Champion 100574 Operator'S Manual Download

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100574 - 3500W DIGITAL HYBRID INVERTER GENERATOR

TABLE OF CONTENTS

Introduction

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Safety Definitions

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Important Safety Instructions

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Fuel Safety

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Safety and Dataplate Labels

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Safety Symbols

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Operation Symbols

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Quickstart Label Symbols

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Controls and Features

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Generator

.......................................................

Control Panel

...................................................

Parts Included

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Assembly

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Unpacking

......................................................

Add Engine Oil

..................................................

Add Fuel: Gasoline

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Add Fuel: Propane (LPG)

.......................................

Grounding

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Operation

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Generator Location

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Surge Protection

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Fuel Selector Switch

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Starting the Engine: Gasoline

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Starting the Engine: Propane (LPG)

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Connecting Electrical Loads

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Do Not Overload Generator

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Eco (Economy) Mode

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12V DC Automotive Style Outlet

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Parallel Operation

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Stopping the Engine

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Moving the Generator

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Operation at High Altitude

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Maintenance

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Cleaning the Generator

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Changing the Engine Oil

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Cleaning and Adjusting the Spark Plug

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Cleaning the Air Filter

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Cleaning the Spark Arrestor

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Adjusting the Governor

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Maintenance Schedule

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Storage

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Short Term Storage (up to 30 days)

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Mid Term Storage (30 days – 1 year)

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Long Term Storage (over 1 year)

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Removing from Storage

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Specifications

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Generator Specifications

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Engine Specifications

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Oil Specifications

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Fuel Specifications

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Temperature Specifications

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Parts Diagram

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Parts List

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Engine Parts Diagram

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Engine Parts List

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Wiring Diagram

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Troubleshooting

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Warranty*

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Warranty Qualifications

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Repair/Replacement Warranty

.................................

Do Not Return The Unit To The Place Of Purchase

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Warranty Exclusions

...........................................

Other Exclusions

...............................................

Limits of Implied Warranty and Consequential Damage

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Contact Information

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Summary of Contents for 100574

Page 1: ...efore 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 meets the requirements of the PGMA Portable Generator Manufacturers Association standard ANSI PGMA G300 2015 Safet...

Page 2: ...g the Engine 22 Moving the Generator 22 Operation at High Altitude 22 Maintenance 23 Cleaning the Generator 23 Changing the Engine Oil 23 Cleaning and Adjusting the Spark Plug 23 Cleaning the Air Filter 24 Cleaning the Spark Arrestor 24 Adjusting the Governor 24 Maintenance Schedule 24 Storage 25 Short Term Storage up to 30 days 25 Mid Term Storage 30 days 1 year 25 Long Term Storage over 1 year 2...

Page 3: ...Every effort has been made to ensure the accuracy and completeness of the information in this manual at the time of publication and we reserve the right to change alter and or improve the product and this document at any time without prior notice CPE highly values how our products are designed manufactured operated and serviced as well as providing safety to the operator and those around the gener...

Page 4: ... 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 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...

Page 5: ...ns could result When starting engine pull the recoil 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 ...

Page 6: ...PG will burn skin if it comes in contact with it Keep any and all LPG away from skin at all times When adding or removing gasoline DO NOT light or smoke cigarettes Turn the generator off and let it cool for at least two minutes before removing the gasoline cap Loosen the cap slowly to relieve pressure in the tank Only fill or drain gasoline outdoors in a well ventilated area DO NOT pump gasoline d...

Page 7: ...nents are extremely HOT and cause burns 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 and regulations relating to fire prevention requirements If installed clean every 100 hours or every season ADVERTENCIA NO TOCAR Los gases de escape el silenciador y los compnonente...

Page 8: ...ments before 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 c...

Page 9: ...l allow you to more safely operate the product SYMBOL MEANING ON STOP or OFF Gasoline Valve ON Propane Valve ON Choke Knob Choke Pull choke knob to CHOKE position Run Push choke knob to RUN position ECO Economy Mode Switch RV Ready Receptacle SYMBOL MEANING Ground Terminal 12V Direct Current Parallel Connection s Output OK Overload Low Oil Neutral Floating Neutral circuit IS NOT electrically conne...

Page 10: ...Engine DANGER Move generator outside and far away from windows doors and intake ventilation covers 1 Check oil level Recommended oil is 10W 30 2 Add fuel 2a If operating on gasoline check gasoline level When adding gasoline use a minimum octane rating of 85 and an ethanol content of 10 or less by volume 2b If operating on propane connect propane tank Open valve on propane tank 3 Fuel selector 3a T...

Page 11: ...ls and features Save this manual for future reference Generator 1 Fuel Cap Remove to add fuel 2 Gasoline Tank 2 9 gal 11 L 3 Air Filter Protects the engine by filtering dust and debris from the intake air 4 Recoil Starter Used to manually start the engine 5 Oil Fill Cap Dipstick Used to check and fill oil level 6 Control Panel See Control Panel section 7 Carrying Handle s Used to lift or carry the...

