ALLPOWER APG3002 User manual

3500WATTGENERATOR
NE PASRETOURNER
AUMAGASIN
888.896.6881 888.896.6881 888.896.6881

3.5KWGENERATOR
Table of Contents
Topic Page
Safety Guidelines - Definitions 3
General Precautions 3
Assembly 11
Specification s 13
General Parts Listing 15
Engine Parts Listing 18
Installation 22
Operation 24
Inspection, Cleaning, and Maintenance 27
Compliance 28
Limited Warranty 29
WARNING! READ AND UNDERSTAND ALL SAFETY
PRECAUTIONS IN THIS MANUAL BEFORE OPERATING.
FAILURE TO COMPLY WITH INSTRUCTIONS IN THIS
MANUAL COULD RESULT IN PERSONAL INJURY,
PROPERTY DAMAGE, AND/OR VOIDING OF YOUR
WARRANTY. ALL-POWER AMERICA WILL NOT BE
LIABLE FOR ANY DAMAGE BECAUSE OF FAILURE TO
FOLLOW THESE INSTRUCTIONS.
2

Owner'sManual
SafetyGuidelines- Definitions
This manual contains important information thatyou need to know and
understand in order to protect YOUR SAFETY and to PREVENT
EQUIPMENT PROBLEMS. The following symbols help you recognize this
information. Please read the manual and pay attention to these sections.
WARNING!WARNINGSINDICATEACERTAINTYORSTRONG
POSSIBILITYOFPERSONALINJURYORDEATHIF INSTRUCTIONS
ARE NOT FOLLOWED.
CAUTION: CAUTIONS INDICATE A POSSIBILITY OF
EQUIPMENT DAMAGE IF INSTRUCTIONS ARE NOT
FOLLOWED.
®Note: Notes give helpful information.
WARNING!IMPROPEROPERATIONORMAINTENANCEOFTHIS
PRODUCTCOULDRESULTIN SERIOUSINJURYANDPROPERTY
DAMAGE.READANDUNDERSTANDALL WARNINGSAND OPERATING
INSTRUCTIONSBEFOREUSINGTHISEQUIPMENT.WHENUSINGAIR
TOOLS,BASICSAFETYPRECAUTIONSSHOULDALWAYSBE
FOLLOWEDTOREDUCETHERISKOFPERSONALINJURY
SaveTheseImportantSafety
Instructions!
Read and understand all of these safety instructions. Be
sure to retain them for future use.
GeneralPrecautions
WARNING!FAILURETOFOLLOWTHESEINSTRUCTIONSCAN
RESULTIN SEVEREINJURYORDEATH.
CAUTION: FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN ALSO RESULT IN DAMAGE TO THE TOOL AND/OR THE
ITEM YOU ARE WORKING ON.
3

3.5KWGenerator
CarbonMonoxide
When this tool is running, ensure thatthe area iswell
ventilated. Never run the engine in an enclosed area. Run the
engine in an open area or with an exhaust evacuation system
in an enclosed area.
WARNING!THEEXHAUSTCONTAINSPOISONOUSCARBON
MONOXIDEGASTHATCANCAUSELOSSOFCONSCIOUSNESSAND
MAYLEADTODEATH.
GasolineandOil
This product requires oil and fuel. Attempting to start the
engine without oil will ruin the engine and void the warranty.
Work in well ventilated area. Keep cigarettes, flames or
sparks away from the work area or where gasoline is stored.
WARNING!GASOL/NE/SEXTREMELYFLAMMABLEANDIS
EXPLOSIVEUNDERCERTAINCONDITIONS.KEEPOUTOFREACHOF
CHILDREN.
Gasoline fuel and fumes are flammable and potentially explosive. Use
proper fuel storage and handling procedures. Always have multiple ABC
class fire extinguishers nearby.
Keep the generator and surrounding area clean at all times.
Fuel or oil spills must be cleaned up immediately. Dispose of fluids and
cleaning materials as per any local, state, or federal codes and
regulations. Store oily rags in a covered metal container.
•Never store fuel or other flammable materials near the generator.
•Do not smoke, or allow sparks, flames or other sources of ignition
around the engine and fuel tank. Fuel vapors are explosive.
Keep grounded conductive objects, such as tools, away from exposed,
live electrical parts and connections to avoid sparking or arcing. These
events could ignite fumes or vapors.
Do not refill the fuel tank while the engine is running or while the engine
is still hot. Do not operate the generator with known leaks in the fuel
system.
•Use only engine manufacturer recommended fuel and oil.
4

