Kohler PRO 2.0 iS User manual

Generator
7PB-F8199-L2
PRINTED IN CHINA
2014.01 !
(E)
PRO 2.0 iS
OWNER’S MANUAL
Read this manual carefully before operating this machine.
7PB-F8199-L2_Hyoshi.indd 1 2014/01/08 16:59:08

- Read this manual carefully before operating this machine. This manual should
stay with this machine if it is sold.
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KohlerPower.com33 590 03
AE00002
INTRODUCTION
Congratulations on your purchase of your new Kohler.
This manual will provide you with a good basic understanding of the operation and
maintenance of this machine.
If you have any questions regarding the operation or maintenance of your machine,
please consult a Kohler portable dealer.
AE00022
PRO 2.0 iS
OWNER’S MANUAL
First edition, January 2014
© 2014 Reprinted by Kohler Co. under license.
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
the copyright holder is expressly prohibited.
Printed in China.
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KohlerPower.com 33 590 03
Particularly important information is distin-
guished in this manual by the following
notations.
This is the safety alert symbol. It is
used to alert you to potential personal
injury hazards. Obey all safety mes-
sages that follow this symbol to avoid
possible injury or death.
WARNING
A WARNING indicates a hazardous sit-
uation which, if not avoided, could
result in death or serious injury.
NOTICE
A NOTICE indicates special precau-
tions that must be taken to avoid dam-
age to the machine or other property.
TIP
A TIP provides key information to make
procedures easier or clearer.
AE00032
WARNING
PLEASE READ AND UNDERSTAND
THIS MANUAL COMPLETELY BEFORE
OPERATING THE MACHINE.
TIP
9 Kohler continually seeks advance-
ments in product design and quality.
Therefore, while this manual contains
the most current product information
available at the time of printing, there
may be minor discrepancies between
your machine and this manual. If
there is any question concerning this
manual, please consult a Kohler por-
table dealer.
9 This manual should be considered a
permanent part of this machine and
should remain with this machine
when resold.
* Product and specifications are subject to
change without notice.
IMPORTANT MANUAL INFORMATION
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KohlerPower.com33 590 03
AE00041
CONTENTS
SAFETY INFORMATION ....................... 1
Exhaust fumes are poisonous ............ 2
Fuel is highly flammable and
poisonous ............................................ 2
Engine and muffler may be hot ........... 2
Electric shock prevention .................... 3
Connection notes ................................ 4
Connection .......................................... 4
Extension cord notes .......................... 4
LOCATION OF IMPORTANT
LABELS ................................................. 5
DESCRIPTION ....................................... 7
Control panel ....................................... 7
CONTROL FUNCTION .......................... 8
Engine switch ...................................... 8
Recoil starter ....................................... 8
Oil warning light (Red) ........................ 8
DC protector ........................................ 9
Economy control switch ...................... 9
AC pilot light (Green) ........................ 10
Overload indicator light (Red) ........... 10
Fuel tank cap .................................... 10
Fuel tank cap air vent knob ............... 11
Fuel cock knob .................................. 11
Ground (earth) terminal .................... 11
Twin Tech .......................................... 12
PREPARATION .................................... 13
Fuel ................................................... 13
Engine oil .......................................... 14
PRE-OPERATION CHECK .................. 16
Pre-operation check .......................... 16
OPERATION ........................................ 17
Starting the engine ............................ 17
Stopping the engine .......................... 19
Connection ........................................ 20
Battery charging ................................ 21
Operating range of DC power
supply ................................................ 24
Application range .............................. 25
High Altitude Operation .................... 26
PERIODIC MAINTENANCE ................ 27
Maintenance chart ............................ 27
Spark plug inspection ....................... 29
Carburetor adjustment ...................... 30
Engine oil replacement ..................... 30
Air filter .............................................. 32
Muffler screen and spark arrester ..... 33
Fuel tank filter ................................... 35
STORAGE ............................................ 36
Drain the fuel ..................................... 36
Engine ............................................... 38
TROUBLESHOOTING ......................... 39
SPECIFICATIONS ................................ 42
Dimensions ....................................... 42
Engine ............................................... 42
Generator .......................................... 42
CONSUMER INFORMATION .............. 43
Identification number records ............ 43
Machine identification ....................... 43
EXHAUST EMISSION CONTROL
SYSTEM AND COMPONENTS ........... 44
WIRING DIAGRAM .............................. 45
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1
7DK-036
AE00071
SAFETY INFORMATION
9 This generator is not designed for on-board use.
Do not use it while installed on the vehicle.
