ALLPOWER APG3008 User manual

3500WATTGENERATOR

3.5KWGenerator
Tableof Contents
Topic Page
Safety Guidelines - Definitions 3
General Precautions 4
Specifications 13
General Parts List 14
Engine Parts List 17
Installation 21
Operation 23
Inspection, Cleaning, and Maintenance 27
Compliance 29
Limited Warranty 30
WARNING!READANDUNDERSTANDALLSAFETYPRECAUTIONSIN
THISMANUALBEFOREOPERATING.FAILURETOCOMPLYWITH
INSTRUCTIONSIN THISMANUALCOULDRESULTIN PERSONAL
INJURY,PROPERTYDAMAGE,AND/ORVOIDINGOFYOUR
WARRANTY.ALLPOWERAMERICAWILLNOTBELIABLEFORANY
DAMAGEBECAUSEOFFAILURETOFOLLOWTHESEINSTRUCTIONS.
2

Owner'sManual
SafetyGuidelines- Definitions
This manual contains important information that you 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
POSSIBILITYOFPERSONALINJURYORDEATHIFINSTRUCTIONS
ARE NOTFOLLOWED.
CAUTION: CAUTIONS INDICA TEA POSSIBILITY OF
EQUIPMENT DAMAGE IF INSTRUCTIONS ARE NOT
FOLL0 WED.
Note: Notes give helpful information.
WARNING!IMPROPEROPERATIONORMAINTENANCEOFTHIS
PRODUCTCOULDRESULTIN SERIOUSINJURYANDPROPERTY
DAMAGE.READAND UNDERSTANDALL WARNINGSANDOPERATING
INSTRUCTIONSBEFOREUSINGTHISEQUIPMENT.WHENUSINGAIR
TOOLS,BASICSAFETYPRECAUTIONSSHOULDALWAYSBE
FOLLOWEDTOREDUCETHERISKOFPERSONALINJURY
SaveThese Important Safety
Instructions!
Read and understand all of these safety instructions. Be
sure to retain them for future use.
3

3.5KWGenerator
GeneralPrecautions
WARNING!FAILURETOFOLLOWTHESEINSTRUCTIONSCAN
RESULTINSEVEREINJURYORDEATH.
CAUTION: FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN ALSO RESULT IN DAMAGE TO THE TOOL AND/OR THE
ITEM YOU ARE WORKING ON.
CarbonMonoxide
When this tool is running, ensure that the area is well
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
MONOXIDEGAS THATCANCAUSELOSSOFCONSCIOUSNESSAND
MAYLEADTODEATH.
GasolineandOil
This product requires oil and fuel. Attempting to start the I _d t}
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!GASOLINEISEXTREMELYFLAMMABLEANDIS
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.
4

Owner'sManual
GeneralPrecautions(cont'd)
GasolineandOil(cont'd)
•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.
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.
• Use only engine manufacturer recommended fuel and oil.
HotComponents
WARNING!ENGINEANDEXHAUSTSYSTEMPARTSBECOMEVERY
HOTANDREMAINHOTFORSOMETIMEAFTERTHEENGINEIS RUN.
WEARINSULATEDGLOVESORWAft UNTILTHEENGINEAND
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. ALL POWER AMERICA IS NOT RESPON-
SIBLE FOR ANY DIRECT OR INDIRECT DAMAGE CAUSED
BY FAILURE TO USE AN APPROVED LINE CONDITIONER.
5

3.5KWGenerator
GeneralPrecautions(cont'd)
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.
Electrical Safety
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 insulated tools 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.
6

Owner'sManual
GeneralPrecautions(cont'd)
ElectricalSafety(cont'd)
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.
Connect the generator only to a load or electrical system (110/120 volt)
that is compatible with the electrical characteristics and rated capacities
of the generator.
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.
7

3.5KWGenerator
GeneralPrecautions(cont'd)
PersonalSafety(cont'd)
•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.
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.
8

Owner'sManual
GeneralPrecautions(cont'd)
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.
Installation
Ensure installationmeets all applicable safety, and local and national
electrical codes. Have installation performed by a qualified, licensed
electrician and building contractor.
All electrical work, includingthe 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.
9

