Owner`s Manual
Contents
1. Owner s Manual Installation NOTE PRIOR TO POWERING TOOLS AND EQUIPMENT MAKE SURE THE GENERATOR S RATED VOLTAGE WATTAGE AND AMPERAGE CAPACITY IS ADEQUATE TO SUPPLY ALL ELECTRICAL LOADS THAT THE UNIT WILL POWER IF POWERING EXCEEDS THE GENERATOR S CAPACITY IT MAY BE NECESSARY TO GROUP ONE OR MORE OF THE TOOLS AND OR EQUIPMENT FOR CONNECTION TO A SEPARATE GENERATOR Electrical and other permits may be required for the installation of emergency power systems Investigate your local building and electrical codes before installing this unit Installation must be completed by licensed contractors WARNING THE GENERATOR WEIGHS APPROXIMATELY 100 POUNDS USE CARE AND THE PROPER LIFTING OR HOISTING EQUIPMENT WHEN MOVING IT TO THE INSTALLATION LOCATION ALWAYS CONNECT HOIST LINES TO THE FRAME OF THE GENERATOR General Location Make sure to locate and install the generator outdoors where cooling air is readily available Install the generator so that the air inlets and outlets are not blocked by obstructions such as bushes trees or snow drifts Locating it in the path of heavy winds or snowdrifts may require the placement of a barrier for protection In normal weather conditions the air vent should face the prevailing wind direction Install the generator on a concrete slab or other area where rain drainage or flood waters can not reach it Generator placement should allow four feet of access to all sid2. APGG4000 Please read and save these instructions HAVE QUESTIONS OR NEED SERVICE DO NOT RETURN TO STORE PLEASE GALL TOLL FREE 888 896 6881 www allpoweramerica com 4000W Generator Table of Contents Topic Page Limited Warrant Safety Guidelines 5 General Precautions 6 Battery 15 Assembly 16 Operation 17 Spark Plug Service 22 Inspection Cleaning Maintenance and Storage 23 Installation 29 Compliance 31 Specifications 32 General Parts Listing 33 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 WILL NOT BE LIABLE FOR ANY DAMAGE BECAUSE OF FAILURE TO FOLLOW THESE INSTRUCTIONS Owner s Manual Limited Warranty All Power warrants to the original purchaser who uses the product in a consumer application personal residential or household usage that all products covered under this warranty are free from defects in material and workmanship for one year from the date of purchase All products covered by this limited warranty which are used in commercial applications i e income producing are warranted to be free of defects in material and workmanship for 90 days from the date of original purchase Products covered under this warranty include air compressors air tools service parts pressure washers and ge
3. T 8 APA Part No Description APG3012 F 01 JD PIVOT ADJUSTING NUT APG3012 F 02 JD ROCKER ARM PIVOT APG3012 F 03 JD ROCKER ARM APG3012 F 04 JD PIVOT BOLT M8 APG3012 F 05 JD PUSH ROD GUIDE PLATE APG3012 F 06 JD PUSH ROD APG3012 F 07 JD VALVE LIFTER APG3012 F 08 JD CAMSHAFT APG3012 F 09 JD VALVE ROTATOR APG3012 F 10 JD EX VALVE SPRING RETAINER APG3012 F 11 JD VALVE SPRING APG3012 F 12 JD IN VALVE SPRING RETAINER APG3012 F 13 JD IN VALVE APG3012 F 14 JD EX VALVE 4000W Generator Recoil starter system assy APA Part No Description APGG4000 G 01 JD RECOIL STARTER ASSY APG3012 G 02 JD SETTING SCREW APG3012 G 03 JD SPRING RETAINER APG3012 G 04 JD PLATEN SPRING APG3012 G 05 JD STARTER RATCHET APG3012 G 06 JD RETURN SPRING APG3012 G 07 JD RECOIL STARTER REEL APG3012 G 08 JD RECOIL STARTER SPRING APGG4000 G 09 JD RECOIL STARTER CASE COMP APG3012 G 10 JD RECOIL STARTER ROPE APG3012 G 11 JD STARTER KNOB APG3012 G 12 JD FLANGE BOLT M6X8 APG3012 G 13 JD RECOIL STARTER SPACER 39 4000W Generator Fan cover system assy APA Part No Description APGG4000 H 01 JD FAN COVER COMP APG3012 H 02 JD FLYWHEEL SIDE PLATE APG3012 H 03 JD SHROUD APG3012 H 04 JD AIR CLEANER SUPPORT APG3012 H 05 JD FLANGE BOLT M6 X 12 APG3012 H 06 JD FLANGE BOLT M6 X 16 40 4000W Generator Carburetor system assy 3 4 APA Part No Description l APGG4000 I 01 JD CARBURETOR ASSY APG
