Champion Global Power Equipment 100522 Page 30 Operator'S Manual Download

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100522 - 3500W PORTAbLE GENERATOR

SPECIfICATIONS

Part Number

Description

Qty.

100011264-0003

Flange Bolt M6 × 16,
GB5789

100002335

Cylinder Head
Cover(Cpe)

100031972

Breather Tube

100066138

Gasket, Cylinder Head
Cover

100011463-0002

Flange Nut M6

100004431

Rocker Arm Assembly

100004512

Shaft, Rocker Arm

100004506

Retainer, Rocker Arm

100004505

Bolt, Rocker Arm

100004478

Guide Plate, Push Rod

100004588

Valve Adjust Cap,
Exhaust

100004585

Valve Spring Seat,
Exhaust

100004564

Spring, Valve

100004600

Oil Seal, Valve

100002464-0001

Flange Bolt M8 × 60

100002389

Cylinder Head

100009378

Spark Plug F6RTC

100010389

Stud Bolt M8 × 35

100010354

Stud Bolt M6 × 96

100092295

Gasket, Insulator

100005599

Insulator, Carburetor

100078606

Gasket, Carburetor

100086220-0001

Carburetor

100066136

Gasket, Air Filter Base

100004745

Air Filter Assembly

100005023

Air Filter Base

100004894

Air Filter Clip

100004877

Air Filter Separator

100011250-0002

Flange Bolt M5 × 14

100004795

Gasket, Air Filter Cover

100004770

Air Filter Element

100004873

Air Filter Cover

100011452-0003

Lock Nut M6, Flange

100007111

Air Guide, Lower

100011261-0004

Flange Bolt M6 × 12,
GB5789

100010213

Gasket, Cylinder Head

100010558

Dowel Pin Ø10 × 16

100004408

Push Rod

Part Number

Description

Qty.

100004550

Valve, Exhaust

100004524

Valve, Intake

100004263

Lifter, Valve

100003245

Piston Ring Set

100003150

1st Piston Ring

100003191

2nd Piston Ring

100003283

Oil Ring

100003221

Circlip, Wrist Pin

100003081

Piston

100003125

Wrist Pin

100003448

Connecting Rod

100003430

Bolt, Connecting Rod

100002664

Crankcase

100010787

Bearing TM6205 - P63

100003770

Crankshaft

100092356

Camshaft

100010025

Oil Level Sensor

100011217-0002

Flange Bolt M6 × 16

100010544

Dowel Pin Ø7 × 14

100010554

Dowel Pin Ø9 × 14

100092294

Gasket, Crankcase
Cover

100002990

Cover, Crankcase

100017651

Oil Seal
Ø25 × Ø41.25 × 6

100011319-0001

Flange Bolt M8 × 32

100004107-0001

Oil Dipstick Assembly

100008296

Gear, Governor

100011215-0001

Flange Bolt M6 × 12

100008186

Control Assembly

100061649

Spring, Governor

100007947

Rod, Governor

100007920

Spring, Throttle Return

100008417

Arm, Governor

100007986

Cotter, Governor Shaft

100017630

Oil Seal Ø6 × Ø11 × 4

100010113

Sealing Ring,
Ø5.2 × 1.9

100007975

Governor Shaft

100005138

Clamp Ø9.5 × 8

100017831

Fuel Pipe,
Ø4 × Ø10 × 126

100010272

Drain Bolt,
M10 × 1.25 × 15

Engine Parts List

Summary of Contents for 100522

Page 1: ...e operating the product Failure to do so could result in serious injury This manual should remain with the product Specifications descriptions and illustrations in this manual are as accurate as known at the time of publication but are subject to change without notice This product is rated in accordance with PGMA Portable Generator Manufacturers Association standard ANSI PGMA G300 Safety and Perfo...

Page 2: ...ngine 19 Connecting Electrical Loads 20 Do Not Overload Generator 20 Stopping the Engine 20 Operation at High Altitude 21 Maintenance 21 Cleaning the Generator 21 Changing the Engine Oil 21 Cleaning and Adjusting the Spark Plug 22 Cleaning the Air Filter 22 Cleaning the Spark Arrestor 22 Adjusting the Governor 22 Maintenance Schedule 23 Storage 23 Short Term Storage up to 30 days 23 Mid Term Stora...

