CHAMPION 75537i User Manual

OWNER’S MANUAL & OPERATING INSTRUCTIONS

3100 Max Watts / 2800 Rated Watts
Wireless Remote, Electric Start

PORTABLE INVERTER GENERATOR

MODEL NUMBER

75537i

12039 Smith Ave.

SAVE THESE INSTRUCTIONS

Important Safety Instructions
are included in this manual.

MADE IN CHINA

REV 75537i-20140703

Santa Fe Springs CA 90670 USA

1-877-338-0999

www.championpowerequipment.com

FCC Statement

1. This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
(1) This device may not cause harmful interference.
(2) This device must accept any interference
received, including interference that may cause
undesired operation.

2. Changes or modifications not expressly approved by
the party responsible for compliance could void the
user’s authority to operate the equipment.

NOTE: This equipment has been tested and found to
comply with the limits for a Class B digital device,
pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against
harmful interference in a residential installation.
This equipment generates uses and can radiate radio
frequency energy and, if not installed and used in

accordance with the instructions, may cause harmful
interference to radio communications. However, there
is no guarantee that interference will not occur in a
particular installation. If this equipment does cause
harmful interference to radio or television reception,
which can be determined by turning the equipment
off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:

– Reorient or relocate the receiving antenna.
– Increase the separation between the equipment and

receiver.

– Connect the equipment into an outlet on a

circuit different from that to which the receiver is

connected.
Consult the dealer or an experienced radio/TV technician
for help.

Have questions or need assistance?

Do not return this product to the store!

WE ARE HERE TO HELP!

Visit our website:

www.championpowerequipment.com

for more info:

• Product Info & Updates

• Frequently Asked Questions

– or –

Call our Customer Care Team Toll-Free at:

1-877-338-0999

• Tech Bulletins

• Product Registration

WARNING:

The Engine Exhaust from this product contains chemicals known to the State of California

to cause cancer, birth defects or other reproductive harm.

*We are always working to improve our products. Therefore, the enclosed product may differ slightly from the image on the cover.

