Champion CPG2500, CPG2500EU, CPG3500EU, CPG3500, CPG4000 E1-EU Owner's Manual & Operating Instructions

This manual covers the following models:

CPG2500 (EU) / CPG3500 (EU) / CPG4000 E1 (EU)
CPG6500 E2 (EU) / CPG 9000 E2 (EU)

OWNER’S MANUAL & OPERATING INSTRUCTIONS

SAVE THESE INSTRUCTIONS

Important Safety Instructions
are included in this manual.

PORTABLE GENERATOR

Frame Type

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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 m inor
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

If you have questions regarding your generator, we can

help. Please contact yor local dealer.

NOTE

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.

Portable Power Generator

This unit is a petrol engine driven AC generator used for

supply electrical pow er.

Accessories

CPE manufactures and supplies a serie s of accesso ries.

See local dealer for more information.

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 exces sively

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 serious injury.
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 before stopping the
generator.
DO NOT tamper with the governed speed.
DO NOT modify the generator in any way.

CAUTION

Generator exhaust contains carbon monoxide, a
colorless, odorless, 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 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

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

The engine exhaust from this product contains
chemicals that are known to cause serious health
problems and even death.

WARNING

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

Fuel and fuel vapors are highly flammable and
extremely ex plosive.
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 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.

Disconnect the spark plug wire.

When storing the genera tor:

Store away from sparks, open flames, pilot lights,

heat and other sources of ignition.

DANGER

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ASSEMBLY

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, contact yor 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 (Optional Extra)

You will need the following tools to install the wheels:

• 17 mm wrench OR adjustable wrench (not included)

• Socket wrench with a 16 mm socket (not included)

• Plier s (not includ ed)

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

2. Slide the M10x120 flange bolt through the washer,

sleeve and wheel.

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

4. Fasten securely with the M10 lock nut.

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

Install the Support Leg

1. Attach the vibration mounts to the support leg with

a flange bolt M8 x 25 and flange lock nuts.

2. Attach the support leg to the generator frame with

flange bolts M8 x 16 and flange lock nuts and

fasten securely. DO NOT over tighten the lock nuts.

3. 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 (Electric Start Models
only)

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 cap screw (M5x10) and secure with

the lock washer (M5).

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

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.

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

NOTE

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

Add Engine Oil

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

ASSEMBLY

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

NOTE

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

NOTE

Add Engine Oil Cont’d.

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 <5ºC (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

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

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

Full Synthetic 5W-30

Degrees Celsiusº

(Outside)

(Outside)

Degrees Fahrenheitº

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ASSEMBLY

Add Fuel 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

Our engines work well with 10% or less ethanol

blend fuels. When using blended fuels there are

some issues worth noting:

– Ethanol-gasoline blends can absorb more water

than gasoline 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

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

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

for fuel expansion, more than ¼ in. (6.4 mm) 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 gasoline with a minimum
octane rating of 85.

Do not mix oil and gasoline.
Fill tank to approximately ¼ in. (6.4 mm) below the
top of the tank to allow for fuel expansion.
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 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

OPERATION

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 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

Starting the Engine

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 Fuel Valve to the “ON” position.

4. Move the choke lever to the “CHOKE” position.

5. Flip the ignition switch to the “ON” position.

6. For models that have an ELECTRIC START: Press

and hold the ignition switch to the “START” position.

Release as the engine begins to roll over. 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.

7. RECOIL START: Pull the starter cord slowly until

resistance is felt and then pull rapidly

8. Do not over-choke. As as soon as engine starts, move

the choke lever to the “RUN” position.

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.

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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

OPERATION

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 Fuel Valve to the “OFF” position.

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

5. Press the Ignition 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.

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

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

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 will
cause the engine not to start.

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. Connecting Electrical Loads Cont’d.

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

OPERATION

Operation at High Altitude

Be aware that engine efficiency can reduce and exhaust

emissions increase when working at high altitude.

Other high altitude issues can include hard starting,

increased fuel consumption and spark plug fouling.

This is a natural trend and cannot be altered by engine

adjustm ent.

11

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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. CPE
recommends that you contact your local dealer for all
other service and/or adjustment needs.

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 three sc rews.

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

CAUTION

MAINTENANCE AND STORAGE

Federal and local laws and administrative requirements
indicate when and where spark arresters are required.

NOTE

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

MAINTENANCE AND STORAGE

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 vapors.

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

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

The owner/operator is responsible for all periodic

maintenance.

Complete all scheduled maintenance in a timely manner.

Correct any issue before operating the generator.

Never operate a damaged or defective generator.

Tampering with the factory set governor will void
your warranty.

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 (no t 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.

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. 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. Refer to spark plug information located in the

“specification” page for this model.

5. Carefully thread the plug into the engine.

6. Use the spark plug tool (not included) to firmly install

the plug.

7. 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

WARNING

WARNING

Improper maintenance will void your warranty.

WARNING

Oil Cont’d.

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