Service parts for the 6ROY
Grouped by system, with how many of each the parts manual calls for.
Air intake
1 requiredOil system
1 requiredPrices captured from merchant listings; some links are affiliate links. Confirm against your serial number before ordering.
Specifications
| Fuel | diesel |
|---|---|
| Frequency | 60.0 Hz |
| Standby power | 6 kW |
| Standby kVA | 6 |
| Prime power | 4.5 kW |
| Controller | Relay Controller; optional Decision-Maker 3 5-Light Microprocessor Controller |
| Oil capacity | 3.4 L |
| Voltage options | 100 V, 120 V, 200 V, 240 V |
| Phase | 1 |
| Rated current | 25 A |
| Power factor | 1.0 |
| Battery cranking | 500 CCA |
| Battery voltage | 12 V |
| Starting system | 12 V DC |
| Coolant capacity | 7.6 L |
| Dimensions (L×W×H) | 1359×737×909 mm |
| Dry weight | 306 kg |
Engine
| Oil capacity | 3.4 L |
|---|---|
| Coolant capacity | 7.6 L |
| Aspiration | Natural Aspiration |
| Rated speed | 1800 rpm |
Maintenance & consumables
for the Yanmar 3TN75E-RK| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | 46452 | eBay FridayParts $107.00 | |||
| Fuel filter | 11981055650 | Amazon Amazon eBay $10.99 eBay $17.99 KuduParts $11.00 | |||
| Fuel filter | Primary | 223414 | Amazon eBay $13.45 NAPA $34.79 | ||
| Oil filter | 11900535170 | eBay $30.91 KuduParts $28.00 FridayParts $29.99 | |||
| Battery | 12 Volt, negative ground, 500 Cold Cranking Amps minimum | — | |||
| Belt | Fan belt deflection 0.4-0.6 in. (10-5) | — | |||
| Coolant | 50% ethylene glycol / 50% clean, softened water | — | |||
| Oil | CC or CD (API) | — |
Service intervals
1| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Fuel level | Check | First service — Before Starting; schedule column X-marks not legible in source. Columns are: Before Starting / After 50 Hrs.-1 Month / Every 100 Hrs.-3 Months / Every 300 Hrs.-6 Months / Every 500 Hrs.-Yearly |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Service specifications
55| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Clearance | Fan belt tension (deflection) | 0.4-0.6 (10-5) | in. (mm) | |
| Gap | Magnetic pick-up air gap | 0.030 in. (0.76 mm) +/-0.010 in. (0.25 mm) | in. (mm) | |
| Gap | Speed Sensor to actuator air gap | 0.030 in. (0.76 mm) +/-0.010 in. (0.25 mm) | in. (mm) | |
| Injection timing | Timing (B.T.D.C.) | 16 +/- 1 | degrees | B.T.D.C. |
| Other | Fuel solenoid current, pull-in / hold | 50 Amps pull-in; 1.0 Amp hold | Amps | |
| Other | Overcrank shutdown, 5-Light controller | 45 seconds continuous cranking or 75 seconds cyclic cranking; 15 seconds if locked rotor | seconds | |
| Other | Overcrank shutdown, relay controller | 30-60 seconds continuous cranking | seconds | |
| Pressure | Anticipatory Low Oil Pressure switch closes | below 8 | psi (55 kPa) | |
| Pressure | Engine oil pressure | 43-57 | psi (294-392 kPa) | |
| Pressure | Fuel injection pressure | 2844 | psi (19609 kPa) | |
| Pressure | Low Oil Pressure shutdown | 7.1 | psi (49 kPa) | |
| Resistance | Fuel solenoid hold coil (black-red leads) | 11-13 | ohms | solenoid disconnected from engine harness |
| Resistance | Fuel solenoid pull-in coil (black-white 14P leads) | 0.12-0.26 | ohms | solenoid disconnected from engine harness |
| Resistance | K1, K2, K3, K4 relay coil (controller circuit board) | approx. 400 | ohms | R x 10 scale |
| Resistance | K20 relay coil (starter solenoid) | 3-4 | ohms | |
| Resistance | Oil pressure sender resistance at 0 psi/kPa | 227-257 | ohms | |
| Resistance | Oil pressure sender resistance at 100 psi (690 kPa) | 21-50 | ohms | |
