Product Manual - Wholesale Solar
Contents
1. OFF to start battery charging 33 590 04 KohlerPower com 20 21 NOTICE Be sure the economy control switch is turned off while charging the battery Be sure to connect the red battery charger lead to the positive battery terminal and connect the black lead to the negative bat tery terminal Do not reverse these positions Connect the battery charger leads to the bat tery terminals securely so that they are not disconnected due to engine vibration or other disturbances Charge the battery in the correct procedure by following instructions in the owner s manual for the battery The DC protector turns m O OFF automati cally if current above the rated flows during battery charging To restart charging the battery turn the DC protector on by pressing its button to I RESET If the DC protector turns off again stop charging the battery immediately and consult a Kohler portable dealer KohlerPower com 33 590 04 33 590 04 762 012 RA AS e Follow instructions in the owner s manual for the battery to determine the end of battery charging e 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 e It is advisable to check the specific gravity of the electrolyte at least once every hour to prevent overcharging the battery Never smoke or make and break connections at the bat2. SERIAL No Serial NO Spec NO PA PRO28i 3001 7VU 24163 70 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 AE00011 Machine identification The machine serial number is stamped in the location as shown Machine serial number TIP Keep a record of serial number for refer ence when ordering parts from a Kohler portable dealer 33 590 04 KohlerPower com 40 AE00751 WIRING DIAGRAM PRO 2 8i Fee Al E po DO L g Le E A O 1 Y kK Y G e p T oe o DO 3 Lat T Ei w L r O ok i je Main coil Pulser coil Color code Sub coil Stepping motor B Black 3 DC rectifier Br Brown Control unit G Green AC pilot light Gy Gray AC receptacle E Blue G F C
3. receptacle O Orange Ground earth terminal R Red 8 Economy control switch Ww White Overload indicator light Y Yellow DC receptacle 2 DC protector Q Engine switch Oil warning light 5 Oil warning unit Oil level gauge 2 Ignition coil Spark plug AC CDI unit 41 KohlerPower com B W Black White G Y Green Yellow W L White Blue 33 590 04 KOHLER PRINTED IN JAPAN 2014 01 0 1x1 A PRINTED ON RECYCLED PAPER 5
4. 10 MOST CLEAN LEAST CLEAN FOR EXTENDED USE Check owner s manual for further details No other adjustments needed amp WARNING e Hot parts can cause severe burns e Do not touch generator while operating or just after stopping e Explosive Fuel can cause fires and severe burns e Do not fill fuel tank while generator is hot or running e Electrical shock can cause injury e Do not touch wires while generator is running e Do not connect generator to a building s electrical system unless using an isolation transfer switch installed by a certified licensed electrician 44 ADVERTENCIA e Las piezas calientes pueden causar quemaduras graves No toque el generador durante el funcionamiento o inmediatamente despu s de pararse e La explosion del carburante puede provocar incendios y quemaduras graves No llene el tanque de combustible mientras el generador est caliente o funcionando Las descargas el ctricas pueden provocar lesiones No toque los cables con el generador en funcionamient e No conecte el generador al sistema el ctrico de un edificio salvo que lo haga a trav s de un conmutador de aislamiento transferencia instalado por un electricista titulado autorizado 7VU 24162 20 NOTICE Use the specified spark plug 33 132 01 S KohlerPower com 33 590 04 793 085 KohlerPower com AE00102 DESCRIPTION Carrying handles shaded 2 Fuel tank 3 Fuel t
5. 26 27 760 023 760 001a Spark plug inspection The spark plug is an important engine components which should be checked periodically 1 Remove the spark plug cap 2 Insert the tool and turn it counterclockwise to remove the spark plug 3 Check for discoloration and remove the carbon The porcelain insulator around the center electrode of spark plug should be a medium to light tan color 4 Check the spark plug type and gap 3 Spark plug gap Standard spark plug 33 132 01 S Kohler Spark plug gap 0 7 0 8 mm 0 028 0 031 in TIP The spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specifi cation 5 Install the spark plug and then tighten it Spark plug tightening torque 18 Nm 1 8 m kgf 13 ft Ibf 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 6 Install the spark plug cap 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 KohlerPower com 33 590 04 33 590 04 700 006a AE00972 Engine oil replacement Avoid draining the engine oil immediately after stopping the engine The oi