Owner'sManual
GeneralPrecautions(cont'd)
GasolineandOil(cont'd)
Excessive buildup of unburned fuel gases in the exhaust system can
create a potentially explosive condition. This buildup can occur after
repeated failed start attempts, valve testing, or hot engine shutdown. If
this occurs, open exhaust system drain plugs, if equipped, and allow the
gases to dissipate before attempting to restart the generator.
HotComponents
WARNING!ENGINEANDEXHAUSTSYSTEMPARTSBECOMEVERY
HOTANDREMAINHOTFORSOMETIMEAFTERTHEENGINEISRUN.
WEARINSULATEDGLOVESORWAITUNTILTHEENGINEAND
EXHAUSTSYSTEMHAVECOOLEDBEFOREHANDLINGTHESE
PARTS.
PowerOutput
This generator is not designed to power sensitive electronic equipment
(including computers and medical devices) without the addition of an
approved line conditioner, which is sold separately.
CAUTION: ATTEMPTING TO POWER SENSITIVE
ELECTRONIC EQUIPMENT WITHOUT THE USE OF AN
APPROVED LINE CONDITIONER MAY CAUSE DAMAGE TO
THE EQUIPMENT. NIKOTA USA IS NOT RESPONSIBLE FOR
ANY DIRECT OR INDIRECT DAMAGE CAUSED BY FAILURE
TO USE AN APPROVED LINE CONDITIONER.
WorkArea
• Keep your work area clean and well lit. Cluttered benches
and dark areas invite accidents.
• Do not operate power tools in explosive atmospheres,
such as in the presence of flammable liquids, gases, or
dust. Generators create sparks which may ignite the dust or fumes.
• Keep bystanders, children, and visitors away while operating a
generator. Provide barriers or shields as needed.
5

3.5KWGenerator
ElectricalSafety
Grounded tools must be plugged into an outlet properly
installed and grounded in accordance with all codes and
ordinances. Never remove the grounding prong or modify
the plug in any way. Do not use any adapter plugs.
Grounding provides a low-resistance path to carry electricity away from
the user inthe event of an electrical malfunction.
Double insulatedtools are equipped with a polarized plug where one
blade is wider than the other. This plug fits in a polarized outlet only one
way. If the plug does not fit fully in the outlet, reverse the plug. If it still
does not fit, contact a qualified electrician to install a polarized outlet. Do
not change the plug in any way. Double insulation eliminates the need
for the three-wire grounded power cord and grounded power supply
system.
Avoid body contact with grounded surfaces such as pipes, radiators,
ranges, and refrigerators. There is an increased risk of electric shock if
your body is grounded.
Do not expose generator to rain or wet conditions. Water entering a
generator will increase the risk of electric shock.
Do not abuse the power cord. Keep power cords away from heat, oil,
sharp edges, or moving parts. Replace damaged power cords
immediately. Damaged power cords increase the risk of electric shock.
When operating a power tool outside, use an outdoor extension cord
marked "W-A" or "W". These extension cords are rated for outdoor use,
and reduce the risk of electric shock.
All connections and conduits from the generator to the load must only be
installed by trained and licensed electricians, and in compliance with all
relevant local, state, and federal electrical codes and standards, and
other regulations where applicable.
The generator must be earth-grounded for fixed installations in
accordance with all relevant electrical codes and standards before
operation.
Do not attempt to connect or disconnect load connections while standing
in water, or on wet or soggy ground.
Do not touch electrically energized parts of the generator and
interconnecting cables or conductors with any part of the body, or with
any non-insulated conductive object.
6

Owner'sManual
GeneralPrecautions(cont'd)
ElectricalSafety(cont'd)
Before servicing equipment powered by the generator, disconnect the
equipment from its power input.
Keep all electrical equipment clean and dry. Replace any wiring where
the insulation is cracked, cut abraded or otherwise degraded. Replace
terminals that are worn, discolored, or corroded. Keep terminals clean
and tight.
Insulate all connections and disconnected wires.
Guard against electric shock. Prevent body contact with grounded
surfaces such as pipes, radiators, ranges, and refrigerator enclosures.
PersonalSafety
Stay alert. Watch what you are doing, and use common
sense when operating a generator. Do not use generator
while tired or under the influence of drugs, alcohol, or
medication. A moment of inattention while operating
generators may result in serious personal injury.
• Dress properly. Do not wear loose clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves away from moving parts. Loose
clothes, jewelry, or long hair can be caught in moving parts.
• Avoid accidental starting. Make sure the power switch is in its "OFF"
position, and disconnect the spark plug wWire when not in use.
• Remove adjusting keys or wrenches before turning the generator on. A
wrench or a key that is left attached to a rotating part of the generator
may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times.
• Use safety equipment. Always wear eye protection. Wear ANSI
approved safety impact eye goggles. Dust mask, non-skid safety shoes,
hard hat, or hearing protection must be used for appropriate conditions.
• Do not force the generator. Use the correct generator for your
application. The correct generator will do the job better and safer at the
rate for which it is designed.
• Do not use the generator if the power switch does not turn it on or off.
Any generator that cannot be controlled with the power switch is
dangerous and must be replaced.
7

