ALLPOWER APG3202 User manual

T

Preface
Thank you for purchasing this ALL-Power Generator, We are proud of our
products and have designed this unit for years of safe, reliable service,
This manual will instruct you in the proper operation and service of your All-Power
generator, Please read this manual prior to using the generator to insure safe and
proper operation, At all times, follow the instructions to keep your generator in the
best working condition and to extend its life, Should you have any comments or
problems, please contact us at 888-896-6881 and we will direct you to an
authorized parts and service center, Unless there was concealed damage, do not
take this unit back to the retailer where you purchased it, We will work with you to
answer any questions and solve any problems,
This manual addresses the general operation of this unit, As products and their
operation can change, this manual is intended only for use with this specific
model and does not refer to any other models offered by our company,
Please pay particular attention to the warning and caution indicators both within
this manual and on the unit itself,
(,_WARNING ] A warning label indicates that severe personal injury or
Jeven death may occur if you do not follow the
instructions,
E,Ac u lo.1 A caution label indicates that either serious personal
injury or equipment damage may result if instructions
are not followed,
The All-Power diesel generator will perform safely and to specification if operated
according to the following instructions, Failure to do so may result in serious
personal injury and/or equipment damage, If you do not understand the contents
of this instruction manual, contact All-Power America, at 626-961-5640 for
further clarification,

Warning:
1. Prevent the threat of fire
oNever add fuel while the engine is running,
o Wipe off any spilled fuel with a clean cloth before starting,
o Keep all explosive and flammable items safely away from the generator,
oMaintain adequate ventilation with at least three feet of clear space
on all sides of the generator from buildings and other pieces of
equipment,
o NEVER operate this unit in a closed room or garage,
o Only operate the generator on a level surface
o Do not store the generator indoors while the engine is still hot,
2. Prevent Inhalation of Exhaust Fumes
3.
4.
o Carbon Monoxide is an odorless gas that can kill .you!
o Do not operate this generator in a confined space where the exhaust
cannot escape, This means:
• Do not use this unit indoors,
• Do not use this unit in a closed garage,
• Do not attempt to vent the exhaust of this unit outdoors while using
the unit indoors,
o Should you experience a headache, ringing in your ears or begin to feel
drowsy, immediately get some fresh air away from the generator,
Prevent being burned
o The muffler and engine body of this generator get very hot when the
engine is operating or shortly thereafter, Do Not Touch these parts or
you may be severely burned,
Prevent Electrical Shocks and Short Circuits
o To avoid electrical shocks or short circuits, do not:
• Touch the unit with wet hands
• Stand in water
• Operate in the rain or place the unit in standing water

o Note:Thisgeneratorisnotwaterproofandthereforeshouldnotbe
placedinrain,snow,standingwateroranyareawheretherecouldbe
waterspray,Operatinga unitin theseenvironmentsmaycause
electricalshortcircuitsthatcancauseelectricalshocks,
oThisgeneratorshouldalsobegroundedtopreventelectricalshocks
fromfaultyappliances,Togroundthisunit,simplyconnectalengthof
heavycopperwirebetweentheunitandagroundsource,
oDoNotpluginanypowercorduntilaftertheunitisoperating,If
equipmentisattachedwhenstartingthegenerator,itmaycausethe
unittomoveresultinginpotentialinjury,
Caution
• Most appliances require more power to start than their rated wattage,
Therefore make certain that you do not overload the generator with too
many appliances,
• Do not exceed the current limit of any of the sockets on the generator,
•Do not connect the generator to a household circuit, The may cause
damage to the generator and also to the wiring in your house as well as
the electrical appliances,
5. Batteries:
• Batteries contain sulfuric acid which can burn your eyes and skin,
Whenever working with a battery, protect your eyes and skin from
exposure to the acid, In case of contact with any acid, act immediately by
thoroughly flushing the affected area with clean cold water and seek
prompt medical attention.
• Batteries also generate hydrogen gas which can be extremely explosive,
Do not smoke or allow flames near a battery, especially while in a
charging mode, Always charge batteries in a fully ventilated area,

Contents
1. Technical Specifications and Data ............................................ 1
2. Configurations ............................................................................ 2
3. Before Starting Your Generator ................................................ 4
4. Starting the Generator ............................................................... 8
5. Operating Your Generator ...................................................... 9
6. Your Generators Capacity ...................................................... 10
7. Stopping Your Generator ....................................................... 14
8. Periodic Maintenance and Testing ........................................ 15
9. Long-Term Storage ................................................................. 19
10. Troubleshooting & Solutions ................................................ 20
11. Generator Parts Diagram ...................................................... 21
12. Limited Warranty ................................................................... 25