Page 3: ...s exercise common sense and always err on the side of caution when operating the product to ensure no accident property damage or injury occurs We want you to continue to use and be satisfied with your CPE product for years to come When contacting CPE about parts and or service you will need to supply the complete model and serial numbers of your product Transcribe the information found on your pr...

Page 4: ...g 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 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 t...

Page 5: ... result When starting engine pull the starter cord slowly until resistance is felt and then pull rapidly to avoid kickback DO NOT start or stop the engine with electrical devices plugged in and turned on CAUTION Exceeding the generator s running capacity can damage the generator and or electrical devices connected to it DO NOT overload the generator DO NOT tamper with the governed speed DO NOT mod...

Page 6: ... relieve pressure in the tank Only fill or drain gasoline outdoors in a well ventilated area DO NOT pump gasoline directly into the generator at the gas station Use an approved container to transfer the fuel to the generator DO NOT overfill the gasoline tank Always keep gasoline away from sparks open flames pilot lights heat and other sources of ignition When starting the generator DO NOT attempt ...

Page 7: ...NS PLOMB SEULEMENT Indice d octane minimal de 85 Maximum 10 d éthanol 1032 L OP A K 109 Colors LPN 1032 L OP Rev A Size 78 x 20 mm Artwork Notes 3mm corner radius 2mm safe margin Revision Changes This artwork belongs to Champion Power Equipment The contents are confidential and privileged and shall not be disclosed to or used by or for outside parties without the explicit consent of Champion Power...

Page 8: ...ore operation Electric Shock Failure to use in dry conditions and to observe safe practices can result in electric shock Improper connections to a building can allow current to backfeed into utility lines creating an electrocution hazard A transfer switch must be used when connecting to a building Fire Explosion Fuel and its vapors are extremely flammable and explosive Fire or explosion can cause ...

Page 9: ...n their meaning Proper interpretation of these symbols will allow you to more safely operate the product SYMBOL MEANING ON STOP or OFF Locking Receptacle RV Ready Receptacle Circuit Breaker Reset Push SYMBOL MEANING Neutral Floating Neutral circuit IS NOT electrically connected to the frame ground of the generator Fuel Gasoline Valve ON OFF Choke Run Ground Terminal ...

Page 10: ...alve to ON position 4 Press engine switch to the ON position 5 Move choke lever to CHOKE position 6 Pull the recoil starter 7 Move the choke lever to RUN position 8 Plug in desired device Stopping the Engine 1 Turn off and unplug all connected electrical loads 2 Press the engine switch to the OFF position 3 Turn the fuel valve to the OFF position 1500 L OP B 3 1 1 2 2 3 4 5 10W 30 7 6 8 K 376 186 ...

Page 11: ...el supply on and off to engine 4 Air Filter Protects the engine by filtering dust and debris from the intake air 5 Recoil Starter Used to manually start the engine 6 Never Flat Wheels 8 in 20 3 cm 7 Oil Fill Cap Dipstick Used to check and fill oil level 8 Control Panel See Control Panel section 9 Fuel Gauge Indicates the amount of gasoline in the fuel tank 10 Folding Handle Used to move unit by li...

Page 12: ...erator against electrical overloads 1 2 3 A B C RECEPTACLES A W 120V AC 30A Locking NEMA L5 30R May be used to supply electrical power for operation of 120 Volt AC 30 Amp single phase 60 Hz electrical loads B t 120V AC 30A RV NEMA TT 30R May be used to supply electrical power for operation of 120 Volt AC 30 Amp single phase 60 Hz electrical loads C A 2 120V AC 20A NEMA 5 20R May be used to supply ...

Page 13: ...rtz Example 60 0 hertz Run Time R Run time of the generator for the current session Example 6 hours Total Run Time Total run time of the generator since first operation Example 16 hours Intelligauge Four mode digital meter for displaying voltage frequency hertz run time and total run time The LCD displays each mode by pressing the button below the display MODE BUTTON ...

Page 14: ...s Wheels 8 in 20 3 cm Never Flat Wheel A 2 Roll Pin B 2 Large R clip C 2 Engine Vibration Mounts Support Leg with Vibration Mounts D 1 Flange Bolt M8 16 E 2 Flange Lock Nut M8 F 2 Folding Handle Handle G 1 Short Pin H 1 Small R clip I 1 Tools Needed Wrench Socket set metric Pliers Screwdriver A B D G H I E F C ...

