Generator OWNER’S MANUAL Read this manual carefully before operating this machine. PRO 2.0 iS PRINTED IN CHINA 2014.01 ! (E) 7PB-F8199-L2_Hyoshi.
- Read this manual carefully before operating this machine. This manual should stay with this machine if it is sold. 7PB-F8199-L2_Hyoshi.
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.
IMPORTANT MANUAL INFORMATION Particularly important information is distinguished 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 messages that follow this symbol to avoid possible injury or death. WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
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.........................................
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 1 Carrying handle 7DK-036 9 Do not place any obstacles on the generator. 1 7PB-F8199-L2.indd KohlerPower.
AE00072 Exhaust fumes are poisonous 7DK-001 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. 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 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. 9 When covering the generator, be sure to do so only after the engine and muffler have completely cooled down.
AE00088 Connection notes 1 9 Avoid connecting the generator to commercial power outlet. 9 Avoid connecting the generator in parallel with any other generator. 2 1 Correct 2 Incorrect AE00091 Connection 1 WARNING 2 7DK-012 Before the generator can be connected to a building’s electrical system, a licensed electrician must install an isolation (transfer) switch in the building’s main fuse box.
AE00062 LOCATION OF IMPORTANT LABELS Please read the following labels carefully before operating this machine. TIP Maintain or replace safety and instruction labels, as necessary. 1 2 3 4 6 5 7DK-013 7PB-014 1 5 7PB-F8199-L2.indd KohlerPower.
2 Hot parts can cause severe burns. Do not touch generator while operating or just after stopping. Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while generator is hot or running. 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. Las piezas calientes pueden causar quemaduras graves.
1 DESCRIPTION 5 2 3 6 4 1 2 3 4 5 6 7 Carrying handle Fuel tank cap air vent knob Fuel tank cap Recoil starter Fuel gauge Muffler Oil filler cap 7 7DK-015 1 2 3 7PB-016 4 5 AE00103 Control panel 6 1 2 3 4 7 8 5 6 7 8 w 9 q 7 7PB-F8199-L2.indd 0 7PB-017 KohlerPower.
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. 2 1 7DK-018 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 1 Recoil starter handle NOTICE 9 Pull the recoil starter handle straight.
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). “I” (ON) 1 Direct current is output. (This is the default position.) “3” (OFF) 2 Direct current is not output.
AC pilot light (Green) The AC pilot light comes on when the engine starts and produces power. 1 AC pilot light 1 7DK-048 AE01087 Overload indicator light (Red) 1 7DK-021 The overload indicator light comes on when an overload of a connected electrical device is detected, the inverter control unit overheats, or the AC output voltage rises. Then, the AC protector will trip, stopping power generation in order to protect the generator and any connected electric devices.
Fuel tank cap air vent knob 2 1 7DK-023 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 Fuel cock knob 1 2 7DK-024 The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has two positions.
Twin Tech (Terminal for connecting special cables for parallel running) 7DK-042a 33 590 03 7PB-F8199-L2.indd This is the terminal for connecting special cables for parallel running of two PRO 2.0 iS. The parallel running 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.
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. 7DK-091 1. 2. 3. 4. 5. Stop the engine. Place the generator on a level surface. Remove the fuel tank cap. Check the fuel level. If low, fill the tank with fuel.
6 Recommended fuel: Unleaded gasoline Fuel tank capacity: Total: 4.2 L (1.11 US gal, 0.92 Imp gal) 5 7DK-093 5 “F” 6 “E” Full 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.
4. Fill the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. NOTICE 7PB-033 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 crankcase. 3 Correct level 3 700-119 25˚C 0˚C å Kohler 10W-30 ∂ SAE 10W ç SAE #20 32˚F 15 7PB-F8199-L2.
AE00845 PRE-OPERATION CHECK WARNING If any item in the Pre-operation check is not working properly, have it inspected and repaired before operating the generator. The condition of a generator is the owner’s responsibility. 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 13) 9 Check fuel level in fuel tank. 9 Refuel if necessary.