| Resistance | Rotor resistance | 2.5-3.1 | ohms | room temperature |
| Resistance | Rotor resistance | 3.5-4.3 | ohms | room temperature |
| Resistance | Rotor resistance | 5.1 | ohms | room temperature |
| Resistance | Stator resistance leads 1-2, 3-4 | 0.07 | ohms | cold, room temperature |
| Resistance | Stator resistance leads 1-2, 3-4 | 0.13 | ohms | cold, room temperature |
| Resistance | Stator resistance leads 1-2, 3-4 | 0.17 | ohms | cold, room temperature |
| Resistance | Stator resistance leads 33-44 | 0.17 | ohms | cold, room temperature |
| Resistance | Stator resistance leads 55-33 | 1.1 | ohms | cold, room temperature |
| Resistance | Stator resistance leads 55-33 | 1.3 | ohms | cold, room temperature |
| Resistance | Stator resistance leads 55-33 | 2.2 | ohms | cold, room temperature |
| Resistance | Water temperature sender resistance at 100 degrees F (38 degrees C) | 450 +/-10% | ohms | |
| Resistance | Water temperature sender resistance at 160 degrees F (71 degrees C) | 130 +/-10% | ohms | |
| Resistance | Water temperature sender resistance at 220 degrees F (104 degrees C) | 47 +/-10% | ohms | |
| Speed | Governor speed, 50 Hz models | 1500 rpm full load; 53 Hz (1590 rpm) no load | rpm | |
| Speed | Governor speed, 60 Hz models | 1800 rpm full load; 63 Hz (1890 rpm) no load | rpm | |
| Speed | Overspeed shutdown | 70 Hz (2100 rpm) | Hz/rpm | 50 and 60 Hz models |
| Speed | Volts/Hz knee frequency (PowerBoost IIIE factory setting) | 57.5 Hz (60 Hz models); 47.5 Hz (50 Hz models) | Hz | |
| Temperature | Anticipatory High Engine Temperature switch closes | above 218 +/-7 | degrees F (103 +/-4 degrees C) | |
| Temperature | Anticipatory Low Water Temperature switch closes | below 60 +/-5 | degrees F (16 +/-8 degrees C) | |
| Temperature | Anticipatory Low Water Temperature switch opens | above 80 +/-5 | degrees F | |
| Temperature | High Engine Temperature shutdown | 230 | degrees F (110 degrees C) | |
| Torque | Cylinder head tightening torque Step 1 | 24-26 | ft. lbs (3.4-3.6 Nm) | |
| Torque | Cylinder head tightening torque Step 1 | 25-31 | ft. lbs (3.5-4.3 Nm) | |
| Torque | Cylinder head tightening torque Step 2 | 49-52 | ft. lbs (6.8-7.2 Nm) | |
| Torque | Cylinder head tightening torque Step 2 | 54-61.5 | ft. lbs (7.5-8.5 Nm) | |
| Torque | Drive disc to flywheel bolt torque | 168 | in. lbs (19 Nm) | |
| Torque | Drive disc to flywheel nut torque | 168 | in. lbs (19 Nm) | |
| Torque | Drive disc to rotor bolt torque | 540 | in. lbs (61 Nm) | |
| Torque | Fan to rotor bolt torque | 260 | in. lbs (29 Nm) | |
| Torque | Generator adapter to flywheel housing bolt torque | 300 | in. lbs (34 Nm) | |
| Torque | Generator adapter to flywheel housing bolt torque | 324 | in. lbs (37 Nm) | |
| Torque | Magnetic pickup actuator to rotor bolt torque | 96 | in. lbs (11 Nm) | |
| Torque | Overbolt torque | 216 | in. lbs (24 Nm) | |
| Valve clearance | Valve clearance, exhaust | 0.008 | in. (0.2 mm) | |
| Valve clearance | Valve clearance, intake | 0.008 | in. (0.2 mm) | |
| Voltage | Controller TB1 test point voltage | slightly less than 12 Volts DC | Volts DC | FASTCHECK toggle in prescribed position |
| Voltage | Megohmmeter insulation test voltage (rotor and stator) | 500 Volts DC; reading of approx. 500K ohms (1/2 megohm) and higher indicates good | Volts DC / ohms | |
| Voltage | Speed Sensor supply voltage at sensor (wire 24 to wire 2) | 9-5 Volts DC (as printed); approx. 7 Volts DC with set running | Volts DC | master switch OFF/OFF-RESET; running |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Recommended fluids
