Champion 500560-UK Operator'S Manual Download Page 40

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500560-UK - 2800W RATED PORTAbLE GENERATOR

SPECIfICATIONS

figure D Engine Parts List

Part Number

Description

Qty.

100078607

Gasket, Insulator

100005599

Insulator, Carburetor

100078606

Gasket 1, Carburetor

100750076-0001

Carburetor

100005717

Fuel Bowl O-Ring

100005754

Main Jet Standard

100005765

Main Jet Altitude
1000-3000m

100006037

Fuel Bowl Mounting
Bolt Gasket

100005725

Fuel Bowl Mounting
Bolt

100005148

Clamp

100017784-0001

Fuel Tube, Ø4 x Ø8 x
126

100005629-0001

Gasket 2, Carburetor

Summary of Contents for 500560-UK

Page 1: ...ing 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 REGISTER YOUR PRODUCT ONLINE at championpowerequipment co uk or visit www championpowerequipment co uk 44 0 1942 715 407 Original Instructi...

Page 2: ... 21 Storage 22 Short Term Storage up to 30 days 22 Mid Term Storage 30 days 1 year 22 Long Term Storage over 1 year 23 Transportation 23 Removing from Storage 23 Specifications 24 Generator Specifications 24 Engine Specifications 24 Oil Specifications 24 Fuel Specifications 24 Temperature Specifications 24 Figure A Parts Diagram 25 Figure A Part List 26 Figure E Parts Diagram 27 Figure E Part List...

Page 3: ...se always 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...

Page 4: ...risk fire A DANGER Operate equipment with guards in place 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 and always wear PPE Tie up long hair and remove jewelry DO NOT wear loose fitting clothing dangling drawstrings or items that could become caught A DANGER Generator produce...

Page 5: ...is felt compression point Gently release cord back and use one strong rapid pull to start to avoid any kickback If engine does not start repeat the process DO NOT rigorously or aggressively pull the cord otherwise you will damage cord or mechanism and void any warranty A CAUTION Exceeding the generator s running capacity can damage the generator and or electrical devices connected to it DO NOT ove...

Page 6: ...tdoors in a well ventilated area away from building garages or sheds including window and doors NEVER pump petrol directly into the generator at the filling station Use an approved container to transfer the fuel to the generator DO NOT overfill the petrol tank E10 or E5 petrol only recommended Always keep petrol away from sparks open flames pilot lights heat and other sources of ignition When star...

Page 7: ...C WARNING DO NOT TOUCH DO NOT use exhaust or muffler extensions in doing so your warranty will be voided 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 1057 BY ...

Page 8: ...ility lines creating an electrocution hazard A transfer switch must be used when connecting to any building Fire Hazard Fuel and its vapors are extremely flammable and explosive Fire or explosion can cause severe burns or death Keep generator at least 5 feet 1 5m from all objects to prevent combustion Risk Of Being Burnt To reduce the risk of injury or damage avoid contact with any hot surface Car...

Page 9: ...nd learn their meaning Proper interpretation of these symbols will allow you to more safely operate the product SYMBOL MEANING ON STOP or OFF Circuit Breaker Reset Flip Neutral Floating Neutral circuit IS NOT electrically connected to the frame ground of the generator Fuel Petrol Valve ON OFF SYMBOL MEANING Choke Run Ground Terminal Petrol Tank Full Petrol Tank Empty ...

Page 10: ...volume y 2 Turn the fuel valve to ON position 3 Press engine switch to the ON position 4 Move choke lever to CHOKE position 5 Pull the recoil starter 6 Move the choke lever to RUN position 7 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 1067 L OP A 3 1 1 2 2 3 4...

Page 11: ... 4 7 gal 17 8 L 2 Choke Used to start the engine 3 Fuel Valve Used to turn fuel 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 Oil Fill Cap Dipstick Used to check and fill oil level 7 Control Panel See Control Panel section 8 Fuel Gauge Indicates the amount of petrol in the fuel tank...

Page 12: ...on 120V 240V 5 Voltage switch Choose between 120V or 240V RECEPTACLES A 12V DC 10A May be used to supply electrical power for operation of 12 Volt DC 10 Amp electrical loads B 240V AC 16A May be used to supply electrical power for operation of 240 Volt AC 16 Amp single phase 50 Hz electrical loads C 120V AC 16A May be used to supply electrical power for operation of 120 Volt AC 16 Amp single phase...

