Customer Manual 1
Customer Manual 1
OPERATION MANUAL
[GV-3000・GV-3200・GV-7000S・GV-7600S]
We continually seek advancements 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. We reserve
the right to make changes at any time without incurring any obligation
This manual should be considered a permanent part of this generator and should
remain with this generator when resold.
1
SAFETY INFORMATION
OPERATOR RESPONSIBILITY
・ Be knowledgeable of how to use all generator controls, output receptacles and
connections.
・ Know ways to stop the generator operation quickly in case of emergency.
・ Person operating the generator must receive proper training and instructions.
・ No child should operate the generator without proper parental or adult instruction.
・ Keep children away from the area of operation.
・ Make sure the generator is on firm and level surface. Do not place on unstable
surface such as sand or snow. Fuel spillage may occur when generator is tilted or
overturned.
2
・ Take care not to spill any fuel on the engine or
muffler when refueling.
3
・ Keep the machine at least 1 m (3 ft) from
building or other equipment, the engine may
overheat.
4
・ Be sure to ground the generator to the earth.
CONNECTION NOTES
・ Do not connecting the generator to commercial power outlet.
・ Do not connecting the generator in parallel with any other generator.
Correct Correct
Incorrect Incorrect
5
COMPONENT IDENTIFICATION
CHOKE
LEVER
OIL FILLER
AIR FILTER CAP
RECOIL MUFFLER
OIL DRAIN
STARTER GRIP
PLUG
<PANEL>
DC CIRCUIT BREAKER DC CIRCUIT BREAKER
AC CIRCUIT BREAKER AC CIRCUIT BREAKER
ENGINE SWITCH ENGINE SWITCH
GV-3000 GV-3200
PILOT LAMP
PILOT LAMP
VOLTAGE METER
VOLTAGE METER
AC RECEPTACLES DC TERMINALS
AC RECEPTACLES DC TERMINALS
GROUND TERMINAL
GROUND TERMINAL
GV-7000S GV-7600S
6
CONTROLS
ENGINE SWITCH
The engine switch controls the
ignition system to start and stop
the engine.
① ON :
Ignition circuit is switched on.
The engine can be started.
② OFF :
Ignition circuit is switched off.
The engine will not run.
GV-7000S GV-3000 ③ START :
Starting circuit is switched on.
GV-7600S GV-3200
The starter motor starts.
(GV-7000S, GV-7600S)
CAUTION Take your hand off the switch immediately after the engine starts.
RECOIL STARTER
To start the engine, pull slowly on the recoil starter
until it is engaged, then pull it briskly.
FUEL VALVE
Before starting the engine, turn the fuel valve to “ON”
position so the fuel flows from the fuel tank to the
carburetor.
Be sure to return the fuel valve lever to the OFF
position after stopping the engine.
7
CHOKE
When starting a cold engine, turn the choke lever to
CLOSE position.
It can be opened and closed by operating the choke
lever manually.
NOTE
The choke is not required to start a warm engine.
AC CIRCUIT BREAKER
The AC circuit breaker turns off automatically when overload or if there is a short circuit.
Reduce the load to the specified generator rated output if the AC circuit breaker turns
off.
GV-3000・GV-3200
GV-7600S
GV-7000S・GV-7600S
8
DC TERMINALS
The DC terminals may ONLY be used for charging
12V batteries for automotive use.
DC CIRCUIT BREAKER
The DC circuit breaker turns off automatically when
DC charging circuit is overloaded or the battery has
problem.
9
PRE-OPERATION CHECK
NOTE Pre-operation checks should be made each time the generator is used.
ENGINE OIL
Engine oil is a major factor affecting engine performance and service life. Make sure the
engine oil is at the upper level of the oil filler hole. Add oil as necessary.
CAUTION 2-stroke gasoline engine oil or diesel engine oils will damage the engine.
AMBIENT TEMPERATURE
2, Check the oil level by inserting the dipstick into the filler neck without screwing it in.
3, If the level is low, add the recommended engine oil until level can reach the upper
mark on the dipstick. After adding, don’t forget to refit and screw the oil dipstick tight.
CAUTION
The generator has been shipped without engine oil. Fill with oil or it will not start.
10
REFUELING
Check the fuel level gauge and make sure there is sufficient fuel in the fuel tank.
Recommended fuel: Unleaded gasoline
EMPTY
CLOSE
OPEN
WARNING
・ Fuel is highly flammable and poisonous. Check “SAFETY INFORMATION”
(See page 3) carefully before refueling.
・ Do not fill above the top of the fuel filter, or it may overflow when the fuel heats
up and expands.
・ Wipe any spilled fuel immediately.
・ After refueling, make sure the tank cap is tightened securely.
GROUND (Earth)
Make sure to ground the generator to prevent
electrical shock. Connect the ground lead between
GROUND
TERMINAL the ground terminal and the ground.
