ACDelco Portable Generator AC G0002 User Manual

use of this generator. Consult a qualified electrician, electrical inspector, and/or the local agency having jurisdiction. Some areas require generators

to be registered with local utility companies. Additional regulations may apply if this generator will be used at a construction site.

IMPORTANT SAFETY INSTRUCTIONS

STOP!

Before using this generator and if you have any questions regarding the hazard and safety notices listed in this manual and/or on this

generator, call 1-866-460-9437, Monday - Friday, 8 AM - 4 PM Central Time.

Carbon Monoxide Gas: When in operation, the exhaust from this generator contains poisonous carbon

monoxide gas. Carbon monoxide gas is both odorless and colorless AND may be present even if you do not

see or smell gas. Breathing this poison gas can lead to headaches, dizziness, drowsiness, loss of

consciousness and eventually death.

• Use this generator ONLY outdoors in non-confined areas.

• Keep at least several feet of clearance on all sides to allow proper ventilation for this generator.

Chemicals: According to the State of California, the exhaust from this generator contains chemicals known to

cause cancer, birth defects, or other reproductive harm.

Flammable Gasoline: This generator may emit highly flammable and explosive gasoline vapors, which can

cause severe burns or even death. A nearby open flame can lead to an explosion even if not directly in contact

with gasoline.

• Do not operate this generator near open flame.

• Do not smoke near this generator.

• Always operate this generator on a firm, level surface.

Gasoline is highly flammable and explosive. Handling fuel can result in serious injury or burns.

• Always shut down this generator before refueling. Refuel in a well-ventilated area. Keep heat, sparks and flame away

while refueling and away from the location where gasoline is stored. Never refuel indoors where gasoline fumes may

reach flames and/or sparks.

• Allow this generator to cool for at least 2 minutes before removing the fuel tank cap. Loosen the cap slowly to relieve

pressure in the fuel tank. Avoid spilling fuel.

• Do not fill the fuel tank above the upper limit line. Gasoline may expand during operation. Do not fill to the top of the

tank.

• Always check for spilled gasoline and immediately wipe it up before starting this generator.

• Empty the fuel tank before storing or transporting this generator.

• Always handle fuel outdoors.

• Before transporting, turn the fuel valve to the "off" position and disconnect the spark plug.

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Powerful Voltage: This generator produces powerful voltage, which can result in electrocution.

• ALWAYS ground this generator before using it. (See “Ground the Generator” section in this manual).

• Only electrical devices should be plugged into this generator, either directly or with an extension cord. NEVER

connect a building electrical system to this generator without a qualified electrician. Such connections must isolate

generator power from utility power and comply with local electrical laws and codes. Failure to comply can create a back

feed into utility lines creating an electrocution hazard, which may result in serious injury or death to utility workers.

Such a back feed may cause this generator to explode, burn and create fires when utility power is restored.

• Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as metal decking or steel work. GFCIs

are available in-line with some extension cords.

• Do not use this generator in wet conditions (rain, snow, active sprinkler system, wet hands, etc.). Always keep this

generator dry and operate it with dry hands.

• Do not touch bare wires or outlets (receptacles).

• Do not allow children or non-qualified persons to operate this generator.

High Temperatures: This generator produces heat when in operation. Temperatures near the exhaust can

exceed 150 Degrees Fahrenheit (65 Degrees Celsius).

• Do not touch hot surfaces. Observe all warning placards on this generator denoting hot surfaces.

• Allow this generator to cool for several minutes after use before touching the engine, muffler or other areas that are

hot during operation and before storing indoors.

• Hot exhaust may ignite some materials. Keep flammable materials away from this generator.

• Keep at least several feet of clearance on all sides of this generator during operation. Do not enclose this generator in

any structure.

Usage: Misuse of this generator can damage it or shorten its life.

• Use this generator only for its intended purpose.

• Operate this generator only on a dry, level surface.

• Allow this generator to run for several minutes before connecting any electrical devices.

• Promptly turn off any malfunctioning devices and disconnect them.

• Do not operate an excessive number of electrical devices in excess of the wattage capacity of this generator.

• Do not turn on electrical devices until after they are connected to this generator.

• Turn off all connected electrical devices before stopping this generator.

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In addition to the previously described safety information, familiarize yourself with all safety and hazard placards on this generator.

–

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PACKAGE CONTENTS

The following items are supplied with this ACDelco Model AC-G0002 3500 Surge Watts / 3000 Running Watts Portable Generator. Verify that all

items are included.

STOP!

If there are missing items, call 1-866-460-9437, Monday - Friday, 8 AM - 4 PM Central Time for customer service. DO NOT RETURN THIS

GENERATOR TO THE RETAILER.

Item List:

NEMA L14-30 plug for connecting 240 Volt electrical devices

Set of 2 DC connector wires for connecting 12 Volt automotive-type batteries

Spark plug wrench

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GENERATOR COMPONENTS

Observe the locations and functions of the various components and controls of this generator.

(1) 120/240 Volt AC Outlet - Used for connecting electrical devices

that run on 120 and/or 240 Volt, 60 Hz, single phase, AC current.

(2) Ground Terminal - Used for connecting grounding wires to

properly ground this generator.

(8) Engine Switch - Used for starting/stopping the engine.

(9) Recoil Starter - Pull-cord for starting the engine.