4. 23 2009 Merrylin Zaw Mon Director Compliance and Innovation Strategies Division Office of Transportation and Air Quality DC electrical Pursuant to Section 213 of Clean Air Act 42 U S C section 7547 and 40 CFR 90 and subject to 12V 83A the terms and conditions prescribed in those provisions this certificate of conformity is hereby issued for the following small non road engine family more fully described in the documentation Gasoline engine required by 40 CFR 90 and produced in the stated model year l This certificate of conformitv covers onlv those new small non road engines which conform in Type areyels ORV air cooled recollistart all material respects to the design specifications described in the documentation required by 40 Displacement 208cc CFR 90 and which are produced during the model year stated on this certificate This certificate oil it 0 63 t 0 6lit of conformity does not cover small non road engines imported prior to the effective date of the capacity 63 quart 0 6liter certificate SMALL NON ROAD ENGINE FAMILY AJDGS 1961GA EPA approved yes It is a term of this certificate that the manufacturer shall consent to all inspections described in 40 CFR 90 126 and 90 506 and authorized in a warrant or court order Failure to comply with the requirements of such a warrant or court order may lead to revocation or suspension of this certificate for reasons specified in 40 CFR 90 It is also a term of this certifi cate that this certifica
5. plugs Grounding provides a low resistance path to carry electricity away from the user in the 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 e 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 Owner s Manual General Precautions cont d Electrical Safety cont d All connections and conduits from the generator to the load must only be installed by trained and licensed ele
6. 3012 l 02 JD CARBURETOR PAPER GASKET APG3012 l 03 JD CARBURETOR INSULATING PLATE APG3012 I 04 JD INTAKE PIPE GASKET 4000W Generator Flywheel system assy APA Part No Description APG3012 J 01 JD FLYWHEEL APG3012 J 02 JD FLANGE BOLT M6 X 25 APG3012 J 03 JD COOLING FAN APG3012 J 04 JD STARTER PULLEY APG3012 J 05 JD FLYWHEEL NUT M16 APG3012 J 06 JD STOP SWITCH CORD APG3012 J 07 JD IGNITION COIL ASSY APG3012 J 08 JD SPARK PLUG CAP ASSY 4000W Generator Control system assy APA Part No Description APG3012 M 01 JD CONTROL UNIT ASSY APG3012 M 02 JD CONTROL BASE COMP APG3012 M 03 JD CONTROL A JUSTING SPRING APG3012 M 04 JD PAN SCREW M5 X 34 APG3012 M 05 JD FLANGE BOLT M6 X 14 APG3012 M 06 JD GOVERNOR SPRING APG3012 M 07 JD THROTTLE RETURN SPRING APG3012 M 08 JD GOVERNOR ROD APG3012 M 09 JD FLANGE NUT M6 APG3012 M 10 JD GOVERNOR ARM BOLT M6 APG3012 M 11 JD GOVERNOR ARM 43 4000W Generator Muffler system assy A 6 a Mi N Co N A 3 kd 6 x 56 4 0 Wi e VN 1 2 APA Part No Description APG3012 N 01 JD MUFFLER STAY COMP APG3012 N 02 JD FLANGE BOLT M8 X 40 APG3012 N 03 JD FLANGE BOLT M6 X 16 APG3012 N 04 JD MUFFLER COMP APG3012 N 05 JD MUFF OUTER PROTECTOR COMP APG3012 N 06 JD FLANGE BOLT M8 X 12 4000W Generator Air cleaner APA Part No Description APG3012 0 01 JD APG3012 O 02 JD APG3012 O 03
7. COME VERV HOT AND COULD DAMAGE THE ENGINE NEVER USE SPARK PLUGS WHICH HAVE AN IMPROPER HEAT RANGE NOTE THE SPARK PLUG MUST BE SECURELY TIGHTENED AN IMPROPERLY USE ONLY RECOMMENDED SPARK PLUS OR EQUIVALENT Owner s Manual Inspection Cleaning and Maintenance WARNING ALWAYS MAKE SURE THE ENGINE POWER SWITCH 2 IS IN ITS OFF POSITION DISCONNECT THE SPARK PLUG WIRE FROM THE ENGINE KN AND ALLOW SUFFICIENT TIME FOR THE ENGINE AND GENERATOR TO COMPLETELY COOL BEFORE PERFORMING ANY INSPECTIONS MAINTENANCE OR CLEANING 23 4000W Generator Fuel Sediment Cup Cleaning The sediment cup prevents dirt or water which may be in the fuel tank from entering the carburetor If the engine has not been run for a long time the sediment cup should be cleaned 1 Turn the fuel valve to the OFF position Remove the sedement cup and O ring 2 Clean the sediment cup and O ring in nonflammable or high flash point solvent 3 Reinstall O ring and sediment cup 4 Turn the fuel valve ON and check for leaks SEDIMENT CUP Owner s Manual Maintenance Guide Periodic maintenance and adjustment is necessary to keep the generator in good operating condition WARNING Exhaust gas contains poisonous carbon monoxide Shut off the engine before performing any maintenance If the engine must be run make sure the areas is well ventilated Before each use inspect the generator Check for L