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Coolant | 50% ethylene glycol / 50% clean, softened water | Permanent-type coolant meeting specifications | Prevents freezing to -34 degrees F (-37 degrees C). Do not use alcohol or methanol antifreeze. Cooling system capacity: 2 gal. (7.6 L) 6ROY/6RFOY and 10ROY/10RFOY; 4.7 gal. (17.8 L) 15ROY/15RFOY. Maintain level approx. 3/4 to 1-1/2 in. (19-38 mm) below radiator filler neck seat when cold. | ||
| Engine oil | CC or CD (API) | API CC, CD/CC or CC | Select SAE grade per Figure 3-1 engine oil selection chart (SAE 10W, 20W-20, 30, 40) for operating temperature range -30 to 40 degrees C (-20 to 104 degrees F). Oil capacity with filter: 3.6 qts. (3.4 L) 6ROY/6RFOY; 5 qts. (4.7 L) 10ROY/10RFOY; 6.1 qts. (5.8 L) 15ROY/15RFOY. Avoid mixing different brands. | ||
| Fuel | No. 2-D diesel | ASTM D975 (Federal Specification W-F-800a); DIN 51 601; BS2869 Class A1 or A2 | Sulphur content less than 0.5%; sediment and water not to exceed 0.1%; cetane number greater than 45; pour point at least 10 degrees F (5.6 degrees C) below lowest outside air temperature. Never store in galvanized containers. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Fault codes
7| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| Emergency Stop | Emergency stop activated | Emergency stop switch activated, or switch disconnected from controller terminals TB1-1 or 1A. | Shutdown | Correct cause, reset emergency stop switch by replacing glass face, toggle master switch OFF/RESET then RUN or AUTO |
| High Engine Temperature | HET lamp lights | Engine coolant temperature above 230 degrees F (110 degrees C). Cooling system malfunction. | Shutdown | Check coolant level, fan belt, radiator obstructions; allow engine to cool; reset controller |
| Low Oil Pressure | LOP lamp lights | Engine oil pressure drops to 7.1 psi (49 kPa). | Shutdown | Check engine lube oil level and oil pressure; correct cause; reset controller |
| Low Water Temperature/Auxiliary | LWT/AUX lamp lights | Engine coolant below safe range in radiator; also emergency stop, overvoltage, high oil temperature, low coolant level, or customer auxiliary shutdown input. | Shutdown | Add coolant to specified level; reset controller |
| Overcrank | Overcrank lamp lights | More than 45 seconds of continuous cranking or 75 seconds cyclic cranking (5-light); 30-60 seconds (relay). Locked rotor stops cranking after 15 seconds. | Shutdown | Check engine fuel supply; wait for complete stop; reset controller |
| Overspeed | Overspeed lamp lights | Governed frequency in excess of 70 Hz (50 and 60 Hz models). | Shutdown | Check governor and engine speed; reset controller |
| Overvoltage | Overvoltage shutdown (if equipped) | Output voltage 15% above nominal voltage for one second or longer. | Shutdown | Check voltage regulator and connections; reset controller |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
124-Lead Voltage and Frequency Adjustment Procedure adjustment
⚠ Hazardous voltage; do not touch voltage regulator heat sink when testing.
Tools: Voltmeter, Frequency meter
- Stop generator set; disconnect engine starting battery, negative lead first.
- Select desired voltage connection and connect leads according to the diagram.
- Turn voltage, Volts/Hz, and stability pots fully counterclockwise; turn remote rheostat to mid-point.
- Reconnect battery; move generator master switch to RUN to start generator set.
- Rotate voltage adjustment pot until desired output voltage is achieved.
- Rotate stability pot clockwise until minimum light flicker is obtained.
