Kohler PRO 2.0 iS Owner's Manual
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Kohler PRO 2.0 iS Owner's Manual

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Generator
OWNER'S MANUAL
Read this manual carefully before operating this machine.
PRO 2.0 iS
7PB-F8199-L2

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Summary of Contents for Kohler PRO 2.0 iS

  • Page 1 Generator OWNER’S MANUAL Read this manual carefully before operating this machine. PRO 2.0 iS 7PB-F8199-L2...
  • Page 2 Read this manual carefully before operating this machine. This manual should stay with this machine if it is sold.
  • Page 3 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.
  • Page 4 If there is any question concerning this A TIP provides key information to make manual, please consult a Kohler por- procedures easier or clearer. table dealer. 9 This manual should be considered a...

  • Page 5: Table Of Contents

    AE00041 CONTENTS SAFETY INFORMATION ....... 1 PERIODIC MAINTENANCE ....27 Exhaust fumes are poisonous .... 2 Maintenance chart ......27 Fuel is highly flammable and Spark plug inspection ....... 29 poisonous ..........2 Carburetor adjustment ...... 30 Engine and muffler may be hot ... 2 Engine oil replacement .....

  • Page 6: Safety Information

    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.

  • Page 7: Exhaust Fumes Are Poisonous

    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 7DK-001 doors and windows are open.

  • Page 8: Electric Shock Prevention

    9 Avoid placing any flammable materials near the exhaust outlet during operation. 7DK-006 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-007 9 Do not operate the engine with a dust cover or other objects covering it.

  • Page 9: Connection Notes

    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.

  • Page 10: Location Of Important Labels

    AE00062 LOCATION OF IMPORTANT LABELS Please read the following labels carefully before oper- ating this machine. Maintain or replace safety and instruction labels, as necessary. 7DK-013 7PB-014 KohlerPower.com 33 590 03...
  • Page 11 Hot parts can cause severe burns. Las piezas calientes pueden causar quemaduras graves. No toque el generador durante el funcionamiento o inmediatamente después Do not touch generator while operating or just after stopping. de pararse. Explosive Fuel can cause fires and severe burns. La explosión del carburante puede provocar incendios y quemaduras graves.

  • Page 12: Description

    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 7DK-015 7PB-016 AE00103 Control panel 1 Oil warning light 2 AC pilot light 3 Overload indicator light 4 Economy control switch (Black)

  • Page 13: Control Function

    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. 7DK-018 Recoil starter The recoil starter is used to start the engine.

  • Page 14: Dc Protector

    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. AE00142 Economy control switch 1 “I” (ON)

  • Page 15: Ac Pilot Light (Green)

    AC pilot light (Green) The AC pilot light comes on when the engine starts and produces power. 1 AC pilot light 7DK-048 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.

  • Page 16: Fuel Tank Cap Air Vent Knob

    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.

  • Page 17: Twin Tech

    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 7DK-042a the rated current is 25.0 A.)

  • Page 18: Preparation

    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.

  • Page 19: Engine Oil

    7DK-093 Full 5 “F” Empty 6 “E” 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...
  • Page 20 This could result in overfilling and damage to the engine. 9 Be sure no foreign material enters the crank- case. 3 Correct level Recommended engine oil: å Kohler 10W-30, SAE 10W-30 or 10W-40 700-119 ∫ SAE #30 ç SAE #20 0˚C 25˚C...

  • Page 21: Pre-Operation Check

    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 9 Check operation. 9 If necessary, consult a Kohler portable dealer. 33 590 03 KohlerPower.com...

  • Page 22: Operation

    AE00846 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.
  • Page 23 4. Turn the engine switch (Red) to “7” (ON). 4 “7” (ON) 7DK-039 5. Pull the choke knob fully out. 5 Choke knob The choke is not required to start a warm engine. Push the choke knob in to the original position. 7DK-040 6.

  • Page 24: Stopping The Engine

    7. After the engine starts, warm up the engine until the engine does not stop when the choke knob is returned to the original position. 6 Original position 7PB-042 When starting the engine, with the economy control switch ON, and there is no load on the generator: 9 in ambient temperature below 0 °C (32 °F), the engine will run at the rated r/min (4,500 r/min) for 5 minutes to warm up the engine.