8. D THRUST WASHER 6mm APG3012 B 10 JD DRAIN PLUG WASHER 10 2mm APG3012 B 11 JD SLIDER WASHER APG3012 B 12 JD BALL BEARING 6205 APG3012 B 13 JD OIL SEAL 25X41 25x6 APG3012 B 14 JD OIL ALERT APG3012 B 15 JD FLANGE NUT M10 and O RING APG3012 B 16 JD GOVERNOR SLIDER APG3012 B 17 JD FLANGE BOLT M6X12 4000W Generator Crankcase cover system assy APA Part No Description APGGA000 C 01 JD CRANKCASE COVER APGG4000 C 02 JD CRANKCASE COVER PAD APG3012 C 03 JD OIL SCALE APG3012 C 04 JD OIL SCALE SEAL APG3012 C 05 JD OIL SEAL 25X641 25X8 APG3012 C 06 JD DOWEL PIN 8X 14 APG3012 C 07 JD FLANGE BOLT M8X28 APG3012 C 08 JD BALL BEARING 6205 35 4000W Generator Crankshaft system assy APA Part No Description APG3012 D 01 JD CRANKSHAFT COMP APG3012 D 02 JD SEMICIRCLE KEY 36 4000W Generator Piston and connecting rod system assy P A T ex E APA Part No Description APGGA000 E 01 JD COMPRESSION RING A APGG4000 E 02 JD COMPRESSION RING B APGG4000 E 03 JD OIL RING A APGG4000 E 04 JD OIL RINGB APG3012 E 05 JD PISTON PIN CLIP APGG4000 E 06 JD PISTON APG3012 E 07 JD PISTON PIN APG3012 E 08 JD CONNECTING ROD APG3012 E 09 JD CONNECTING COVER APG3012 E 10 JD CONNECTING ROD BOLT 4000W Generator Recoil starter system assy i 10 X 2 og ka PON ILO ta ia c RO N ex N 2 14 4 3 a ms 7 ve V 5 N 6 e vt Vv 13
9. E Never run the generator without the air cleaner Rapid engine wear will result 1 Unsnap the air cleaner cover clips remove the air cleaner cover and remove the element 2 Wash the element in a solution of household detergent and warm water then rinse thoroughly or wash in nonflammable or high flash point solvent Allow the element to dry thorughly 3 Soak the element in clean engine oil and squeeze out the excess oil The engine will smoke during initial start up if too much oil is left in the element 4 Reinstall the air cleaner element and the cover breakdown Owner s Manual 4000W Generator Transporting Storage Transporting Storage When transporting the generator turn the engine switch and the fuel valve OFF Keep the generator level to prevent fuel spillage Fuel vapor or spilled fuel may ingite WARNING Contact with a hot engine or exhaust system can cause serious burns or fires Let the engine cool before transporting or storing the generator Take care not to drop or strike the generator when transporting Do not place heavy objects on the generator 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 RECOMMENDED SERVICE PROCEDURE STORAGE TIME TO PREVENT HARD STARTING Less than 1 month No preparation required 1 to 2 months Fill with fresh gasoline and add gasol
10. JD APG3012 O 04 JD APG3012 O 05 JD APG3012 O 06 JD APG3012 O 07 JD AIR CLEANER COVER COMP AIR CLEANER ELEMENT FLANGE NUT M5 AIR CLEANER SEPARATOR AIR CLEANER SEAL AIR CLEANER CASE COMP GASKET 4000W Generator Fuel tank system assy st st APA Part No Description APGG4000 P 01 JD FUEL FILLER CAP COMP APGG4000 P 02 JD FUEL FILTER APGG4000 P 03 JD FUEL TANK COMP APGG4000 P 04 JD FUEL METER ASSY APGG4000 P 05 JD FLAT SCREW APGG4000 P 06 JD APGG4000 P 07 JD APGG4000 P 08 JD APGG4000 P 09 JD APGG4000 P 10 JD APGG4000 P 11 JD APGG4000 P 12 JD FLANGE BOLT AIR DUCT WASHER TANK CUSHION WASHER TANK CUSHION RUBBER FUEL VALVE TUBE CLIP FUEL TUBE 4000W Generator Control box assy APA Part No APGG4000 Q 01 JD APGG4000 Q 02 JD APGG4000 Q 03 JD APGG4000 Q 04 JD APGG4000 Q 05 JD APGG4000 Q 06 JD APGG4000 Q 07 JD APGG4000 Q 08 JD Description ENGINE SWITCH ASSY POWER LAMP CONTROL PANEL COMP 120V RECEPTACLE DC 12V OUTPUT EARTH TERMINAL SCREW CIRCUIT PROTECTOR CIRCUIT PROTECTOR 47 4000W Generator Frame Comp Assy APA Part No APGG4000 R 01 JD APGG4000 R 02 JD APGG4000 R 03 JD APGGA000 R 04 JD APGG4000 R 05 JD APGG4000 R 06 JD APGG4000 R 07 JD APGG4000 R 08 JD APGG4000 R 09 JD APGG4000 R 10 JD APGG4000 R 11 JD APGG4000 R 12 JD APGG4000 R 13 JD Description BOLT REAR COVER NUT FLANGE NUT FLANGE BOLT MUFFLER SUPPORTER U