9 Do not modify the generator or use it with its parts
removed.
9 Do not allow children to operate the generator.
9 Be sure to carry the generator only by its carrying
handle.
1 Carrying handle
9 Do not place any obstacles on the generator.
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7DK-001
AE00072
Exhaust fumes are poisonous
9 Using a generator indoors CAN KILL YOU IN
MINUTES. Generator exhaust contains carbon
monoxide. This is a poison you cannot see or
smell.
9 NEVER use inside a home or garage, EVEN IF
doors and windows are open.
9 Only use OUTSIDE and far away from windows,
doors, and vents.
7DK-002
7DK-003
7DK-004
7DK-005
AE00843
Engine and muffler may be hot
9 Place the generator in a place where pedestrians
or children are not likely to touch the machine.
AE00075
Fuel is highly flammable and poisonous
9 Always turn off the engine when refuelling.
9 Never refuel while smoking or in the vicinity of an
open flame.
9 Take care not to spill any fuel on the engine or
muffler when refueling.
9 Do not leave the generator inside the vehicle or in
the trunk.
9 If you swallow any fuel, inhale fuel vapor, or allow
any to get in your eye(s), see your doctor immedi-
ately. If any fuel spills on your skin or clothing,
immediately wash with soap and water and
change your clothes.
9 When operating or transporting the generator, be
sure it is kept upright. If it tilts, fuel may leak from
the carburetor or fuel tank.
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1
7PB-011
7DK-008a
7DK-009
7DK-010
AE00083
Electric shock prevention
9 Never operate the engine in rain or snow.
9 Never touch the generator with wet hands or elec-
trical shock will occur.
9 Connect the Ground (earth) terminal to a ground
source. In order to prevent electrical shock, the
generator must be grounded when using an elec-
trical device with a ground plug.
1 Ground (earth) terminal
9 Do not operate the engine with a dust cover or
other objects covering it.
9 When covering the generator, be sure to do so
only after the engine and muffler have completely
cooled down.
7DK-007
9 In order to prevent overheating, ensure adequate
airflow by keeping the machine at least 1 m (3 ft)
from objects or other equipment.
7DK-006
9 Avoid placing any flammable materials near the
exhaust outlet during operation.
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7DK-012
1
2
1
2
AE00088
Connection notes
9 Avoid connecting the generator to commercial
power outlet.
9 Avoid connecting the generator in parallel with any
other generator.
1 Correct
2 Incorrect
AE00091
Connection
WARNING
Before the generator can be connected to a build-
ing’s electrical system, a licensed electrician must
install an isolation (transfer) switch in the build-
ing’s main fuse box. The switch is the connection
point for generator power and allows selection of
generator or main line power to the building. This
will prevent the generator from charging the main
power line (backfeeding) when the main power
supply has failed or has been turned off for line
repair. Backfeeding can electrocute or injure line
maintenance personnel. Also, generator and build-
ing electrical system damage can occur when nor-
mal operating power returns if unit is used without
an isolation switch.
AE00086
Extension cord notes
Extension cords should be protected by a tough flexi-
ble rubber sheath (IEC 245) or the equivalent to with-
stand mechanical stresses.
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AE00062
LOCATION OF IMPORTANT LABELS
Please read the following labels carefully before oper-
ating this machine.
TIP
Maintain or replace safety and instruction labels, as
necessary.
1
12
7DK-013
3
4
5
6
7PB-014
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4
6
2
5
Hot parts can cause severe burns.
Do not touch generator while operating or just after stopping.
Electrical shock can cause injury.
Do not touch wires while generator is running.
Do not connect generator to a building's electrical system unless using
an isolation (transfer) switch installed by a certified, licensed electrician.
Explosive Fuel can cause fires and severe burns.
Do not fill fuel tank while generator is hot or running.
Las piezas calientes pueden causar quemaduras graves.
No toque el generador durante el funcionamiento o inmediatamente después
de pararse.
La explosión del carburante puede provocar incendios y quemaduras graves.
