Champion CPG7500E2-DF-EU, 3500 E2 DF, CPG3500E2-DF-EU, 7500 E2 DF Owner's Manual & Operating Instructions

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Page 1

U.S. Patent No. D710,802

OWNER’S MANUAL & OPERATING INSTRUCTIONS

SAVE THESE INSTRUCTIONS

Important Safety Instructions are included in this manual.

DUAL FUEL GENERATOR

Frame Type Electric Start

This manual covers the following models:

3500 E2 DF (EU) / 7500 E2 DF (EU)

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MANUAL CONVENTIONSINTRODUCTION

Please familiarize yourself with the following symbols. The safety symbol and key words are safety warnings. Follow all

safety messages to avoid accidents or injury.

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.

CAUTION

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

DANGER

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

WARNING

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.

Champion Power Equipment Support

Model Number

Serial Number

Date of Purchase

Purchase Location

For Oi l Type see ‘Add Engine Oil‘ section. For Fue l Type see ‘Add Fuel‘ section.

Introduction

Congratulations on purchasing your generator. Please

and maintain correctly.

Accessories

CPE manufactures and supplies a serie s of access ories.

See local dealer for more information.

Portable Power Generator

This unit is a petrol engine driven AC generator used for

supply electrical pow er.

This Booklet

We reserve the right to change, alter or improve the

product and this manual without prior notice.

Page 3

SAFETY RULES SAFETY RULES

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 v ibrate s exce ssively

CAUTION

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 device s plugg ed in.

WARNING

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 and disconnect before stopping the gener ator. DO NOT tamper with the governed speed. DO NOT modify the generator in any way.

CAUTION

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 opening s. DANGER CARBON MONOXIDE: using a generator indoor s CAN KILL YOU IN MINUTES.

DANGER

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

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.

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.

DANGER

Sparks can result in ﬁre or electrical shock.

When servicing the gener ator:

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 91.4 cm (3 ft.) of clearance on all sides to ensure adequate cooling. Maintain at least 1.5 m (5 ft.) of clearance from combustible materials.

WARNING

Medical and Life Support Uses.

In an emergency, call Emergency Services 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.

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 that are known to cause serious health problems and even death.

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

Page 4

Petrol and Petrol Vapours:

– PETROL IS HIGHLY FLAMMABLE AND EXPLOSIVE.

– Petrol can cause a ﬁre or explosion if ignited.

– Petrol is a liquid fuel but it’s vapours can ignite.

– Petrol is a skin irritant and needs to be cleaned up

immediately if spilled on skin or clothes.

– Petrol has a distinctive odour, this will help detect

potential leaks quickly.

– In any petrol ﬁre, ﬂames should not be extinguished

unless by doing so the fuel supply valve can be

turned OFF. This is because if a ﬁre is extinguished

and a supply of fuel is not turned OFF, then an

explosion hazard could be created.

– Petrol expands or contracts with ambient

temperatures. Never ﬁll the petrol tank to full

capacity, as petrol needs room to expand if

temperature s rise.

Liqueﬁed Petroleum Gas (L PG):

– LPG IS HIGHLY FLAMMABLE AND EXPLOSIVE.

– Flammable gas under pressure can cause a ﬁre or

explosion if ignited.

– LPG is heavier than air and can settle in low places

while dissip ating.

– LPG has a distinctive odour added to help detect

potential leaks quickly.

– In any petroleum gas ﬁre, ﬂames should not be

extinguished unless by doing so the fuel supply

valve can be turned OFF. This is because if a ﬁre is

extinguished and a supply of fuel is not turned OFF,

then an explosion hazard could be created.

– When exchanging LPG cylinders, be sure the cylinder

valve is of the same type.

– Always keep the LPG cylinder in an upright position.

– LPG will burn skin if it comes in contact with it.

Keep any and all LPG away from skin at all times.

SAFETY RULES

Fuel Safety

PETROL, PETROL VAPOURS AND LIQUID PETROLEUM GAS (LPG) ARE HIGHLY FLAMMABLE AND EXPLOSIVE.

Fire or explosion can cause severe burns or death. Unintentional startup can result in entanglement, traumatic amputation or laceration.

DANGER

When adding or removing Petrol:

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 petrol directly into the generator at the

petrol 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 petrol 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 genera tor:

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. Make certain that a LPG cylinder is not attached to

generator and is securely stowed away.

Disconnect the spark plug wire.

When storing the genera tor:

Store away from sparks, open ﬂames, pilot lights, heat

and other sources of ignition.

Do not store generator, petrol or LPG cylinder near

furnaces, water heaters, or any other appliances that

produce heat or have automatic ignitions.