6. INFORMATION e This generator is not designed for on board use Do not use it while installed on the vehicle e Do not modify the generator or use it with its parts removed e Do not allow children to operate the generator e Be sure to carry the generator only by its carrying handle s Carrying handle s shaded e Do not place any obstacles on the generator KohlerPower com 33 590 04 AE00072 Exhaust fumes are poisonous e Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poison you cannot see or smell iia e NEVER use inside a home or garage EVEN IF doors and windows are open e Only use OUTSIDE and far away from windows doors and vents AE00075 Fuel is highly flammable and poisonous e Always turn off the engine when refuelling e Never refuel while smoking or in the vicinity of an open flame e Take care not to spill any fuel on the engine or muffler when refuelling e Do not leave the generator inside the vehicle or in the trunk e If you swallow any fuel inhale fuel vapor or allow 741 005 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 e 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 e Place the generat
7. filler cap S 2 Correct level 700 110 11 KohlerPower com 33 590 04 oe Ga Recommended engine oil lt ia A Kohler 10W 30 SAE 10W 30 or 10W 40 B SAE 30 C SAE 20 D SAE 10W SAE 10W SAE 20 SAE 30 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 Ground earth terminal 33 590 04 KohlerPower com 12 AE00845 PRE OPERATION CHECK 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 owners 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 e Check fuel level in fuel tank e Refuel if necessary Fuel line e Check fuel hose for crack or damage e Replace if necessary Engine oil See page 11 e Check oil level in engine e If necessary add recommended oil to specified level e Check generator for oil leakage The po
8. 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 KohlerPower com 4 AE00062 TIP necessary EMISSION CONTROL INFORMATION KOHLER THIS ENGINE MEETS U S EPA EXH EVP REGS AND CALIFORNIA EXH EVP SI SORE REGS FOR EMISSION COMPLIANCE PERIOD HOURS EF kikik soe DISPLACEMENT cc EVAP F CARB veo EVAP F EPA tree ECS EM 4 DANGER Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poison you cannot see or smell se a NEVER use inside a home Only use OUTSIDE and or garage EVEN IF doors far away from windows and windows are open door and vents 7CG 24877 00 LOCATION OF IMPORTANT LABELS Please read the following labels carefully before oper ating this generator Maintain or replace safety and instruction labels as The air index of this engine is 3 QUIE 0 2 4 6 8
9. supplying precision equipment electronic controllers PCs electronic computers microcomputer based equipment or battery chargers keep the generator a sufficient distance away to prevent electrical interference from the engine Also ensure that electrical noise from the engine does not inter fere with any other electrical devices located near the generator If the generator is to supply medical equipment advice should first be obtained from the manufacturer a medical professional or hospital Some electrical appliances or general purpose electric motors have high starting currents and cannot therefore be used even if they lie within the supply ranges given in the above table Consult the equipment manufacturer for further advice High Altitude Operation This engine may require a high altitude carburetor kit to ensure correct engine opera tion 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 per form the necessary carburetor modification This engine should be operated in its origi nal configuration below 4000 ft 1219 meters as damage may occur if high altitude carburetor kit is installed and operated below 4000 ft 1219 meters 17 KohlerPower com 33 590 04 AE01001 Connection Alternating Current AC Be sure any electric devices are turned off before plugging them in NOTICE e Be sure all electric devi
10. Check fuel hose for cracks or damage Fuel hose Replace if necessary e Check oil level in engine Engine oil e Replace e Check condition Air filter element e Clean e Check condition Muffler screen e Clean and replace if necessary e Check condition Spark arrester j e Clean and replace if necessary Fuel tank filter e Clean and replace if necessary Fuel strainer e Clean and replace if necessary 25 KohlerPower com 33 590 04 Pre Every Routine operation 6 months 12 months check jor 100 Hr or 300 Hr e Check breather hose for cracks or damage e Replace if necessary Crankcase breather hose e Decarbonize cylinder head Cylinder heag e More frequently if necessary After every 500 e Check and adjust when engine is Valve clearance cold Idle speed e Check and adjust idle speed Recoil starter e Check recoil starter for damage e Check all fittings and fasteners e Correct if necessary Fittings fasteners The point where abnormality was recognized by use 1 Initial replacement of the engine oil is after one month or 20 hours of operation 2 The air filter element needs to be cleaned more frequently when using in unusually wet or dusty areas x Since these items require special tools data and technical skills have a Kohler portable deal er perform the service 33 590 04 KohlerPower com