(10) Fuel Filter Cup - Traps dirt and water from the fuel prior to

entering the engine.

(3) 120 Volt AC Outlet - Used for connecting electrical devices that

run on 120 Volt, 60 Hz, single phase, AC current.

(4) Voltage Selector - Used to select between 120 or 240 Volt output.

(5) Circuit Breaker- Reset switch that protects this generator from

electrical overload.

(6) 12 Volt DC Outlet - Only used for charging 12 Volt automotive-

type batteries.

(7) Oil Filler/Dipstick Cap - Location for checking and filling the

engine crankcase oil.

(11) Fuel Valve - Allows gasoline to pass into the engine.

(12) Air Filter - A removable, cleanable, sponge-like element that limits

the amount of dirt pulled into the engine.

(13) Choke Lever - Adjusts the amount of air allowed into the engine.

(14) Fuel Gauge - Indicates the amount of gasoline remaining in the

fuel tank.

(15) Fuel Tank Cap - Access to the fuel tank for adding gasoline.

(16) Volt Meter - A gauge indicating the voltage output.

(17) Muffler - Reduces the engine noise level.

(18) Spark Plug - Provides ignition to the engine.

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PREPARING THE GENERATOR FOR USE

Using this Generator for the First-Time

STOP!

The following section describes the required steps for preparing this generator for the first use. Failure to correctly perform these steps

can damage this generator and/or shorten its life. If still unsure about how to perform any of these steps after reading this section, call

1-866-460-9437 Monday - Friday, 8 AM - 4 PM Central Time for customer service.

If this generator is being used for the first time, the following few steps are required to prepare it for operation:

Step 1 - Add Oil

This generator requires engine oil to function. Engine oil is a major factor affecting engine performance and service life. When new from

the package, this generator contains no oil in the engine crankcase. The correct quantity of oil is equal to the oil capacity of the engine crankcase

and is 20 fluid oz (0.6 L) for this ACDelco Model AC-G0002 3500 Surge Watts / 3000 Running Watts Portable Generator. Add the correct quantity of

oil before operating this generator for the first time. When replenishing oil for subsequent use of this generator, always determine that this generator

has the correct quantity of oil.

Model AC-G0002 Oil Capacity (fluid oz./L)

Model AC-G0002 Oil Type Recommended

20 / 0.6

SAE-30

To add oil:

1. Confirm that this generator is on a level surface.

2. Unscrew the oil filler/dipstick cap from the engine as illustrated in Figure 1.

3. Using a funnel, add high detergent motor oil to fill the engine crankcase to the correct quantity as stated above. SAE-30 oil is recommended for

general, all-temperature use. When the engine crankcase is full, the oil level should reach the lower lip of the oil filling opening as illustrated in

Figure 2.

4. Replace the oil filler/dipstick cap.

Figure 1 - Unscrewing the Oil Cap

Figure 2 - Adding Oil

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Step 2 - Add Gasoline

Gasoline and gasoline fumes are highly flammable and explosive. Handling fuel can result in serious injury or burns.

• Do not fill the fuel tank near a heat, sparks or an open flame. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power

tools, etc.

• Do not overfill the fuel tank. Always check for fuel spills and immediately wipe them up. Spilled fuel is a fire hazard and causes environmental

damage.

To add gasoline:

To ensure that this generator runs smoothly, use only FRESH, UNLEADED GASOLINE WITH AN OCTANE RATING OF 87 OR HIGHER. Unleaded

gasoline produces fewer engine and spark plug deposits and extends the life of the exhaust system.

1. Confirm that this generator is on a level surface.

2. Unscrew fuel tank cap and set aside. (NOTE: The fuel tank cap may be tight and difficult to unscrew.)

3. Slowly add fresh, unleaded gasoline (with an octane rating 87 or higher) to the fuel tank. Be careful not to fill the fuel tank above the upper limit

line. The fuel tank capacity for this ACDelco Model AC-G0002 3500 Surge Watts / 3000 Running Watts Portable Generator is 4 gallons (15 L). The

fuel gauge, located on the top of this generator, indicates how much gasoline is currently in the fuel tank. NOTE: Because gasoline can expand, do

not fill the fuel tank to the very top.

4. Securely tighten the fuel tank cap and immediately wipe up any spilled gasoline with a dry cloth.

Model AC-G0002 Fuel Tank Capacity (gals /L)

Model AC-G0002 Fuel Type

4 / 15

Fresh, Unleaded Gasoline Octane Rating 87 or Higher

IMPORTANT:

• Use only UNLEADED gasoline with an octane rating of 87 or higher.

• Never use a mixture of oil and gasoline.

• Never use old and/or contaminated gasoline.

• Avoid getting dirt and/or water in the fuel tank.

• Gasoline can age in the fuel tank and make it difficult to start this generator. Never store this generator for extended time with gasoline in the fuel

tank.

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Step 3 - Ground the Generator

Failure to properly ground this generator can result in electrocution.

Ground this generator by tightening the grounding nut against a grounding wire as illustrated in Figure 3. A No. 12 AWG (American Wire Gauge)

stranded copper wire is generally an acceptable grounding wire. The other end of this grounding wire should be connected to a copper or brass

grounding rod that is driven into the earth.

