Champion 3000 3500 Generator Owners Manual

Rev C40012-20070228 C40012 1-877-338-0999 10006 Santa Fe Springs Rd. Santa Fe Springs, CA 90670 Made in China 2004-2007 Champion Power Equipment Owners Manual and Operating Instructions 3500 Peak Watts 3000 Running Watts PORTABLE GENERATOR Table of Contents Introduction . 1 Portable Power Generator 1 Accessories 1 This Booklet 1 Manual Conventions .2 Safety Rules 3 Controls and Features . 5 Generator 5 Power Panel 6 Parts Included 7 Assembly 8 Remove the Generator from the Shipping Carton 8 Install the Wheel Kit .8 Install the Support Leg .8 Install the Handle .8 Install the Spark Arrester .8 Add Engine Oil .

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9 Add Fuel 9 Grounding . 9 Operation . 10 Generator Location . 10 Grounding . 10 Surge Protection . 10 Starting the Engine . 10 Connecting Electrical Loads . 10 Stopping the Engine . 10 Do Not Overload Generator 11 Capacity 11 Power Management .11 Wattage Reference Chart 12 Maintenance . 13 Engine Maintenance . 13 Oil 13 Spark Plugs . 13 Air Filter 13 Spark Arrester . 14 Cleaning 14 Adjustments 14 Maintenance Schedule 14 Generator Maintenance 14 Storage . 15 Engine Storage 15 Generator Storage . 15 Specifications . 16 Engine Specifications 16 Generator Specifications . 16 Fuel 16 Oil 16 Spark Plugs . 16 Valve Clearance . 16 Parts Diagram . 17 Parts List .18 Wiring Diagram . 20 Troubleshooting . 21 Warranty 22 Warranty Qualifications .22 Repair/Replacement Warranty 22 Do not return the unit to the place of purchase 22 Warranty Exclusions .22 Normal Wear .22 Installation, Use and Maintenance .22 Other Exclusions .22 Limits of Implied Warranty and Consequential Damage .22 Contact Information .23 Address 23 Customer Service 23 Technical Service .23 Notes 27 Introduction Introduction Congratulations on your purchase of a Champion Power Equipment generator. CPE designs and builds generators to strict specifications. With proper use and maintenance, this generator will bring years of satisfying service. Accessories Champion Power Equipment manufactures and sells accessories designed to help you get the most from your purchase. To find out more about our covers, power cables and storm kits, please visit our web site at www.championpowerequipment.com Portable Power Generator This unit is an electric-start gasoline engine driven, alternating current (AC) generator. It is designed to supply electrical power for lighting, appliances, tools and similar equipment. This Booklet Every effort has been made to ensure the accuracy and completeness of the information in this manual. We reserve the right to change, alter and/or improve the product and this document at any time without prior notice. 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 (877) 338-0999 Model Number C40012 Serial Number Date of Purchase Purchase Location Rev C40012-20070228 1 Manual Conventions Manual Conventions This manual uses the following symbols to help differentiate between different kinds of information. The safety symbol is used with a key word to alert you to potential hazards in operating and owning power equipment. Follow all safety messages to avoid or reduce the risk of serious injury or death. CAUTION 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. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. NOTE WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. If you have questions regarding your generator, we can help. Please call our help line at (877) 338-0999. 2 Rev C40012-20070228 Safety Rules Safety Rules WARNING Read this manual thoroughly before operating your generator. Failure to follow instructions could result in serious injury or death. 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. WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm. WARNING Sparks can result in fire or electrical shock. DANGER Generator exhaust contains carbon monoxide, a colorless, odorless, poison gas. Breathing carbon monoxide will cause nausea, dizziness, fainting or death. Operate generator outdoors only in a well ventilated area DO NOT operate the generator inside any building, 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 openings. When servicing the generator: 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 three feet of clearance on all sides to ensure adequate cooling. Maintain at least five feet of clearance from combustible materials. 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. Rev C40012-20070228 3 Safety Rules DANGER Fuel and fuel vapors are highly flammable and extremely explosive. Fire or explosion can cause severe burns or death. Unintentional startup can result in entanglement, traumatic amputation or laceration. WARNING 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 devices plugged in. 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 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. CAUTION 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 generator. DO NOT tamper with the governed speed. DO NOT modify the generator in any way. 