Page 15: ... or gasoline to the generator NOTICE DO NOT attempt to run generator without first removing the shipping support brackets Damage to the generator as a result of not removing the brackets will void the warranty 1 BEFORE filling the engine with oil or gasoline tip the generator onto it s recoil end Tip onto the flattened cardboard box the generator came in or other protective surface so as to not sc...

Page 16: ... 30 Synthetic 10W 40 5W 30 1 Place the generator on a flat level surface 2 Remove oil fill cap dipstick to add oil 3 Using a funnel add up to 18 6 fl oz 0 6 qt 0 6 L of oil not included and replace oil fill cap dipstick DO NOT OVERFILL 4 Check engine oil level at every use and add as needed NOTICE Once oil has been added a visual check should show oil about 1 2 threads from running out of the fill...

Page 17: ...or smoke when filling the tank DO NOT mix oil and gasoline DO NOT overfill the tank Fill tank to approximately in 6 4 mm below the top of the tank to allow for gasoline expansion DO NOT pump gasoline directly into the generator at the pump Use an approved container to transfer the gasoline to the generator DO NOT fill tank indoors DO NOT fill tank when the engine is running or hot WARNING Pouring ...

Page 18: ...t 1 5 m of clearance from all combustible material In addition to clearance from all combustible material generators must also have at least 3 ft 91 4 cm of clearance on all sides to allow for adequate cooling maintenance and servicing Generators should never be started or operated in the back of a SUV camper trailer in the bed of a truck regular flat or otherwise under staircases stairwells next ...

Page 19: ...on as engine starts move the choke to the RUN position over a 2 5 second duration 8 Connect electrical loads NOTICE Keep choke in CHOKE position for only 1 pull of the recoil starter After first pull move choke to RUN position for up to 3 pulls of the recoil starter Too much choke leads to spark plug fouling engine flooding due to lack of incoming air This will cause the engine not to start NOTICE...

Page 20: ...l 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 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 run...

Page 21: ... number corresponding to the carburetor code found on your particular carburetor Carb Code High Alt Jet Part Number Min Altitude Z922 100082378 3281 ft 1000 m 100123767 6562 ft 2000 m WARNING Operation using the alternative main jet at elevations lower than the recommended minimum altitude can damage the engine For operation at lower elevations the originally supplied standard main jet must be use...

Page 22: ...t included or a 13 16 in 21 mm 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 0 024 0 031 in 0 6 0 8 mm SPARK PLUG GAP 5 Refer to the spark plug types in Specifications when replacing the plug 6 Firmly re install the plug 7 Attach the spark plug cable to the spa...

Page 23: ...fler FIRST 5 HOURS BREAK IN Change oil EVERY 50 HOURS OR ANNUALLY Clean air filter Change oil if operating under heavy load or in hot environments EVERY 100 HOURS OR ANNUALLY Change oil Clean adjust spark plug Check adjust valve clearance Clean spark arrestor Clean fuel tank and filter EVERY 250 HOURS Clean combustion chamber EVERY 3 YEARS Replace fuel line To be performed by knowledgeable experie...

Page 24: ... year For storage over 1 year the gasoline tank and carburetor must be completely drained of gasoline 1 Follow steps 1 4 according to Mid Term Storage 1a Turn engine switch to the OFF position and allow generator to cool completely before continuing 2 Use the drain bolt on the carburetor to empty any excess gasoline from the gasoline tank and carburetor into an appropriate container Use a funnel a...

Page 25: ...ended Engine Oil Type 80 100 120 28 9 F C 17 8 6 7 4 4 15 6 26 7 37 8 48 9 10W 30 5W 30 Synthetic 10W 40 5W 30 NOTICE Temperature will affect engine oil and engine performance Change the type of engine oil used based on the temperature to suit the engine needs Fuel Specifications Use unleaded gasoline with a minimum octane rating of 85 and an ethanol content of 10 or less by volume DO NOT USE E15 ...