Grounding codes can vary by location. Contact a local electrician for information on grounding regulations for your area.

Figure 3 - Attaching the Grounding Wire to this Generator

Subsequent Use of this Generator

For subsequent uses of this generator after the first use, certain steps still must be completed to prepare it for operation.

IMPORTANT: Be familiar with the procedures described in the previous section titled “Using the Generator for the First Time” of this

manual. If not, review this section now.

Step 1 - Verify Oil Level

Even though this generator is equipped with an automatic shutoff to protect it from damage due to low oil, it is important to check the oil level in the

engine crankcase before each use to ensure that there is sufficient quantity.

1. Verify that this generator is on a level surface.

2. Unscrew the oil filler/dipstick cap from the engine.

3. With a dry cloth, wipe the oil off of the dipstick that is located on the inside of the cap.

4. Fully insert the dipstick without screwing the filler/dipstick cap and then remove again. There should be oil on the dipstick. If there is no oil on the

dipstick, or oil is visible only at the very end of the dipstick, add oil until the engine crankcase is filled. (See “Changing/Adding Oil” in the

“Maintenance/Care” section of this manual).

5. Confirm that the oil filler/dipstick cap is properly screwed in place when finished verifying the oil level.

NOTE: The oil capacity for this ACDelco Model AC-G0002 3500 Surge Watts / 3000 Running Watts Portable Generator is 20 fluid oz (0.6 L).

Model AC-G0002 Oil Capacity (fluid oz./L)

Model AC-G0002 Oil Type Recommended

20 / 0.6

SAE-30

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Step 2 - Verify Gas Level

Before starting this generator, verify that there is sufficient gasoline in the fuel tank. The fuel gauge, located on the top of this generator, indicates the

gas level currently in the fuel tank. If necessary, add fresh unleaded gasoline with an octane rating of 87 or higher according to “Step 2 - Add

Gasoline” of the “Using this Generator for the First Time” section of this manual.

Model AC-G0002 Fuel Tank Capacity (gals /L)

Model AC-G0002 Fuel Type

4 / 15

Fresh, Unleaded Gasoline Octane Rating 87 or Higher

Gasoline and gasoline fumes are highly flammable and explosive. Handling fuel can result in serious injury or burns.

• Do not fill the fuel tank near a heat, sparks or an open flame. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power

tools, etc.

• Always allow several minutes for the engine to cool before refueling.

• Do not overfill the fuel tank. Always check for fuel spills and immediately wipe them up. Spilled fuel is a fire hazard and causes environmental

damage.

IMPORTANT:

• Use only fresh UNLEADED gasoline with an octane rating of 87 or higher.

• Never use old and/or contaminated gasoline.

• Never use a mixture of oil and gasoline.

• Avoid getting dirt and/or water in the fuel tank.

• Never store generator for extended time with gasoline in the fuel tank.

Step 3 - Ground the Generator

Failure to properly ground this generator can result in electrocution.

Ground this generator by tightening the grounding nut against a grounding wire as previously illustrated in Figure 3. A generally acceptable

grounding wire is a No. 12 AWG (American Wire Gauge) stranded copper wire. The other end of this grounding wire should be connected to a

copper or brass grounding rod that is driven into the earth.

Grounding codes can vary by location. Contact a local electrician for information on grounding regulations for your area.

STARTING THE GENERATOR

STOP!

Before starting this generator, confirm that all the steps in the section titled, “Preparing the Generator for Use,” of this manual have been

correctly completed. If unsure about how to perform any of these steps, call 1-866-460-9437, Monday - Friday, 8 AM - 4 PM Central Time for

customer service.

Disconnect all electrical loads from this generator before attempting to start.

To start this generator:

1. Confirm that there are no electrical devices connected to this generator. Connected devices may increase the difficulty in starting the engine.

2. Confirm that this generator is properly grounded. (See “Ground the Generator” section of this manual.)

3. Turn the fuel valve to the “on” position as shown in Figure 4.

4. Move the choke lever to the “closed” position as shown in Figure 5.

5. Set the engine switch to the “on” position.

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6. Slowly pull on the recoil starter handle, shown in Figure 6, until a slight resistance is felt. Then pull briskly to start the engine. Gently return the

cord into the generator to avoid damage to the starter or housing. Never allow the cord to snap back.

7. If the engine fails to start, repeat step 6. NOTE: After repeated attempts to start the engine, consult the troubleshooting guide before attempting

again. If problems persist, call 1-866-460-9437, Monday - Friday, 8 AM - 4 PM Central Time.

8. Once the engine has started and runs for about a minute, move the choke lever approximately half way towards the “open” position. Wait an

additional 30 seconds and then move the choke lever completely over to the “open” position.

9. Allow this generator to run for several minutes before connecting any electrical devices.

Figure 4 - Fuel Valve in the “on” position

Figure 5 - Choke Lever in the “closed” position. (Refer to the Generator

Components chart to find the location of the Choke Lever.)

Figure 6 - Pull-cord for starting the engine.

USING THE GENERATOR

After the engine has been running for several minutes, electrical devices may be connected to this generator.

AC Usage

Electrical devices running on AC current may be connected according to their wattage requirements. The rated (running) and surge wattage for this

ACDelco Model AC-G0002 3500 Surge Watts / 3000 Running Watts Portable Generator is 3,000 and 3,500, respectively.