11. PPER MUFFLER SUPPORTER NETHER BOLT NUT GENERATOR FRAME CONTROL PANEL BOX FRONT COVER SCREW 48 4000W Generator Generator APA Part No Description APGGA000 S 01 JD STATOR COVER APGG4000 S 02 JD STATOR ASSY APGG4000 S 03 JD COOLING FAN APGG4000 S 04 JD BRUSH ASSY APGG4000 S 05 JD TAPPING SCREW APGG4000 S 06 JD GENERATOR STAY APGGA000 S 07 JD NUT 5mm APGGA000 S 08 JD FLANGE BOLT M6X155 APGG4000 S 09 JD AUTO VOLTAGE REG ASSY APGGA000 S 10 JD REAR COVER APGGA000 S 11 JD NUT APGGA000 S 12 JD FLANGE BOLT APGG4000 S 13 JD ROTOR COMP APGG4000 S 14 JD BEARING ASSY APGG4000 S 15 JD PLAIN WASHER APGG4000 S 16 JD FLANGE BOLT M8X227 APGG4000 S 17 JD HEX BOLT M5 X 20 APGG4000 S 18 JD VOLT CHANGE TERMINAL BR AC W APGG4000 S 19 JD PLAIN WASHER 5mm APGG4000 S 20 JD FRONT COVER APGG4000 S 21 JD FLANGE BOLT M8X30 49 4000W Generator Wheel amp Hand Assy APA Part No Description PIN SPLIT WSHER PLAIN WHEEL BAFFLE SHAFT FLANGE BOLT M6X 35 FLANGE NUT M6 RUBBER BOLT FLANGE NUT STANDER FLANGE BOLT M6X 16 APGG4000 T 12 JD NUT APGG4000 T 13 JD HANDLE APGG4000 T 14 JD BOLT APGG4000 T 15 JD BRACKET APGG4000 T 16 JD FLANGE BOLT APGG4000 T 17 JD LOCK PIN 50 Distributed by ALL POWER AMERICA 730 S Epperson Dr City Of Industry CA91748 www allpoweramerica com
12. SCREW AND REMOVE THE ENGINE S OIL DIPSTICK LOCATED AT THE BOTTOM OF THE ENGINE CRANKCASE FILL THE ENGINE S CRANKCASE UNTIL THE OIL LEVEL IS LEVEL WITH THE UPPER MARKED LINE ON THE DIPSTICK THEN SCREW THE DIPSTICK BACK INTO THE OIL FILL HOLE Before Starting the Generator 1 Check that the engine power switch is in its OFF position 2 Before the first use remove the fuel tank cap and fill the fuel tank with unleaded gasoline When fueling be sure that the fuel strainer is in place Replace the fuel tank cap Thereafter check the engine s fuel gauge for the amount of unleaded gasoline in the fuel tank If necessary FUEL LEVEL GAUGE refill the fuel tank with unleaded gasoline the generator must be turned off and cooled down before refilling the fuel tank Use gasoline with a pump octane rating of 90 or higher We recommend unleaded gasoling because it produces fewer engine and spark plug deposits and extends exhaust system life Never use stale or contaminated gasoline or oil gasoline mixture Avoid getting dirt or water in the fuel tank 17 4000W Generator Operation cont d Starting 1 Turn the engine switch to the ON position The engine switch enables and disables the ignition system OFF To stop the engine ON To run the engine 2 The fuel valve is located under the fuel tank When the valve lever is in the ON position fuel is allowed to flow from the fuel tank to the carbureto
13. ctricians 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 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 Personal Safety 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
14. enerator 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 4000W Generator General Precautions cont d 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 when engine parts are moving fast they cannot be seen clearly Nameplate Amps full load Cord Lengths O ft 50 ft 50 ft 100 ft 100 ft 150 ft 150 ft 200 ft Keep access doors on enclosures closed and locked when access is not required 0 5 16AWG 16 AWG 12 AWG 12 AWG When working on or around the generator always wear protective clothing including ANSI 5 1 8 16AWG 14 AWG 10AWG approved safety gloves safety eye goggles and safety hat 8 1 12 14 AWG 12 AWG Do not alter or adjust any part of the generator that is assembled and supplied by the manufacturer 12 1 15 12AWG 10AWG e Alwavs follow and complete scheduled engine and generator maintenance 15 20 10AWG 10AWG E gt 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 vomit
15. es for maintenance Place the generator as close as possible to the electrical tools and equipment being powered to reduce the length of extension cords 4000W Generator Installation cont d Supporting and Mounting Mount the generator on a concrete slab capable of supporting the weight of the generator The slab must extend on all sides beyond the frame by at least one foot Contact a cement contractor for slab specifications if necessary Attach the frame to the concrete slab using 3 8 diameter expansion anchor bolts not supplied Grounding NOTE IT IS RECOMMENDED THAT ONLY A TRAINED AND LICENSED ELECTRICIAN PERFORM THIS PROCEDURE Connect a 6 AWG grounding wire not included from the ground connector 8 on the generator to a grounding rod not included that has been driven at least 24 inches deep into the earth The grounding rod must be an earth driven copper or brass rod electrode which can adequately ground the generator 29 30 s M l 2000W G Owner s Manua Specifications ompliance p AG electrical UNITED STATES ENVIRONMENTAL PROTECTION AGENCY WASHINGTON DC 20460 Current Output 120V AC 27 5A 60Hz 2010 Model Year Certifcate of Conformity e Manufacturer Jiangsu Jiangdong Group Co Ltd Continuous rated Wattage 3 300 e Certificate Number JDG NRSI 10 09 Peak Wattage 4 000 Effective Date 12 23 2009 F ene Outlet Four 120V outlets One 120V twist lock Date Issued 12
