Champion Power Equipment 70008 Users Manual

2015-02-05

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70008

Rev 70008-20071026

Owner’s Manual and Operating Instructions

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 Spark Arrester ......................... 8

Add Engine Oil ......................................... 8

Connect LPG cylinder ............................... 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 ............................... 22

Address ................................................ 22

Customer Service ................................ 22

Technical Service ................................. 22

Notes .............................................. 26

Introduction

Rev 70008-20071026 1

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.

Portable Power Generator

This unit is a liquefied petroleum gas (LPG)

engine driven, alternating current (AC)

generator. It is designed to supply electrical

power for lighting, appliances, tools and

similar equipment.

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

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

1-877-338-0999

Model Number

70008

Serial Number

Date of Purchase

Purchase Location

Manual Conventions

2 Rev 70008-20071026

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.

DANGER

DANGER indicates an imminently hazardous

situation which, if not avoided,

will

result in death

or serious injury.

WARNING

WARNING indicates a potentially hazardous

situation which, if not avoided,

could

result in

death or serious injury.

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.

NOTE

If you have questions regarding your generator,

we can help. Please call our help line at 1-877-

338-0999.

Safety Rules

Rev 70008-20071026 3

Safety Rules

WARNING

Read this manual thoroughly before operating

your generator. Failure to follow instructions

could result in serious injury or death.

WARNING

The engine exhaust from this product contains

chemicals known to the state of California to

cause cancer, birth defects, or other reproductive

harm.

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.

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.

WARNING

Sparks can result in fire or electrical shock.

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.

Safety Rules

4 Rev 70008-20071026

DANGER

Propane (LPG) is highly flammable and explosive.

Fire or explosion can cause severe burns or death

if the gas is ignited.

Before starting the generator

Turn the generator off.

Inspect your LPG tank for damage or leaks.

Attach only approved tanks that have been

properly filled by an approved station.

DO NOT light or smoke cigarettes.

Replace the hose at the first sign of a leak or if

age-cracking becomes apparent.

When starting the generator

DO NOT attempt to start a damaged generator.

Make certain that the LPG tank, air filter, spark

plug, fuel lines and exhaust system are properly

in place.

Make certain that the generator 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 oil to spill.

When transporting or servicing the

generator:

Make certain that the LPG tank is disconnected

and properly shut off.

Disconnect the spark plug wire.

When storing the generator:

Store away from sparks, open flames, pilot lights,

heat and other sources of ignition.

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.

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.

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

Controls and Features

Rev 70008-20071026 5

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 Valve – Turn this valve to the

“On” position to supply fuel to the engine..

(2) Choke – Used to start the engine.

(3) Air Cleaner – Protects the engine by

filtering dust and debris from the intake air.

(4) Gas Hose and Regulator – 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”

Controls and Features

6 Rev 70008-20071026

Power Panel

(1) Gas Inlet – Nipple for LPG hose

connection.

(2) Engine switch – Flip switch to the

“On” position to start the generator. Flip to

the “Off” position to turn off the generator.

(3) Circuit Breakers – Protects the

generator against electrical overload.

(4) Intelligauge – Three mode digital

meter for running hours, voltage and hertz.

(5) Parameter Button – Push-button

selector for the Intelligauge.

(6) 120 V 30 A Twist-Lock – protected by

a 30 A push-to-reset circuit breaker, this

receptacle powers 120 Volt AC, 60 Hz, single

phase loads requiring up to 29.2 A or3500

Watts of power.

(7) 120 V 20 A Duplex – each receptacle

is 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.

(8) Ground Terminal – Consult an

electrician for local grounding regulations.

Controls and Features

Rev 70008-20071026 7

Parts Included

Your Model 70008 Gasoline Powered Generator ships with the following parts:

Wheel Kit

Axle 1 piece

8” Solid Wheel 2 pieces

Support Leg 1 piece

Vibration Mounts 2 pieces

Bolt Kit

Wheel Retaining Pins 2 pieces

Flat Washers 2 pieces

Cap Screws and Nuts 4 sets

Oil Funnel 1 piece

Wrench 1 piece

Spark Plug Socket 1 piece

Spark Arrester Kit

Spark Arrester 1 piece

Cover Plate 1 piece

Screws, Lock Washers 2 pieces

Gas Hose and Regulator 1 piece

Assembly

8 Rev 70008-20071026

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, call our help

line at 1-877-338-0999. Please have your

serial number and model number available.

Remove the Generator from

the Shipping Carton

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

CAUTION

The wheel kit is not intended for over-the-road

use.