Model AC-G0002 Rated (Running) Wattage

Model AC-G0002 Surge Wattage

3000

3500

The rated (running) wattage corresponds to the maximum wattage a generator can output on a continuous basis.

The surge wattage corresponds to the maximum amount of power a generator can output for a short time. Many electrical devices, such as a

refrigerator, require short bursts of extra power for starting and stopping fan motors, etc., in addition to their listed rated wattage. Motorized devices

typically require more than their rated wattage for startup. The surge wattage ability of a generator allows for this extra power requirement.

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The total running wattage requirement of the electrical devices connected to a generator should not exceed the rated wattage of the generator itself.

To calculate the total wattage requirement of the electrical devices to be connected, look up the rated (running) wattage of each device and add

these numbers together to find the total wattage that all of the devices together will draw from the generator. If the total wattage of the selected

devices exceeds the rated wattage of the generator, DO NOT connect all of the devices. Select a combination of the electrical devices that will have

a total wattage less than or equal to the rated wattage for the generator, i.e., no more than 3000 for this ACDelco Model AC-G0002 3500 Surge

Watts / 3000 Running Watts Portable Generator.

This generator can run at its surge wattage capacity for only a short time. Connect electrical devices requiring a rated (running) wattage

equal to or less than the rated wattage of this generator. Never connect devices requiring a rated wattage equal to the surge wattage of a

generator.

A device's rated (running) wattage should be listed somewhere on the device itself and/or in its manual. If the wattage specification for a device is not

available, the wattage can be calculated by multiplying the Voltage requirement (120 or 240) by the Amperage drawn.

Watts = Volts x Amperes

Or, the wattage required by a device can be estimated by using the following chart (see Figure 7). The chart provides only estimates and it is better

to know the exact wattage of each electrical device to be powered by this generator.

Electrical Device

Rated (Running) Watts Additional Surge Watts

air compressor (1 HP)

air compressor (1 - 1/2 HP)

airless sprayer (1/3 HP)

box fan

1500

2500

600

300

3000

2500

1200

600

clock radio AM/FM

coffee maker

computer w/17 inch monitor

deep freezer

electric drill (1/2 HP)

DVD/CD player or VCR

furnace fan blower (1/2 HP)

garage door opener (1/2 HP)

hot plate

1500

800

500

1000

100

800

480

2500

500

1000

1300

520

light bulb (75 watt)

microwave oven (1000 watt)

quartz halogen work light

refrigerator/freezer (18 Cu. Ft.)

saw - circular (7 1/4 inch)

saw - miter (10 inch)

saw - radial arm

saw - reciprocating

saw - table/radial (10 inch)

security system

1000

800

1500

1800

2000

960

1600

1500

1800

2000

1040

2000

180

stereo receiver

450

electric stove - single element

sump pump

1500

800

1800

500

4000

1000

1200

300

1200

1800

table planer (6 inch)

television (27 inch color)

electric water heater (40 gallon)

well water pump (1/3 HP)

window air conditioner (10000 BTU)

window fan

2000

1800

600

Figure 7 - Estimated wattage requirements for common electrical devices.

Connect electrical devices to this generator according to the following procedure:

1. Allow the engine to run for several minutes after it has been started.

2. Confirm that the electrical device is switched off prior to plugging it into this generator.

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Connect only electrical devices that are in good working order. Faulty devices or power cords present the risk of electrical shock.

Immediately turn off and disconnect any device that commences to operate abnormally, sluggish or abruptly stops. Determine if the

problem was the device or the rated load capacity of this generator has been exceeded.

NOTE: Plug appliances into the correct outlet. Connect standard 120 Volt, single phase, 60 Hz loads to the 120 Volt outlet. Connect 240/120Volt,

single phase, 60Hz loads with a NEMA L14-30 plug only to the 240/120 Volt outlet. See Figure 8 for an illustration of these outlets.

Even though this ACDelco AC-G0002 Portable Generator has an overall rated wattage of 3000, do not attempt to draw more than 3400

Watts (20 A) from any ONE of the 120 Volt outlets. Draws higher than 3400 Watts (20 A) will damage this generator and void the warranty.

3. Switch the circuit breaker to the “on” position.

NOTE: While this generator is running, power is available from either the standard 120 Volt outlets or the 240/120 Volt NEMA outlet. Both 120 Volts

and 240 Volts can be simultaneously drawn from this generator.

4. Turn on the connected electrical devices beginning with the device with the highest rated wattage requirement and then each additional device

with the next lower rated wattage requirement.

Do not connect 50Hz or 3-phase loads to this generator.

Figure 8 - Outlets Available on this Generator, from left to right,

12V DC, 120V AC, and 240/120 AC (NEMA L14-30 plug).

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SOME NOTES ABOUT POWER CORDS

Long or thin cords can require more wattage from a generator to power an electrical device. Figure 9 shows the recommended cords according to

the power requirement of the electrical device. When using cords that exceed these specifications, allow for the electrical device to have a slightly

higher rated wattage requirement.

Device Requirements

Max. Cord Length (ft) by Wire Gauge

Amps

2.5

7.5

Watts (120V)

300

Watts (240V)

600

#8 wire #10 wire #12 wire #14 wire #16 wire

175

150

125

1000

500

350

250

150

125

100

600

300

200

150

100

375

200

125

100

250

125

100

600

900

1200

1800

2400

3600

4800

6000

7200

9600

1200

1800

2400

3000

3600

4800

NR = Not Recommended.