Page 12: ... is overloaded and power to receptacles is cut 8 Oil Warning Indicator Light When ON engine will shut down and not run Check oil level 9 Parallel Outlets Used for parallel operation parallel kit sold separately 10 Ground Terminal Consult an electrician for local grounding regulations 11 Circuit Breakers Push Reset Protects the generator against electrical overloads RECEPTACLES A z 12V DC 8 Amp Aut...

Page 13: ...00574 3500W DIGITAL HYBRID INVERTER GENERATOR CONTROLS AND FEATURES 13 Parts Included Accessories Oil Funnel 1 Dual 2 4A Port USB Adapter 1 Battery Charging Cables 1 3 3 ft 1 m LPG Hose with Regulator 1 ...

Page 14: ...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 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 20 3 fl oz 0 6 qt 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 MAX MIN OIL DIP STICK NOTICE Once oil has b...

Page 15: ...ner 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 gasoline too fast through the fuel screen may result in gasoline splashing over the generator and operator while filling NOTICE The generator engine works well with 10 or less ethanol blend gasoline When using ethanol gasoline blends there are some issues worth ...

Page 16: ...f the cylinder valve and generator LPG 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 WARNING If there is a strong smell of LPG Close valve on the cylinder Check all connections for leaks by wetting the fittings with a solution of soap and water Bubbles which appear or bubbles ...

Page 17: ...ns may void manufacturer s warranty WARNING 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 will become hot If adequate cooling and breathing space are no...

Page 18: ...or gasoline restarts with hot engine in hot ambient 86 F 30 C Keep the choke in 75 of the CHOKE position for 1 2 pulls of the recoil cord After first pulls push choke to the RUN position for up to 3 more pulls of the recoil cord Too much choke leads to spark plug fouling engine flooding due to the lack of incoming air This will cause the engine not to start NOTICE For gas starting in cold ambient ...

Page 19: ...rter cord slowly until resistance is felt and then pull rapidly 9 Allow the engine to warm up several seconds before gradually pushing the choke to the RUN position NOTICE For LPG restarts with hot engine in hot ambient temperature 86 F 30 C move the choke to the half CHOKE position and prime the engine with only 1 2 slow pulls Then follow normal starting procedure NOTICE For LPG starting in cold ...

Page 20: ...he desired 120 or 240 if applicable Volt AC single phase 60 Hz electrical loads DO NOT connect 3 phase loads to the generator DO NOT overload the generator WARNING 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 injur...

Page 21: ...et turn the Eco Mode switch to the OFF position WARNING Do not operate a device while it is plugged in to the 12V DC outlet Prolonged exposure to engine exhaust can cause serious injury or death CAUTION While charging a device do not place on the exhaust side of the generator Extreme heat caused by exhaust can damage the device and cause a potential fire hazard Battery Charging 1 Before connecting...

Page 22: ...dled safely typically 15 30 minutes Lift unit up by the frame with 2 people and move to the desired location Do not drop or strike unit or place under heavy objects Failure to follow these instructions could result in personal injury or damage to the generator Operation at High Altitude The density of air at high altitudes is lower than at sea level Engine power is reduced as the air mass and air ...

Page 23: ...slots and damage the generator windings It can also contaminate the fuel system 1 Use a damp cloth to clean exterior surfaces of the generator 2 Use a soft bristle brush to remove dirt and oil 3 Use an air compressor 25 PSI to clear dirt and debris from the generator 4 Inspect all air vents and cooling slots to ensure that they are clean and unobstructed To prevent accidental starting remove and g...

Page 24: ...ews removed in step 2 CAUTION Failure to clean the spark arrestor will result in degraded engine performance NOTICE Federal and local laws and administrative requirements indicate when and where spark arrestors are required When ordered spark arrestors are required for operation of this generator in National Forest lands In California this generator must not be used on any forest covered land brus...

Page 25: ...up and clog the carburetor if the generator is not run or carburetor drained within 4 weeks 1 Be sure all appliances are disconnected from the generator 2 Start the generator as instructed in Starting the Engine section 3 Turn the fuel valve to the horizontal OFF LPG position 4 Let the engine run until fuel starvation has stopped the engine This usually takes a few minutes 5 Move the engine switch...

Page 26: ...f necessary under the carburetor drain bolt to avoid spillage 3 When gasoline stops flowing from the carburetor replace and tighten the carburetor drain bolt and be sure to properly dispose of the drained gasoline according to local regulations or guidelines 4 Turn the fuel valve to the horizontal OFF position 5 Follow steps 8 11 according to Mid Term Storage Removing from Storage If the generator...

Page 27: ...ecommended 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...

Page 28: ...6 20 22 23 24 17 18 19 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 4 12 13 8 2 8 21 40 41 42 43 44 45 23 46 47 48 4 49 50 51 52 23 4 53 54 55 28 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 73 74 75 76 77 78 71 72 79 80 81 82 83 84 85 86 87 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 89 88 ...