16. g of 90 p Hot Components 45 35 3 345 45 T 58h Degrees Fahrenheit WARNING ENGINE AND EXHAUST SYSTEM PARTS BECOME VERY HOT AND REMAIN HOT FOR SOME TIME AFTER THE ENGINE IS RUN WEAR INSULATED GLOVES OR WAIT UNTIL THE ENGINE AND EXHAUST SYSTEM HAVE COOLED BEFORE HANDLING THESE PARTS Power Output 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 IS NOT RESPONSIBLE FOR ANY DIRECT OR INDIRECT DAMAGE CAUSED BY FAILURE TO USE AN APPROVED LINE CONDITIONER 4000W Generator General Precautions cont d Work Area 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
17. gas you cannot see or smell If you can smell the generator exhaust you are breathing CO But even If you cannot smell the exhaust you could be breathing CO NEVER use a generator inside homes garages crawlspaces or other partly enclosed areas Deadly levels of carbon monoxide can build up in these areas Using a fan or opening windows and doors does NOT supply enough fresh air ONLY use a generator outdoors and far away from open windows doors and vents These openings can pull in generator exhaust Even when you use a generator correctly CO may leak into the home ALWAYS use a battery powered or battery backup CO alarm in the home If you start to feel sick dizzy or weak after the generator has been running move to fresh air RIGHT AWAY See a doctor You could have carbon monoxide poisoning WARNING THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS THAT CAN CAUSE LOSS OF CONSCIOUSNESS AND MAY LEAD TO DEATH Gasoline and Oil 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 GASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS KEEP OUT OF REACH OF CHILDREN Gasoline fuel and fumes are flammable and potentially explosive Use proper fuel storage and handling procedures Always have multiple ABC class f
18. ine conditioner 2 months to 1 year Fill with fresh gasoline and add gasoline conditioner Drain the carburetor float bowl Drain the fuel sediment cup 1 year or more Fill with fresh gasoline and add gasoline conditioner Drain the carburetor float bowl Drain the fuel sediment cup Remove the spark plug Put a tablespoon of engine oil into the cylinder Turn the engine slowly with the pull rope to distribute the oil Reinstall the spark plug Change the engine oil After removal from storage drain the stored gasoline into a suitable container and fill with fresh gasoline before starting 27 1 Drain the carburetor by loosening the drain screw Drain the gasoline into a suitable container 4 Gasoline is extremely flammable and is explosive under certain conditions Perform this task in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the area during this procedure DRAIN SCREW 2 Change the engine oil 3 Remove the spark plug and pour about a tablespoon of clean engine oil into the cylinder Crank the engine several revolutions to distribute the oil then reinstall the spark plug 4 Slowly pull the starter grip until resistance is felt At this point the piston is coming up on its compression stroke and both the intake and exhaust valves are closed Storing the engine in this position will help to protect it from internal corrosion Bim B cain
19. ing 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 Noise Prolonged exposure to noise levels above 68 DBA is hazardous to hearing Always wear ANSI approved ear protection when operating or working around the generator when it is running 13 14 G Owner s Manual 4000W Generator Battery Assembly This product does not need a battery Unpacking 1 Remove the generator and loose parts box from the carton 2 Compare the accessory with the inventory list below Loose Parts Wheel kit and handle Check all loose parts against the following list Contact your dealer toll free at 888 896 6881 if any of the loose parts shown are not included with your generator Hardware Check Your Hardware Kit should include 1 Two Handles with bolts nuts pin with chain and brackets 2 One axle shaft with bolts and nuts 3 Two washers 4 Two cotter pins 5 One generator leg with bolts and nuts 6 Two wheels LM A da 99 i 2 5 e L ME B a E L 2 66 66 uu H ku E 15 16 Owner s Manual Operation iet Control Panel Chokelever Handle Oil plug Air filter Recoil Start NOTE THE PARTS LISTED ABOVE ARE HELPFUL FOR LOCATING THE CONTROLS MENTIONED BELOW CAUTION PRIOR TO FIRST USING THE GENERATOR THE ENGINE MUST BE FILLED WITH OIL OF A HIGH QUALITY SAE 10W 30 GRADE ENGINE OIL TO DO SO UN