Never use a petrol container, LPG connector hose, petrol tank, LPG cylinder or any other fuel item that is damaged or appears damaged.

WARNING

AS SEMBLY

Your generator requires some assembly. This unit ships

from our factory without oil. It must be properly serviced

with fuel and oil before operation.

If you have any questions regarding the assembly of your

generator, call your local dealer. Please have your serial

number and model number available.

Remove the Generator from the Shipping Car ton

1. Set the shipping carton on a solid, ﬂat surface.

2. Remove everything from the carton except the

generator.

3. Carefully cut each corner of the box from top to

bottom. Fold each side ﬂat on the ground to provide a

surface area to install the wheel kit and support leg.

Install the Wheel Kit

You will need the following tools to install the wheels:

• Adjustable wrench (not included)

• Socket wrench (not included)

• Plier s (not inclu ded)

1. Before adding fuel and oil, tip the generator on it’s side.

2. Slide the wheel bolt through the ﬂat washer, bushing

and whe el.

3. Slide the bolt through the mount point on the frame.

4. Fasten securely with the lock nut.

5. Repeat steps 2-4 to attach the second wheel.

Install the Support Leg

1. Attach the support leg to the generator frame with

ﬂange bolt and ﬂange lock nuts.

2. Tip the generator slowly so that it rests on the

wheels and support leg.

The wheel kit is not intended for over-the-road use.

CAUTION

Connect the Batter y

1. Remove the protective cover from the red (+) lead on

the bat ter y.

2. Attach the red (+)lead to the red (+) terminal on the

battery with the ﬂange bolt and secure with the

ﬂange nut.

3. Repeat steps 1-2 for the black (–) battery lead.

Install the handle (selected models)

1. Place the handle over the mounting channel on the

frame.

2. Secure the handle to the frame using the two handle

bolts.

3. Place the lock nut on the end of each bolt and

fasten securely. DO NOT over tighten the lock nuts.

Page 5

Add Engine Oil

AS SEMBLY

Add Engine Oil Cont’d.

1. Place the generator on a ﬂat, level surface.

2. Remove oil ﬁll cap/dipstick to add oil.

3. Add oil and replace oil ﬁll cap/dipstick. DO NOT

OVERFILL .

4. Check engine oil level daily and add as needed.

Full Synthetic 5W-30

Degrees Celsiusº

(Outside)

Degrees Fahrenheitº

The engine is equipped with a low oil shut-off and will stop when the oil level in the crankcase falls below the threshold level.

CAUTION

DO NOT attempt to crank or start the engine before it has been properly ﬁlled with the recommended type and amount of oil. Damage to the generator as a result of failure to follow these instructions will void your warranty.

CAUTION

The generator rotor has a sealed, pre-lubricated ball bearing that requires no additional lubrication for the life of the bearing.

NOTE

The recommended oil type is 10W-30 automotive oil.

NOTE

Synthetic oil may be used after the 5 hour initial break-in period. Using synthetic oil does not increase the recommended oil change interval. Full synthetic 5W-30 oil will aid in starting in cold ambient <5°C (41ºF)

NOTE

We consider the ﬁrst 5 hours of run time to be the break-in period for the unit. During the break in period stay at or below 50% of the running watt rating and vary the load occasionally to allow stator windings to heat and cool. Adjusting the load will also cause engine speed to vary and help seat piston rings. After the 5 hour break-in period, change the oil.

NOTE

Once oil has been added, a visual check should show oil about 1-2 threads from running out of the ﬁll hole. If using the dipstick to check oil level, DO NOT screw in the dipstick while checking.

NOTE

Weather will affect engine oil and engine performance. Change the type of engine oil used based on weather conditions to suit the engine needs.

NOTE

Check oil often during the break-in period. Refer to the Maintenance section for rec ommended servic e intervals.

NOTE

AS SEMBLY

Add Fuel (Petrol) Cont’d.

Our engines work well with 10% or less ethanol

blend fuels. When using blended fuels there are

some issues worth noting:

– Ethanol-petrol blends can absorb more water

than petrol alone.

– These blends can eventually separate, leaving

water or a watery goo in the tank, fuel valve and

ca rbu re to r.

– With gravity-fed fuel supplies, this compromised

fuel can be drawn into the carburetor and cause

damage to the engine and/or potential hazards.

– There are only a few suppliers of fuel stabilizer

that are formulated to work with ethanol blend

fuels.

– Any damages or hazards caused by using

improper fuel, improperly stored fuel, and/

or improperly formulated stabilizers, are not

covered by manufacture’s warrant y.

It is advisable to always shut off the fuel supply,

run the engine to fuel starvation and drain the tank

when the equipment is not in use for more than 30

days.