You will need the following tools to install

the wheels:

12 mm wrench

Socket wrench with a 12 mm socket

Pliers

1. Before adding oil to the engine, tip the

generator slowly so that the engine side

is up.

2. Slide the axle through both mounting

brackets.

3. Slide a wheel onto the axel.

4. Place a washer on the end.

5. Install the cotter pin through the hole on

the end of the axle.

6. Carefully bend the legs of the cotter pin

back around the axle.

7. Repeat steps 3-6 to attach the second

wheel.

Install the Support Leg

1. Attach the rubber vibration mount to

the support leg with a cap screw

(M8x30) and lock nut (M8).

2. Attach the support leg to the generator

frame with cap screws (M8x20) and lock

nuts (M8).

3. Tip the generator slowly so that it rests

on the wheels and support leg.

Install the Spark Arrester

Insert the spark arrester screen into the

muffler outlet. Secure the spark arrester by

placing the cover plate over the end of the

screen, with the lettering facing outward.

Secure the cover plate with the two screws

and lock washers provided with the spark

arrester kit.

NOTE

Federal and local laws and administrative

requirements indicate when and where spark

arresters are required. When ordered, spark

arresters are required for operation of this

generator in National Forest lands. In California,

this generator must not be used on any forest-

covered land, brush-covered land, or grass-

covered land unless the engine is equipped with

a spark arrester.

CAUTION

Failure to install the spark arrester may result in

an increased risk of fire..

Add Engine Oil

CAUTION

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.

1. Place the generator on a flat, level

surface.

2. Remove oil fill cap/dipstick to add oil.

Assembly

Rev 70008-20071026 9

3. Add 1.16 qt (1.1 L) of oil and replace oil

fill cap/dipstick. See “Specifications” for

oil recommendations based on

operating conditions.

4. Check engine oil level daily and add as

needed.

CAUTION

The engine is equipped with a low-oil-shutoff and

the will stop when the oil level in the crankcase

falls below the threshold level.

NOTE

Check oil often during the break-in period. Refer

to the Maintenance section for recommended

service intervals.

NOTE

The generator rotor has a sealed, pre-lubricated

ball bearing that requires no additional lubrication

for the life of the bearing.

Connect LPG cylinder

This engine is certified to operate on liquid

petroleum gas (lpg).

1. Turn off the fuel valve on the generator.

2. Attach the LPG connector to the gas

inlet.

3. Open the manual shutoff valve on the

LPG cylinder.

4. Open the fuel valve on the generator.

WARNING

Liquefied Petroleum Gas is extremely flammable

and explosive.

If there is a strong smell of gas:

Close off the gas supply at the cylinder.

Use soapy water which will produce a large

bubble at the point of any leak, to check the

cylinder valve, connections and the generator.

Do not smoke or light a cigarette.

Contact a qualified technician to inspect and

repair the LPG system.

CAUTION

Use approved LP cylinders equipped with an OPD

(overfilling prevention device) valve.

Always keep the cylinder in a vertical position

with the valve on top and installed at ground

level on a flat surface

Cylinders must not be installed near any heat

source and should not be exposed to sun, rain,

dust and heat.

Regulators to be used on the cylinders must be

of the diameter as the cylinder valve.

Regulators should always be in the off position

when the cylinder is not in use.

Grounding

Your generator must be properly connected

to an appropriate ground to help prevent

electric shock.

WARNING

Failure to properly ground the generator can

result in 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.

Operation

10 Rev 70008-20071026

Operation

Generator Location

Please consult your local authority. In some

areas, generators must be registered with

the local utility.

Generators used at construction sites may be

subject to additional rules and regulations.

This generator must have at least five feet of

clearance from combustible material. Leave

at least three feet of clearance on all sides of

the generator to allow for adequate cooling,

maintenance and servicing.

Place the generator in a well-ventilated area.

DO NOT place the generator near vents or

intakes where exhaust fumes could be drawn

into occupied or confined spaces. Carefully

consider wind and air currents when

positioning generator.

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.

Surge Protection

CAUTION

Voltage fluctuation may impair the proper

functioning of sensitive electronic equipment.

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.

2. Obtain an Uninterruptible Power

Supply (UPS) device.

Most UPS devices come with a

rechargeable battery between the

electronic equipment and power supply

source. The device buffers the voltage

and protects against virtually all short-

duration voltage fluctuations.

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. Open the manual shutoff valve on the

LPG cylinder.

4. Turn the fuel valve to the “On” position.

5. Move the choke lever to the “Choke”

position.