Check “SAFETY INFORMATION” on page 6.
11
BATTERY
WARNING
・ If improper operation, the battery may be explosive and may potentially hurt
persons nearby. Keep the fire and inflammable materials far away from the
battery.
・ The battery will release the explosive gas, please keep the fire far away from it.
Keep a good air ventilation condition when battery is being charged or used.
NOTE
・ Clamp the red wire to the positive (+) terminal first, then the black wire to the
negative (-) terminal of the battery. Do not reverse these positions. Otherwise
serious damage may be caused to the generator set and battery.
・ Please read the enclosed user’s manual for proper usage of the battery you have
purchased.
12
OPERATION
CAUTION
The generator has been shipped without engine oil. Fill with oil or it will not start.
NOTE Before starting the engine, do not connect any electric devices.
1. Turn the AC circuit breaker to “OFF” position. The generator may be hard to start if a
load is connected.
2. Turn the fuel valve lever to the ON position.
3. To start a cold engine, move the choke lever to the CLOSED position. To restart
a warm engine, leave the choke lever in the OPEN position.
4. Turn the engine switch to the ON position.
5. Pull slowly on the recoil starter until it is engaged, then pull it briskly.
NOTICE
Do not allow the starter grip to snap back against the engine. Return it gently to prevent
damage to the starter or housing.
6. Turn the choke lever back to the “OPEN” position.
・ Take your hand off the switch immediately after the engine starts.
・ If the engine fails to start, release the switch, wait a few seconds, and then try
again. Each attempt should be as short as possible to preserve the battery. Do
not crank the engine more than 10 seconds on any one attempt.
13
APPLICATION RANGE
Most motorized appliances require more than their rated wattage for start-up.
Please use the list below as reference.
AC DC
NOTE
Application wattage is indicated when each device is used by itself.
CAUTION
Substantial overloading will switch off the AC circuit breaker. Exceeding the time limit for
maximum power operation or slightly overloading the generator may not switch the AC
circuit breaker OFF, but will shorten the life of the generator.
Limit operation requiring maximum power to 30 minutes.
Maximum power is:
GV-3000: 2.2kVA, GV-3200: 2.5kVA, GV-7000S:5.5kVA, GV-7600S:6kVA
For continuous operation, do not exceed the rated power.
Rated power is:
GV-3000: 2kVA, GV-3200: 2.3kVA, GV-7000S:5kVA, GV-7600S:5.5kVA
The total power requirements (VA) of all appliances connected must be considered.
Appliance and power tool manufacturers usually list rating’s information near the model
number or serial number.
NOTE
Some precision equipment is voltage sensitive and may require a more uniform voltage
supply than portable generators provide. Examples include some medical equipment,
personal computers and some inverters that sense peak and RMS voltage values.
Consult the precision equipment vendor before relying on any portable generator to
provide power to such equipment.
14
CONNECTION
WARNING
A battery can explode if you do not follow the correct procedure, seriously injuring
anyone nearby. Keep all sparks, open flames, and smoking materials away from the
battery.
DC CIRCUIT
BREAKER The terminal colored red is positive terminal (+),
and colored black is negative terminal (-).
Do not reverse these positions.
15
Alternating Current (AC) OPERATION
CAUTION
・ Be sure all electric devices including the lines and plug connections are in
good condition before connecting to the generator.
・ Be sure any electric devices are turned off before plugging in.
・ Be sure the total load is within generator rated output.
・ Be sure the receptacle load current is within receptacle rated current.
・ Limit maximum power operation to 30 minutes.
CAUTION
If an overloaded circuit causes AC circuit breaker to turn OFF reduce the
electrical load on the circuit, wait a few minutes and then reset AC circuit breaker.
In an emergency:
Turn the engine switch to the “OFF” position.
In normal use:
1. Turn off any electric devices.
2. Turn the AC circuit breaker to the OFF position.
3. Disconnect any electric devices.
Disconnect the DC battery charging cables.
4. Turn the fuel valve to “OFF” position.
When using the generator at a high altitude, more than 1000m (3300ft)
NOTE
above sea level, consult an authorized generator dealer.
16
PERIODIC MAINTENANCE
MAINTENANCE CHART
The engine must be properly maintained to ensure its operation be safe, economy and
zero-failure, as well as eco-friendly.
In order to keep your gasoline engine in good working condition, it must be periodically
serviced. Please follow this Maintenance Schedule:
Engine oil
Check-Refill √
Replace √ √
Check √
Air filter element Clean √
Replace √
Deposit cup
(if applicable) Clean √
Spark Plug Check-adjust √*
Idling(if applicable)** Check-adjust √
Valve clearance** Check-adjust √
Fuel tank & fuel filter** Clean √
Fuel line Check Every 2 years (change if neccessary)
Cylinder head,
Clean up carbon** <225cc, Every 125hrs
piston
≧225cc, Every 250hrs
* These items should be replaced if replacement needed.