No llene el tanque de combustible mientras el generador esté caliente o
funcionando.
Las descargas eléctricas pueden provocar lesiones.
No toque los cables con el generador en funcionamient.
No conecte el generador al sistema eléctrico de un edificio salvo que lo haga
a través de un conmutador de aislamiento (transferencia) instalado por un
electricista titulado autorizado.
7PB-F4162-20
3
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12
3
4
7DK-015
DESCRIPTION
1 Carrying handle
2 Fuel tank cap air vent knob
3 Fuel tank cap
4 Recoil starter
5 Fuel gauge
6 Muffler
7 Oil filler cap
AE00103
Control panel
1 Oil warning light
2 AC pilot light
3 Overload indicator light
4 Economy control switch
(Black)
5 Engine switch (Red)
6 Fuel cock knob
7 Choke knob
8 Twin Tech (parallel running
terminal)
9 AC receptacle
0 DC protector (breaker)
q Ground (earth) terminal
w DC receptacle
1 2 3 4 5
6
7
8
9
0
q
w
7PB-017
5
6
7
7PB-016
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KohlerPower.com33 590 03 8
1
2
7DK-018
1
700-115
AE00111
Oil warning light (Red)
When the oil level falls below the lower level, the oil
warning light comes on and then the engine stops
automatically. Unless you refill with oil, the engine will
not start again.
TIP
If the engine stalls or does not start, turn the engine
switch to “7” (ON) and then pull the recoil starter. If
the oil warning light flickers for a few seconds, the
engine oil is insufficient. Add oil and restart.
AE00101
CONTROL FUNCTION
AE00121
Engine switch
The engine switch controls the ignition system.
1 “7” (ON)
Ignition circuit is switched on.
The engine can be started.
2 “5” (STOP)
Ignition circuit is switched off.
The engine will not run.
Recoil starter
The recoil starter is used to start the engine.
Pull the recoil starter slowly until it is engaged, then
pull it briskly.
1 Recoil starter handle
NOTICE
9 Pull the recoil starter handle straight.
9 Return the recoil starter handle slowly.
9 Do not touch the recoil starter handle while
the generator is operating.
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AE00142
Economy control switch
1 “I” (ON)
When the economy control switch is turned to ON, the
economy control unit controls the engine speed
according to the connected load. The results are bet-
ter fuel consumption and less noise.
2 “3” (OFF)
When the economy control switch is turned to OFF,
the engine runs at the rated r/min (4,500 r/min)
regardless of whether is a load connected or not.
TIP
The economy control switch must be turned to OFF
when using electric devices that require a large start-
ing current, such as a compressor of a submersible
pump.
1
2
7DK-020
NOTICE
Reduce the load of the connected electric device
below the specified rated output of the generator
if the DC protector turns off. If the DC protector
turns off again, stop using the device immediately
and consult a Kohler portable dealer.
DC protector
The DC protector turns to “3” (OFF) automatically
when electric device being connected to the generator
is operating and current above the rated flows. To use
this equipment again, turn on the DC protector by
pressing its button to “I” (ON).
1
2
7PB-052
1 “I” (ON)
Direct current is output. (This is the default position.)
2 “3” (OFF)
Direct current is not output.
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AE01087
Overload indicator light (Red)
The overload indicator light comes on when an over-
load of a connected electrical device is detected, the
inverter control unit overheats, or the AC output volt-
age rises. Then, the AC protector will trip, stopping
power generation in order to protect the generator and
any connected electric devices. The AC pilot light
(Green) will go off and the overload indicator light
(Red) will stay on, but the engine will not stop running.
1 Overload indicator light
When the overload indicator light comes on and power
generation stops, proceed as follows:
1. Turn off any connected electric devices and stop
the engine.
2. Reduce the total wattage of connected electric
devices within the rated output.
3. Check for blockages in the cooling air inlet and
around the control unit. If any blockages are
found, remove.
4. After checking, restart the engine.
TIP
The overload indicator light may come on for a few
seconds at first when using electric devices that
require a large starting current, such as a compressor
or a submersible pump. However, this is not a mal-
function.
1
7DK-021
7DK-022
Fuel tank cap
Remove the fuel tank cap by turning it counterclock-
wise.
AC pilot light (Green)
The AC pilot light comes on when the engine starts
and produces power.