6. Turn the engine switch on.

7. Pull the starter cord slowly until

resistance is felt and then pull rapidly

8. As engine warms up, move the choke

lever to “Run”.

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.

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 Volt

AC single phase, 60 Hz electrical loads.

DO NOT connect 3-phase loads to the

generator.

DO NOT connect 50 Hz loads to the

generator.

DO NOT overload the generator.

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.

Operation

Rev 70008-20071026 11

2. Let the generator run at no-load for

several minutes to stabilize internal

temperatures of the engine and

generator.

3. Turn the engine switch to the “Off”

position.

4. Turn the fuel valve to the “Off” position.

5. Close the OPD valve on the LPG

cylinder.

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 watts:

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.

NOTE

Never exceed the generator capacity when

adding loads.

Operation

12 Rev 70008-20071026

Wattage Reference Chart

Use the chart to determine approximate

wattage requirements for your equipment.

NOTE

Starting watts can exceed three times the

running watts. The values in the following table

are approximate. Refer to your tool or appliance

for actual wattage consumption.

Item Running

Watts Starting

Watts

Essentials

Light Bulb 100W 100

Refrigerator/Freezer 1200 2400

Freezer 500 500

Sump Pump 600 1800

Well Pump 1 HP 2000 4000

Water Heater 4000

Security System 180

AM/FM Radio 300

Garage Door Opener 1/2 HP 500 600

Battery Charger 12V DC 110

Heating/Cooling

Air Conditioner 12000 BTU 1700 2500

Fan 300 600

Furnace Fan 1/3 HP 1200 2000

Home Appliances

Microwave 1000W 1000

Electric Range - One Element 1500

Electric Skillet 1250

Coffee Maker 1500

Clothes Washer 1200

Entertainment

CD/DVD Player 100

VCR 100

Stereo Receiver 450

Television 27" 500

PC with 15" Monitor 800

Job Site

Belt Sander 3" 1000 1500

Bench Grinder 6" 700 1500

Circular Saw 1500 1500

Compressor 1 1/2 HP 2500 2500

Edge Trimmer 500 500

Hand Drill 1/2" 1000 1000

Lawn Mower 1200 1800

Paint Sprayer 600 1200

Table Saw 2000 2000

Maintenance

Rev 70008-20071026 13

Maintenance

The owner/operator is responsible for all

periodic maintenance.

WARNING

Never operate a damaged or defective generator.

WARNING

Tampering with the factory set governor will void

your warranty.

WARNING

Improper maintenance will void your warranty.

Complete all scheduled maintenance in a

timely manner. Correct any issue before

operating the generator.

NOTE

For service or parts assistance, contact our help

line at 1-877-338-0999.

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 environment.

1. Remove the oil drain plug with a 15 mm

socket and extension.

2. Allow the oil to drain completely.

3. Replace the drain plug.

4. Remove oil fill cap/dipstick to add oil.

5. Add 1.16 qt (1.1 L) of oil and replace oil

fill cap/dipstick.

6. Dispose of used oil at an approved waste

management facility.

Spark Plugs

1. Remove the spark plug cable from the

spark plug.

2. Use the spark plug tool that shipped

with your generator 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 0.7 -

0.8mm (0.028 - 0.031 in.).

5. Refer to the spark plug recommendation

chart when replacing the plug.

6. Carefully thread the plug into the

engine.

7. Use the spark plug tool to firmly install

the plug.

8. Attach the spark plug wire to the plug.

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 excess oil.

6. Place the filter in the assembly.

7. Reattach the air filter cover and snap in

place.

Maintenance

14 Rev 70008-20071026

Spark Arrester

1. Allow the engine to cool completely

before servicing the spark arrester.

2. Remove the two 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 two screws.

Cleaning

CAUTION

DO NOT spray engine with water.

Water can contaminate the fuel system.

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.

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 our service

line at 1-877-338-0999 for all other service

and/or adjustment needs.

Maintenance Schedule

Follow the service intervals indicated in the

schedule below.

Service your generator more frequently

when operating in adverse conditions.

Contact our help line at 1-877-338-0999 to

locate the nearest Champion Power

Equipment certified service dealer for your

generator or engine maintenance needs.

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 3 years

Replace fuel line

* To be performed by knowledgeable,

experienced owners or Champion Power

Equipment certified service dealers

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.

CAUTION

DO NOT use a garden hose to clean the

generator.

Water can enter the generator through the

cooling slots and damage the generator

windings.

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.

Storage

Rev 70008-20071026 15

Storage

The generator should be started at least once

every 14 days and allowed to run for at least

20 minutes. For longer term storage, please

follow these guidelines.