** These items should be maintained and repaired by our authorized dealer, unless the owner has
appropriate tools and are proficient with mechanical maintenance.
● If the gasoline engine frequently work under high temperature or high load,
NOTE change the oil every 25 hours.
● If the engine frequently work under dusty or other harsh circumstances, clean the air filter element
every 10 hours; If necessary, change the air filter element every 25 hours.
● The maintenance period and the exact time (hour), the one which comes first should govern.
● If you have missed the scheduled time to maintain your engine, do it as soon as possible.
Stop the engine before servicing. Put the engine in horizontal position
WARNING
and remove the spark plug cap to prevent the engine from starting.
Do not operate the engine in an unventilated room or other enclosed area, be sure to keep
good ventilation in working area. The exhaust from the engine contains toxic CO,
inhaling of it would cause shock, unconsciousness and even death.
17
ENGINE OIL REPLACEMENT
O-RING 1. Place the machine on a level surface and warm
up the engine for several minutes.
Then stop the engine.
CAUTION
Be sure no foreign material enters the crankcase.
18
AIR FILTER
A dirty air cleaner will restrict air flow into the carburetor. To prevent carburetor
malfunction, service the air cleaner regularly. Service more frequently when operating
the generator in extremely dusty areas.
CAUTION Do not wring out the element. This could cause to tear.
NOTE
Be sure the element sealing surface matches the air filter so there is no air leak.
CAUTION The engine should never run without the element, excessive
piston and cylinder wear may result.
CARBURETOR ADJUSTMENT
The carburetor is vital part of the engine. Adjusting should be left to a dealer with
professional knowledge.
19
FUEL VALVE
1. Stop the engine.
2. Turn the fuel valve to “OFF”.
3. Remove the sediment cup, fuel filter and O-ring.
4. Clean the cup with solvent and wipe it off.
5. Check the fuel filter and O-ring. Replace if damaged.
6. Reinstall the O-ring, fuel filter and sediment cup.
FUEL FILTER
O-RING
SEDIMENT CUP
20
STORAGE
Before storing the unit for an extended period:
1. Be sure the storage area is free of excessive humidity and dust.
2. Service according to the table below:
21
Storage Procedure
1 . Drain the fuel tank, the carburetor and the fuel sediment cup.
WARNING
Gasoline is highly flammable and explosive. You can be burned or
seriously injured when handling fuel.
DRAIN
PLUG
22
TROUBLESHOOTING
23
Generator won’t produce power:
NO
Is the AC circuit breaker ON? Turn the AC circuit breaker ON.
YES NO
DEFECTS
Check the electrical appliance Take the generator to
or equipment for any defects. KOSHIN dealer
YES
NO
Is the DC circuit protector on? Turn the DC circuit breaker ON.
YES
Take the generator to
KOSHIN dealer
24
SPECIFICATIONS
Dimensions
Model GV-3000 GV-3200 GV-7000S GV-7600S
Length 615mm (24.2in) 697mm (27.4in)
Width 445mm (17.5in) 525mm (20.7in)
Height 457mm (18in) 530mm (20.9in)
Dry weight 43kg 86kg
Engine
Model KOSHIN K210 KOSHIN K420
Engine Type 4-Stroke, overhead valve, single cylinder
Displacement 212cc 420cc
〔Bore×Stroke〕 170×55mm 190×66mm
Compression Ratio 8.5 : 1
Engine Speed 3,000rpm 3,600rpm 3,000rpm 3,600rpm
Starting Method Recoil Recoil + Electric starter
Cooling System Forced air
Ignition System Transistorized magneto
Oil capacity 0.6L 1.1L
Fuel Tank Capacity 12.6L 22.6L
Spark Plug LG F6TC (NGK BP6ES)
Generator
AC Rated Voltage 220V 230V 220V 220V 230V 220V
Rated Frequency 50Hz 60Hz 50Hz 60Hz
Rated Ampere 9.1A 8.7A 10.5A 22.7A 21.7A 25A
Rated Output 2kVA 2.3kVA 5kVA 5.5kVA
Maximum Output 2.2kVA 2.5kVA 5.5kVA 6kVA
Rated Power
1
Factor (Cosφ)
DC Rated 8.3A / 12V / 100VA
Control Panel
Receptacle
25
WIRING DIAGRAM
GV-3000
26
GV-3200
27
GV-7000S
28
GV-7600S
29
Installation Instructions
Wheel Kit and Handle Assembly
30
MEMO
31
High Performance Gasoline Generator
OPERATION MANUAL
[GV-3000・GV-3200・GV-7000S・GV-7600S]