Page 26: ... 24 25 23 31 30 32 37 38 38 34 35 35 36 39 40 41 42 43 44 45 46 47 48 51 52 53 54 55 56 57 58 59 60 66 67 68 61 62 64 65 69 73 74 76 75 86 85 27 26 88 87 89 90 91 92 63 63 63 31 33 39 39 39 39 49 50 53 53 62 61 70 71 72 78 82 80 79 77 81 32 83 44 84 65 7 13 14 15 1 12 9 10 11 5 4 3 6 29 93 8 28 ...

Page 27: ... 5 32 100009075 Rubber Damper 3 Part Number Description Qty 33 100009983 Grounding Line 150 mm 1 34 100011421 0003 Flange Nut M6 1 35 100010920 0002 Flat Washer Ø6 2 36 100010828 0002 Butterfly Type Nut M6 1 37 100011025 0001 Lock Washer Ø6 Toothed 1 38 100010886 0004 Spring Washer Ø6 2 39 100011453 0003 Lock Nut M8 Flange 10 40 100020978 0001 Support Leg Assembly 1 41 100011452 0003 Lock Nut M6 F...

Page 28: ...77 100000658 Clamp 2 2 78 100005148 Clamp 1 1 79 100095515 Connection Tube 1 800 mm 1 80 100095519 Connection Tube 2 245 mm 1 81 100005135 Clamp Ø11 5 10 2 82 100094372 Carbon Canister 380 cc 1 83 100004241 Bushing Ø8 5 9 2 84 100011422 0004 Flange Nut M8 2 85 100006936 Gasket Exhaust Pipe 1 86 100087308 Exhaust Muffler Assembly 1 87 100097575 0001 Flange Bolt M6 10 4 88 100006811 Muffler Cover 1 ...

Page 29: ...100522 3500W Portable Generator Specifications 29 Engine Parts Diagram ...

Page 30: ...uide Lower 1 35 100011261 0004 Flange Bolt M6 12 GB5789 6 36 100010213 Gasket Cylinder Head 1 37 100010558 Dowel Pin Ø10 16 2 38 100004408 Push Rod 2 Part Number Description Qty 39 100004550 Valve Exhaust 1 40 100004524 Valve Intake 1 41 100004263 Lifter Valve 2 42 100003245 Piston Ring Set 1 43 100003150 1st Piston Ring 1 44 100003191 2nd Piston Ring 1 45 100003283 Oil Ring 1 46 100003221 Circlip...

Page 31: ...07550 Pulley Starter 1 86 100011459 0003 Flange Nut M14 1 5 1 87 100099123 0001 Recoil Starter Assembly 1 88 100007659 0002 Fan Cover Yellow 1 89 100099122 0001 Recoil Starter Black 1 90 100010894 0001 Washer Ø6 3 91 100011528 0004 Flange Bolt M6 10 3 92 100127017 Cylinder Head Assembly 1 93 100082397 Fuel Bowl O Ring 1 94 100123334 Main Jet Standard 1 100082378 Main Jet Altitude 1000 2000m 100123...

Page 32: ...100522 3500W Portable Generator Specifications 32 Wiring Diagram ...

Page 33: ...Generator cannot supply enough power or overheating Generator is overloaded Review load and adjust See Connecting Electrical Loads Dirty air filter Clean or replace air filter No AC output Power cord 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 C...

Page 34: ...oaded beyond the product s limits modified installed improperly or connected incorrectly to any electrical component Normal maintenance is not covered by this warranty and is not required to be performed at a facility or by a person authorized by CPE Other Exclusions This warranty excludes Cosmetic defects such as paint decals etc Wear items such as filter elements o rings etc Accessory parts such...

Page 35: ...n system catalytic converter and other exhaust emission related assemblies Where a warrantable condition exits CPE will repair your small off road engine SORE at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE This exhaust and evaporative emission control system is warranted for two years If any exhaust and evaporative emission related part on your engine or equ...

Page 36: ...ted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by CPE according to Subsection d below Any such exhaust and evaporative emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to th...

Page 37: ...ive Controls Fuel Tank Fuel Cap Fuel Lines for liquid fuel and fuel vapors Fuel Line Fittings Clamps Pressure Relief Valves Control Valves Control Solenoids Electronic Controls Vacuum Control Diaphragms Control Cables Control Linkages Purge Valves Gaskets Liquid Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector TO OBTAIN WARRANTY SERVICE You must take your ...

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