- Adjust engine speed to desired cut-in frequency (factory setting 57.5-58 Hz for 60 Hz models).
- Rotate Volts/Hz adjustment pot clockwise until voltage level begins to drop.
Fuel Solenoid Linkage Adjustment adjustment
⚠ Improper adjustment may cause burn-out of the pull-in coil.
- Remove linkage to allow fuel solenoid plunger to be manually compressed.
- With solenoid fully compressed, align linkage and check injection pump lever travel.
- Fuel solenoid should fully compress and injection pump lever should be 1/16 in. (1.6 mm) before lever contacts internal stop.
- If alignment is not correct, check linkage and mounting brackets.
- Loosen locknuts and adjust ball joint length in or out to attain proper alignment.
- Tighten locknuts.
Separate Excitation Test diagnostic
⚠ Hazardous voltage; perform electrical service only as prescribed in equipment manual.
Tools: DC ammeter, 12-Volt automotive battery, 10 Amp fuse
- Disconnect all leads from voltage regulator.
- Connect DC ammeter, 10 Amp fuse, and 12-Volt automotive battery to positive and negative brush leads.
- Note and record ammeter reading (battery voltage divided by specified rotor resistance).
- Start engine and check ammeter remains stable; increasing or unstable reading indicates rotor fault.
- Check for AC output across stator leads and compare to Section 10 Specifications.
- If rotor and stator test good, voltage regulator is probably defective.
Speed Sensor Test Procedure diagnostic
Tools: DC voltmeter, 12 Volt DC power supply
- Remove Speed Sensor from end bracket.
- Connect Speed Sensor, voltmeter, and DC voltage source as shown.
- Touch sensing surface with a flat piece of iron or steel at least 1/4 cubic inch.
- Voltmeter test reading should equal source voltage.
- Remove iron or steel from sensing surface; voltmeter should indicate no voltage.
- Reinstall Speed Sensor to end bracket using all original hardware.
Resetting Procedure - Fault Shutdown (Relay Controller) maintenance
⚠ See Safety Precautions before proceeding.
- Move generator master switch to OFF/RESET until fault lamp goes out.
- Disconnect generator set from load with line circuit breaker or transfer switch.
- Correct cause of fault shutdown.
- Move generator master switch to normal position (RUN or AUTO) for start-up.
Storage Procedure maintenance
- Drain oil while still warm from crankcase and refill with proper viscosity oil.
- Drain fuel from fuel tank to prevent accumulated moisture.
- Check engine coolant protection.
- Disconnect battery (negative lead first) and place in storage.
- Seal all openings in engine with non-absorbent adhesive tape.
- Clean exterior of generator and apply light film of oil to unpainted metallic surfaces.
5-Light Controller Starting (Local and Auto) operation
⚠ Alarm horn will sound whenever generator master switch is not in AUTO position.
- For local starting, move generator master switch to RUN position.
- For auto starting, move generator master switch to AUTO position.
- For cyclic cranking leave TB1-9 open; jumper TB1-2 to TB1-9 for continuous cranking.
5-Light Controller Stopping operation
- Disconnect load from generator set and allow it to run without load for 5 minutes.
- Move generator master switch to the OFF/RESET position; engine stops.
Emergency Stopping (5-Light Controller) operation
⚠ Emergency Stop Switch(es) are to be used for emergency shutdowns only.
- Move generator master switch to OFF/RESET or activate remote emergency stop for immediate shutdown.
- LOW WATER TEMPERATURE/AUXILIARY lamp lights and unit shuts down.
Relay Controller Starting Procedure operation
- Move controller or remote Start/Stop switch to RUN position until engine starts.
- If engine fails to start after cranking 30 seconds, unit stops on overcrank.
- Wait for complete stop before attempting restart.
- Place switch in RESET/OFF then to RUN position.
Relay Controller Stopping Procedure operation
- Run generator set at no load for 5 minutes to allow engine cooldown.
- Move controller or remote Start/Stop switch to Off/Reset position.
Resetting Procedure - Remote Emergency Stop operation
⚠ Low Water Temp/Auxiliary lamp lights if master switch is in RUN or AUTO during resetting.