Page 13: ...in hertz Example 50 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: ...tor onto it s recoil end Tip onto the flattened cardboard box the generator came in or other protective surface so as to not scratch the frame 2 Remove the bolts from the orange support brackets Bolts and brackets can be discarded 3 Tip the generator upright Add Engine Oil A CAUTION DO NOT attempt to crank or start the engine before it has been properly filled with the recommended type and amount ...

Page 15: ...ngs to heat and cool Adjusting the load will also cause engine speed to vary slightly and help seat piston rings After the 5 hour break in period change the oil NOTICE 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 41º F 5º C temperatures Add F...

Page 16: ...ted to the frame of the generator has been provided see Controls and Features for terminal location 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 Neutral Floating Neutr...

Page 17: ...rogrammable 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 Install plug in surge suppressors on the outlets feeding your sensitive equipment Surge suppressors come in single or multi outlet sty...

Page 18: ...e generator DO NOT overload the generator NEVER use both 120V 240V or DC12V together they MUST be used separately A 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 injury or even death to you or a utility work...

Page 19: ...2 weeks or longer please see the Storage section for proper engine and fuel storage 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 fuel ratio decrease Engine power and generator output will be reduced approximately 3 for every 1000 ft of elevation above sea level At high altitudes increased exhaust emission...

Page 20: ...ces 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 ground the spark plug wire before performing any service Changing the Engine Oil Recommended 10W 30 Change oil when the eng...

Page 21: ...tion the spark arrestor on the muffler and attach with the screws removed in step 2 A CAUTION Failure to check and clean the spark arrestor will cause degraded engine performance recommended check every 100 hours Improper maintenance will result in voiding any warranty NOTICE Federal and local laws and administrative requirements indicate when and where spark arrestors are required When ordered sp...

Page 22: ...gine switch to the OFF position Mid Term Storage 30 days 1 year Petrol in the tank has a maximum shelf life of up to 1 year with the addition of a properly formulated fuel stabilizer and stored in a cool dry place 1 Be sure all appliances are disconnected from the generator 2 Add a properly formulated fuel stabilizer to the petrol tank 3 Turn the fuel valve to the ON position 4 Start and run the g...

Page 23: ...hen putting the generating set on a vehicle If the generating set is left in an enclosed vehicle for many hours high temperature inside the vehicle could cause fuel to vaporize resulting in a possible explosion Do not drive on a rough road for an extended period with the generating set on board If you must transport the generating set on a rough road drain the fuel from the generating set beforeha...

Page 24: ...OT OVERFILL Type See chart below Capacity 20 3 fl oz 0 6 qt 0 6 L 20 0 20 40 60 Ambient temperature Recommended 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 Full 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 unle...

Page 25: ...500560 UK 2800W Rated Portable Generator Specifications 25 Figure A Parts Diagram ...

Page 26: ...H 1 13 100005127 Clamp Ø11 x 10 1 14 100010439 0001 Washer Ø6 5 x 2 x Ø25 4 15 100750073 Fuel Tank Assembly See Figure F 1 16 100005148 Calmp Ø8 2 17 100720118 0001 Connection Tube 1 18 100011269 0012 Flange Bolt M6 x 28 1 19 1ZC7DFN28 Engine 224 cc 1 20 100750074 Alternator Assembly See Figure E 1 21 100733751 Muffler Assembly 1 22 100757369 Gasket Muffler 1 23 100011261 0014 Flange Bolt M6 x 12 ...

Page 27: ...500560 UK 2800W Rated Portable Generator Specifications 27 Figure E Parts Diagram ...

Page 28: ...ing Washer Ø5 1 9 100010919 0002 Flat Washer Ø5 1 10 100011299 0002 Flange Bolt M6 x 175 4 11 100750811 End Housing 1 12 100148753 0002 Flange Bolt M8 x 1 x 230 1 13 100010899 0005 Washer Ø8 1 14 100734620 0001 Alternator Assembly Al Ø160 x 130 mm 1 15 100161949 Stator Cover 122 5 mm 1 16 100735648 Stator Assembly Al Ø160 x 130 mm 1 17 100018701 Terminal Block 1 18 100722067 0001 Support Block 1 1...

