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

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.

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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

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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.

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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)

(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

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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

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.