- Investigate cause of emergency stop and correct problem(s).
- Reset remote emergency stop switch by replacing glass face on switch.
- Toggle generator master switch to OFF/RESET and then to RUN or AUTO to resume operation.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Voltage reconnection
| Voltage | Phase | Connection | Leads | Notes |
|---|---|---|---|---|
| 100-120 | 1 | Dual voltage connection | LO-L1, LO-L2 | Jumper lead is not used in dual voltage systems; L1 and L2 are different phases and must never be connected together. |
| 100-120 | 1 | Single voltage connection LO-L1 | LO-L1 | 60 Hz and 50 Hz. Jumper lead should be placed on the line side of the circuit breaker; recommended for all straight 100-120 Volt systems to help balance load. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Common questions
What size generator is the Kohler 6ROY?
The Kohler 6ROY is rated 6 kW standby (6.0 kVA).
What engine is in the Kohler 6ROY?
The Kohler 6ROY is powered by the Yanmar 3TN75E-RK engine.
Is the Kohler 6ROY diesel or gas?
The Kohler 6ROY runs on diesel.
What is the oil capacity of the Kohler 6ROY?
The Yanmar 3TN75E-RK engine in the Kohler 6ROY has an oil capacity of 3.4 liters.
How much coolant does the Kohler 6ROY hold?
The Kohler 6ROY cooling system holds 7.6 liters (2.0 US gallons) for the radiator system including the engine, per the manufacturer specification sheet.
What is the prime power rating of the Kohler 6ROY?
The Kohler 6ROY is rated 4.5 kW prime (4 kVA), against 6 kW standby.
What is the dry weight of the Kohler 6ROY?
The Kohler 6ROY has a dry weight of 306 kg (674 lb).
What voltage does the Kohler 6ROY produce?
The Kohler 6ROY is offered in 100 V, 120 V, 200 V, 240 V, 1-phase.
What battery does the Kohler 6ROY use?
The Kohler 6ROY uses 12 V each, 500 CCA, per the manufacturer specification sheet. The starting system is 12 V DC.
What oil filter does the Kohler 6ROY use?
The Kohler 6ROY uses oil filter part number 11900535170.
What fuel filter fits the Kohler 6ROY?
The Kohler 6ROY uses fuel filter part numbers 11981055650, 223414.
Which air filter part number does the Kohler 6ROY take?
The Kohler 6ROY uses air filter part number 46452.
Troubleshooting
6Symptoms & remedies
| Symptom | Cause | Remedy |
|---|---|---|
| Unit will not crank | Weak or dead battery | Recharge or replace battery |
| Unit will not crank | Reversed or poor battery connections | Check connections |
| Unit will not crank | Defective starter/starter solenoid | Rebuild or replace |
| Unit will not crank | Defective start/stop switch (local or remote) | Test function; replace if defective |
| Unit will not crank | Fuse blown in controller | Replace fuse; if fuse blows again, check circuit and components |
| Unit will not crank | Open in wiring, terminals, pin, circuit board, etc. | Check continuity |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Kohler 6ROY troubleshooting guide (199 entries) →
Repair guides
7- 4-Lead Voltage and Frequency Adjustment Procedure
- 5-Light Controller Starting (Local and Auto)
- Fuel Solenoid Linkage Adjustment
- Relay Controller Starting Procedure
- Resetting Procedure - Fault Shutdown (Relay Controller)
- Resetting Procedure - Remote Emergency Stop
- Speed Sensor Test Procedure
Step-by-step procedures compiled from the Kohler service manual for this model.
Parts
1| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 252898 | Filter, fuel | Fuel filter | Amazon eBay $19.28 |
Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.
Fuel consumption
| Rating | Load | L/h | gal/h |
|---|---|---|---|
| Standby | 25% | 0.6 | 0.15 |
| Standby | 50% | 1.2 | 0.31 |
| Standby | 75% | 1.7 | 0.46 |
| Standby | 100% | 2.3 | 0.61 |
Available documents
Reference (Kohler)Parts manual — g260412 (Kohler)Service manual — tp5555 (Kohler)
This page was generated from the 3 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.