11. Extension Cord notes nern 4 EXHAUST EMISSION CONTROL LOCATION OF IMPORTANT SYSTEM AND COMPONENTS 38 LABELS coincidan 5 SPECIFICATIONS ocios 39 DESCRIPTION cccsccecccsesseeeseeeeee 6 dE 99 Control panel N 6 ENGNG detain Adie ce 39 Generator ecdesiae 39 CONTROL FUNCTION MS E CONSUMER INFORMATION 40 Oil warning light red eee 7 Sai a Identification number records 40 Recoil starter c ccceceeceeeceeeeeeeeeee 7 Paar O E Machine identification 40 Engine SWItC c ociosa ecc 7 Economy control switch AN 8 WIRING DIAGRAM rada 41 DC os AA 8 PRO 2 Bii eiaeaen nai 41 G F C I Receptacle eee 9 PREPARATION ceeceeeeeeereees 10 A enoe deae 10 Engine Oilarra ee 11 Ground earth terminal 12 PRE OPERATION CHECK 13 Pre operation CNeCK eeeeeeeeees 13 OPERATION oieee 14 Starting the engine ceeeeeeee 14 Application range eccere 16 High Altitude Operation 17 COMMECTION we cseacceeessseiszestieverscareesevee 18 Battery Charging 20 Stopping the engine eeeee 24 PERIODIC MAINTENANCE 25 Maintenance chart eeen 25 Spark plug inspection eee 27 Carburetor adjustment 27 Engine oil replacement 28 Muffler screen and spark arrester 29 A cada a aei 31 33 590 04 KohlerPower com AE00071 SAFETY
12. KOHLER Generator OWNER S MANUAL A Read this manual carefully before operating this machine PRO 2 8 i 7VU 28199 L1 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm KOHLER A Read this manual carefully before operating this machine This manual should stay with this machine if it is sold 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 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 33 590 04 KohlerPower com IMPORTANT MANUAL INFORMATION Particularly important information is distin guished in this manual by the following notations A 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 A WARNING indicates a hazardous sit uation which if not avoided could result in death or seriou
13. ank cap Fuel level gauge Ground earth terminal Oil filler cap Oil drain bolt Recoil starter O Choke knob Fuel cock Air filter case cover 2 Muffler Spark plug AE00103 Control panel Engine switch Economy control switch 3 DC receptacle AC receptacle G FC I receptacle Ground earth terminal DC protector Overload indicator light AC pilot light Oil warning light 704 016 763 084 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 MM If the engine stalls or does not start turn the engine switch to Z 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 Recoil starter The recoil starter is used to start the engine Pull the recoil starter slowly until it is engaged then pull it briskly Recoil starter handle NOTICE e Pull the recoil starter handle straight e Return the recoil starter handle slowly e Do not touch the recoil starter handle while the generator is operating AE00122 Engine switch The engine switch controls the ignition system O 8 ON Ignition circuit is switched on The engine can be started E Q STOP Ignition circu
14. ces including the lines and plug connections are in good condition before connection to the generator e Be sure the total load is within generator rated output e Be sure the receptacle load current is within receptacle rated current 1 Start the engine 2 Plug into the AC receptacle 3 Make sure the AC pilot light green is on O AC pilot light green ONLY E a 1 RESET e B orr re PROTECTOR oa oS 760 022a 33 590 04 KohlerPower com 18 4 Turn the economy control switch to I ON and turn on any electric devices I ON TIP The economy control switch must be turned to O OFF when using electric devices that require a large starting current such as a compressor or a submers ible pump 763 129a AE00788 Overload indicator light red The overload indicator light red comes on when an overload of a connected electrical device is detected the inverter control unit overheats or the AC output volt e age rises The electronic breaker will then activate Ea stopping power generation in order to protect the gener O peser ator and any connected electric devices The AC pilot a O de light green will go off and the overload indicator light O o at red will stay on but the engine will not stop running A 760 021a Overload indicator light red When the overload indicator light comes on and power generation stops proceed as follows 1 Turn off any connected el