1. Technical Specifications and Data
Model APG3202
Rated frequency (Hz) 60
Rated voltage (V) 240/120
Rated current (A) 25/50
Rated output power (kVA) 5.0
Max output power (kVA) 6.5
Rated rotation speed (rpm) 3600
Power factor cosq_ 1
Phase number Single
Pole number 2
self-excitation constant voltage
Excitation Transistorized (AVR)
ATS type without ATS
Alternator type KT5
Structure type Silent type
Fuel tank capacity(L) 16
Continuous running time(hr)(at rated power) 8
Noise level [dBA/7m](zero Ioad_full load) 70
Starter system electric starter/recoil start
0# (summer),- 10# (winter),
Fuel type --35#(chill cold) diesel
Lube oil brand SAE10W30 (above CC grade)
Single cylinder,4-stroke,air-
Engine type cooled,vertical,diesel engine
Bore x stroke(mm) 86x72
Compression ratio 19:1
Engine Power 10HP
Rotation direction(from the flywheel) clockwise
The lowest fuel consumption(g/kw.h) 3600r/min:281

2. Configurations
2.1 Parts name
FUEL FILLER CAP
LIFTING EYE
EXHAUST PIPE
\
LOW OIL PRESSURE
INDICATOR
OUTLET FOR
COOLING AIR
ENGINE STARTER SWITCH
AC OUTPUT
CIRCUIT BREAKER
DC OUTPUT

2.2 Control panel

3. Before Starting Your Generator
3.1 Selection and handling of diesel fuel
•Only use light diesel fuel
• Keep dust and water out of the fuel. Failure to do so will create problems
with the injection pump and nozzles.
• Do not overfill the tank beyond the red plug inside the fuel oil filter. Doing
so can be very dangerous.
Warning:
• Refuel in a well-ventilated area with the engine off.
• Do not smoke or allow open flames or sparks near where you are
refueling or where the fuel is stored.
• Do not overfill the tank. Make sure that the fuel cap is securely tightened
after refueling.
• Do not spill any fuel. If fuel is spilled, make certain that the spilled fuel is
removed before starting the engine.
3.2 Check and refill engine oil
Warning:
• Before every start, make certain that your generator is on a level surface
and then check the oil level.
• The engine may be damaged if it is operated with insufficient oil.
• Too much oil may cause a sudden increase in engine speed also
damaging your generator.
Caution: Your All-Power generator is equipped with a "low oil" warning system. This
system automatically stops the engine when the oil level becomes dangerously
low, preventing major damage to your generator. Do not rely totally on this
system for maintaining proper oil levels, as it only represents an emergency
situation and not a method for checking your generator's oil level.

•Oil Selection
It is very important that you select the proper engine oil to maintain the life and
performance of your generator. If inferior or the wrong weight oil is used, or if your
engine oil is not replaced periodically, there is a risk of major damage to your
engine due to overheating. All-Power recommends CC/CD oil only classified by API.
Choose the applicable viscosity according to your local temperature.
3.3 Servicing the air filter
1. Remove the wing nut from the air
filter cap and then the cover itself.
This will allow you to remove the filter.
Caution:
• Do not wash the filter with
detergent.
• Replace the air filter when it
impedes the flow of air and cannot
be completely cleaned. One
indicator is when the engine
exhaust changes color.
• Never operate the generator
without the air filter.
Reattach the air filter cover and
tighten the wing nut.

3.4 Checking the Generator
1. Make certain that you turn off the
mail1 switch and any other electrical
load before inspecting the generator.
Warning:
• Turn off the main switch
before starting
• The generator must be grounded
to prevent electrical shocks.
Low oil warning lamp
AC output receptacle Ground terminal
2. Operating dual voltage generators.
• Make sure that you use the correct
outlet for the rated voltage of the
device being powered.
Caution:
• The main switch must be in the "on"
position during operation.
• Before starting the engine, either unplug the devices to be powered or
make certain that all of the devices are turned "off". If the switches for the
devices are left in the "on" position and the generator is started the sudden
surge in power can be very dangerous.

3.5 How to open the cabinet door
covers of the generator.
1. Always open the generator cabinet door
and inspect the engine prior to starting
the generator. To do this, simply turn the
lever counterclockwise and raise the
door.
2. Loosen the wing nut of the air cleaner
and inspect the cleaner.
3. Open the wing nut on the cover and
inspect the nozzle cover.
and remove the protective
3.6 Breaking in your new generator
The first 20 hours of operation are required to properly seat your generator's
operating parts. During this period, the following steps must be taken:
• During the initial operation, run the generator at low speed and with nothing
plugged in for a minimum of five minutes,
• Avoid applying any heavy demands to the unit during the break-in period.
All-Power recommends that the engine be operated at 3,000 RPM with no more
than a 50% load for the first 20 hours of operation.