TABLE OF CONTENTS

75537i

3100 Max Watts / 2800 Rated Watts

Wireless Remote, Electric Start

PORTABLE INVERTER GENERATOR

Introduction ............................ 1

Introduction .......................... 1

Portable Power Generator ................. 1

Accessories .......................... 1

This Booklet .......................... 1

Manual Conventions ....................... 2

Safety Rules ............................ 3

Controls and Features ..................... 5

Generator ............................ 5

Parts Included ........................ 5

Power Panel .......................... 6

Wireless Remote Control ................. 7

Remote Control Power Consumption ......... 7

Power Panel Load Management ............. 7

Assembly .............................. 8

Remove the Generator from the Shipping Carton . 8

Connecting the Battery .................. 8

Add Engine Oil ........................ 8

Add Fuel ........................... 10

Grounding .......................... 10

Operation ............................. 11

Generator Location .................... 11

Grounding .......................... 11

Wireless Remote Start .................. 11

Electric and Recoil Start ................ 12

Manual Choke Start .................... 13

Economy Control Switch ................. 13

Connecting Electrical Loads .............. 14

12V DC Outlet ....................... 14

12V DC Outlet – Battery Charging .......... 14

Stopping the Engine ................... 14

Do Not Overload Generator ............... 15

Capacity ......................... 15

Power Management .................. 15

Overload Operation .................... 15

Operation at High Altitude ............... 15

Wireless Set Button .................... 16

Smart Charger ....................... 16

Maintenance and Storage .................. 17

Engine Maintenance ................... 17

Oil ............................. 17

Spark Plugs ....................... 17

Air Filter ......................... 18

Cleaning ......................... 18

Spark Arrester Cleaning ............... 18

Adjustments ....................... 18

Maintenance Schedule ................ 18

Generator Battery .................... 18

Charge the Battery ................... 19

Disconnect the Battery ................ 19

Remote Control Battery ................ 19

Generator Maintenance ................. 19

Storage ............................ 19

Generator Storage ................... 19

Specifications .......................... 20

Engine Specifications .................. 20

Generator Specifications ................ 20

Fuel .............................. 20

Oil ............................... 20

Spark Plugs ......................... 20

Maintenance Valve Clearance ............. 20

An Important Message About Temperature .... 20

Parts Diagram ........................ 21

Parts List ........................... 22

Engine Parts Diagram .................. 23

Engine Parts List ..................... 24

Wiring Diagram ....................... 25

Troubleshooting ......................... 26

Warranty ............................. 27

Warranty Qualifications ................. 27

Repair/Replacement Warranty ............. 27

Do Not Return The Unit To

The Place Of Purchase .................. 27

Warranty Exclusions. . . . . . . . . . . . . . . . . . . . 27

Normal Wear ...................... 27

Installation, Use and Maintenance ........ 27

Other Exclusions .................... 27

Limits of Implied Warranty

And Consequential Damage ............ 27

Contact Information .................... 27

Address .......................... 27

Customer Service ................... 27

Technical Service ................... 27

INTRODUCTION

ENGLISH 75537i

Introduction

Congratulations on your purchase of a Champion Power
Equipment inverter generator. CPE designs and builds
generators to strict specifications. With proper use and
maintenance, this generator will bring years of satisfying
service.

Portable Power Generator

This unit is a gasoline engine driven, alternating current
(AC) generator. It is designed to supply electrical power
for lighting, appliances, tools and similar equipment.

Record the model and serial numbers as well as date and place of purchase for future reference. Have this
information available when ordering parts and when making technical or warranty inquiries.

Accessories

Champion Power Equipment manufactures and sells
accessories designed to help you get the most from
your purchase. To find out more about our covers, power
cables and storm kits, please visit our web site at:

www.championpowerequipment.com

This Booklet

Every effort has been made to ensure the accuracy and
completeness of the information in this manual. We reserve
the right to change, alter and/or improve the product and
this document at any time without prior notice.

Champion Power Equipment Support

1-877-338-0999

Model Number

75537i

Serial Number

Date of Purchase

Purchase Location

For O il Typ e see ‘Add Engine Oil‘ section. For Fue l Typ e see ‘Add Fuel‘ section.

1 REV 75537i-20140703

75537i ENGLISH

MANUAL CONVENTIONS

This manual uses the following symbols to help differentiate between different kinds of information. The safety symbol
is used with a key word to alert you to potential hazards in operating and owning power equipment.
Follow all safety messages to avoid or reduce the risk of serious injury or death.

DANGER

DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.

WARNING

WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury.

CAUTION

CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which, if
not avoided, may result in property damage.

NOTE

If you have questions regarding your generator, we can
help. Please call our help line at 1-877-338-0999

REV 75537i-20140703 2

SAFETY RULES

ENGLISH 75537i

WARNING

Read this manual thoroughly before operating your
generator. Failure to follow instructions could result
in serious injury or death.

WARNING

The engine exhaust from this product contains
chemicals known to the state of California to cause
cancer, birth defects, or other reproductive harm.

DANGER

Generator exhaust contains carbon monoxide, a
colourless, odourless, poison gas. Breathing carbon
monoxide will cause nausea, dizziness, fainting or
death. If you start to feel dizzy or weak, get to fresh
air immediately.

Operate generator outdoors only in a well ventilated
area.
DO NOT operate the generator inside any building,
including garages, basements, crawlspaces and
sheds, enclosure or compartment, including the
generator compartment of a recreational vehicle.
DO NOT allow exhaust fumes to enter a confined
area through windows, doors, vents or other
openings.
DANGER CARBON MONOXIDE: using a generator
indoors CAN KILL YOU IN MINUTES.

DANGER

Rotating parts can entangle hands, feet, hair,
clothing and/or accessories.
Traumatic amputation or severe laceration can result.

DANGER

Generator produces powerful voltage.

DO NOT touch bare wires or receptacles.
DO NOT use electrical cords that are worn, damaged
or frayed.
DO NOT operate generator in wet weather.
DO NOT allow children or unqualified persons to
operate or service the generator
Use a ground fault circuit interrupter (GFCI) in damp
areas and areas containing conductive material such
as metal decking.
Use approved transfer equipment to isolate generator
from your electric utility and notify your utility
company before connecting your generator to your
power system.

WARNING

Sparks can result in fire or electrical shock.

When servicing the generator:

Disconnect the spark plug wire and place it where it
cannot contact the plug.
DO NOT check for spark with the plug removed.
Use only approved spark plug testers.

WARNING

Running engines produce heat. Severe burns can
occur on contact.
Combustible material can catch fire on contact.