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 ventilated area. 9 Before starting the engine, do not connect any electric devices. 9 Clean dusts, dirt or water off the receptacle before use. 7PB-047 NOTICE The generator has been shipped without engine oil. Do not start the engine until you have filled it with the sufficient engine oil. Starting the engine 1.
4. Turn the engine switch (Red) to “7” (ON). 4 “7” (ON) 4 7DK-039 5. Pull the choke knob fully out. 5 5 Choke knob TIP The choke is not required to start a warm engine. Push the choke knob in to the original position. 7DK-040 6. Pull the recoil starter slowly until it is engaged, then pull it briskly. WARNING 7DK-041 Be careful to use the recoil starter. In rare cases, the recoil starter handle can be drawn back quickly by the engine kickback.
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 6 Original position 7PB-042 TIP 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.
5. Turn the fuel cock knob to OFF. 3 3 OFF 7DK-045 6. Turn the fuel tank cap air vent knob to OFF after the engine has completely cooled down. 4 OFF 4 7DK-092 AE00839 Connection Alternating Current (AC) WARNING Be sure any electric devices are turned off before plugging them in. NOTICE 9 Be sure all electric devices including the lines and plug connections are in good condition before connection to the generator. 9 Be sure the total load is within generator rated output.
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 1 7DK-048 4. Turn the economy control switch to “I” (ON). 2 “I” (ON) 5. Turn on any electric devises. 2 7DK-049 TIP The economy control switch must be turned to “3” (OFF) to increase engine speed to rated r/min. Battery charging NOTICE Do not connect a VRLA (Valve Regulated Lead Acid) battery. To charge a VRLA battery, a special (constant-voltage) battery charger is required.
2 1. Start the engine. 2. Connect the red battery charger lead to the positive (+) battery terminal. 1 1 Red battery charger lead 2 Black battery charger lead 762-040 3. Connect the black battery charger lead to the negative (–) battery terminal. 4. Turn the economy control switch “3” (OFF) to start battery charging. NOTICE 6v 6v 12v 762-041 33 590 03 7PB-F8199-L2.indd 9 Be sure the economy control switch is turned off while charging the battery.
3 4 3 4 7PB-052 “I” (ON) “3” (OFF) TIP 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 determine if the battery is fully charged. At full charge, the electrolyte specific gravity is between 1.26 and 1.28. 9 It is advisable to check the specific gravity of the electrolyte at least once every hour to prevent overcharging the battery.
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 batteries 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. When the specific gravity of the battery reaches 1.26 to 1.28, charging is complete. When charging, check the battery’s specific gravity once an hour.
AE00812 Application range When using the generator, make sure the total load is within rated output of a generator. Otherwise, generator damage may occur. DC AC Power factor 1 0.8–0.95 0.4–0.75 (Efficiency 0.85) PRO 2.0 iS –1,600 W –1,280 W –544 W Rated voltage 12 V Rated current 8A TIP 9 “–” means below. 9 Application wattage indicates when each device is used by itself. 9 The simultaneous usage of AC and DC power is possible but total wattage should not exceed the rated output.
High Altitude Operation This engine may require a high altitude carburetor kit to ensure correct engine operation at altitudes above 4000 ft. (1219 meters). If you operate your engine at altitudes above 4000 ft. (1219 meters) consistently, have your local Kohler portable dealer perform the necessary carburetor modification. This engine should be operated in its original configuration below 4000 ft. (1219 meters) as damage may occur if high altitude carburetor kit is installed and operated below 4000 ft.
AE00401 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your generator in the safest and most efficient condition possible. The most important points of generator inspection, adjustment, and lubrication are explained on the following 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.
Item Routine Every Preoperation 6 months 12 months check or 100 Hr or 300 Hr Crankcase breather hose • Check breather hose for cracks or damage. • Replace if necessary. Cylinder head • Decarbonize cylinder head. • More frequently if necessary. Valve clearance • Check and adjust valve clearance. ★ Idle speed • Check and adjust idle speed. ★ Recoil starter • Check recoil starter for damage. ★ Fittings / fasteners • Check all fittings and fasteners. • Correct if necessary.