15. ectric devices and stop the engine 2 Reduce the total wattage of connected electric devices within the application range 3 Check for blockages in the cooling air inlet and around the control unit If any blockages are found remove them 4 After checking restart the engine TIP AO e The generator AC output automatically resets when the engine is stopped and then restarted e 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 submergible pump However this is not a malfunction 19 KohlerPower com 33 590 04 Battery charging NOTICE e Do not connect a VRLA Valve Regulated Lead Acid battery To charge a VRLA battery a spe cial constant voltage battery charger is required e Do not use AC and DC power at the same time or the generator may be damaged TIP e The generator DC rated voltage is 12 V e Start the engine first and then connect the gener ator to the battery for charging e Before starting to charge the battery make sure that the DC protector is turned I RESET 1 Start the engine 2 Press in the DC protector P RESET E O OFF 3 Connect the red battery charger lead to the posi tive battery terminal 3 Red wire Black wire 4 Connect the black battery charger lead to the negative battery terminal 5 Turn the economy control switch O
16. ended that these items be serviced by a Kohler portable dealer 33 590 04 KohlerPower com 38 AE00701 SPECIFICATIONS AE00702 Dimensions PRO 2 8 i Overall length 487 19 2 Overall width 395 15 6 Overall height 425 16 7 Dry weight 31 66 1 AE00704 Engine PRO 2 8 i Type Air cooled 4 stroke gasoline OHV Cylinder arrangement Inclined 1 cylinder Displacement cm 171 Bore x Stroke mm in 66 0 x 50 0 2 60 x 1 97 Operation hours Hr 6 7 14 7 rated load 1 4 load Fuel Unleaded gasoline Fuel tank capacity L US gal Imp gal 9 7 2 55 2 12 Engine oil quantity L US qt Imp qt 0 6 0 63 0 53 Ignition system CDI Spark plug Type 33 132 01 S Kohler Gap mm in 0 7 0 8 0 028 0 031 Noise level dB Lwa 94 dB A 7 m 65 68 Noise level is measured when the economy control switch is turned to ON Lwa shows the sound power level under the 1503744 satisfied test conditions The noise level in dB A 7 m is the arithmetic mean value in four directions measured 7 meters away from each side of the generator The noise level may vary in different environments AE00707 Generator PRO 2 381 AC Output Rated voltage 120 Rated frequency 60 Rated current 20 8 Rated output 2 5 Safety device Type Electronic DC Output Rated voltage 12 Rated current 10 Safety device Type DC protector 39 KohlerPower com 33 590 04 CONSUMER INFORMATION SERIAL NUMBER MODEL
17. 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 Fuel is highly flammable and poisonous Check SAFETY INFORMATION See page 2 carefully NOTICE Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted sur faces or plastic parts 3 Turn the engine switch to Z ON 8 ON 4 Turn the fuel cock lever to ON ON 5 Start the engine and leave it run until it stops The engine stops in approximately 20 minutes time by running out of fuel TP e Do not connect with any electrical devices unloaded operation e Duration of the running engine depends on the amount of the fuel left in the tank KohlerPower com 36 7VU 004 712 010 37 6 11 Drain the fuel remaining in the carburetor into an approved container by loosening the drain screw on the carburetor float chamber Drain screw Tighten the drain screw Turn the engine switch to Q STOP Turn the fuel cock lever to OFF Tighten further if any screws bolts and nuts are loose Store the generator in a dry well ventilated place with the cover placed over it AE00621 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 oi
18. immediately and consult a Kohler portable dealer KohlerPower com 8 763 105a 763 060a AE00848 G F C I Receptacle The G F C 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 G FC I Ground Fault Circuit Interrupter Reset button 3 Pops out TO REDUCE THE CHANCE OF ELECTRICAL SHOCK e Do not attempt to operate equipment if the ground fault circuit interrupter reset button pops out repeatedly during use e Test the ground fault circuit interrupter during the pre operation checks according to the maintenance instructions on page 33 e Remember that only receptacles labeled GFCI have ground fault circuit interrupter protec tion KohlerPower com 33 590 04 PREPARATION AE00856 Fuel e Fuel is highly flammable and poisonous Check SAFETY INFORMATION See page 2 carefully before filling e Do not overfill the fuel tank otherwise it may overflow when the fuel warms u
