Kohler PRO 2.8 i User manual

Generator
7VU-28199-L1
PRINTED IN JAPAN
2014.01-0.1×1 !
(E)
PRO 2.8 i
OWNER’S MANUAL
Read this manual carefully before operating this machine.
PRINTED ON RECYCLED PAPER
7VU-28199-L1_Hyoshi.indd 1 2014/01/08 17:27:07

- Read this manual carefully before operating this machine. This manual should
stay with this machine if it is sold.
7VU-28199-L1_Hyoshi.indd 2 2014/01/08 17:27:07

KohlerPower.com33 590 04
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.
PRO 2.8 i
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 Japan.
AE00022
7VU-28199-L1.indd 1 2014/01/09 10:15:54

KohlerPower.com 33 590 04
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.
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
7VU-28199-L1.indd 2 2014/01/09 10:15:55

KohlerPower.com33 590 04
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 ....................................... 6
Control panel ....................................... 6
CONTROL FUNCTION ......................... 7
Oil warning light (red) .......................... 7
Recoil starter ....................................... 7
Engine switch ...................................... 7
Economy control switch ...................... 8
DC protector ........................................ 8
G.F.C.I. Receptacle ............................. 9
PREPARATION .................................... 10
Fuel ................................................... 10
Engine oil .......................................... 11
Ground (earth) terminal .................... 12
PRE-OPERATION CHECK .................. 13
Pre-operation check .......................... 13
OPERATION ........................................ 14
Starting the engine ............................ 14
Application range .............................. 16
High Altitude Operation .................... 17
Connection ........................................ 18
Battery charging ................................ 20
Stopping the engine .......................... 24
PERIODIC MAINTENANCE ................ 25
Maintenance chart ............................ 25
Spark plug inspection ....................... 27
Carburetor adjustment ...................... 27
Engine oil replacement ..................... 28
Muffler screen and spark arrester ..... 29
Air filter .............................................. 31
Fuel cock ........................................... 32
Fuel tank filter ................................... 32
G.F.C.I. Receptacle test .................... 33
TROUBLESHOOTING ......................... 34
STORAGE ............................................ 36
Drain the fuel ..................................... 36
Engine ............................................... 37
EXHAUST EMISSION CONTROL
SYSTEM AND COMPONENTS ........... 38
SPECIFICATIONS ................................ 39
Dimensions ....................................... 39
Engine ............................................... 39
Generator .......................................... 39
CONSUMER INFORMATION .............. 40
Identification number records ............ 40
Machine identification ....................... 40
WIRING DIAGRAM .............................. 41
PRO 2.8 i .......................................... 41
7VU-28199-L1.indd 3 2014/01/09 10:15:55

KohlerPower.com1 33 590 04
AE00071
SAFETY INFORMATION
9 This generator is not designed for on-board use.
Do not use it while installed on the vehicle.
741-057
1
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(s).
1 Carrying handle(s) (shaded)
9 Do not place any obstacles on the generator.
7VU-28199-L1.indd 1 2014/01/09 10:15:55

KohlerPower.com33 590 04 2
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.
741-002
741-003
741-005
741-004
741- 006
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 refuelling.
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.
AE00843
Engine and muffler may be hot
9 Place the generator in a place where pedestrians
or children are not likely to touch the generator.
7VU-28199-L1.indd 2 2014/01/09 10:15:56

KohlerPower.com3 33 590 04
741-010
741-011
7VU-002 741-009
1
741-007
741-008a
9 Avoid placing any flammable materials near the
exhaust outlet during operation.
9 In order to prevent overheating, ensure adequate
airflow by keeping the machine at least 1 m (3 ft)
from objects or other equipment.
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.
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
7VU-28199-L1.indd 3 2014/01/09 10:15:57

KohlerPower.com33 590 04 4
1
2
1
2
741-040
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.
7VU-28199-L1.indd 4 2014/01/09 10:15:58