4. Starting the Generator
Warning: Do not plug in tools or devices prior to startingyour generator.
4.1 Electric Starting
1. Starting ( The preparations for electric
starting are the same as for recoil
starting)
• Open the fuel valve
Set the engine speed lever on
"RUN"
ENGINE SPEED LEVER
• Turn the ignition key clockwise to the "START" position removing your
hand from the key as soon as the engine starts. If the engine does not
start in 10 seconds, wait 15 seconds and repeat the process.

2.Battery:Ifthebatteryhasanopencell
design,checkthewaterleveleverymonth.
Ifitislow,refillusingdistilledwateruntil
thecellisfull.Ifthebatteryisasealedunit,
checksforcracksandleaks.
Caution
Ifthedistilledwaterlevelistoolow,theenginemayfailtostartbecausethere
isn'tsufficientbatterypower.Ifthewaterlevelistoohigh,thefluidwillcorrode
surroundingpartsshorteningthelifeofthebattery.Alwaysmaintainthelevelof
distilledwaterattherecommendedlevel.Neverusewellortapwaterasthe
mineralsinthewaterwilldestroyyourbattery.
5. Operating Your Generator
1, Before plugging anything into the
generator, let your generator run
for a minimum of three minutes at
normal speed.
2. If your generator has a "low oil"
light, check to make certain that it
is not illuminated.
Caution
• The low oil warning light is activated by either a low pressure level or an
inadequate amount of oil in the reservoir. When the low oil light is activated,
9

theenginewillautomaticallystop.Ifyouattempttostartthegenerator
withoutaddressingtheproblem,theunitwillnotstart.Whenthe"lowoil"
lightilluminates,checktheoillevelfirsttomakecertainthatthereis
adequateoilinthereservoir.
Donotadjusteithertheenginegovernorboltthatcontrolsenginespeedor
thefuelinjectionboltthatcontrolsfuelmix.Doingsowillaffecttheoverall
performanceofyourgenerator.
5.2 Operational System Checks
• Determine whether there is abnormal sound or vibration
• Determine whether the engine misfires or runs rough.
• Examine the color of the exhaust. If it is too black or too white, shut off your
generator and contact your All-Power service representative.
Caution:
• If your generator has been in operation, the muffler will be extremely hot. Do
Not touch the muffler as you can be severely burned.
• Never refill the fuel tank while the engine is running.
6. Your Generators Capacity
Caution
• Do not attempt to start two or more devices simultaneous. First plug in or
start one device and then the next and then the next.
• Do not use floodlights with other devices.
6.1 AC application
• Make certain that you operate the generator at its rated speed in RPM's. If
this is not done, the AVR or Automatic Voltage Regulator will incorrectly
produce too much voltage shortening the life of the AVR.
• After switching on the air switch, check the voltmeter on the control panel.
The voltmeter should point to 120V +!- 5% for a single phase generator and
230V +!- 5% (50 Hz) for a multiphase generator.
10

• Whenthedualvoltagegeneratorexceedsorisbelowtheselevels,thenthe
"air"switchshouldbeinthe"OFF"position.Ifnotboththegeneratorandthe
devicespoweredbyitcanbedamaged.
• Alwaysconnectdevicestothegeneratorwiththehighestdemanddevice
firstandthenthelesserdemanddevicesafterward.If theoperation
becomesoverloaded,thegeneratorenginewilllagorstopsuddenly.Ifthis
happens,unplugalldevicesimmediately,turnoffthemainswitchonthe
generatorandcheckallsystems.
• Threephasegenerators
• Makecertainthatyoubalanceallthreephasesduringoperation.Stop
theengineandchecktoseeifthegeneratingisoperatingwithin20%of
specification.Iftheengineisnot,reduceyourloadorturnoffthe
generator.
• Thesumoftheloadforeachphasemustbebelowtheoverallrated
load.Inaddition,theoverallcurrentdrawnmustbelessthantheoverall
ratedcurrent.
• ThephasearrangementA,B,C,D(orU,V,W,N)shouldbefromleft-
to-rightorclockwise.
• Ifyouareattemptingtostartthreenon-synchronousmotors,always
startwiththeheaviestdutymotorfirstandthenprogresstothelighter
dutyunits.
Note:Ifoverloadingthecircuittripsthecircuitbreaker,reducetheelectricalload
onthecircuitandthenwaitafewminutesbeforeresumingoperation.
6.2 DC application
1. The DC terminals are only for charging the 12V battery included with your
generator.
2. Set the "air" switch in the "OFF" position while charging the battery. On the
12V output terminals, a charge switch can be installed so that the unit can
be turned on and off as desired.
3. If your generator has an automatic battery with separate leads, make certain
that you disconnect the negative lead while you are charging the battery.
11