19. int where abnormality was recognized by use e Check operation e If necessary consult a Kohler portable dealer KohlerPower com 33 590 04 33 590 04 ae l oe 761 073 700 006a 763 126b 705 037 763 084h AE00955 OPERATION e 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 e Before starting the engine do not connect any electric devices e 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 Correct level AE00989 Starting the engine 1 Turn the economy control switch to O OFF O OFF 2 Turn the fuel cock lever to the ON position ON 3 Turn the engine switch to the ON position ON KohlerPower com 14 4 Pull the choke knob fully out 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 704 016 returned to the original position 7 Push the choke knob back to the original position Original position TIP AO When starting the e
20. ion of the reset button 763 105 O Test button Reset button G F C I Reset Button Position GFO Receptacle Operation after Test Pop Out Correct 763 059 Stay In Incorrect 3 If G F C I operation is correct push in the reset button If the G F C I operates incorrectly consult a Kohler portable dealer Do not operate the generator with a faulty G F C I circuit Electric shock could occur Have the gen erator repaired by a qualified mechanic 33 KohlerPower com 33 590 04 AE00512 TROUBLESHOOTING Engine won t start 1 Fuel systems No fuel supplied to combustion chamber No fuel in tank Supply fuel Fuel in tank Fuel cock lever to ON Clogged fuel line Clean fuel line Foreign matter in fuel cock Clean fuel cock Clogged carburetor Clean carburetor 707 001 oo0oo0o00 705 037a 2 Engine oil system Insufficient O Oil level is low Add engine oil 700 006 wm Electrical systems Engine switch to amp ON and pull the recoil starter E ON Poor spark Spark plug dirty with carbon or wet Remove carbon or wipe spark plug dry y E O Faulty ignition system Consult a Kohler porta T ble dealer 791 001d AE00785 Generator won t produce power O Safety device AC to OFF Stop the engine then restart Safety device DC protector to m O OFF Press to I RESET the DC p
21. it is switched off The engine will not run KohlerPower com 33 590 04 763 124a je eye BATTERY CHARGE a ONLY j I Freser og OVER LOAD 33 590 04 3 A D i Bor SPROTECTOR 769 1980 763 006 AE00787 Economy control switch O P 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 E O OFF When the economy control switch is turned O 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 O 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 l RESET O P RESET Direct current is output This is the default position E O 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
22. l See page 12 into the spark plug hole and reinstall the spark plug only Recoil start the engine by turning over several times with ignition off to coat the cylinder walls with oil Pull the recoil starter until you feel compression Then stop pulling This prevents the cylinder and valve from rusting Clean exterior of the generator and apply a rust inhibitor Store the generator in a dry well ventilated place with the cover placed over it The generator must remain in a vertical position when stored carried or operated KohlerPower com 33 590 04 AE00789 EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS Item Acronym e CARB ASSY LH amp JT scecccssseeseeeees CARB Carburetor CARBURETOR2 e C D I UNIT ASSY amp C D D cesses El Electronic Ignition MAGNETO ASSY amp PLUG SPARK e CRANKCASE1 8 HEAD cceeeeees PCV Positive Crankcase CYLINDER1 Ventilation e AIR FILTER ASSY eccceseeesssseeeseeeees ACL Air Cleaner e MUFF 2 CAP NET WIRE2 ARRESTER SPARK The above items and the corresponding acronyms are provided in accordance with U S EPA REGULATIONS FOR NEW NONROAD SPARK IGNITION NONHANDHELD ENGINES and the CALIFORNIA REGULATIONS FOR 1995 AND LATER SMALL OFF ROAD ENGINES 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 recomm
23. l is hot and should be handled with care to avoid burns 1 Place the generator on a level surface and warm up the engine for several minutes Then stop the engine 2 Remove the oil filler cap Oil filler cap 3 Place an oil pan under the engine Remove the oil drain bolt and gasket so that the oil can be com pletely drained 2 Oil drain bolt 3 Gasket 4 Check the oil drain bolt oil filler cap and O ring Replace them if damaged O ring 5 Install a new gasket and the oil drain bolt and then tighten the bolt Oil drain bolt tightening torque 17 Nm 1 7 m kgf 12 ft Ibf 6 Add engine oil to the correct level NOTICE Be sure no foreign material enters the crankcase Correct level KohlerPower com 28 orc 25 C lt A Kohler 10W 30 SAE 10W SAE 30 741 001 711 067 711 0540 29 Recommended engine oil A Kohler 10W 30 SAE 10W 30 or 10W 40 B SAE 30 C SAE 20 D 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 7 Install the O ring and the oil filler cap AE00443 Muffler screen and spark arrester The engine and muffler will be very hot after the engine has been run Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or repair 1 Loosen the muffler cap bolt and then