Figure 9 - Maximum Extension Cord Lengths by Power Requirement

DC Usage

The DC outlet is only for recharging 12 Volt automotive-type batteries. Do not connect any other device to this outlet.

Use this generator only for recharging 12 Volt batteries. NEVER attempt to jumpstart a car with this generator.

Failing to use the correct procedure can cause a battery to explode, seriously injuring anyone nearby. Keep heat, sparks, flame and

smoking materials away from the battery.

To connect 12 Volt batteries to the DC outlet:

1. Connect one charging wire to the positive terminal of the battery and the other charging wire to the negative terminal of the battery.

2. Connect the free end of the positive wire to the positive side of the outlet on this generator.

3. Start this generator.

4. Carefully connect the free end of the negative wire to the negative side of the outlet on this generator.

5. When disconnecting, always disconnect the wires from this generator first to avoid a spark.

Storage batteries emit highly explosive hydrogen gas when charged.

Batteries also contain acid, which can cause severe chemical burns.

• Do not allow open flames or cigarettes nearby for several minutes after charging a battery.

• Always wear protective goggles and rubber gloves when charging a battery.

• If battery acid gets on the skin, flush with water.

• If battery acid gets in the eyes, flush with water and immediately call a physician.

• If battery acid is swallowed, drink large quantities of milk and immediately call a physician.

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STOPPING THE GENERATOR

To stop this generator:

1. Turn off all connected electrical devices and then unplug them.

2. Switch the circuit breaker to the “off” position.

3. Allow this generator to run for several more minutes with no electrical devices connected to help stabilize the temperature of this generator.

4. Set the engine switch to the “off” position.

5. Turn the fuel valve to the “off” position.

Allow this generator to cool down before touching areas that become hot during operation.

Allowing gasoline to sit in this generator's fuel tank for extended time without use can increase the difficulty in starting this generator in

the future. Never store this generator for extended time with gasoline in the fuel tank.

MAINTENANCE/CARE

Proper routine maintenance of this generator is essential for safe, economical, and trouble-free operation. It will help prolong the life of this generator

as well as help reduce air pollution. Perform maintenance checks and procedures according to the schedule in Figure 10.

STOP!

If you have questions about any maintenance procedures described in this manual, call 1-866-460-9437 , Monday - Friday, 8 AM - 4 PM Central

Time.

Never perform maintenance procedures while this generator is running. Allow this generator to cool before commencing any maintenance

procedures. Keep heat, sparks and flame away.

Improper maintenance and/or failure to correct any problems prior to operating this generator can cause a malfunction which could cause

death or serious injury. Always follow the inspection and maintenance recommendations and schedules in this manual.

Recommended Maintenance Schedule

Each Use

Every Month or

Each 20 Hrs

Every 3 Months or Every 6 Months or Every Year or

Each 50 Hrs

Each 100 Hrs

Each 300 Hrs

Engine Oil

Air Filter

Check Level

Replace

Check

Clean

Fuel Filler Cap

Spark Plug

Fuel Tank

Clean

Check/Clean

Verify Gas Level

Clean

Figure 10 - Recommended maintenance schedule

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Cleaning the Generator

Always try to use this generator in a cool dry place. If this generator becomes dirty, the exterior can be cleaned with a damp cloth, soft brush,

vacuum and/or pressurized air.

Never clean this generator with a bucket of water and/or a hose as water can get inside and cause a short circuit or corrosion.

Never use gasoline to clean parts of this generator.

Checking the Oil Level

Even though this generator is equipped with an automatic shutoff to protect it from damage due to low oil, it is important to check the oil level in the

engine crankcase before each use to ensure that there is a sufficient quantity.

To check the oil level:

1. Verify that this generator is shut down and on a level surface.

2. Unscrew the oil filler/dipstick cap from the engine as illustrated in Figure 11.

3. With a dry cloth, wipe the oil off of the dipstick that is located on the inside of the cap.

4. Insert the dipstick as if replacing the cap and then remove again. There should be oil on the dipstick. If there is no oil on the dipstick, or oil is

visible only at the very end of the dipstick, add oil until the engine crankcase is filled (see “Changing/Adding Oil” in this section of this manual).

5. Confirm that the oil filler/dipstick cap is properly in place when finished verifying the oil level.

Figure 11 - Checking the Oil

Changing/Adding Oil

The oil level in this generator should be checked before each use. (See Figure 10.) When the oil level is low, add oil until the level is sufficient to

operate this generator.

The oil capacity for this ACDelco Model AC-G0002 3500 Surge Watts / 3000 Running Watts Portable Generator engine is 20 fluid oz. (0.6 L).

To drain the oil from this generator:

It is necessary to drain the oil from the crankcase only if it has become contaminated with water and/or dirt.

1. Place a bucket underneath this generator to catch oil as it drains.

2. Using a 10 mm hex wrench, unscrew the oil drain plug located on the crankcase underneath the oil filler/dipstick cap as illustrated in Figure 12.