  • Page 25: Connection

    5. Turn the fuel cock knob to OFF. 3 OFF 7DK-045 6. Turn the fuel tank cap air vent knob to OFF after the engine has completely cooled down. 4 OFF 7DK-092 AE00839 Connection Alternating Current (AC) WARNING Be sure any electric devices are turned off before plugging them in.

  • Page 26: Battery Charging

    1. Start the engine. 2. Plug in to AC receptacle. 7PB-043 3. Make sure the AC pilot light is on. 1 AC pilot light 7DK-048 4. Turn the economy control switch to “I” (ON). 2 “I” (ON) 5. Turn on any electric devises. 7DK-049 The economy control switch must be turned to “3”...
  • Page 27 To restart charging the battery, turn the DC protector on by pressing its button to “I” (ON). If the DC protector turns off again, stop charging the battery immediately and consult a Kohler portable dealer. 33 590 03 KohlerPower.com...
  • Page 28 “I” (ON) “3” (OFF) 9 Follow instructions in the owner’s manual for the battery to determine the end of battery charging. 9 Measure the specific gravity of electrolyte to 7PB-052 determine if the battery is fully charged. At full charge, the electrolyte specific gravity is between 1.26 and 1.28.

  • Page 29: Operating Range Of Dc Power Supply

    Operating range of DC power supply (exclusively for charging 12 V battery) This power source is designed to charge batteries up to 40 Ah that are half-discharged. Do not charge bat- teries of a higher capacity than 40 Ah. 12 V battery The time required for recharging a battery varies depending on the discharge level of the battery.

  • Page 30: Application Range

    Otherwise, generator damage may occur. 0.4–0.75 Power factor 0.8–0.95 (Efficiency 0.85) Rated voltage 12 V PRO 2.0 iS –1,600 W –1,280 W –544 W Rated current 9 “–” means below. 9 Application wattage indicates when each device is used by itself.

  • Page 31: High Altitude Operation

    4000 ft. (1219 meters). If you operate your engine at altitudes above 4000 ft. (1219 meters) consistently, have your local Kohler portable dealer per- form the necessary carburetor modification. This engine should be operated in its origi- nal configuration below 4000 ft.

  • Page 32: Periodic Maintenance

    The most impor- tant points of generator inspection, adjustment, and lubrication are explained on the fol- lowing pages. WARNING If you are not familiar with maintenance work, have a Kohler portable dealer do it for you. AE00403 Maintenance chart WARNING Stop the engine before starting maintenance work.
  • Page 33 *2 ..The air filter element needs to be cleaned more frequently when using in unusually wet or dusty areas. ★ ..Since these items require special tools, data and technical skills, have a Kohler portable deal- er perform the service.

  • Page 34: Spark Plug Inspection

    5. Check the spark plug type and gap. a Spark plug gap Standard spark plug: 33 132 02-S (Kohler) Spark plug gap: 760-001a 0.6–0.7 mm (0.024–0.028 in) The spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specifi- cation.

  • Page 35: Carburetor Adjustment

    8. Install the cover and tighten the screws. AE00431 Carburetor adjustment The carburetor is a vital part of the engine. Adjusting should be left to a Kohler portable dealer with the pro- fessional knowledge, specialized data, and equipment to do so properly. AE00412...
  • Page 36 This could result in overfilling and damage to the engine. 7DK-033 9 Be sure no foreign material enters the crank- case. 5 Correct level Recommended engine oil: å Kohler 10W-30, SAE 10W-30 or 10W-40 700-006a ∫ SAE #30 0˚C 25˚C ç SAE #20 å...

  • Page 37: Air Filter

    9. Install the O-ring and the oil filler cap. 10. Install the cover and tighten the screws. 6 Screw 7 Cover 7PB-030 AE01084 Air filter 1. Remove the screws, and then remove the cover. 1 Screw 2 Cover 7PB-030 2. Remove the screw and then remove the air filter case cover.