DO NOT touch hot surfaces.
Avoid contact with hot exhaust gases.
Allow equipment to cool before touching.
Maintain at least 3 ft. (91.4 cm) of clearance on all
sides to ensure adequate cooling.
Maintain at least 5 ft. (1.5 m) of clearance from
combustible materials.

WARNING

Keep hands and feet away from rotating parts.
Tie up long hair and remove jewelry.
Operate equipment with guards in place.
DO NOT wear loose-fitting clothing, dangling
drawstrings or items that could become caught.

WARNING

This product contains a button battery. If
swallowed, it could cause severe injury or death in
just 2 hours. Seek medical attention immediately.

3 REV 75537i-20140703

Medical and Life Support Uses.

In case of emergency, call 911 immediately.
NEVER use this product to power life support
devices or life support appliances.
NEVER use this product to power medical devices
or medical appliances.
Inform your electricity provider immediately if you
or anyone in your household depends on electrical
equipment to live.
Inform your electrical provider immediately if a
loss of power would cause you or anyone in your
household to experience a medical emergency.

75537i ENGLISH

SAFETY RULES

DANGER

Fuel and fuel vapours are highly flammable and
extremely explosive.
Fire or explosion can cause severe burns or death.
Unintentional startup can result in entanglement,
traumatic amputation or laceration.

When adding or removing fuel:

Turn the generator off and let it cool for at least two
minutes before removing the fuel cap. Loosen the
cap slowly to relieve pressure in the tank.
Only fill or drain fuel outdoors in a well-ventilated area.
DO NOT pump gas directly into the generator at the
gas station. Use an approved container to transfer
the fuel to the generator.
DO NOT overfill the fuel tank.
Always keep fuel away from sparks, open flames,
pilot lights, heat and other sources of ignition.
DO NOT light or smoke cigarettes.

When starting the generator:

DO NOT attempt to start a damaged generator.
Make certain that the gas cap, air filter, spark plug,
fuel lines and exhaust system are properly in place.
Allow spilled fuel to evaporate fully before
attempting to start the engine.
Make certain that the generator is resting firmly on
level ground.

When operating the generator:

DO NOT move or tip the generator during operation.
DO NOT tip the generator or allow fuel or oil to spill.

When transporting or servicing the generator:

Make certain that the fuel shutoff valve is in the off
position and the fuel tank is empty.
Disconnect the spark plug wire.

When storing the generator:

Store away from sparks, open flames, pilot lights,
heat and other sources of ignition.

WARNING

Operation of this equipment may create sparks that
can start fires around dry vegetation.

A spark arrestor may be required. The operator
should contact local fire agencies for laws or
regulations relating to fire prevention requirements.

WARNING

Rapid retraction of the starter cord will pull hand and
arm towards the engine faster than you can let go.
Unintentional startup can result in entanglement,
traumatic amputation or laceration.
Broken bones, fractures, bruises or sprains could result.

When starting engine, pull the starter cord slowly
until resistance is felt and then pull rapidly to avoid
kickback.
DO NOT start or stop the engine with electrical
devices plugged in.

CAUTION

Exceeding the generator’s running capacity can
damage the generator and/or electrical devices
connected to it.

DO NOT overload the generator.
Start the generator and allow the engine to stabilize
before connecting electrical loads.
Connect electrical equipment in the off position,
and then turn them on for operation.
Turn electrical equipment off before stopping the
generator.
DO NOT tamper with the governed speed.
DO NOT modify the generator in any way.

CAUTION

Improper treatment or use of the generator can
damage it, shorten its life and void your warranty.

Use the generator only for intended uses.
Operate only on level surfaces.
DO NOT expose generator to excessive moisture,
dust, or dirt.
DO NOT allow any material to block the cooling slots.
If connected devices overheat, turn them off and
disconnect them from the generator.
DO NOT use the generator if:

– Electrical output is lost
– Equipment sparks, smokes or emits flames
– Equipment vibrates excessively

REV 75537i-20140703 4

ENGLISH 75537i

CONTROLS AND FEATURES

Read this owner’s manual before operating your generator. Familiarize yourself with the location and function of the
controls and features. Save this manual for future reference.

Generator

1

2

(1) Fuel Cap – Remove to add fuel.

(2) Recoil Starter – Used to start the engine.

(3) Power Panel

(4) Foldaway Handle – Do not use the foldaway handle

3 4

to lift or carry the unit.