20. inoperative because of ordinary wear misuse cold heat rain excessive humidity freeze damage use of improper chemicals negligence accident failure to operate the product in accordance with the instructions provided in the Owner s Manual s supplied with the product improper maintenance the use of accessories or attachments not recommended by All Power or unauthorized repair or alterations Repair and transportation costs of merchandise determine not to be defective Costs assoiciated with assembly required oil adjustments or other installation and start up costs Expendable parts or accessories supplied with the product which are expected to become inoperative or unusable after a reasonable period of use Merchandise sold by All Power which has been manufactured by and identified as the product of another company such as gasoline engines The product manufacturer s warranty if any will apply ANY INCIDENTAL INDIRECT OR CONSEQUENTIAL LOSS DAMAGE OR EXPENSE THAT MAY RESULT FROM ANY DEFECTS FAILURE OR MALFUNCTION OF THE PRODUCT IS NOT COVERED BY THIS WARRANTY Some states do not allow the exclusion so it may not apply to you IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you O
21. ire extinguishers nearby Keep the generator and surrounding area clean at all times Owner s Manual 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 General Precautions cont d Gasoline and Oil 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 Fuel Oil Fuel capacity is 4 US gallons 15 L Use regular Oil capacity is 0 63 qt 0 6 L unleaded gasoline with a minium octane ratin
22. nerators All Power will repair or replace at All Power sole option products or components which have failed within the warranty period Service will be schelduled according to the normal work flow and business hours at the service center location and the availibility of replacement parts All decisions of All Power with regard to this limited warranty shall be final This warranty gives you specific legal rights and you may also have other rights which vary from state to state RESPONSIBILITY OF ORIGINAL PURCHASER initial User To process a warranty claim on this product DO NOT return item to the retailer The product must be evaluated by an Authorized Warranty Service Center For the location of the nearest Authorized Warranty Service Center call 888 896 6881 Retain original cash register sales receipt as proof of purchase for warranty to work Use reasonable care in the operation and maintenance of the product as described in the Owner s Manual s Deliver or ship the product to the Authorized Warranty Service Center Freight costs if any must be paid by the purchaser If the purchaser does not receive satisfactory results form the Authorized Warranty Sercive Center the purchser should contact All Power 4000W Generator Limited Warranty cont d THIS WARRANTY DOES NOT COVER Merchandise sold as reconditioned used as rental equipment or floor or display models Merchandise that has become damaged or
23. njury Heart Pacemakers PHYSICIAN S BEFORE USING THIS PRODUCT ELECTROMAGNETIC FIELDS IN CLOSE PROXIMITY TO A HEART PACEMAKER COULD CAUSE INTERFERENCE TO OR FAILURE OF THE PACEMAKER WARNING PEOPLE WITH PACEMAKERS SHOULD CONSULT THEIR 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 4000W Generator General Precautions cont d Installation cont d e 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 e The generator weighs 100lbs approx 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 sh
24. 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 4000W Generator General Precautions cont d Personal Safety cont d Avoid accidental starting Make sure the power switch is in its OFF position and disconnect the spark plug wire 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 Generator Use and Care Make sure the power switch is in its OFF position and disconnect the spark plug wire before making any adjustment changing accessories or