1 AC pilot light
1
7DK-048
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1
2
7DK-023
2
1
7DK-024
1
7PB-011
Fuel cock knob
The fuel cock supplies fuel from the fuel tank to the
carburetor.
The fuel cock has two positions.
1 ON
With the knob in this position, fuel flows to the carbu-
retor. Normal using is done with the knob in this posi-
tion.
2 OFF
With the knob in this position, fuel will not flow. Always
turn the knob to this position when the engine is not
running.
Ground (earth) terminal
Ground (earth) terminal connects the earth line for
prevention of electric shock.
When the electric device is grounded, be sure to
ground the generator also.
1 Ground (earth) terminal
Fuel tank cap air vent knob
The fuel tank cap is provided with an air vent knob to
stop fuel flow.
The air vent knob must be turned to ON. This will
allow fuel to flow to the carburetor and the engine to
run. When the engine is not in use, turn the air vent
knob to OFF to stop fuel flow.
1 Air vent knob
2 Fuel tank cap
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7DK-042a
Twin Tech
(Terminal for connecting special cables for
parallel running)
This is the terminal for connecting special cables for
parallel running of two PRO 2.0 iS. The parallel run-
ning requires two PRO 2.0 iS and the special cables.
(The rated output in parallel running is 3.0 kVA and
the rated current is 25.0 A.)
The handling, operation procedure and the notes on
usage are described in the Parallel Power Cable Kit
owner’s manual included in the Parallel Power Cable
Kit. Consult a Kohler portable dealer for this Parallel
Power Cable Kit.
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KohlerPower.com13 33 590 03
3
4
7DK-037
7DK-091
1
2
7DK-028
707-095
PREPARATION
AE00856
Fuel
WARNING
9 Fuel is highly flammable and poisonous.
Check “SAFETY INFORMATION” (See page 2)
carefully before filling.
9 Do not overfill the fuel tank, otherwise it may
overflow when the fuel warms up and expands.
9 After fill the fuel, make sure the fuel tank cap
is tightened securely.
1. Stop the engine.
2. Place the generator on a level surface.
3. Remove the fuel tank cap.
4. Check the fuel level.
5. If low, fill the tank with fuel.
NOTICE
9 Immediately wipe off spilled fuel with a clean,
dry, soft cloth, since fuel may deteriorate
painted surfaces or plastic parts.
9 Use only unleaded gasoline. The use of leaded
gasoline will cause severe damage to internal
engine parts.
Make sure there is sufficient fuel in the tank.
When refueling, be sure to fill the tank up to the
“LEVEL” (red) mark of the fuel tank filter.
1 Fuel level
2 Fuel tank filter
3 Fuel level gauge
4 “LEVEL” (red) mark
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2
7PB-031
AE00222
Engine oil
NOTICE
The generator has been shipped without engine
oil. Do not start the engine until you have filled it
with the sufficient engine oil.
3. Remove the oil filler cap.
2 Oil filler cap
1
7PB-030
5
6
7DK-093
5 “F” Full
6 “E” Empty
Your Kohler engine has been designed to use regular
unleaded gasoline with a pump octane number ((R +
M)/2) of 86 or higher, or research octane number of
91 or higher.
Recommended fuel:
Unleaded gasoline
Fuel tank capacity:
Total:
4.2 L (1.11 US gal, 0.92 Imp gal)
1. Place the generator on a level surface.
2. Remove the panel.
1 Panel
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KohlerPower.com15 33 590 03
7PB-033
700-119
3
4. Fill the specified amount of the recommended
engine oil, and then install and tighten the oil filler
cap.
NOTICE
9 Do not tilt the generator when adding engine
oil. This could result in overfilling and damage
to the engine.
9 Be sure no foreign material enters the crank-
case.
0˚C
å Kohler 10W-30
∂ SAE 10W ç SAE #20 ∫ SAE #30
32˚F
25˚C
80˚F
3 Correct level
5. Install the panel.
Recommended engine oil:
å Kohler 10W-30,
SAE 10W-30 or 10W-40
∫ SAE #30
ç SAE #20
∂ SAE 10W
Recommended engine oil grade:
API Service SE type or higher
Engine oil quantity:
0.4 L (0.42 US qt, 0.35 Imp qt)
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