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 generator: 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. CAUTION 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 vibrates excessively When storing the generator: Store away from sparks, open flames, pilot lights, heat and other sources of ignition. 4 Rev C40012-20070228 Controls and Features Controls and Features Read this owner’s manual before operating your generator. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference. Generator (1) Fuel Tank ­ 4.0 gallon capacity fuel tank. (2) Fuel Valve ­ Turn this valve to the “On ” position to supply fuel to the engine. (3) Choke ­ Used to start the engine (4) Air Cleaner ­ Protects the engine by filtering dust and debris from the intake air. (5) Recoil Starter ­ Used to start the engine (6) Serial Number ­ Please have this number available when calling for assistance. (7) Low Oil Sensor ­ Senses the level of oil in the crankcase and shuts the engine down if the level falls too low. (8) Oil Filler Cap ­ Check and fill engine oil level. (9) Power Panel ­ See “Power Panel ” Rev C40012-20070228 5 Controls and Features Power Panel (1) Ignition Switch ­ Flip switch to the “On ” position to start the generator. Flip to the “Off ” position to turn off the generator. (2) Voltmeter ­ Displays the output voltage of the generator. (3) Circuit Breakers ­ Protects the generator against electrical overload. (4) 120 V 30 A Twist-Lock ­ protected by a 25 A push-to-reset circuit breaker. This receptacle powers 120 Volt AC, 60 Hz, single phase loads requiring up to 30 Amps or 3000 watts of power. (5) 120 V 20 A Duplex ­ protected by a 20 A push-to-reset circuit breaker to operate 120 Volt AC, single phase, 60 Hz loads requiring up to 20 A 0r 2400 Watts of power. (6) Ground Terminal ­ Consult an electrician for local grounding regulations. 6 Rev C40012-20070228 Controls and Features Parts …..

(90 days for commercial & industrial use). Transportation charges on product submitted for repair or replacement under this warranty are the sole responsibility of the purchaser. This warranty only applies to the original purchaser and is not transferable. 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 force majeure events beyond the manufacturer’s control. Problems cause by parts that are not original Champion Power Equipment parts. This warranty does not apply to generators used for prime power in place of a utility. Do not return the unit to the place of purchase Contact CPE’s Technical Service and CPE will troubleshoot any issue via phone or email. If the problem is not corrected by this method, CPE will, at its option, authorize evaluation, repair or replacement of the defective part or component at a CPE Service Center. CPE will provide you with a case number for warranty service. Please keep it for future reference. Repairs or replacements without prior authorization, or at an unauthorized repair facility, will not be covered by this warranty. Limits of Implied Warranty and Consequential Damage Champion Power Equipment disclaims any obligation to cover any loss of time, use of this product, freight, or any incidental or consequential claim by anyone from using this generator. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE 22 Rev C40012-20070228 Warranty A unit provided as an exchange will be subject to the warranty of the original unit. The length of the warranty governing the exchanged unit will remain calculated by reference to the purchase date of the original unit. This warranty gives you certain legal rights which may change from state to state. Your state may also have other rights you may be entitled to that are not listed within this warranty. Contact Information Address Champion Power Equipment, Inc. Customer Service 10006 Santa Fe Springs Rd. Santa Fe Springs, CA 90670 Customer Service Mon ­ Fri 8:30 AM ­ 5:00 PM (PST/PDT) Toll Free: 1-877-338-0999 Fax no.: 1-562-236-9429 Technical Service Mon ­ Fri 8:30 AM ­ 5:00 PM (PST/PDT) Toll Free: 1-877-338-0999 tech@championpowerequipment.com Rev C40012-20070228 23 Warranty Champion Power Equipment, Inc (CPE), and the United States Environment Protection Agency (U.S. EPA.) Emission Control System Warranty Your Champion Power Equipment (CPE) engine complies with the U.S. EPA emission regulations. YOUR WARRANTY RIGHTS AND OBLIGATIONS: The US EPA AND CPE are pleased to explain the Federal Emission Control Systems Warranty on your 2005 and later, small off-road engine. New engines must be designed, built and equipped, at the time of sale, to meet U.S. EPA regulations for small non-road engines. CPE must warrant the emission control system on your small off-road engine for the period of time listed below, provided there has been no abuse, neglect, unapproved modification, or improper maintenance