NOTE

Add Fuel (Petrol)

1. Use clean, fresh, regular unleaded fuel with a

minimum octane rating of 85 and an ethanol content

of less than 10% by volume.

2. DO NOT mix oil with fuel.

3. Clean the area around the fuel cap.

4. Remove the fuel cap.

5. Slowly add fuel to the tank. DO NOT OVERFILL.

Fuel can expand after ﬁlling. A minimum of

6.4 mm (¼ in.) of space left in the tank is required

for fuel expansion, more than 6.4 mm (¼ in.) is

recommended. Fuel can be forced out of the tank as

a result of expansion if it is overﬁlled, and can affect

the stable running condition of the product. When

ﬁlling the tank, it is recommended to leave enough

space for the fuel to expand.

6. Screw on the fuel cap and wipe away any spilled fuel.

Use regular unleaded petrol with a minimum octane rating of 85.

Do not mix oil and petrol. Fill tank to approximately 6.4 mm (¼ in.) below the top of the tank to allow for fuel expansion. DO NOT pump petrol directly into the generator at the petrol station. Use an approved container to transfer the fuel to the generator. DO NOT ﬁll fuel tank indoors. DO NOT ﬁll fuel tank when the engine is running or hot. DO NOT overﬁll the fuel tank. DO NOT light cigarettes or smoke when ﬁlling the fuel tank.

CAUTION

Pouring fuel too fast through the fuel screen may result in blow back of fuel at the operator while ﬁlling.

WARNING

Page 6

AS SEMBLY

Do not allow children to tamper or play with the cylinder or hose connections.

CAUTION

Use approved LPG cylinders equipped with an OPD (overﬁlling prevention device) valve. Always keep the cylinder in a vertical position with the valve on top and installed at ground level on a ﬂat surface Cylinders must not be installed near any heat source and should not be exposed to sun, rain, and dust. When transporting and storing, turn off the cylinder valve and fuel valve, and disconnect the cylinder. Plug the outlet, usually by a plastic protective cap, if one is available. Keep cylinders away from heat and ventilated when in a vehicle.

CAUTION

Connecting LPG Cylinder Cont’d.

Grounding

Your generator must be properly connected to an

appropriate ground to help prevent electric shock.

A ground terminal connected to the frame of the generator

has been provided on the power panel. For remote

grounding, connect of a length of heavy gauge

(12 AWG minimum) copper wire between the generator

ground terminal and a copper rod driven into the ground.

We strongly recommend that you consult with a qualiﬁed

electrician to ensure compliance with local electrical codes.

Failure to properly ground the generator can result in electric shock.

WARNING

– Use only standard 20 or 30 pound capacity LP

tanks with Type 1, right hand Acme threads.

– Verify the requaliﬁcation date on the tank has

not expired.

– All new cylinders must be purged of air and

moisture prior to ﬁlling. Used cylinders that have

not been plugged or kept closed must also be

purged.

– The purging process should be done by a LPG

supplier. (Cylinders from an exchange supplier

should have been purged and ﬁlled properly

alrea dy).

– Always position the cylinder so the connection

between the valve and the gas inlet won’t cause

sharp bends or kinks in the hose.

NOTE

Connecting Liquid Petroleum Gas (LPG) Cylinder

1. Make sure the fuel valve on the generator is in the off

position.

2. Attach the LPG hose (included) to the LPG hose

connector on the side of the generator and tighten

with an adjustable wrench.

Important: DO NOT use tape or any other type of

sealant to seal LPG hose connection.

3. Remove the safety plug or cap from the cylinder

valve.

4. Attach the other end of the hose to the LPG

connector on the cylinder and hand tighten.

5. Check all connections for leaks by wetting the ﬁttings

with a solution of soap and water. Bubbles which

appear or bubbles which grow indicate that a leak

exists. If a leak exists at a ﬁtting then turn off the

gas valve at the tank and tighten the ﬁtting. Turn the

gas back on and recheck the ﬁtting with the soap

and water solution. If the leak continues or if the leak

is not at a ﬁtting then do not use the generator and

contact customer service.

If there is a strong smell of gas: Close off the gas supply at the cylinder. Use soapy water, which will produce a large bubble at the point of any leak, to check the hose, and connections on the cylinder valve and the generator. Do not smoke or light a cigarette, or check for leaks using a match, open ﬂame source or lighter. Contact a qualiﬁed technician to inspect and repair the LPG system if a leak is found, before using the generator.

WARNING

AS SEMBLY

Generator Location

Never operate the generator inside any building! (See

safety warnings section). In some areas generators must

be registered with the local utility company. Generators

used on construction sites may be subject to local

rules and regulations. Keep on a ﬂat, level surface.