Spark plug inspection The spark plug is an important engine component, which should be checked periodically. 1. Remove the screws, and then remove the cover. 1 2 7PB-030 4 3 1 Screw 2 Cover 2. Remove the spark plug cap and cap, and insert the tool through the hole from the outside of the cover. 3 Spark plug cap 4 Cap 7DK-053 6 3. Insert the handlebar into the tool and turn it counterclockwise to remove the spark plug. 5 5 Tool 6 Handlebar 7DK-054 4. Check for discoloration and remove the carbon.
6. Install the spark plug. Spark plug tightening torque: 20 Nm (2.0 m·kgf, 14 ft·lbf) TIP If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. 7. Install the spark plug cap and cap. 8. Install the cover and tighten the screws. AE00431 Carburetor adjustment The carburetor is a vital part of the engine.
3. Remove the oil filler cap. 3 4 3 Oil filler cap 4 O-ring 7DK-031 4. Place an oil pan under the engine. Tilt the generator to drain the oil completely. 5. Check the oil filler cap and O-ring. Replace them if damaged. 6. Place the generator on a level surface. 7DK-055 7. Add engine oil to the correct level. NOTICE 7DK-033 5 Correct level 5 700-006a 25˚C 0˚C å Kohler 10W-30 ∂ SAE 10W ç SAE #20 32˚F ∫ SAE #30 80˚F 9 Do not tilt the generator when adding engine oil.
9. Install the O-ring and the oil filler cap. 10. Install the cover and tighten the screws. 6 6 Screw 7 Cover 7 7PB-030 AE01084 Air filter 1. Remove the screws, and then remove the cover. 1 1 Screw 2 Cover 2 7PB-030 2. Remove the screw and then remove the air filter case cover. 4 3 Screw 4 Air filter case cover 7DK-061 3 3. Remove the foam element. 5 Screw 6 Air filter case cover 7 Foam element 7 6 4. Wash the foam element in solvent and dry it.
Recommended oil: Foam-air-filter oil or engine oil (See page 15) 6. Insert the foam element into the air filter case. NOTICE The engine should never run without the foam element; excessive piston and cylinder wear may result. TIP Be sure the foam element sealing surface matches the air filter so there is no air leak. 7. Install the air filter case cover in its original position and tighten the screw. 8. Install the cover and tighten the screws.
5 4 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 3 7DK-063 3. Use a flathead screw driver to pry the spark arrester out from the muffler. 7DK-064 4. Remove the spark arrester. 6 6 Spark arrester 7DK-065 5. Remove the carbon deposits on the muffler cap, muffler screen and spark arrester using a wire brush.
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) 7DK-068 9. Install the muffler cover and tighten the muffler cover screws. AE00471 Fuel tank filter 1 WARNING 2 Never use gasoline while smoking or in the vicinity of an open flame. 1. Remove the fuel tank cap and fuel tank filter. 1 Fuel tank cap 2 Fuel tank filter 2. 3. 4. Clean the fuel tank filter with gasoline. Replace it if damaged.
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) 1 7DK-044 2. Remove the fuel tank cap and fuel tank filter. Extract the fuel from the fuel tank into an approved gasoline container using a commercially available hand siphon. Then, install the fuel tank filter and fuel tank cap. WARNING Fuel is highly flammable and poisonous.
4. Turn the fuel tank cap air vent knob and fuel cock knob to ON. 3 ON 4 ON 3 7DK-035 4 7DK-038 5. Start the engine and leave it run until it stops. The engine stops in approximately 20 minutes time by running out of fuel. TIP 9 Do not connect with any electrical devices. (unloaded operation) 9 Duration of the running engine depends on the amount of the fuel left in the tank. 6. Remove the screws, and then remove the cover. 5 Screw 6 Cover 5 6 7PB-030 7.
Engine Perform the following steps to protect the cylinder, piston ring, etc. from corrosion. 1. Remove the spark plug, pour about one tablespoon 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 ignition off) to coat the cylinder walls with oil. 2. Pull the recoil starter until you feel compression. Then stop pulling. (This prevents the cylinder and valves from rusting). 3.