of your small off-road engine. Your emission control system may include parts such as the carburetor, fuel-injection system, the ignition system, catalytic converter and fuel lines. Also included may be hoses, belts, connectors and other emission related assemblies. Where a warrantable condition exits, CPE will repair your small off-road engine at no cost to you including diagnosis, parts and labor. MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE: This emission control system is warranted for two years, subject to provisions set forth below. If, during the warranty period, emission related part on your engine is defective in materials or workmanship, the part will be repaired or replaced by CPE. OWNER WARRANTY RESPONSIBILITIES: As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in your Owner’s Manual. CPE recommends that you retain all your receipts covering maintenance on your small off-road engine, but CPE cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. As the small off-road engine owner, you should however be aware that CPE may deny you warranty coverage if your small, off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. You are responsible for presenting your small off-road engine to an Authorized CPE service outlet, CPE dealer or CPE, Santa Fe Springs, Ca. as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should contact: Champion Power Equipment, Inc. Customer Service 10006 Santa Fe Springs Road Santa Fe Springs, CA 90670 Tel: (888) 696-0668 The emission warranty is a defects warranty. Defects are judged on normal engine performance. The warranty is not related to an in-use emission test. 24 Rev C40012-20070228 Warranty EMISSION CONTROL SYSTEM WARRANTY The following are specific provisions relative to your Emission Control System Warranty Coverage. Emission Control System Warranty (ECS Warranty) for 1997 and later model year small off-road engines: 1. APPLICABILITY: This warranty shall apply to 1997 and later model year small off-road engines. The ECS Warranty Period shall begin on the date the new engine or equipment is delivered to its original, end-use purchaser, and shall continue for 24 consecutive months thereafter. 2. GENERAL EMISSIONS WARRANTY COVERAGE CPE warrants to the original, end-use purchaser of the new engine or equipment and to each subsequent purchaser that each of its small off-road engines is: a. Free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to the part as described in the engine manufacturer’s application for certification for a period of two years. 3. THE WARRANTY ON EMISSION-RELATED PARTS WILL BE INTERPRETED AS FOLLOWS: a. Any warranted part that is not scheduled for replacement as required maintenance in the Owners Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by CPE according to Subsection “d ” below. Any such part repaired or replaced under the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period. b. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the Owners Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary “, shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period. c. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted 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 emissions-related part repaired or replaced under the ECS Warranty, shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part. d. Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a CPE Authorized Service Outlet. e. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in fact defective, provided that such diagnostic work is performed at a CPE Authorized Service Outlet. f. CPE shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of an emission-related part covered by the ECS Warranty. g. Throughout the ECS Warranty Period, CPE shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand for such emission-related parts. h. Any CPE Authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty maintenance or repair and will be provided without charge to the owner. Such use shall not reduce CPE’s warranty obligation. i. Unapproved add-on or modified parts may not be used to modify or repair a CPE engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an Rev C40012-20070228 25 Warranty ECS Warranty claim. CPE shall not be liable hereunder for failures of any warranted parts of a CPE engine caused by the use of such an unapproved add-on or modified part. 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 hours. Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used. If you have any questions regarding your warranty rights and responsibilities, or to obtain warranty service, please write or call the Customer service of Champion Power Equipment, Inc. Champion Power Equipment, Inc. 10006 Santa Fe Springs Road Santa Fe Springs, CA 90670 (888) 696-0668 Attn: Customer Service 26 Rev C40012-20070228 Notes Notes Rev C40012-20070228 27 …

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