25. onnect the power cord of a 12 VDC powered tool or equipment to the DC Terminals CAUTION MAKE SURE TO CONNECT THE POSITIVE LEAD OF THE POWER CORD TO THE POSITIVE TERMINAL ON THE GENERATOR AND CONNECT THE NEGATIVE LEAD OF THE POWER CORD TO THE NEGATIVE TERMINAL ON THE GENERATOR THE 12V DC IS FOR BATTERY CHARGING ONLY 21 4000W Generator Spark Plug Service In order to service the spark plug you will need a spark plug wrench commercially available Recommended spark plugs NHSP LD F7TC or NGKBPRGES but we recommend our OEM spark plug To ensure proper engine operation the spark plug must be properly gapped and free of deposits 1 Remove the spark plug cap 2 Clean any dirt from around the spark plug base 3 Use a spark plug wrench to remove the spark plug un CM Ti Rue cao N 4 Visually inspect the spark plug Discard it if the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused 5 Measure the plug gap with a feeler gauge Correct as necessary by carefully bending the side electrode The gap should be 0 70 0 80 mm 0 028 0 031in i 0 70 0 80 mm 0 028 0 031 im ml 6 Check that the spark plug washer is in good condition 7 After the spark plug is seated tighten with a spark plug in bv hand to prevent cross threading 8 After the spark plug is seated tighten with a spark plug wrench to compress the washer TIGHTENED SPARK PLUG CAN BE
26. oose screws Misaligned or binding moving parts Cracked or broken parts Damaged electrical wiring Any other condition that may affect safe operation If an engine problem occurs have it checked by a qualified service technician before further use Do not use damaged equipment Before each use make sure the engine s oil and gas levels are adequate If necessary fill the crankcase until the oil level is even with the oil hill hole and or fill the fuel tank Before each use remove all debris with a soft brush rag or vacuum Lubricate all moving parts using a premium quality lightweight machine oil Every 50 hours of use drain the old engine oil and replace with a high a high quality NX SAE 10W 30 grade engine oil Upper Level Every 300 hours of use have a qualified certified technician perform thorough maintenance on the generator and engine For long term storage either drain fuel into suitable container or add a fuel preservative stabilizer not included to prevent fuel 4000W Generator Air cleaner service A dirty air cleaner will restrict air flow to the carburetor To prevent carburetor malfuncion service the air cleaner regularly Service more frequently when operating the generator in extremely dusty areas can cause a fire or explosion Use only soapy water or nonflammable A WARNING Using gasoline or flammable solvent to clean the filter element solvent A NOT
27. ould 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 Owner s Manual General Precautions cont d Mechanical cont d Do not operate the generator with safety guards removed While the g
28. r Be sur to return the fuel valve lever to the OFF position after stopping the engine 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 The choke lever opens and closes the choke valve in the carburetor The CLOSED position enriches the fuel mixture from Choke d starting a cold engine ORC EN The OPEN position provides the correct fuel mixture for operation after starting and for restarting a warm J engine 18 Owner s Manual Operation cont d Starting 4 Operate the Recoil Starter Pull the starter grip lightly until you feel resistance then pull briskly Return the starter grip gently Pulling the starter grip operates the recoil starter to eater crank the engine 5 If the choke has been moved to the CLOSED position to start the engine gradually move it to the OPEN position as the engine warms up Stopping Engine 1 Turn the engine switch to the OFF position 2 Turn the fuel valve lever to the OFF position When the engine is not in use leave the fuel valve in the OFF position to prevent carburetor flooding and to reduce the possibility of fuel leakage 4000W Generator Operation cont d Powering 120 Volt AC Tools And Equipment 1 Prior to powering tools and equipment make sure the generator s rated voltage and amperage capacity 120 VAC 27 5 AMPs is adequate to