Generators must have at least 5 ft (1.5m) clearance

from all combustible material. In addition they must

have at least 3 ft (91.4cm) of clearance on all sides to

allow for adequate cooling, maintenance and servicing.

Generators should never be started or operated in ant

location that will not allow for adequate cooling of

the generator and/or the mufﬂer. Allow generators to

cool before storage or transportation. Do not place the

generator near any vents or intakes. Carefully consider

wind and air currents when placing generator. Failure

to follow the proper safety instructions may void the

manufacturer’s warranty.

Failure to follow proper safety precautions may void

manufacturer’s warranty.

Do not operate or store the generator in rain, snow, or wet weather.

Using a generator or electrical appliance in wet conditions, such as rain or snow, or near a pool or sprinkler system, or when your hands are wet, could result in electrocution.

WARNING

During operation the mufﬂer and exhaust fumes produced will become hot. If adequate cooling and breathing space are not supplied, or if the generator is blocked or contained, temperatures can become extremely heated and may lead to ﬁre.

Surge Protection

Electronic devices, including computers and many

programmable appliances use components that are

designed to operate within a narrow voltage range and

may be affected by momentary voltage ﬂuctuations.

While there is no way to prevent voltage ﬂuctuations, you

can take steps to protect sensitive electronic equipment.

1. Install UL1449, CSA-listed, plug-in surge suppressors

on the outlets feeding your sensitive equipment.

Surge suppressors come in single- or multi-outlet

styles. They’re designed to protect against virtually

all short-duration voltage ﬂuctuations.

Voltage ﬂuctuation may impair the proper functioning of sensitive electronic equipment.

CAUTION

Grounding

The generator system ground connects the frame to the

ground terminals on the power panel. The system ground is

connected to the AC neutral wire.

Page 7

OPERATION

The fuel selector switch cover is speciﬁcally

designed not to slide to either side while a speciﬁc

fuel has been selected and the valve is in the “ON”

position. Only when the fuel valves are in the “OFF”

position can the cover slide side to side.

NOTE

The fuel selector is locked into place once a

“CLICK” sound is made. Only then can a fuel valve

be turned to the vertical position.

NOTE

Fuel Selector Switch

The fuel selector switch on the front panel of the

generator is designed speciﬁcally to choose between the

fuel source desired, Petrol or LPG.

To select a fuel source simply slide the switch cover to

either the right or left, and this will uncover the fuel

valve of the fuel selected.

The LPG fuel valve (A) is to the left of the switch cover.

The petrol fuel valve (B) is to the right of the switch cover.

Once a fuel source has been selected, the user must

turn the fuel valve to the vertical position to open the

fuel valve. (1)

To turn a fuel valve to the off position the valve must be

in the horizontal position. (2)

Starting the Engine in ambient > 15°C (59°F)

Petrol

1. Make certain the generator is on a ﬂat, level surface.

2. Disconnect all electrical loads from the generator.

Never start or stop the generator with electrical

devices plugged in or turned on.

3. Turn the petrol fuel valve to the “ON” position.

4. Move the choke lever to the “100% CHOKE” detent

position.

a. For restarting a warm engine, move the choke

lever to the “75% CHOKE” detent position.

5. Push the battery switch to the “ON” position.

6. Push the ignition switch to the “ON” position.

7. ELECTRIC START: Press and hold the ignition switch

to the “START” position. Release as the engine begins

to start. If the engine fails to start within ﬁve seconds,

release the switch and wait at least ten seconds before

attempting to start the engine again.

8. RECOIL START: Pull the starter cord slowly until

resistance is felt and then pull rapidly.

9. Do not over-choke. As soon as engine starts, gradually

move the choke lever to the “RUN” position over a 2-5

second duration.

Keep choke lever in “Choke” position for only 1 pull of the recoil starter. After ﬁrst pull, move choke lever to the “Run” position for up to the next 3 pulls of the recoil starter. Too much choke leads to sparkplug fouling/engine ﬂooding due to the lack of incoming air. This will cause the engine not to start.

NOTE

For restarts with hot engine in hot ambient > 30°C (86°F) keep choke lever in “75% Choke” detent position for only 1 pull of the recoil starter. After ﬁrst pull, move choke lever to the “Run” position for up to the next 3 pulls of the recoil starter. Too much choke leads to sparkplug fouling/engine ﬂooding due to the lack of incoming air. This will cause the engine not to start.

NOTE

For petrol starting in in cold ambient < 15°C (59°F) the choke must be in the 100% “CHOKE” detent position for both electric and recoil start procedures. Do not over-choke. As soon as engine starts, gradually move the choke lever to the “RUN” position over a 5-20 second duration.