  • Page 38: Muffler Screen And Spark Arrester

    Recommended oil: Foam-air-filter oil engine oil (See page 15) 6. Insert the foam element into the air filter case. NOTICE The engine should never run without the foam ele- ment; excessive piston and cylinder wear may result. Be sure the foam element sealing surface matches the air filter so there is no air leak.
  • Page 39 2. Loosen the muffler cap bolt and then remove the muffler cap and muffler screen. 3 Muffler cap bolt 4 Muffler cap 5 Muffler screen 7DK-063 3. Use a flathead screw driver to pry the spark arrester out from the muffler. 7DK-064 4.

  • Page 40: Fuel Tank Filter

    8. Install the muffler screen and muffler cap, and then tighten the muffler cap bolt. Muffler cap bolt tightening torque: 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) 9. Install the muffler cover and tighten the muffler 7DK-068 cover screws. AE00471 Fuel tank filter WARNING Never use gasoline while smoking or in the vicini- ty of an open flame.

  • Page 41: Storage

    AE00601 STORAGE Long term storage of your machine will require some preventive procedures to guard against deterioration. AE01056 Drain the fuel 1. Turn the engine switch to “5” (STOP). 1 “5” (STOP) 2. Remove the fuel tank cap and fuel tank filter. 7DK-044 Extract the fuel from the fuel tank into an approved gasoline container using a commercially...
  • Page 42 4. Turn the fuel tank cap air vent knob and fuel cock knob to ON. 3 ON 4 ON 5. Start the engine and leave it run until it stops. 7DK-035 The engine stops in approximately 20 minutes time by running out of fuel. 9 Do not connect with any electrical devices.

  • Page 43: Engine

    Engine Perform the following steps to protect the cylinder, pis- ton ring, etc. from corrosion. 1. Remove the spark plug, pour about one table- spoon of engine oil (See page 15) into the spark plug hole and install the spark plug. Recoil start the engine by turning over several times (with igni- tion off) to coat the cylinder walls with oil.

  • Page 44: Troubleshooting

    AE00512 TROUBLESHOOTING Engine won’t start 1. Fuel systems No fuel supplied to combustion chamber. 2 No fuel in tank ..Supply fuel. 7DK-091 2 Fuel in tank ..Fuel tank cap air vent knob and fuel cock knob to ON. 1 ON 2 ON 2 Clogged fuel line ..
  • Page 45 7DK-039 7DK-041 Poor spark 2 Spark plug dirty with carbon or wet ..Remove carbon or wipe spark plug dry. 2 Faulty ignition system ..Consult a Kohler porta- ble dealer. 791-001d AE00515 Generator won’t produce power 2 Safety device (DC protector) to OFF ···· Press the DC protector to ON.

  • Page 46: Air Filter Element

    Replace or Clean the spark adjust gap. plug. Does not spark Clean Check the following. O Clogged 9 Fuel line clogging replace. Engine does not start. 9 Air filter element clogging. Consult a Kohler portable dealer. KohlerPower.com 33 590 03...

  • Page 47: Specifications

    AE00701 SPECIFICATIONS AE00702 Dimensions Unit PRO 2.0 iS Overall length mm (in) 490 (19.3) Overall width mm (in) 280 (11.0) Overall height mm (in) 445 (17.5) Dry weight kg (lb) 20 (44) AE00704 Engine Unit PRO 2.0 iS Type Air cooled 4-stroke gasoline OHV...

  • Page 48: Consumer Information

    The machine serial number is stamped in the location as shown. 1 Machine serial number Keep a record of serial number for refer- 7PB-073 ence when ordering parts from a Kohler portable dealer. Serial No. Spec. No. PA-PRO 2.0 iS-3001 7PB-XXXXXX KohlerPower.com...

  • Page 49: Exhaust Emission Control System And Components

    The acronyms conform to the latest version of the SAE’s recommended practice docu- ment J1930, “Diagnostic Acronyms, Terms, and Definitions For Electrical/Electronic System”. It is recommended that these items be serviced by a Kohler portable dealer. 33 590 03 KohlerPower.com...

  • Page 50: Wiring Diagram

    AE00751 WIRING DIAGRAM 7DK-10 Color code 1 Sub coil p Oil level gauge 2 DC coil Black 3 Main coil Brown 4 DC rectifier Green 5 DC protector (breaker) Blue 6 Twin Tech (parallel Orange running terminal) 7 DC receptacle White 8 AC pilot light Yellow...
  • Page 52 PRINTED IN CHINA 2014.01 !

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