29. 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 10 Owner s Manual General Precautions cont d Servicing Maintain labels and name plates on the generator and engine These carry important information If unreadable or missing contact our service center toll free at 888 896 6881 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 i
30. supply all electrical loads that the unit will power If powering exceeds the generator s capacity it may be necessary to group one or more of the tools and or equipment for connection to a separate generator CAUTION ATTEMPTING TO POWER SENSITIVE ELECTRONIC EQUIPMENT WITHOUT THE USE OF AN APPROVED LINE CONDITIONER MAY CAUSE DAMAGE TO THE EQUIPMENT ALL POWER IS NOT RESPONSIBLE FOR ANY DIRECT OR INDIRECT DAMAGE CAUSED BY FAILURE TO USE AN APPROVED LINE CONDITIONER 2 Once the generator is running simply connect the power cords of 120 volt AC powered tools and equipment into the 120 volt AC dual outlets NOTE THE GENERATOR FEATURES AN AC NON FUSE THERMAL PROTECTOR TO PROTECT THE AC CIRCUIT IN CASE OF AN OVERLOAD SHOULD AN OVERLOAD OCCUR THE BREAKER WILL POP 3 Disconnect all electrical powered tools and equipment from the generator s 120 volt AC duel outlets 4 After the engine and generator have completely cooled store generator in a safe clean dry location if not already installed Owner s Manual Operation cont d Powering 12 Volt DC tools and Equipment 1 Prior to powering tools and equipment make sure the generator s rated voltage and amperage capacity 12V DC is adequate to supply all electrical loads that the unit will power If powering exceeds the generator s capacity it may be necessary to group one or more of the tools and or equipment for connection to a separate generator 2 C
31. te Fuel may be revoked or suspended or rendered void ab initio for other reasons specified in 40 CFR Part 90 Type Unleaded gasoline This certificate does not cover small non road engines sold offered for sale or introduced or Capacity 4 gallons delivered for introduction into commerce in the U S prior to the effective date of the certificate Running time 8 hours approx on 1 2 load Fuel gauge included Weight Approximate weight 107 Ibs e m 4000W Generator Cylinder head system assy I c A Mis i vr A T2 PARI wy i 3 AST u 3 5 2 B APA Part No Description A APGG4000 A 01 JD CYLINDER HEAD COMP APG3012 A 02 JD EX VALVE GUIDE APG3012 A 03 JD IN VALVE GUIDE APG3012 A 04 JD VALVE GUIDE CLIP APGG4000 A 05 JD CYLINDER HEAD SEALING PAD APG3012 A 06 JD HEAD COVER COMP APG3012 A 07 JD HEAD COVER PACKING APG3012 A 08 JD TUBE APG3012 A 09 JD HEAD COVER COMP BOLT MX12 APG3012 A 10 JD CARBURETOR STUD BOLT APG3012 A 11 JD EXHAUST PIPE STUD BOLT APG3012 A 12 JD DOWEL PIN 10X16 APG3012 A 13 JD FLANGE BOLT M8X58 APG3012 A 14 JD SPARK PLUG 4000W Generator Cvlinder barrel UI APA Part No Description APGG4000 B 01 JD CRANK CASE APG3012 B 02 JD OIL LEVEL SWITCH ASSY APG3012 B 03 JD GOVERNOR GEAR ASSY APG3012 B 04 JD SLIDER SHAFT APG3012 B 05 JD GOVERNOR ARM SHAFT APG3012 B 06 JD LOCK PIN 8mm APG3012 B 07 JD WASHER APG3012 B 08 JD DRAIN PLUG BOLT APG3012 B 09 J
32. wner s Manual Safety Guidelines 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 Save These Important Safety Instructions Read and understand all of these safety instructions Be sure to retain them for future use WARNING WARNINGS INDICATE A CERTAINTY OR STRONG POSSIBILITY OF PERSONAL INJURY OR DEATH IF INSTRUCTIONS ARE NOT FOLLOWED CAUTION CAUTIONS INDICATE A POSSIBILITY OF EQUIPMENT DAMAGE IF INSTRUCTIONS ARE NOT FOLLOWED A NOTE NOTES GIVE HELPFUL INFORMATION WARNING IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY AND PROPERTY DAMAGE READ AND UNDERSTAND ALL WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT WHEN USING AIR TOOLS BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF PERSONAL INJURY 4000W Generator General Precautions WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SEVERE INJURY OR DEATH RESULT IN DAMAGE TO THE TOOL AND OR THE ITEM YOU ARE WORKING CAUTION FAILURE TO FOLLOW THESE INSTRUCTIONS CAN ALSO ON A DANGER CARBON MONOXIDE Using a generator indoors WILL KILL YOU IN MINUTES Generator exhaust contains high levels of carbon monoxide CO a poisonous
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