KohlerPower.com5 33 590 04
145
3
2AE00062
LOCATION OF IMPORTANT LABELS
Please read the following labels carefully before oper-
ating this generator.
TIP
Maintain or replace safety and instruction labels, as
necessary.
DANGER
Using a generator indoors CAN KILL YOU IN MINUTES.
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,
door, and vents.
7CG-24877-00
2
1
3
4 5
7VU-28199-L1.indd 5 2014/01/09 10:15:58

KohlerPower.com33 590 04 6
AE00102
DESCRIPTION
1 Carrying handles (shaded)
2 Fuel tank
3 Fuel tank cap
4 Fuel level gauge
5 Ground (earth) terminal
6 Oil filler cap
7 Oil drain bolt
8 Recoil starter
9 Choke knob
0 Fuel cock
q Air filter case cover
w Muffler
e Spark plug
0
q
3
2
5
6
1
1 1
1
4
87
e
w
9
4
6
7
8
9
05
321
793-085
AE00103
Control panel
1 Engine switch
2 Economy control switch
3 DC receptacle
4 AC receptacle
5 G.F.C.I. receptacle
6 Ground (earth) terminal
7 DC protector
8 Overload indicator light
9 AC pilot light
0 Oil warning light
3
2
5
6
114
87
9
793-084
PRO 2.8 i
7VU-28199-L1.indd 6 2014/01/09 10:15:58

KohlerPower.com7 33 590 04
AE00101
CONTROL FUNCTION
AE00111
Oil warning light (red)
When the oil level falls below the lower level, the oil
warning light (red) 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” 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.
700-027c
763-084f
1
2
704-016
1
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.
AE00122
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.
7VU-28199-L1.indd 7 2014/01/09 10:15:59

KohlerPower.com33 590 04 8
1
2
763-124a
763-188a
2
1
763-006
AE00787
Economy control switch
1 “I” (ON)
When the economy control switch is turned “I” (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 “3” (OFF),
the engine runs at the rated r/min (3,600 r/min)
regardless of whether there is a load connected or
not.
TIP
The economy control switch must be turned to “3”
(OFF) when using electric devices that require a large
starting current, such as a compressor or a submers-
ible pump.
AE00780
DC protector
The DC protector turns off automatically when electric
device being connected to the generator is operating
and current above the rated flows. To use this equip-
ment again, turn on the DC protector by pressing its
button to “I” (RESET).
1 “I” (RESET)
Direct current is output. (This is the default position.)
2 “3” (OFF)
Direct current is not output.
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.
7VU-28199-L1.indd 8 2014/01/09 10:15:59

KohlerPower.com9 33 590 04
2
1
763-105a
763-060a
3
AE00848
G.F.C.I. Receptacle
The G.F.C.I. (Ground Fault Circuit Interrupter) shuts off
power to the protected receptacles if a ground fault
(electrical leak) is detected.
If the reset button pops out, the equipment plugged
into the receptacle may be faulty. If this happens,
check the equipment carefully. If the equipment
appears to be in good condition, press the reset but-
ton firmly until a click is heard. This will restore power.
If the reset button pops out again, unplug the equip-
ment immediately. Have the equipment inspected and
repaired by a qualified repairperson before attempting
to use it again.
1 G.F.C.I (Ground Fault Circuit Interrupter)
2 Reset button
3 Pops out
WARNING
TO REDUCE THE CHANCE OF ELECTRICAL
SHOCK:
9 Do not attempt to operate equipment if the
ground fault circuit interrupter reset button
pops out repeatedly during use.
9 Test the ground fault circuit interrupter during
the pre-operation checks according to the
maintenance instructions on page 33.
9 Remember that only receptacles labeled “GFCI”
have ground fault circuit interrupter protec-
tion.
7VU-28199-L1.indd 9 2014/01/09 10:15:59

KohlerPower.com33 590 04 10
3
4
707-033a
707-001
1
2
707-051
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 bot-
tom edge of the fuel tank filter.
1 Fuel level
2 Fuel tank filter
3 Fuel level gauge
4 Bottom edge of the fuel tank filter
7VU-28199-L1.indd 10 2014/01/09 10:15:59