3. Allow all the oil to drain from this generator.

4. Replace the oil drain plug and tighten with a 10 mm hex wrench.

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NOTE: Never dispose of used motor oil in the trash, down a drain or on the ground. Put oil in a sealed container and contact your local

recycling center or auto garage to arrange oil disposal.

To add oil to the engine crankcase:

1. Confirm that this generator is on a level surface.

2. Unscrew the oil filler/dipstick cap from the engine as illustrated in Figure 11 above.

3. Using a funnel, add high detergent motor oil to fill the engine crankcase to the correct quantity. SAE-30 oil is recommended for general use. When

the engine crankcase is full, the oil level should reach the lower lip of the oil filling opening as shown in Figure 13.

Model AC-G0002 Oil Capacity (fluid oz./L)

Model AC-G0002 Oil Type Recommended

20 / 0.6

SAE-30

Figure 12 - Draining Oil

Figure 13 - Adding Oil

Air Filter Maintenance

Routine maintenance of the air filter helps maintain proper airflow to the carburetor.

Occasionally verify that the air filter is free of excessive dirt. The air filter will require more frequent cleaning when operating this generator in

extremely dusty areas.

1. Unhinge the clasps at the top and bottom of the air filter cover as shown in Figure 14.

2. Remove the sponge-like elements from the casing.

3. Wipe the dirt from inside the empty air filter casing.

4. Wash the sponge-like elements in household detergent and warm water. Do not use gasoline or a flammable solvent.

5. Allow the sponge-like elements to dry thoroughly.

6. Soak the dry sponge-like elements in engine oil. Squeeze out any excess oil. The engine will smoke during initial startup if too much oil is left in

the air filter.

7. Replace the sponge-like elements in the air filter casing (the fine element first) and replace the cover.

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Figure 14 - Removing the Air Filter Casing.

Fuel Filter Cup Cleaning

The fuel filter cup is a small well underneath the fuel valve which helps trap dirt and water that may be in the fuel tank before entering the engine.

To clean the fuel filter cup:

1. Turn the fuel valve to the “off” position.

2. Unscrew the fuel filter cup from the fuel valve using a wrench. (Turn the valve toward you to unscrew as illustrated in Figure 15.)

3. Using a rag or brush, clean the cup of all sediment.

4. Reinstall the fuel filter cup.

Figure 15 - Removing the Fuel Filter Cup

Spark Plug Maintenance

The spark plug is essential for proper engine operation. The spark plug should be intact, free of deposits, and properly gapped. A bad or incorrectly

installed spark plug can cause engine damage.

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Model AC-G0002 Spark Plug Type

F6TC

Model AC-G0002 Spark Plug Gap (in/mm)

0.028-0.031/0.7-0.8

To inspect the spark plug:

1. Remove the spark plug by pulling on the spark plug cap.

2. Unscrew the spark plug from this generator by using the included spark plug wrench as illustrated in Figure 16.

3. Visually inspect the spark plug. If it is cracked and/or chipped, discard and install a new spark plug. A F6TC spark plug, such as NGK BPR5ES, is

recommended.

4. Measure the spark plug electrode gap with a gauge. The gap should be 0.028-0.031in (0.7-0.8mm). (See Figure 17.)

5. If re-using the spark plug, use a wire brush to clean any dirt from around the spark plug base and then re-gap the spark plug.

6. Screw the spark plug back into place on this generator by using the included spark plug wrench.

7. Replace the spark plug cap.

Figure 16 - Removing the Spark Plug

Figure 17 - Measuring the Spark Plug Gap

Emptying the Fuel Tank

To store this generator for extended time, drain the gasoline from the fuel tank.

To drain gasoline from this generator:

1. Turn the fuel valve to the “off” position.

2. Remove the fuel filter cup. (See “Fuel Filter Cup Cleaning” earlier in this section.)

3. Empty the fuel filter cup of any fuel.

4. Place a receptacle underneath this generator to catch gasoline as it drains.

5. Turn the fuel valve to the “on” position and allow all gasoline to drain.

6. Turn the fuel valve to the “off” position.

7. Replace the fuel filter cup.

8. Store the drained gasoline in a suitable place.

Do not store gasoline for more than 3 months.

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STORAGE/TRANSPORT PROCEDURES

Never place any type of storage cover on this generator while it is still hot.

When transporting or storing this generator for extended time:

• Allow generator to fully cool before moving it. A hot engine and exhaust system can burn you and ignite some materials.

• Empty the fuel tank. (See “Emptying the Fuel Tank” in the “Maintenance/Care” section.)

• Turn the fuel valve to the “off” position.

• Disconnect the spark plug. (See Figure 16, Removing the spark plug.)

• Do not obstruct any ventilation openings.

• Do not drop or strike this generator while moving it.

• Store this generator in a cool dry area, free of excessive dust.

Storage Time

Less than 1 month

1 to 2 months

Recommended Storage Procedure (which will help prevent difficult starts)

No storage procedure required.

Fill with fresh gasoline and add gasoline conditioner

2 months to 1 year

1 year or more

Empty the fuel tank. (See “Emptying the Fuel Tank” in the “Maintenance/Care” section.)

Disconnect the spark plug. (See Figure 16, Removing the spark plug.)

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TROUBLESHOOTING

IMPORTANT: If trouble persists, call our customer help line at 1-866-460-9437, Monday - Friday, 8 AM - 4 PM Central Time.