Page 29: ...her Ø24 Ø6 5 1 5 Black 4 33 1 93 06 Lock Washer Ø6 4 34 1 5789 0620 1 Flange Bolt M6 20 Black 4 35 24 070014 01 Pipe Reversal Valve 720 32mm 1 Part Number Description Qty 36 2 06 006 Clamp Ø7 Ø1 3 37 24 070800 00 Reversal Valve 1 38 122 070100 07 Fuel Tank Cap 1 39 122 070300 03 Fuel Filter 1 40 85 070014 01 Pipe Air Cleaner 260 30mm 1 41 122 070700 00 Carbon Canister 320CC 1 42 1 5789 0610 1 Flan...

Page 30: ... 5 1120 010 Receptacle 5 20R Duplex 1 87 1 6177 1 04 1 Lock Nut M4 Flange Black 6 88 1 845 4216 Screw ST4 2 16 1 89 5 1820 004 Charger 1 90 5 1870 008 Receptacle Cover Receptacle 5 20R Duplex 1 91 5 1870 004 Receptacle Cover Receptacle TT 30R 1 92 1 9074 4 0514 1 Screw Washer Assembly M5 14 Black 4 93 85 061200 02 2 Guide Plate Rope Black 1 94 113 200106 00 Protector Front Cover 1 95 1 5789 0615 1...

Page 31: ...5 37 38 12 40 41 42 43 44 46 47 21 22 23 24 32 34 36 39 51 52 60 62 61 63 65 66 67 68 69 70 71 72 74 25 93 94 95 92 91 90 26 78 79 80 82 83 84 85 86 87 88 76 77 1 33 81 73 15 20 48 14 55 45 54 64 53 11 18 17 89 75 49 50 59 58 77 28 29 100 19 16 56 57 27 96 19 31 99 98 30 101 35 26 39 74 73 36 78 79 81 80 91 102 103 ...

Page 32: ... 90 2 37 85 030100 01 Crankcase 1 38 21 127000 02 Oil Level Sensor 1 39 26 010100 01 Cylinder Head 224cc 1 40 27 050200 00 Connecting Rod 1 41 85 050100 01 Crankshaft 1 Part Number Description Qty 42 1 276 6205 Bearing 6205 2 43 24 030008 00 Gasket Crankcase Cover 1 44 46 031000 00 48 Oil Dipstick Assembly Yellow 1 45 1 6177 06 Flange Nut M6 2 46 85 030007 01 Cover Crankcase 1 47 1 5789 0832 Flang...

Page 33: ...1 06 Lock Nut M6 Flange 2 89 1 5789 0620 Flange Bolt M6 20 1 90 24 040201 00 Retainer Rocker Arm 1 91 23 040010 00 Bolt Rocker Arm 2 92 27 040005 00 Push Rod 2 93 21 020002 01 Gasket Cylinder Head Cover 1 94 24 021000 00 Cover Cylinder Head 1 95 23 020001 02 Breather Tube 112 35 mm 1 96 27 131017 01 Main Jet Standard 1 27 131017 01 01 Main Jet Altitude 97 1 6177 1 05 Lock Nut M5 Flange 3 98 85 130...

Page 34: ...THYST O ORANGE OUTPUT PANEL 5 20R R W R R B B G Y C G Y G G G Y TT 30R STEPPING MOTOR THROTTLE PARALLEL TERMINAL Red Black R R W W G Y R IGNITION COIL B G B G SWITCH a c d f b e 3 4 2 1 Charger ECO SW STOP SW W G W G W G 3 4 2 1 OFF ON COMBINATION SWITCH GAS LPG SWITCH c e a b f d B G Y G Y 1 2 3 4 G G O C CONTROL UNIT W B W O O Y L C R R R Y Y R W B R W C 6 1 4 3 2 5 J1 J2 J3 J6 J4 J5 SPARK PLUG ...

Page 35: ...verheating Generator is overloaded Review load and adjust See Connecting Electrical Loads Dirty air filter Clean or replace air filter Choke in wrong position Move choke until it stops under RUN position or push in completely Engine is running but no AC output Poor cord connection Check all connections Circuit breaker is open Reset circuit breaker Loose wiring Inspect and tighten wiring connection...

Page 36: ...ctly 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 as starting batteries and storage covers Failures due to acts of God and other forc...

Page 37: ...table 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 equipment is defective in the part will be repaired or replaced by CPE OWNER WARRANTY RESPON...

Page 38: ...ed 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 the...

Page 39: ... Mounting Brackets Carburetor Purge Port Connector TO OBTAIN WARRANTY SERVICE You must take your CPE engine or the product on which it is installed along with your warranty registration card or other proof of original purchase date at your expense to any Champion Power Equipment dealer who is authorized by Champion Power Equipment Inc to sell and service that CPE product during his normal business...

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