3.5KWGenerator
GeneralPrecautions(cont'd)
Installation(cont'd)
•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 weighs 1121bs.Two or more people should assist when
moving or lifting this product. 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.
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 it will
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.
10

Owner'sManual
GeneralPrecautions(cont'd)
Mechanical(cont'd)
•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 geenerator
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 iffuel is swallowed. For skin contact, immediately wash with
soap and water. For eye contact, immediately flush eyes with clean
water and seek medical attention.
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.
11

3.5KWGenerator
GeneralPrecautions(cont'd)
ExtensionCord
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:
Nameplate Amps (@
full load)
Cord Lengths
0'-50' 50'-100' 100'-150' 150'-200'
0-5 16 16 12 12
5.1 -8 16 14 10 -
8.1 - 12 14 12
12.1-15 12 10
15- 20 10 10
12

Owner'sManual
Specifications
AC electrical
Current output
Continuous/rated wattage
Peak wattage
Outlet
10/120VAC @ 27.5A, 60Hz
3,000
3,500
two 110/120 VAC, 3-prong
grounded
DC electrical
Current output 12VDC @ 10A
Gasoline engine
Horsepower 6.5
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 3.96 gallons (15 liters)
Running time 7.8 hours (approx.)
Fuel gauge included
Weight
Approximate weight 112 Ibs
13

3.5KWGenerator
GeneralPartsListing
®
®
®
@
®
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.
14

Owner'sManual
GeneralPartsListing(cont'd)
# Item Qty. # Item Qty.
1 Bolt w/Lock 9 19 Bolt M4xl 6 3
Washer M6x12
2 Engine Power 1 20 Cable Sheath 1
Switch
3 Control Panel 1 21 Bolt M8x242 1
4 Voltmeter 1 22 Bolt M6x172 4
5 Circuit Breaker 1 23 Bolt M5x20 4
6 Outlet 2 24 Connection 1
Board
7 DC Terminal 2 25 Nut (M5) 4
8 Ground 1 26 Stator 1
Connector
9 DC Fuse 1 27 Rotor 1
10 Pilot Light 1 28 Cooling Fan 1
11 Shock Absorber 4 29 Insulation Board 1
12 Shock Absorber 4 30 Fuel Tank 1
Foot
13 Lock Washer Nut 4 31 Fuel Filter 1
14 Stator Cover 1 32 Seal Ring 1
15 Alternator Back 1 33 Fuel Tank cap 1
Cover
16 Capacitor 1 34 Fuel Gauge 1
17 Bolt M5x16 4 35 Bolt M6x12 2
18 Rectifier 1 36 Lock Bolt M6xl 2 4
15

3.5KWGenerator
GeneralPartsListing(cont'd)
# Item Qty. # Item Qty.
37 Spacer 4 41 Frame 1
38 Rub Washer 4 42 Switch Box Cover 1
39 Bushing 4 43 Engine 1
40 Fuel Valve 1 44 Spark Arrestor 1
16

Owner'sManual
EnginePartsListing
may not be available as individual re
This list is provided for reference purposes only. All repairs and part
replacement should be performed by a qualified technician. Some parts
)lacements.
17

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 Bolt M6 4
Cover
5 Lock Nut 2 18 Air Cleaner Cover 1
6 Adjusting Screw 2 19 Air Cleaner 1
Element
7 Rocker Arm 3 20 Air Cleaner 1
Separator
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
18

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
19

3.5KWGenerator
EnginePartsListing(cont'd)
# Item Qty. # Item Qty.
59 Plug M10x15 2 71 Camshaft Assy. 1
60 Plug Washer 2 72 Locating Pin 4
61 Oil Alert 1 73 Oil Seal 2
62 Bolt (M6) 2 74 Connecting Rod 2
Bolt
63 Crankshaft 1 75 Connecting Rod 1
Cap
64 Crankshaft Gear 1 76 Connecting Rod 1
65 Oil Dipstick 2 77 Piston 1
66 Oil Dipstick Seal 2 78 Compression 1
Ring Ring l
67 Gear Casing 1 79 Compression 1
Ring II
68 Bolt (M8x35) 6 80 Oil Scraper Ring 1
69 Gear Case 2 81 Piston Pin 1
Packing
70 Bearing 2 82 Piston Pin Circlip 2
20