Symptom

Cause

Solution

Engine will not start.

Engine switch is set to "off."

Fuel valve is turned to "closed."

Choke is open.

Set engine switch to "on."

Turn fuel valve to "open."

Close the choke.

Engine is out of gasoline.

Engine is filled with contaminated and/or old

gasoline.

Add gasoline.

Drain gasoline from the engine and add new

gasoline.

Spark plug is dirty.

Clean spark plug.

Spark plug is broken.

Generator is not on level surface.

Replace spark plug.

Move generator to a level surface to prevent

triggering the low oil shutdown.

Add or replace oil.

Oil is low.

Engine runs but there is no electrical output.

Circuit breaker is off.

Reset button is "off."

Bad connecting wires/cables.

Bad electrical device connected to generator.

Flip circuit breaker to "on."

Push reset button to "on."

Try a different extension cord.

Disconnect device, try connecting another

device.

Generator runs but does not support all

connected electrical devices.

Generator is overloaded.

Reduce draw on generator to within this

generator's rated wattage by reducing number

of connected electrical devices.

Disconnect any faulty or short-circuited

electrical loads.

Short in one of the connected devices.

Air filter is dirty.

Clean or replace air filter.

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SPECIFICATIONS

ACDelco Model AC-G0002 3500 Surge Watts / 3000 Running Watts Portable Generator

Generator

Type

Brush, Revolving Magnetic Field, Self Exciting, 2-Pole, Single Phase

AC Output

Rated Wattage (W)

Surge Wattage (W)

Rated Voltage (V)

Rated Amperage

3000

3500

120/240

12.5A+12.5Aat 120 V

12.5 A at 240 V

Rated Frequency (Hz)

Phase

Single

DC Output

Voltage (V)

Circuit Breaker Amperage (A)

8.3

Dimensions and Weight

Dimensions (in.)

Gross Weight (lbs)

Net Weight (lbs)

23.2 Length, 17.2 Width, 17.2 Height

115

106

Engine

Approvals

CARB/EPA/MTL/CTL

Engine Model (HP)

Engine Type

6.5

4-stroke OHV single cylinder with forced air cooling system.

Ignition System

Starting System

Displacement (cm3)

Max Output (hp/rpm)

non-contact transistor (T.C.I.)

Recoil

196

6.5/3600

Fuel Tank Capacity (Fresh, Unleaded gasoline, 87 or higher octane) (US 4 / 15

gal./L)

Continuous Operating Hours

9 @ 50% Load

Oil Capacity (SAE-30) (fl oz./Qts/L)

Run Time on 50% Load (hours)

Noise Rating (at 7 m, 0% load) (dB)

20 / 0.63 / 0.6

<78

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Model AC-G0002 3500 EXPLODED VIEW AND PARTS LIST

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Model AC-G0002 3500 PARTS LIST

Item Part

Qty Description

Item Part

Qty Description

Bolt 8 mm × 205 mm

168F-2BV

Gasoline engine

39 31933

Generator fan

41100

Frame complete

Bottom rubber mount A

Bottom rubber mount B

Flange nut 8 mm

Nut 6 mm

40 31141/2GF-3

41 31996/2GF-3

42 30100

Bolt 5 mm × 14 mm

Stator & rotor Assembly

Fuel tank

41310/2GF-3

41320/2GF-3

GB6177-86

GB802-88

41350/2GF-3

GB5787-86

41116

43 16610/2GF-3

44 16500/2GF-3

45 16521/2GF-3

46 16916/2GF-3

47 37820/2GF-3

48 GB819-85

49 GB5787-86

50 16821/2GF-3

51 16811/2GF-3

Fuel filler cap complete

Packing ring

Cushion, frame

Fuel filler

Bolt 6 mm × 12 mm

Rubber pad

Fuel sensor

Screw 5 mm × 10 mm

Flange bolt 6 mm × 22 mm

Washer

10 32520

Ground connector

Wire harness Assembly

Receptacle (DC)

Current protector 8A

Receptacle (4 holes)

Low oil indicator

Control panel Assembly

Control panel case

Flange bolt 6 mm × 12 mm

Circuit protector

Ignition switch

11 32100

12 35550

Cushion

13 31750

Outlet pipe (φ9×φ4.5×130)

Tube clip

14 35510

16931/2GF-3

15 37880

53 16937/168F

54 16930/2GF-3

55 16812/2GF-3

56 16824/2GF-3

57 37825/2GF-3

58 18300/168F-BV

59 18611/2GF-3

60 GB5787-86

61 18110/168F-BV

62 18221/168F-BV

63 18720/2GF-3

64 18710/2GF-3

65 GB5787-86

66 GB6187-86

67 GB5787-86

68 12255/168F

69 GB5787-86

70 37330

Fuel cock

16 37300

Stripe, fuel tank

Fitting brush, fuel tank

Gasket, fuel sensor

Muffler

17 37321

18 GB5787-86

19 31710

20 35410

Muffler guard

21 37420

Voltmeter

Flange bolt 8 mm × 16 mm

Exhaust pipe complete

Muffler gasket

22 31820

Voltage selector switch

Receptacle (GFCI)