3.5KWGENERATOR
GeneralPrecautions(cont'd)
GeneratorUseandCare
•Make sure the power switch is in its "OFF" position and disconnect
the spark plug wire before making any adjustment, changing
accessories, or Storing the generator. Such preventive safety
measures reduce the risk of starting the generator accidentally.
• Store idle generators out of reach of children and other untrained
persons. Generators are dangerous in the hands of untrained users.
• Maintain generators with care. Do not use damaged generator. Tag
damaged generators "Do not use" until repaired.
• Check for misalignment or binding of moving parts, breakage of parts,
and any other condition that may affect the generator' s operation. If
damaged, have the generator serviced before using. Many accidents
are caused by poorly maintained generators.
• Use only accessories that are recommended by the manufacturer for
your model. Accessories that may be suitable for one generator may
become hazardous when used on another generator.
Servicing
• Maintain labels and name plates on the generator and engine. These
carry important information. If unreadable or missing, contact
ALL-POWER AMERICA immediately for a replacement.
• Generator service must be performed only qualified repair personnel.
Service or maintenance performed by unqualified personnel could result
in a risk of injury.
• When servicing a generator, use only identical replacement parts.
Follow all appropriate instructions in this manual. Use of unauthorized
parts or failure to follow maintenance instructions may create a risk of
electric shock or injury.
HeartPacemakers
WARNING!PEOPLEWITHPACEMAKERSSHOULDCONSULTTHEIR
PHYSICIAN(S)BEFOREUSINGTHISPRODUCT.ELECTROMAGNETIC
FIELDSIN CLOSEPROXIMITYTOA HEARTPACEMAKERCOULD
CAUSEINTERFERENCETOORFAILUREOFTHEPACEMAKER.
8

Owner'sManual
GeneralPrecautions(cont'd)
Installation
Ensure installation meets all applicable safety, and local and national
electrical codes. Have installation performed by a qualified, licensed
electrician and building contractor.
All electrical work, including the earth-ground connection, should be
completed by a licensed electrician.
Any separate fuel storage or generator supply facility must be built or
installed in full compliance with all relevant local, state, and federal
regulations.
It is recommended to use the generator only in well ventilated outdoor
areas. A running gasoline engine will generate carbon monoxide, a
colorless, odorless gas that, if inhaled, can cause serious injury or
death. If the generator is installed indoors, exhaust fumes must be piped
out of the building using leak-free, heat resistant piping. Pipes and
silencer should not use any flammable materials, nor should they be
installed near the same. Generator exhaust fumes must be within legal
limits and installation must always meet local building codes.
If the generator is installed outdoors, it must be weatherproofed and
should be soundproofed. It should not be run outdoors without
protection to the generator and wiring conduit.
The generator's weight is very heavy. Two or more people should assist
when moving or lifting this product without using the wheels. Never lift
the Generator using the engine or alternator lifting lugs. Connect lifting
equipment to the frame of the generator.
• Before lifting the generator, ensure the lift rigging and supporting
structure are in good condition, and are rated to lift such a load.
• Keep all personnel away from the suspended generator during
relocating.
• The supporting floor/ground surface should be level, and strong enough
to safely hold the weight of the generator. If the floor/grounded surface is
not level, strong cross members should be placed under the full length
of the generator frame at its low side.
•For trailer installation, the generator should be mounted on the center
point of the trailer, over the wheels. The trailer must be capable of
supporting the weight of the generator and all contents (tools, etc.)
• Install sound-and weather-proofing only when it is not raining or snowing
to avoid trapping moisture within the generator's area.
9