NOTE

OPERATION

If the engine starts but does not run make certain that the generator is on a ﬂat, level surface. The engine is equipped with a low oil sensor that will prevent the engine from running when the oil level falls below a critical threshold.

NOTE

When the battery switch is in the “ON” position, the switch will light up if the battery is sending out a charge. If the switch does not light up while in the “ON” position, check that the battery connection is still good.

NOTE

The supplied 12V 15AH battery does re-charge while the engine is running, but it is also recommended that the battery be fully charged at least once per month.

NOTE

Starting the Engine Cont’d.

If the ignition switch is held down in the “Start” position longer than 5 seconds it could damage the starter.

CAUTION

LPG

1. Make certain the generator is on a ﬂat, level surface.

2. Disconnect all electrical loads from the generator.

Never start or stop the generator with electrical

devices plugged in or turned on.

3. Fully open the LPG cylinder fuel knob.

4. Turn the LPG fuel valve to the “ON” position.

5. Push the battery switch to the “ON” position.

6. Push the ignition switch to the “ON” position.

7. ELECTRIC START: Move the choke lever to the “75%

Choke” detent position.

a. For restarting a warm engine, move the choke

lever to the “75% CHOKE” detent position.

8. Press and hold the ignition switch to the “START”

position. Release as the engine begins to start. If the

engine fails to start within ﬁve seconds, release the

switch and wait at least ten seconds before attempting

to start the engine again.

9. Do not over-choke. As soon as engine starts, gradually

move the choke lever to the “RUN” position over a 2-5

second duration.

10. RECOIL START: Move the choke lever to the “100%

Choke” detent position.

a. For restarting a warm engine, move the choke

lever to the “100% CHOKE” detent position.

11. PULL-TO-PRIME: Pull the starter cord slowly until

resistance is felt and then pull rapidly. Pull with

“100% Choke” 1-2 times until you feel a few

combustion pulses that indicates that the engine

momentarily started.

12. Move the choke lever to the “RUN” position.

13. Pull the starter cord slowly until resistance is felt and

then pull rapidly.

14. If engine fails to start in 1-pull with choke in the

“RUN”, then move choke to “100% Choke” and

repeat the PULL-TO-PRIME step.

For LPG starting in cold ambient < 15°C (59°F)

Move the choke lever to the “75% Choke” position

for electric starting and “100% Choke” for recoil

start. For electric start, gradually move the choke

lever to the “RUN” position over a 2-10 second

duration. To pull to prime for recoil start Pull with

“100% Choke” 1-3 times until you feel a few

combustion pulses that indicates that the engine

momentarily started.

NOTE

Page 8

OPERATION

Starting the Engine Cont’d. Stopping the Engine Cont ’d.

NOTE

Observing frost on LPG containers and regulators is common during operation and normally is not an indication of a problem. As LPG vapourizes and travels from the tank to the generator engine it expands. The amount of frost that forms can be affected by the size of the container, the amount of fuel being used, the humidity of the air and other operating conditions. In unusual situations this frost may eventually restrict the ﬂow of gas to the generator resulting in deteriorating performance. For example, if the tank temperature is reduced to a very low level then the rate at which the LPG vaporizes is also reduced and may not provide sufﬁcient fuel ﬂow to the engine. This is not an indication of a problem with the generator but only a problem with the ﬂow of gas from the LPG container. If generator performance seems to be deteriorating at the same time that ice formation is observed on tank valve, hose or regulator then some actions may be taken to eliminate this symptom. In these rare situations it can be helpful to reduce or eliminate the cold fuel system effects by doing one of the following:

– Exchanging fuel tanks to allow the ﬁrst tank to

warm up, repeating as necessary

– Placing the LPG container at the end of the

generator near the handle, where engine fan air ﬂows out from the generator. This air is slightly heated by ﬂowing over the engine. The container should not be placed in the path of the mufﬂer outlet.

– The container can be temporarily warmed by

pouring warm water over the top of the tank.

Connecting Electrical Loads

1. Let the engine stabilize and warm up for a few minutes after starting

2. Plug in and turn on the desired 120/240 Volt AC single phase, 50 Hz electrical loads.

– DO NOT connect 3-phase loads to the generator. – DO NOT connect 60 Hz loads to the generator. – DO NOT overload the generator.

Connecting a generator to your electric utility company’s power lines or to another power source may be against the law. In addition this action, if done incorrectly, could damage your generator and appliances and could cause serious injury or even death to you or a utility worker who may be working on nearby power lines. If you plan to run a portable electric generator during an outage, please notify your electric utility company immediately and remember to plug your appliances directly into the generator. Do not plug the generator into any electric outlet in your home. Doing so could create a connection to the utility company power lines. You are responsible for ensuring that your generator’s electricity does not feed back into the electric utility power lines. If the generator will be connected to a building electrical system, consult your local utility company or a qualiﬁed electrician. Connections must isolate generator power from utility power and must comply with all applicable laws and codes.