Handle unit

23 35540

24 47160

Supporting plate

Muffler stay

25 41136

Feet

26 GB5787-86

27 GB6187-86

28 31200

Bolt 8 mm x 40 mm

Nut 8 mm

Bolt 8 mm × 25 mm

Nut 8 mm

Stator Assembly

Stator cover

Flange bolt 6 mm × 12 mm

Exhaust pipe gasket

29 31936

30 31100

Rotor Assembly

Brush Assembly

Generator stay

31 31370

Bolt 6 mm × 12 mm

Curved panel

32 31411/2GF-3

33 31938/2GF-3

34 31995/2GF-3

35 31600

Generator end cover

Bolt 5 mm×12 mm

Voltage regulator

Bearing 6202-2RS

Plain washer

71 42000

Wheel kit Assembly

Bolt 8 mm × 16 mm

Wheel kit

72 GB5787-86

73 42150

36 GB276-89/2GF-3

37 31134/2GF-3

38 31931

74 GB6187-86

75 42130

Nut 8 mm

Wheel axel

Flange bolt 6 mm × 150 mm

76 16650

Carbon Canister

Spark Plug Cap

77 34310/168F

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MODEL AC-G0002 3500 SURGE WATTS / 3000 RUNNING WATTS PORTABLE GENERATOR

WIRING DIAGRAM

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NOTES:

Model AC-G0002 3500 Surge Watts / 3000 Running Watts Portable Generator

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WARRANTY

LIMITED WARRANTY for ACDelco Generators from New Buffalo Corporation.

Remember to save your receipt and to accurately fill out and mail your product registration card. You must provide proof of purchase for

all warranty work.

ACDelco generators are warranted to be free from defects in materials and workmanship for a period of one (1) year from date of original purchase.

Generators used for Commercial or Rental use have a warranty period of 90 days from date of original purchase. Keep purchase receipt and mail in

the product registration card for proof of purchase.

ACDelco by New Buffalo Corporation will repair or replace, at its discretion, any part that is proven to be defective in materials or workmanship under

normal use during the one (1) year warranty period. Warranty repairs or replacements will be made without charge for parts or labor. Parts replaced

during warranty repairs will be considered as part of the original product and will have the same warranty period as the original product.

To exercise this warranty, DO NOT RETURN TO RETAILER. Instead, call the toll free Customer Service number: 1-866-460-9437 and you will be

instructed on where to take the engine for warranty service. Take this generator and proof of purchase (your receipt) to the repair facility

recommended by the Customer Service Representative.

The warranty does not extend to generators damaged or affected by fuel contamination, accidents, neglect, misuse, unauthorized alterations, use in

an application for which the product was not designed and any other modifications or abuse.

ACDelco by New Buffalo Corporation is not liable for any indirect, incidental or consequential damages from the sale or use of this product. Any

implied warranties are limited to one (1) year as stated in this written limited warranty. Some states do not allow the exclusion or limitation of

incidental or consequential damages. Some states do not allow limitation on the length of an implied warranty. This warranty gives you specific legal

rights, and you may have other rights that vary from state to state.

REGISTRATION

Return this product registration form, along with a copy of the sales receipt and UPC bar code to:

NEW BUFFALO CORPORATION, 1220 NORTH PRICE ROAD, ST. LOUIS, MO 63132

Name:___________________________________________________________________________________

Address: _________________________________________________________________________________

City: _______________________________________State: _____________Zip: ________________________

Phone: ________________________________E-mail: ____________________________________________

Date Purchased: ________________________Model #: ___________________________________________

Store Where Purchased: ____________________________________________________________________

Store Address: ____________________________________________________________________________

Receipt or Transaction #: __________________Serial #: ___________________________________________

This registration form must be returned to New Buffalo Corporation within 10 days of purchase. This registration card is the

only information New Buffalo Corporation will have to notify you of any information regarding this product.

This information is for the sole purpose of product registration and will not be sold or used for any other purpose.

YOU MAY ALSO REGISTER THIS GENERATOR ONLINE AT www.buffalotools.com.

c/o

New Buffalo Corporation

1220 North Price Road

St. Louis MO 63132

Phone: 866-460-9437 or

314-373-2740

Fax: 636-537-1055

www.buffalotools.com

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PORTABILITY KIT INSTALLATION

The manufacturer recommends when using your ACDelco generator for recreational or utility functions that you properly install the Portability Kit

included with your generator purchase. All ACDelco generator models include a Portability Kit for optional installation. Portability Kits are not

required for ACDelco generators to properly operate.

Model # AC-G0002

3500 Watt Generator

Step 1

1. Install wheel axle, insert bolts (2) 8mm x 16mm through axle and generator's frame and tighten 8mm nut (2) onto bolt.

2. Slip wheels (2) over the axle on both ends, insert cotter pins (2) through axle and spread the pins to hold wheels in place.

Step 2

1. Install stabilizer feet (2), insert bolts (4) 6mm x 12mm through feet and generator frame and tighten 6mm nut (2) onto bolt.

Step 3

1. Insert handle unit into the center of the stationary bracket located on the top center of the frame, slide bolt 8mm x 40mm through both bracket

and handle unit, tighten 8mm nut onto bolt.

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Model AC-G0002 3500 Surge Watts / 3000 Running Watts Portable Generator

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(AC3500070922)

Model AC-G0002 3500 Surge Watts / 3000 Running Watts Portable Generator

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