5

6

7 98

(5) Muffler

(6) Carrying Handle

(7) Maintenance Cover

(8) Never Flat Wheels

(9) Battery Access Cover

Parts Included

Your 75537i gasoline powered generator ships with the
following parts:

– Automotive style USB adapter

(2.1A and 1A ports) ...................... 1

– Automotive style battery charger cables ........1

– Smart charger ..........................1

– Oil funnel .............................1

– Spark plug socket .......................1

– Remote ..............................1

5 REV 75537i-20140703

75537i ENGLISH

Power Panel

CONTROLS AND FEATURES

16 12 11

15

14

13

1

2

3

4

5

6

7

8

9

9

10

(1) Fuel Valve Knob

(2) Push-Button Choke

(3) Economy Control Switch

(4) Wireless Set Button

(5) Red Pilot Lamp

(6) 12V DC Input

(7) Ground Terminal – Consult an electrician for local

grounding regulations.

(8) 12V DC Outlet*

(9) Circuit Breaker (Push-button) – Protects the

generator against electrical overload.

(10) 120 Volt AC, 20 Amp Duplex (NEMA 5-20R) –

May be used to supply electrical power for the
operation of 120 Volt AC, 20 Amp, single phase
60 Hz electrical loads.

*Warning: Do not operate a device while it is plugged into the 12V DC outlet. Prolonged exposure to engine exhaust can cause
serious injury or death. While charging a device do no place on the exhaust side of the generator. Extreme heat caused by exhaust
can damage the device, and cause a potential fire hazard.

(11) Battery Switch

(12) 120 Volt AC, 30 Amp Receptacle (NEMA TT-30R)

May be used to supply electrical power for the

–

operation of 120 Volt AC, 30 Amp, single phase
60 Hz electrical loads.

(13) Oil Warning Light – Check oil level when this light

turns on. Engine will not run when indicator is lit.

(14) Overload Indicator Light – This light turns ON

when the generator is overloaded and will cut
power to the receptacles.

(15) Output Light – Remains ON during normal

operating conditions. Shuts OFF when generator is
overloaded.

(16) Engine Switch

REV 75537i-20140703 6

CONTROLS AND FEATURES

ENGLISH 75537i

Wireless Remote Control

This generator is equipped with a wireless remote
control system for starting and stopping. The system
consists of (4) main components:

1. Receiver Control Module (RCM)

2. Wireless Remote

3. Battery Switch

4. Ignition Switch
The Remote Control functions are enabled when:

1. The Ignition Switch is in the “ON” position, AND

2. The Battery Switch is in the “ON” position.
The Remote Control functions are disabled if either of
the above conditions is not met.
To start the generator by Remote Control, press the
“START” button on the Remote one time. The engine
will attempt to start (6) times. The RCM controls
the Auto Choke during each attempt to start. If the
generator does not start, call Champion Customer Care
team for assistance at 1-877-338-0999.
To stop the generator by Remote Control, press the

“STOP” button on the Remote one time.

Power Panel Load Management Cont’d.

voltage delay when the pushbutton electric start or recoil
start method is used.

When the pushbutton electric start or recoil start
method is used, the operator must be sure all electrical
loads (appliances) are turned OFF during startup and
shutdown. Damage to the generator or the attached
appliances can be caused by starting or stopping the
generator while appliances are plugged in and turned ON.

Remote Control Power Consumption

While the Ignition Switch is in the “ON” position, the
RCM is active and waiting for a remote signal. This
function requires electrical current from the battery.
If the Ignition Switch is left in the “ON” position for
extended periods (several weeks), the battery can be
completely drained.
Moving the Ignition Switch to the “OFF” position
disables the Remote functions, but the RCM still
consumes approximately 2 mA from the battery.
To prevent battery drain, press the Battery Switch to the
“OFF” position. This disconnects power to the RCM so

there is no current draw on the battery.

Power Panel Load Management

When the generator initially starts by the Remote, no
voltage is supplied to the Power Panel for approximately
15 seconds. This allows the engine to reach full speed
before electrical loads are applied to the generator.
When the generator is stopped by the Remote, the
voltage to the Power Panel is immediately turned off.
Then the engine stops approximately 5 seconds after
the “STOP” button on the Remote is pressed. Turning
the Power Panel voltage off before the engine shutdown
protects connected appliances from being damaged by
non-60 Hz voltage while the generator coasts to a stop.

The on/off voltage delay at startup and shut down only
happen when the Remote Control is used. There is no

7 REV 75537i-20140703