3.5KWGenerator
GeneralPrecautions(cont'd)
Mechanical
Always make sure the power switch is in its "OFF" position. Disconnect
the spark plug wire, and allow the engine to completely cool before
carrying out maintenance.
Check for damaged parts. Before using the generator, any part that
appears damaged should be carefully checked to determine that itwill
operate properly and perform its intended function. Check for alignment
and binding of moving parts, any broken parts or mounting fixtures, and
any other condition that may affect proper operation technician.
The generator is designed with guards for protection from moving parts.
In any case, care must still be taken to protect personnel and equipment
from other mechanical hazards when working around the generator.
Do not operate the generator with safety guards removed. While the
Generator is running, do not attempt to reach around the safety guard
for maintenance or any other reason.
Keep hands, arms, long hair, loose clothing, and jewelry away from
moving parts. Be aware that when engine parts are moving fast they
cannot be seen clearly.
Keep access doors on enclosures closed and locked when access is not
required.
When working on or around the generator always wear protective
clothing including ANSI approved safety gloves, safety eye goggles, and
safety hat.
Do not alter or adjust any part of the generator that is assembled and
supplied by the manufacturer.
Always follow and complete scheduled engine and generator
maintenance.
Chemicals
Avoid contact with hot fuel, oil, exhaust fumes, and hot solid surfaces.
Avoid body contact with fuels, oils, and lubricants used in the generator.
If swallowed, seek medical treatment immediately. Do not induce
vomiting if fuel is swallowed. For skin contact, immediately wash with
soap and water. For eye contact, immediately flush eyes with clean
water and seek medical attention.
10

Owner's Manual
General Precautions (cont'd)
Noise
Prolonged exposure to noise levels above 85 dBA is hazardous to hearing.
Always wear ANSI approved ear protection when operating or working
around the Generator when it is running.
Extension Cord
If an extension cord (not included) is used, make sure to use only UL
approved cords having the correct gauge and length according to the
following table:
NameplateAmps (@ Cord Lengths
full load) 0'-50' 50'-100'
0-5 16 16
5.1 -8 16 14
8.1 - 12 14 12
12.1 - 15 12 10
15-20 10 10
100'-150'
12
10
150'-200'
12
Assembly
Wheel and Handle Assembly
Confirm that the following sub-assembly components are included:
• 2 Heavy Duty Wheels
• 6 V-Leg Mounting Bolts/Nuts-M6
• 1 Handle
• 1 Handle Rubber Mount
• 2 V-Leg Cushions
• 2 spring washers-¢ 16
• 2 Wheel Axles
• 1Handle Mounting Bolt/Nut-M8
• 2 Support V-Legs
• 2 Wheel Axle Bolt Mounting Nuts
• ] Handle Rubber Mount Mounting
/Nuts-M6 Bolts
_/1

3.5KW Generator
Assembly (cont'd)
Wheel Assembly
Perform the following tasks to install the heavy duty wheels onto the generator
assembly(see Fig.2 Fig.3):
1. Insert axles through brackets located on frame at bottom of generator and
twist the mounting nuts onto each end of axle.
2. Insert wheels on the opposite end of the axles and twist the mounting nuts untile
the nut is fully seated against wheel hub.
Handle Assembly
Perform the following tasks to install the handle onto the generator frame(see
Fig.1 ):
1. Insert mounting bolt (M8)completely through handle and bracket.
2. Install a mounting nut onto bolt and tighten, making sure handle can
swivel.
V- Leg Support Assembly
Perform the following tasks to install the V-leg support bracket(see Fig.4):
1. Place V- leg support with mounting holes aligned with the mounting
holes in the bottom of the frame.
2. Insert one mounting bolt completely through each mounting hole.
3. Twist mounting screws to catch the threads in the frame mounted
fasteners and tighten until support leg is secure.
/2

Owner's Manual
Fig1
sub-assembly components:
• 1 Handle
• 1Handle Mounting Bolt/Nut-M8
Fig2
sub-assembly components:
• 2 Wheel Axles
• 2 spring washer _])16
Fig3
sub-assembly components:
• 2 Heavy Duty Wheels
• 2 Wheel Axle Mounting Nuts-M16
Fig4
sub-assembly components:
• 2 Support V-Legs
• 4 V-Leg Mounting Bolts/Nuts-M6
/3

Owners Manual
Specifications
AC electrical
Current output 120/240VAC @ 24/12A, 60Hz
Continuous/rated wattage 2,800
Peak wattage 3,500
Outlets Two 120 VAC, 3- spring grounded
One 120/240 VAC, twist and lock, 4- spring grounded
DC electrical
Current output 12VDC @8.3A
Gasoline engine
Horsepower 6.5 HP
Type 4-cycle OHV air-cooled recoil start
Displacement 196cc
Oil capacity 0.63 quart (0.6 liter)
EPA approved yes
Fuel
Type unleaded gasoline
Capacity 4 gallons (15 liters)
Running time 9 hour/full load (approx.)
Fuel gauge included
Weight
Approximate weight 107 Ibs
14