24. ngine 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 15 KohlerPower com 33 590 04 AE00812 Application range When using the generator make sure the total load is within rated output of a genera tor Otherwise AC generator damage may occur HE Power factor 0 4 0 75 Efficiency 0 85 PRO 2 8 i 33 590 04 850 W TIP oon means below Rated voltage 12V Rated current 10A e Application wattage indicates when each device is used by itself e The simultaneous usage of AC and DC power is possible but total wattage should not exceed the rated output EX Generator rated output 2 500 VA Frequency Power factor 1 0 AC 2 380 W 0 8 1 880 W DC e Borr e re PROTECTOR As Ge 760 021a 19 for more details Overload indicator light KohlerPower com 120 W 12 V 10 A The overload indicator light comes on when total wattage exceeds the application range See page 16 NOTICE Do not overload The total load of all electrical appliances must not exceed the supply range of the generator Overloading will damage the generator When
25. or in a place where pedestrians or children are not likely to touch the generator 741 006 33 590 04 KohlerPower com 2 e Avoid placing any flammable materials near the exhaust outlet during operation 741 007 e In order to prevent overheating ensure adequate airflow by keeping the machine at least 1 m 3 ft from objects or other equipment e Do not operate the engine with a dust cover or other objects covering it e When covering the generator be sure to do so only after the engine and muffler have completely cooled down AE00083 Electric shock prevention e Never operate the engine in rain or snow e Never touch the generator with wet hands or elec trical shock will occur 741 011 e 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 Ground earth terminal 3 KohlerPower com 33 590 04 33 590 04 AE00088 Connection notes e Avoid connecting the generator to commercial power outlet e Avoid connecting the generator in parallel with any other generator Correct 2 Incorrect AE00091 Connection 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
26. p and expands e After fill the fuel make sure the fuel tank cap is tightened securely 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 707 001 20 N NOTICE e Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfaces or plastic parts e Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts 707 051 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 Fuel level 2 Fuel tank filter 3 Fuel level gauge Bottom edge of the fuel tank filter 33 590 04 KohlerPower com 10 Recommended fuel Unleaded gasoline Fuel tank capacity Total 9 7 L 2 56 US gal 2 13 Imp gal OFP Full 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 Oil filler cap 700 108a 3 Fill the specified amount of the recommended engine oil and then tighten the oil
27. remove the muffler cap and muffler screen Muffler cap bolt Muffler cap Muffler screen 2 Use a flathead screw driver to pry the spark arrester out from the muffler KohlerPower com 33 590 04 3 Remove the spark arrester Spark arrester 711 054e 4 Remove the carbon deposits on the muffler screen muffler cap and spark arrester using a wire brush NOTICE When cleaning use the wire brush lightly to avoid damaging or scratching of the muffler screen muf fler cap and spark arrester 5 Check the muffler screen and spark arrester Replace them if damaged 711 050 6 Install the spark arrester TIP Align the spark arrester lump to the hole in the muffler pipe 711 054d Spark arrester lump Hole 7 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 Ibf 711 067a 33 590 04 KohlerPower com 30 31 AE00451 Air filter 1 Remove the screws and then remove the air filter case cover 2 Remove the foam element Screw 2 Air filter case cover 3 Foam element 3 Wash the foam element in solvent and dry it Never use solvent while smoking or in the vicinity of an open flame 4 Oil the foam element and squeeze out excess oil The foam element should be wet but not dripping NOTICE Do not wring out the foam element when squeez ing it This could ca
28. rent to flow through the gener ator which will burn out the coil e Do not connect a VRLA Valve Regulated Lead Acid battery To charge a VRLA battery a spe cial constant voltage battery charger is required KohlerPower com 33 590 04 AE00992 Stopping the engine 1 Turn off any electric devices 2 Turn the economy control switch to the O OFF position O O OFF 763 126b 3 Disconnect any electric devices 33 590 04 4 Turn the engine switch to the Y STOP position O 8 STOP 763 085e 5 Turn the fuel cock lever to OFF OFF 705 038 KohlerPower com 24 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 impor tant points of generator inspection adjustment and lubrication are explained on the fol lowing pages If you are not familiar with maintenance work have a Kohler portable dealer do it for you AE00403 Maintenance chart Stop the engine before starting maintenance work NOTICE Use only Kohler specified genuine parts for replacement Ask an authorized Kohler portable dealer for further attention Pre Every Routine operation 6 months 12 months check or 100 Hr or 300 Hr Spark plu Check condition a e Clean and replace if necessary Fuel e Check fuel level and leakage e