NOTE

Stopping the Engine

1. Turn off and unplug all electrical loads. Never start or stop the generator with electrical devices plugged in or turned on.

2. Let the generator run at no-load for several minutes to stabilize internal temperatures of the engine and generator.

3. Turn the Petrol Fuel Valve to the “OFF” position if operating by petrol.

4. Turn the LPG cylinder knob to the “CLOSE” or off position if operating by LPG.

5. Let the engine run until fuel starvation has stopped the engine. This usually takes a few minutes.

6. Press the ignition switch to the “OFF” position.

7. Turn battery switch to the “Off” Position.

Important: Always ensure that the Fuel Valve and the Ignition Switch are in the “OFF” position when the engine is not in use.

When turning off the generator after LPG operation, make sure the LPG cylinder knob is in the fully closed position.

NOTE

If the engine will not be used for a period of two (2) weeks or longer, please see the Storage section for proper engine and fuel storage.

NOTE

OPERATION

Do Not Overload Generator

Capacity

Follow these simple steps to calculate the running and

starting watts necessary for your purposes.

1. Select the electrical devices you plan on running at

the same time.

2. Total the running watts of these items. This is

the amount of power you need to keep your items

running.

3. Identify the highest starting wattage of all devices

identiﬁed in step 1. Add this number to the number

calculated in step 2. Surge wattage is the extra

burst of power needed to start some electric driven

equipment. Following the steps listed under “Power

Management” will guarantee that only one device will

be starting at a time.

Power Management

Use the following formula to convert voltage and

amperage to w atts:

Volts x Amps = Watts

To prolong the life of your generator and attached

devices, follow these steps to add electrical load:

1. Start the generator with no electrical load attached

2. Allow the engine to run for several minutes to stabilize.

3. Plug in and turn on the ﬁrst item. It is best to attach

the item with the largest load ﬁrst.

4. Allow the engine to stabilize.

5. Plug in and turn on the next item.

6. Allow the engine to stabilize.

7. Repeat steps 5-6 for each additional item.

Never exceed the speciﬁed capacity when adding loads to the generator.

NOTE

Page 9

MAINTENANCE AND STORAGE

The owner/operator is responsible for all periodic

maintenance.

Complete all scheduled maintenance in a timely manner.

Correct any issue before operating the generator.

Air Filter

1. Remove the snap-on cover holding the air ﬁlter to

the assembly.

2. Remove the foam element.

3. Wash in liquid detergent and water. Squeeze

thoroughly dry in a clean cloth.

4. Saturate in clean engine oil.

5. Squeeze in a clean, absorbent cloth to remove all

exce ss oil.

6. Place the ﬁlter in the assembly.

7. Reattach the air ﬁlter cover and snap in place.

Spark Plugs

1. Remove the spark plug cable from the spark plug.

2. Use a spark socket (not included) to remove the plug.

3. Inspect the electrode on the plug. It must be clean and

not worn to produce the spark required for ignition.

4. Make certain the spark plug gap is 0.7 - 0.8 mm or

(0.028 - 0.031 in.).

5. Refer to the spark plug recommendation chart when

replacing the plug.

6. Carefully thread the plug into the engine.

7. Use a spark plug socket (not included) to ﬁrmly

install the plug.

8. Attach the spark plug wire to the plug.

Maintenance, replacement, or repair of emission control devices and systems may be performed by any non-road engine repair establishment or individual.

NOTE

Improper maintenance will void your warranty.

WARNING

Oil Cont’d.

0.7 - 0.8 mm

0.028 - 0.031 in.

Engine Maintenance

To prevent accidental starting, remove and ground spark

plug wire before performing any service.

Oil

Change oil when the engine is warm. Refer to the oil

speciﬁcation to select the proper grade of oil for your

operating env ironment.

1. Remove the oil drain plug with a 15 mm socket and

extension (not included).

2. Allow the oil to drain completely.

3. Replace the d rain plug.

4. Remove oil ﬁll cap/dipstick to add oil.

5. Add oil and replace oil ﬁll

cap/dipstick. DO NOT OVERFILL.

6. Dispose of used oil at an approved waste

manag ement facilit y.

Once oil has been added, a visual check should show oil about 1-2 threads from running out of the ﬁll hole. If using the dipstick to check oil level, DO NOT screw in the dipstick while checking.

NOTE

Never operate a damaged or defective generator.

WARNING

Tampering with the factory set governor will void your warranty.