AE00512 TROUBLESHOOTING 7DK-091 Engine won’t start 1. Fuel systems No fuel supplied to combustion chamber. 2 No fuel in tank .... Supply fuel. 2 Fuel in tank .... Fuel tank cap air vent knob and fuel cock knob to ON. 1 ON 2 ON 1 7DK-035 2 Clogged fuel line .... Clean fuel line. 2 Clogged carburetor .... Clean carburetor. 2 7DK-038 2. Engine oil system Insufficient 2 Oil level is low .... Add engine oil. 700-006 39 7PB-F8199-L2.indd KohlerPower.
3. Electrical systems 2 Engine switch to “7” (ON) and pull the recoil starter. 3 “7” (ON) 3 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 portable dealer. 791-001d AE00515 Generator won’t produce power 2 Safety device (DC protector) to OFF ···· Press the DC protector to ON. 1 2 7PB-052 1 2 “I” (ON) “3” (OFF) 2 Safety device (AC) to OFF .... Stop the engine, then restart.
AE00515 A ENGINE DOES NOT START B Turn the engine switch to “7” (ON), then pull the recoil starter and check if the oil warning light flickers. E C H Does not flicker D Check engine oil level. Flickers Pull the recoil starter and check the spark plug for spark strength. (See “WARNING”) F OK Consult a Kohler portable dealer. G Level low Add engine oil. WARNING 9 To prevent FIRE HAZARDS be sure fuel is not present in the spark plug area.
AE00701 SPECIFICATIONS AE00702 Dimensions Overall length Overall width Overall height Dry weight Unit mm (in) mm (in) mm (in) kg (lb) PRO 2.0 iS 490 (19.3) 280 (11.0) 445 (17.5) 20 (44) AE00704 Engine Unit Type Cylinder arrangement Displacement cm3 Bore × Stroke mm (in) Operation hours Hr Fuel Fuel tank capacity L (US gal, Imp gal) Engine oil quantity L (US qt, Imp qt) Ignition system Spark plug: Type Gap mm (in) Noise level* dB / LWA dB (A) / 7 m PRO 2.
CONSUMER INFORMATION SERIAL NUMBER: AE00012 Identification number records Record your serial number in the spaces provided, to assist you in ordering spare parts from a Kohler portable dealer. Also record and keep the serial number in a separate place in case your machine is stolen. MODEL SERIAL No. AE00011 Machine identification The machine serial number is stamped in the location as shown.
AE00789 EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS Item Acronym 9 CARB. ASSY., LH. & JT., . ...................... CARB (Carburetor) CARBURETOR2 9 T.C.I. MAGNETO ASSY. & ...................... EI (Electronic Ignition) PLUG, SPARK 9 CRANKCASE1 & HEAD, ........................ PCV (Positive Crankcase CYLINDER1 Ventilation) 9 AIR FILTER ASSY. .................................. ACL (Air Cleaner) 9 MUFF.
AE00751 WIRING DIAGRAM L W 1 R 5 2 L L O O B L 7 4 O Br O 3 R O G O Br R Br G 6 Br B 8 Br Br R R Br Br R R R 9 t u G G Y R L O R L Br R/W B p Y Y B/W B/W B R/W Br B R/W Br B B Br R/W y L O R B O L Y G/Y q O i o 0 B R B R Y G/Y O G/Y w Y Y L L e O Y r 7DK-10 1 Sub coil 2 DC coil 3 Main coil 4 DC rectifier 5 DC protector (breaker) 6 Twin Tech (parallel running terminal) 7 DC receptacle 8 AC pilot light 9 AC receptacle 0 Economy control switch
- Read this manual carefully before operating this machine. This manual should stay with this machine if it is sold. 7PB-F8199-L2_Hyoshi.
Generator OWNER’S MANUAL Read this manual carefully before operating this machine. PRO 2.0 iS PRINTED IN CHINA 2014.01 ! (E) 7PB-F8199-L2_Hyoshi.
