areas away
from ignition sources.

Carburetor cleaners and solvents
are extremely fl ammable. Follow
cleaner manufacturer’s warnings
and instructions on its proper and
safe use. Never use gasoline as a
cleaning agent.

WARNING

WARNING

Electrical Shock can
cause injury.

Do not touch wires while
engine is running.

Never operate generator in rain or
snow.

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

Hazardous Voltage.
Backfeed to utility system

can cause property
damage, severe injury, or
death.

Never plug a portable generator
directly into a building outlet.

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

CAUTION

CAUTION

2 37 690 01 Rev. --KohlerPower.com

Specifi cations

ENGINE IDENTIFICATION NUMBERS

Kohler engine identifi cation numbers (model, specifi cation and serial) should be referenced for effi cient repair,
ordering correct parts, and engine replacement.

Model . . . . . . . . . . . . . . . . . . . . . PRO5.2E

PRO

Numerical Designation

Optional

Specifi cation . . . . . . . . . . . . . . . PA-PRO52E-3001

Serial . . . . . . . . . . . . . . . . . . . . . 4323500328

Year Manufactured Code Factory Code
Code Year
43 2013
44 2014
45 2015

SPECIFICATIONS PRO 5.2/PRO 5.2 E PRO 7.5/PRO 7.5 E

Overall Dimensions (L x W x H) 670 mm (26.4 in.)

545 mm (21.5 in.)
535 mm (21.1 in.)

Dry Weight 76 kg (168 lbs.)/86 kg (189 lbs.) 90 kg (199 lbs.)/100 kg (220 lbs.)

AC Rated Power

AC Surge Power

DC Rated Power 100 Watt (12 Volts x 8.3 Amps)

Fuel Tank 30.2 L (8 gal.)

4500 Watt

5200 Watt

(120 Volts x 37.5 Amps)
(240 Volts x 18.8 Amps)

(120 Volts x 43.3 Amps)
(240 Volts x21.7 Amps)

6300 Watt

7500 Watt

(120 Volts x 52.5 Amps)
(240 Volts x 26.3 Amps)

(120 Volts x 62.5 Amps)
(240 Volts x 31.3 Amps)

337 690 01 Rev. -- KohlerPower.com

Specifi cations

TORQUE SPECIFICATIONS

3

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
M8 Screws

9.9 N·m (87 in. lb.)

25.0 N·m (221 in. lb.)

Carbon Canister Mounting Bracket 9.9 N·m (87 in. lb.)

Control Panel Back Cover 5.8 N·m (51 in. lb.)

Control 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.)

Engine/Alternator Isolators 18.3 N·m (162 in. lb.)

Frame Assembly

M6 Screws
M10 Screws

11.5 N·m (102 in. lb.)

30.0 N·m (266 in. lb.)

Fuel Tank Mounting 9.9 N·m (87 in. lb.)

Muffl er Assembly

M8 Screws
M10 Screws

Muffl er Cover Assembly

Rotor Assembly

Stator Assembly

Wire Connector

25.0 N·m (221 in. lb.)

32.5 N·m (288 in. lb.)

9.9 N·m (87 in. lb.)

22.0 N·m (195 in. lb.)

10.4 N·m (92 in. lb.)

2.5 N·m (22 in. lb.)

3

Values are in Metric units. Values in parentheses are English equivalents.

4 37 690 01 Rev. --KohlerPower.com

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

Size Grade 2 Grade 5 Grade 8

Tightening Torque: N·m (in. lb.) ± 20%

8-32 2.3 (20) 2.8 (25) — 2.3 (20)
10-24 3.6 (32) 4.5 (40) — 3.6 (32)
10-32 3.6 (32) 4.5 (40) — —

1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70)

1/4-28 9.6 (85) 15.8 (140) 22.6 (200) —
5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150)
5/16-24 18.7 (165) 30.5 (270) — —

3/8-16 29.4 (260) — — —

3/8-24 33.9 (300) — — —

Tightening Torque: N·m (ft. lb.) ± 20%

5/16-24 — — 40.7 (30) —

3/8-16 — 47.5 (35) 67.8 (50) —

3/8-24 — 54.2 (40) 81.4 (60) —
7/16-14 47.5 (35) 74.6 (55) 108.5 (80) —
7/16-20 61.0 (45) 101.7 (75) 142.5 (105) —

1/2-13 67.8 (50) 108.5 (80) 155.9 (115) —

1/2-20 94.9 (70) 142.4 (105) 223.7 (165) —
9/16-12 101.7 (75) 169.5 (125) 237.3 (175) —
9/16-18 135.6 (100) 223.7 (165) 311.9 (230) —

5/8-11 149.5 (110) 244.1 (180) 352.6 (260) —

5/8-18 189.8 (140) 311.9 (230) 447.5 (330) —

3/4-10 199.3 (147) 332.2 (245) 474.6 (350) —

3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

Specifi cations

Into Aluminum

Metric Fastener Torque Recommendations for Standard Applications

Size

4.8

Tightening Torque: N·m (in. lb.) ± 10%

M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)
M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)
M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)

Tightening Torque: N·m (ft. lb.) ± 10%

M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)
M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)
M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)

Property Class

5.8

8.8

10.9 12.9

Torque Conversions

N·m = in. lb. x 0.113 in. lb. = N·m x 8.85

N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737

Noncritical

Fasteners

Into Aluminum

537 690 01 Rev. -- KohlerPower.com

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 engine troubles are listed below and vary by engine specifi cation. Use these to
locate causing factors.

Condition Possible Cause Solution

No AC output Circuit breaker in OFF position. Switch circuit breaker to ON.

Circuit protector popped out. Press circuit protectors.

Engine not operating at rated RPM. Adjust engine running at normal operating

temperature to 3750 ± 100 RPM.

Circuit breaker or receptacles faulty. Test for voltage 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 stator Field polarity was lost. Flash rotor fi eld.

Alternator can't output
rated power

Tests

Stator voltage

Engine not operating at rated RPM. Adjust engine running at normal operating

temperature to 3750 ± 100 RPM.

Overload condition. Calculate electrical power required by

electric appliances (in Watts). Reduce
total wattage of connected electric devices
within application range.

Appliance is faulty. Repair faulty appliance.

6 37 690 01 Rev. --KohlerPower.com

Remove rear cover and start engine with
no load. Check if stator terminals have
correct voltage.