WARNING

Adjustments

The air-fuel mixture is not adjustable. Tampering with the governor can damage your generator and your electrical devices and will void your warranty.

Maintenance Schedule

Follow the service intervals indicated in the following

maintenance schedule.

Service your generator more frequently when operating

in adverse conditions.

Use a damp cloth to clean exterior surfaces of the engine. Use a soft bristle brush to remove dirt and oil. Use an air compressor (25 PSI) to clear dirt and debris from the engine.

Cleaning

DO NOT spray engine with water.

CAUTION

Water can contaminate the fuel system.

Spark Arrester

1. Allow the engine to cool completely before servicing the spark arrester.

2. Remove the screws holding the cover plate which retains the end of the spark arrester to the mufﬂer.

3. Remove the spark arrester screen.

4. Carefully remove the carbon deposits from the spark arrester screen with a wire brush.

5. Replace the spark arrester if it is damaged.

6. Position the spark arrester in the mufﬂer and attach with the screws .

Failure to clean the spark arrester will result in degraded engine performance.

CAUTION

MAINTENANCE AND STORAGE

*To be performed by knowledgeable, experienced owners or Champion Power Equipment certiﬁed dealers.

Generator Maintenance

Make certain that the generator is kept clean and stored properly. Only operate the unit on a ﬂat, level surface in a clean, dry operating environment. DO NOT expose the unit to extreme conditions, excessive dust, dirt, moisture or corrosive vapours.

Use a damp cloth to clean exterior surfaces of the generator. Use a soft bristle brush to remove dirt and oil. Use an air compressor (25 PSI) to clear dirt and debris from the generator. Inspect all air vents and cooling slots to ensure that they are clean and unobstructed.

DO NOT use a garden hose to clean the generator.

Water can enter the generator through the cooling slots and damage the generator windings.

CAUTION

Every 8 hours or daily

Check oil level

Clean around air intake and mufﬂer

Check hoses for leaks

First 5 hours

Change oil

Every 50 hours or every season

Clean air ﬁlter

Change oil if operating under heavy load or in hot environments

Every 100 hours or every season

Change oil

Clean/Adjust spark plug

Check/Adjust valve clearance*

Clean spark arrester

Clean fuel tank and ﬁlter*

Every 250 hours

Clean combustion chamber*

Every 3 years

Replace fuel line and LPG hose

Page 10

TROUBLESHOOTING

Problem Cause Solution

Generator will not start

No fuel Add fuel

Faulty spark plug Replace spark plug

Unit loaded during start up Remove load from unit

Generator will not start; Generator starts but runs roughly

Low oil level

Fill crankcase to the proper level

Place generator on a ﬂat, level surface

Choke in the wrong position Adjust choke

Spark plug wire loose Attach wire to spark plug

Generator will not start electrically

Generator battery is dead Recharge generator battery

Battery switch is in the “OFF” position Turn battery switch to “ON” position

Generator shuts down during operation

Out of fuel Fill the petrol tank or ﬁll LPG cylinder

Low oil level

Fill crankcase to the proper level. Place generator on a ﬂat, level surface

Generator cannot supply enough power or overheating

Generator is overloaded

Review load and adjust. See “Power Management”

Insufﬁcient ventilation

Check for air restriction. Move to a well ventilated area

No AC output

Cable not properly connected Check all connections

Connected device is defective Replace defective device

Circuit breaker is open Reset circuit breaker

Faulty brush assembly Replace brush assembly (Service Center)

Faulty AVR (auto voltage regulator) Replace AVR (Service Center)

Loose w iring Inspect and tighten wiring connections

Other Contact the help line

Repeated circuit breaker tripping

Overload

Review load and adjust. See “Power Management”

Faulty cords or device

Check for damaged, bare or frayed wires. Replace defective device

MAINTENANCE AND STORAGE

Storage

The generator should be started at least once every 14 days and allowed to run for at least 20 minutes. For longer term storage, please follow these guidelines.

Generator Storage

1. Add a properly formulated fuel stabilizer to the tank.

2. Be sure all appliances are disconnected from the generator.

3. Run the generator for a few minutes so the treated fuel cycles through the fuel system and carburetor.

4. Turn the fuel valve to the “Off” position.

5. Let the generator run until fuel starvation has stopped the engine. This usually takes a few minutes.

6. The generator needs to cool completely before cleaning a nd stor age.

7. Clean the generator according to the maintenance section.

8. Change the oil.

9. Remove the spark plug and pour about 14.8 mL (1⁄2 ounce) of oil into the cylinder. Crank the engine slowly to distribute the oil and lubricate the cylinder.

10. Reattach the spark plug.

11. Store the unit in a clean, dry place out of direct

sunlight .