Page 29: ...500560 UK 2800W Rated Portable Generator Specifications 29 Figure F Parts Diagram ...

Page 30: ...ty 1 100714493 Fuel Filter Assembly 1 2 100712045 Fuel Gauge 1 3 100099571 Reversal Valve 1 4 100713756 0001 Fuel Tank 17 7 L Yellow 1 5 100032369 Vibration Mounting Fuel Tank 4 6 100021118 Bushing Ø12 x Ø9 x 13 4 7 100726113 Fuel Tank Cap 1 8 100021153 Fuel Valve 1 Figure F Part List ...

Page 31: ...500560 UK 2800W Rated Portable Generator Specifications 31 Figure G Parts Diagram ...

Page 32: ...16Amp Circuit Breaker Push Button 1 6 100749706 Commutator Switch 1 7 100020019 32Amp DE Type Receptacle 1 8 100020013 16Amp DE Type Receptacle 1 9 100120180 Breaker Cover 2 10 100749705 Breaker 1 11 100746656 Control Panel Housing 1 12 100746657 Control Panel 1 13 100755507 Oil Sensor 1 14 100749935 Wire Harness Assembly 1 15 100031552 O Ring 2 16 100126121 Breaker Cover Switch 1 17 100757322 Bre...

Page 33: ...500560 UK 2800W Rated Portable Generator Specifications 33 Figure H Parts Diagram ...

Page 34: ...r Description Qty 1 100749208 0001 Damping Support 4 2 100011261 0016 Flange Bolt M6 x 12 4 3 100755602 0001 Frame 25mm 590 x 464 x 504 5 1 4 100011453 0006 Lock Nut M8 Flange 8 5 100020986 0002 Vibration Mount 2 2 6 100021000 0002 Vibration Mount 1 2 Figure H Part List ...

Page 35: ...500560 UK 2800W Rated Portable Generator Specifications 35 Figure B Engine Parts Diagram ...

Page 36: ... M6 x 14 GB5789 4 31 100011528 0002 Flange Bolt M6 x 10 3 32 100008417 Arm Governor 1 33 100720109 0001 Air Filter Assembly 1 34 100727318 Air Filter Base 1 35 100005078 Air Filter Baffle 1 Part Number Description Qty 36 100004771 Air Filter Element 1 37 100087055 Air Filter Cover 1 38 100004949 Air Filter Bolt 1 39 100011261 0014 Flange Bolt M6 x 12 1 40 100021030 0001 Bracket Air Cleaner Support...

Page 37: ...500560 UK 2800W Rated Portable Generator Specifications 37 Figure C Engine Parts Diagram ...

Page 38: ...ate Push Rod 1 3 100050896 Valve Collet 4 4 100073758 Valve Spring Seat Upper 2 5 100713979 Spring Valve 2 6 100004599 Oil Seal Intake Valve 1 7 100010389 0001 Stud Bolt M8 x 35 2 8 100713981 Exhaust Valve 1 9 100009378 Spark Plug F6RTC 1 10 100713980 Intake Valve 1 11 100079792 Cylinder Head 1 12 100010354 0001 Stud Bolt M6 x 96 2 13 100155656 Gasket Cylinder Head 1 ...

Page 39: ...500560 UK 2800W Rated Portable Generator Specifications 39 Figure D Engine Parts Diagram ...

Page 40: ...r Carburetor 1 3 100078606 Gasket 1 Carburetor 1 4 100750076 0001 Carburetor 1 5 100005717 Fuel Bowl O Ring 1 6 100005754 Main Jet Standard 1 100005765 Main Jet Altitude 1000 3000m 7 100006037 Fuel Bowl Mounting Bolt Gasket 1 8 100005725 Fuel Bowl Mounting Bolt 1 9 100005148 Clamp 1 10 100017784 0001 Fuel Tube Ø4 x Ø8 x 126 1 11 100005629 0001 Gasket 2 Carburetor 1 ...

Page 41: ...500560 UK 2800W Rated Portable Generator Specifications 41 Wiring Diagram ...

Page 42: ...l 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 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...

Page 43: ...whole Installation Use and Maintenance This warranty will not apply to parts and or labor if the product is deemed to have been misused neglected involved in an accident abused loaded beyond the product s limits modified installed improperly or connected incorrectly to any electrical improper maintenance component Normal maintenance is not covered by this warranty and is not required to be perform...

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