Caution
• Identify and connect positive-to-positive and negative-to-negative poles from,
the battery to the engine. Crossing the wires will destroy both the battery
and the electrical components of your generator.
• If you attempt to use a larger battery than recommended you will create
excessive current that will blow the fuse in the generator.
• Do not attempt to operate the generator while it is still connected to the
battery.
• Do not use a 12V battery and AC current at the same time.
Caution
• All lead batteries emit explosive gas when being charged. Keep sparks,
flames and cigarettes away from the battery while charging. To prevent
sparks, always connect the booster cables to the battery first and then to the
generator. When the battery is charged, disconnect the cables from the
generator first.
• Charge the battery in a well ventilated place.
• Unless the battery is sealed, remove the caps from each cell before
charging.
Stop charging if the battery feels extremely hot. If the temperature exceeds
45C or 113F then the battery is too hot.
12

6.3 All electrical appliances, particularly motor driven equipment,
have extremely highly levels of current draw during their start-up
period. The table below provides a quick reference regarding
connecting different types of devices to the generator.
WATTAGE EXAMPLE
_PICAL
TYPE APPLIANCE
STARTINGRATED APPLIANCE STARTINGRATED
xl x!
" Incande-
scent
_emp
•Heating
applian-
ce
•F_uoresc_
eat
lamp
X2 Xl,5
X3-5 X2
,Motor-
driven
equip-
ment
In_ndes_r_t
_amp TV
Fluorescent
lamp
Refrigerator
Electric
fan
incandescent
tamp
100W
Fluorescent
lamp
Refrigerator
i 50W
100VA tOOVA
(W) (W)
80VA 60VA
(W) (W)
300VA
13

7. Stopping Your Generator
Step I: Disconnect all electrical plugs from the generator outlets before turning
off the generator7
Step I1:Turn off the "AIR" switch on the generator.
Step II1: Set the speed level in the "run" position, operating the generator for
about three minutes with nothing plugged in. Note: Do Not stop the generator
without this step, as the operating temperature of the engine will increase thereby
damaging the unit.
Step IV: Depress the "stop" lever
Step V: If the unit has an electric starter, turn the key to the "off" position.
1. Move the fuel lever to the "S" position.
Step VI: Retract the recoil starter handle until you feel resistance. (At this point
both the intake and exhaust valves are closed). Leave the handle in the position
as it prevents damp air from entering the engine and thereby prevents rust from
forming.
Warning:
• Should the engine continue to operate when the speed lever is placed in
the "Stop" position, either turn the fuel valve to the "Close" position or
loosen the nut of the high pressure fuel pipe on the pump side of the
engine. If you do this, remember to tighten it again before attempting to
start the engine.
• Do not attempt to stop the engine with the decompression lever.
• Always make certain that all electrical plugs are removed from the
generator outlets before turning off your generator.
14

8. Periodic Maintenance and Testing
Periodic inspections and service are very important for maintaining your
generator's engine in proper working order. The following chart indicates your
inspection and service frequency. Please keep this chart handy and refer to it as
needed.
Warning:
• Turn off the engine before performing any service. If the engine must be in
operation, only do so in a well ventilated area as the exhaust contains
carbon monoxide which can be fatal.
• After the generator has been operated, remove all dirt and sediments from
the outside cover to prevent corrosion.
___ ! or 20 H_ ! or i00 Hrs
Check andrefil_Ne{ eit °" '
Drain outNei oii .......... _ ................................
Checka_ refitWe_ineoil " " "
Check for oii leakage ............... :..................................
Checkandtightenfasten.....
Repiace engine oii O IO
Clean engine oit fiiter
Replace air cleaner
Clean fuel oil fiiter
Check nozzle
Check fuel pipe
Adjust ciearan_ dintake/
exhaast vanes
Gdndin_.akeiexhaustvanes
Replace piston ring
Check battery e{ectrolyte
3_ckcarbonbrusha_dsiipri_
Checkinsulationresistence
(Sewice more frequently when
'_[x_m0nth
or 500 HrE
i
(Replay)
Everyyearo_
1000Hrs
Eve_ month
[ t
een stored more than
Note:"O" indicates that special tools are required, please contact with agent. 15