Generator exhaust contains odourless and colourless carbon monoxide gas.

To avoid accidental or unintended ignition of your remote start generator during periods of storage, the following precautions should be followed:

– When storing the generator for short periods of

time make sure that the Ignition Switch, the Fuel Valve and the Battery Switch are set in the OFF position.

– When storing the generator for extended periods

of time make sure that the Ignition Switch, the Fuel Valve and the Battery Switch are set in the the the OFF position and the battery leads have been disconnected from the battery.

DANGER

Generator Battery

This product is equipped with an automatic battery

charging circuit. The battery will receive charging

voltage when the engine is running. The battery will

maintain a proper charge if the unit is used on a

regular basis (about once every two weeks). If it is used

less frequently, the battery should be connected to a

trickle charger (not included) or battery maintainer (not

included) to keep the battery properly charged. If the

battery is not able to start the engine, it can be started

by manually pulling the engine recoil cord. If the battery

voltage is extremely low, the charging circuit may not be

able to re-charge the battery. In this case, the battery

must be connected to a standard automotive style

battery charger for re-charging before it can be used.

Disconnect the Battery

1. Remove the protective cover from the black/negative

battery lead.

2. Disconnect the black/negative lead from the black/

negative terminal on the battery and store the cap

screw (M5x10) and nu t (M5).

3. Repeat steps 1-2 for the red/positive battery lead.

4. Store the battery in a cool, dry place.

A Float Charger will maintain the battery condition over long storage periods.

NOTE

Charge the Batter y

For a generator equipped with batteries for electric

starting, proper battery maintenance and storage should

be followed. An automatic battery charger (not included)

with automatic trickle charging capability should be used

to charge the battery. Maximum charging rate should not

exceed 1.5 amps. Follow the instructions included with

the battery charger. The battery should be fully charged

at least once per month.

Page 11

SPECIFICATIONSSPECIFICATIONS

SPECIFICATIONS CPG3500 E2-DF-EU

Gasoline Starting Watts 2800W

Gasoline Running Watt s 2500W

Propane Starting Watts 2600W

Propane Running Watts 2300W

Gasoline Starting Amps 12.73A

Gasoline Running Amps 11. 36 A

Propane Starting Amps 11 .8 2A

Propane Running Amps 10. 45A

Volts 220

Frequency 50Hz

Outlets 220V 16A Euro 2Pin

GFCI Outlets No

Covered Outlets Yes

Gasoline Run Time at 1/2 Load 10.0 h.

Propane Run Time at 1/2 Load 11.0 h.

Noise Level 68.0 dBA

Inverter No

Parallel C apability No

DC Operation No

Voltmeter Intelligau ge

Automatic Voltage Regulation Yes

Battery Yes

Sta rt Typ e Recoil/Electric Start

Engine Brand Champion

Engine Size 224cc

Engine Type 4-stro ke

Engine Speed 3000

Fue l Typ e Gasoline, Propane (LPG)

Fuel Gauge No

Gasoline Capacity 13L

Gasoline Tank Material Steel

Engine Oil Type 10W-30

Engine Oil Capacity 0.6 L

Engine Oil Included No

Low Oil Shut-Off Yes

Wheels Yes

Whe el Type So lid

Wheel Diameter 8.0 in.

ECCC Approved Ye s

SPECIFICATIONS CPG7500E2-DF-EU

Gasoline Starting Watts 7000W

Gasoline Running Watt s 6000W

Propane Starting Watts 5500W

Propane Running Watts 5000W

Gasoline Starting Amps 31.82 A

Gasoline Running Amps 27.27A

Propane Starting Amps 25 A

Propane Running Amps 22 .73A

Volts 220

Frequency 50Hz

Outlets 220V 16A Euro 2Pin

GFCI Outlets No

Covered Outlets Yes

Gasoline Run Time at 1/2 Load 8.0 h.

Propane Run Time at 1/2 Load 5.5 h.

Noise Level 74. 0 d BA

Inverter No

Parallel C apability No

DC Operation No

Voltmeter Intelligau ge

Automatic Voltage Regulation Yes

Battery Yes

Sta rt Typ e Recoil/Electric Start

Engine Brand Champion

Engine Size 439cc

Engine Type 4-stro ke

Engine Speed 3000

Fue l Typ e Gasoline, Propane (LPG)

Fuel Gauge No

Gasoline Capacity 23L

Gasoline Tank Material Steel

Engine Oil Type 10W-30

Engine Oil Capacity 1.1 L

Engine Oil Included Yes

Low Oil Shut-Off Yes

Wheels Yes

Whe el Type So lid

Wheel Diameter 9.5 in.

ECCC Approved Ye s

Page 12