KohlerPower.com11 33 590 04
700-006
700-110
2
700-108a
1
56
7DF-020
Recommended fuel:
Unleaded gasoline
Fuel tank capacity:
Total:
9.7 L (2.56 US gal, 2.13 Imp gal)
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.
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.
1. Place the generator on a level surface.
2. Remove the oil filler cap.
1 Oil filler cap
3. Fill the specified amount of the recommended
engine oil, and then tighten the oil filler cap.
2 Correct level
7VU-28199-L1.indd 11 2014/01/09 10:15:59

KohlerPower.com33 590 04 12
1
700-006
0°C
å Kohler 10W-30
∂ SAE 10W ç SAE #20 ∫ SAE #30
32°F
25°C
80°F
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:
0.6 L (0.63 US qt, 0.53 Imp qt)
NOTICE
The generator has been shipped without engine
oil. Do not start the engine till fill with the suffi-
cient engine oil.
AE00241
Ground (earth) terminal
Make sure to Ground (earth) terminal the generator.
Check “SAFETY INFORMATION” (see page 3).
1 Ground (earth) terminal
7VU-28199-L1.indd 12 2014/01/09 10:16:00

KohlerPower.com13 33 590 04
AE00845
PRE-OPERATION CHECK
WARNING
If any item in the Pre-operation check is not work-
ing properly, have it inspected and repaired before
operating the generator.
The condition of a generator is the owner’s responsi-
bility. Vital components can start to deteriorate quickly
and unexpectedly, even if the generator is unused.
TIP
Pre-operation checks should be made each time the
generator is used.
Pre-operation check
Fuel (See page 10)
9 Check fuel level in fuel tank.
9 Refuel if necessary.
Fuel line
9 Check fuel hose for crack or damage.
9 Replace if necessary.
Engine oil (See page 11)
9 Check oil level in engine.
9 If necessary, add recommended oil to specified
level.
9 Check generator for oil leakage.
The point where abnormality was recognized by
use
9 Check operation.
9 If necessary, consult a Kohler portable dealer.
7VU-28199-L1.indd 13 2014/01/09 10:16:00

KohlerPower.com33 590 04 14
700-006a
1
763-126b
2
705-037
3
763-084h
4
AE00955
OPERATION
WARNING
9 Never operate the engine in a closed area or it
may cause unconsciousness and death within
a short time. Operate the engine in a well ven-
tilated area.
9 Before starting the engine, do not connect any
electric devices.
9 Clean dusts, dirt or water off the receptacle
before use.
NOTICE
The generator has been shipped without engine
oil. Do not start the engine till fill with the suffi-
cient engine oil.
1 Correct level
761-073
AE00989
Starting the engine
1. Turn the economy control switch to “3” (OFF).
2 “3” (OFF)
2. Turn the fuel cock lever to the ON position.
3 ON
3. Turn the engine switch to the “7” (ON) position.
4 “7” (ON)
7VU-28199-L1.indd 14 2014/01/09 10:16:00

KohlerPower.com15 33 590 04
704-016
701-047a
6
701-047b
5
4. Pull the choke knob fully out.
5 Choke knob
TIP
The choke is not required to start a warm engine.
Push the choke knob in to the original position.
5. Pull the recoil starter slowly until it is engaged,
then pull it briskly.
6. After the engine starts, warm up the engine until
the engine does not stop when the choke knob is
returned to the original position.
7. Push the choke knob back to the original position.
6 Original position
TIP
When starting the engine in areas where the ambient
temperature is below 0°C (32°F), the engine automati-
cally operates at the rated r/min (3,600 r/min) for three
minutes to warm up the engine regardless of the
economy control switch position. The economy control
unit operates normally afterwards if the economy con-
trol switch is turned to “I” (ON).
7VU-28199-L1.indd 15 2014/01/09 10:16:00