3.5KWGenerator
GeneralPartsListing(Fig.A)
This list is provided for reference purposes only. All repairs and part
replacement should be performed by a qualified technician. Some parts
may not be available as single replacements.
15

Owner'sManual
GeneralPartsListing(cont'd)
# Item Qty.
1 Bolt w/Lock 9
Washer M6x12
2 Engine Power 1
Switch
3 AC Protector 2
4 Voltage-on button 1
5 DC outlet 1
6 120/240V Outlet 1
7 V-leg support 2
8 V-leg cushion 2
9 Wheel Axle 2
10 Lockn ut 4
11 Shock Absorber 4
12 Shock Absorber 4
Foot
13 Lock Washer Nut 4
14 Stator Cover 1
15 Alternator Back 1
Cover
16 Capacitor 1
17 Bolt M5x16 4
18 Rectifier 1
# Item Qty.
19 Bolt M4x16 3
20 Cable Sheath 1
21 Bolt M8x242 1
22 Bolt M6x172 4
23 Bolt M5x20 4
24 ConnectionBoard 1
25 Nut (M5) 4
26 Stator 1
27 Rotor 1
28 Cooling Fan 1
29 Insulation Board 1
30 Fuel Tank 1
31 Fuel Filter 1
32 Seal Ring 1
33 Fuel Tank cap 1
34 Fuel Gauge 1
35 Bolt M6x12 2
36 Lock Bolt M6x12 4
16

3.5KWGenerator
GeneralPartsListing(cont'd)
#Item Qty. # Item
37 Spacer 4 44 120V outlet
38 Rub Washer 4 45 Indicator
39 Bushing 4 46 Grounding bolt
40 Fuel Valve 1 47 Wheel
41 Frame 1 48 Handle grip
42 Contol board 1 49 Rubber mount
43 Engine 1 50 Voltage-selector
Qty.
1
1
1
2
1
1
1
17

Owner's Manual
Engine Parts Listing (Fig. B)
This list is provided for reference purposes only. All repairs and part
replacement should be performed by a qualified technician. Some parts
may not be available as individual replacements.
18

3.5KWGenerator
EnginePartsListing(cont'd)
# Item Qty. # Item Qty.
1 Muffler 1 14 Carburetor 1
Assembly
2 Cylinder Head 4 15 Air Cleaner Case 1
Bolt
3 Cylinder Head 4 16 Air Cleaner Seal 1
Cover Bolt
4 Cylinder Head 1 17 Air Cleaner 1
Cover Separator
5 Lock Nut 2 18 Air Cleaner Cover 1
6 Adjusting Screw 2 19 Air Cleaner 1
Element
7 Rocker Arm 3 20 Bolt M6 4
8 Rocker Arm Bolt 2 21 Choke Lever 1
9 Valve Push Rod 1 22 Carburetor 1
Guiding Board Packing
10 Valve Push Rod 2 23 Stud Bolt M6.109 2
11 Cylinder Head 1 24 Intake Valve 1
12 Carburetor 1 25 Exhaust Valve 1
Shield
13 Carburetor 1 26 Cylinder Head 1
Packing Gasket
19

Owner'sManual
EnginePartsListing(cont'd)
# Item Qty. # Item Qty.
27 Exhaust Pipe 2 42 Starting Case 1
Stud Assy.
28 Spark Plug 1 43 Spiral Spring 1
29 Valve Guide 2 44 Starting Wheel 1
30 Valve Spring 2 45 Circlip 1
31 Rocker Shaft 2 46 Starting Ratchet 2
Circlip
32 Valve Stem 2 47 Friction Plate 1
Protector Screw
33 Cylinder Head 1 48 Cover 1
Cover Packing
34 Governor Spring 1 49 Starter Pulley 1
35 Bolt 1 50 Cooling Fan 1
36 High Tension 1 51 Flywheel 1
Line Magneto
37 Ignition Coil 1 52 Cylinder Block 1
38 Nut (Special 1 53 Speed Control 1
14mm) Lever
39 Starter Ratchet 2 54 Governor Arm 1
Spring
40 Start Rope 1 55 Governor Spring 1
41 Start Handle 1 56 Governor 1
Support
57 Bolt M6x15 2 58 Oil Alert Nut 1
20