29. rotector 33 590 04 KohlerPower com 34 AE00515 ENGINE DOES NOT START B Turn the engine switch to Z ON then pull the recoil starter and check if the oil warning light flickers Does not flicker Flickers Pull the recoil starter and check the spark plug for spark strength See WARNING A e To prevent FIRE HAZARDS be sure fuel is not present in the spark plug area To prevent FIRE HAZARDS be sure to place the spark plug as far away as possible from the spark plug hole and carburetor area To prevent ELECTRIC SHOCK do not hold spark plug lead with hand while testing Does not spark Check the following e Fuel line clogging ol Clogged e Air filter element clogging OK 35 KohlerPower com E Check engine oil level OK Level low Consult a Kohler portable dealer Add engine oil K Check the spark plug e Type BPR4ES e Gap 0 7 0 8 mm 0 028 0 031 in L Incorrect OK Replace or Clean the spark adjust gap replace S Engine does not start Consult a Kohler portable dealer 33 590 04 JUU 33 590 04 763 085e 763 084h 705 037 704 016 AE00601 STORAGE Long term storage of your generator will require some preventive procedures to guard against deterioration AE00611 Drain the fuel 1 Turn the engine switch to Q STOP O Y STOP 2 Remove the fuel tank cap and
30. s 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 KohlerPower com 851 005 PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE MACHINE TIP OOO e 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 e 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 33 590 04 AE00041 CONTENTS SAFETY INFORMATION 5 1 A A 32 Exhaust fumes are poisonous 2 Fuel tank filter riaient 32 Fuel is highly flammable and G F C Receptacle test 33 poisonous onda 2 TROUBLESHOOTING n 34 Engine arid mutiler may DE NON 2 STORAGE cicoiioidaciniacccnrcic ancianas eid 36 Electric shock prevention 3 Drain the fuel cccseeseeeeeeeeeeee 36 Connection notes eeeeeeeeeneeeees 4 ENJIN siciliana ina deca 37 Connection c ooooccnoccccnoncncononcccnnnnnnonononons 4
31. tery while charging Sparks may ignite the battery gas Battery electrolyte is poisonous and dangerous causing severe burns etc contains sulfuric sul phuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vege table oil Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explo sive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in closed space Always cover eyes when working near bat teries KEEP OUT OF REACH OF CHILDREN KohlerPower com 22 23 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 When the specific gravity of the battery reaches 1 26 to 1 28 charging is complete When charging check the bat tery s specific gravity once an hour The average time for charging a half discharged 40 Ah battery is approximately 5 hours Be sure to check the battery fluid level before charging NOTICE e Do not connect any load to the battery or use the engine starter motor while charging This causes high cur
32. use it to tear Recommended oil Foam air filter oil or engine oil See page 29 5 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 TIP Be sure the foam element sealing surface matches the air filter so there is no air leak 6 Install the air filter case cover and tighten the screws KohlerPower com 33 590 04 AP o 33 590 04 Fuel cock Never use the gasoline while smoking or in the vicinity of an open flame 1 Stop the engine 2 Turn the fuel cock lever to OFF 3 Remove the fuel cock cup gasket and fuel strainer 4 Clean the cup and fuel strainer with gasoline and wipe it off 5 Check the gasket Replace it if damaged 6 Install the fuel strainer gasket and fuel cock cup Be sure the fuel cock cup is tightened securely Fuel cock cup Gasket E Fuel strainer Fuel tank filter Never use the gasoline while smoking or in the vicinity of an open flame 1 Remove the fuel tank cap and fuel tank filter Fuel tank cap Fuel tank filter 2 Clean the fuel tank filter with gasoline Replace it if damaged 3 Wipe the fuel tank filter and insert it 4 Install the fuel tank cap Be sure the fuel tank cap is tightened securely KohlerPower com 32 AE01007 G F C I Receptacle test 1 Start the engine 2 Press the test button then check the posit
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