Engine Storage

1. Allow the engine to cool completely

before storage.

2. Clean the engine according to the

instructions in the Maintenance section.

3. Change the oil.

4. Remove the spark plug and pour about

½ ounce of oil into the cylinder. Crank

the engine slowly to distribute the oil

and lubricate the cylinder.

5. Reattach the spark plug.

Generator Storage

1. Allow the generator to cool completely

before storage.

2. Turn off the fuel supply at the fuel valve.

3. Clean the generator according to the

instructions in the Maintenance section.

4. Store the unit in a clean, dry area.

5. Store in a clean, dry place out of direct

sunlight.

Specifications

16 Rev 70008-20071026

Specifications

Engine Specifications

Engine 338 cc OHV CPE

CARB and EPA certified

Generator Specifications

Running Wattage 3500 Watts

Starting Wattage 4200 Watts

AC Load 120 V

Phase Single

Frequency 60 Hz

Fuel Capacity Liquefied Petroleum Gas

Weight 174.17 lbs. (79 kg)

Height 28.35 inches (72.0 cm)

Width 27.28 inches (69.3 cm)

Length 25.79 inches (65.5 cm)

Fuel

Use only an approved LPG cylinder

equipped with an OPD valve.

Flow rate: ≥2.0 kg/hr

Outlet pressure: 2.8 kpa ± 0.5 kpa

Oil

Oil capacity is 1.16 qt (1.1 L).

Spark Plugs

Your generator comes equipped with a ¾”

long reach plug (19mm)

Use only “Green Power” brand replacement

LPG spark plugs.

CAUTION

Failure to use the proper plug may damage your

engine and will void your warranty.

Make certain the spark plug gap is 0.7 -

0.8mm (0.028 - 0.031 in.).

Valve Clearance

Intake: 0.09 - 0.11 mm (.003 - .004 in.)

Exhaust: 0.11 - 0.13 mm (.004 - .005 in.)

Specifications

Rev 70008-20071026 17

Parts Diagram

Specifications

18 Rev 70008-20071026

Parts List

No Part Number Description Qty

1 CG500-031604F2 Gas Inlet Combination 1

2 ST02FD-1151205A Engine Switch 1

3 2630 Intelligauge 1

4 2631 Touch Switch 1

5 ST188FD-1710001 Receptacle L5-30R 1

6 ST188FD-1710003 Receptacle 5-20R 2

7 ST05FD-1151208-M Grounding Bolt 1

8 GB5781-B6-12 Bolt M6×12 30

9 GB5781-B6-40 Bolt M6×40 3

10 ST188FD-1151201-K Control Box 1

11 1920-20A 20A Circuit Breaker 2

12 1920-30A 30A Circuit Breaker 1

13 CG500-020202 Rubber Tube 1

14 ST188F-1020001 Grommet 2

15 ST05FD-05060300 Control Panel 1

16 ST05FD-1170003-B Grommet 1

17 ST05FD-1151209 Conduit 1

18 ST02FD-1151201 Grommet 1

19 ST05FD-03401010 Transom 1

20 GB5781-B5-10 Bolt M5×10 2

21 ST05FD-1152002 Generator End Cover 1

22 GB5781-B6-10 Bolt M6×10 7

23 ST168F-1152032 Terminal 1

24 ST05F-1152031 AVR 1

25 ST05FD-1152035 Brush Assembly 1

26 ST05FD-1152032 End Cover 1

27 GB5789-FB6-179 Flange Bolt M6×179 4

28 ST05FD-1152001 Stator Cover 1

29 GB5789-FB10-1.25-165 Flange Bolt M10×1.25×265 1

30 ST04FD-1152020-CSA Stator Assembly 1

31 GB93-LW-10 Lock Washer ø10 1

32 GB90-W-10 Washer ø10 1

33 ST04FD-1152010-CSA Rotor Comp 1

34 ST05FD-1151600 Cover 1

35 ST188FD-1030011 Crankcase Cover 1

36 ST1P60F-1030004 O-Ring 1

37 ST188F-1030003 Oil Filler Cap 1

38 ST182FD-1000000G Engine 1

39 ST05FD-1151300B Bottom Rubber 2 2

40 ST05FD-1151300A Bottom Rubber 1 2

41 GB41-N-8 Nut M8 12

42 ST182FD-1152200-A Axle 1

43 GB41-N-10 Nut M10 4

44 ST05FD-03381000 Frame 1

45 CG500-021700 Fuel Switch 1

46 CG500-000007 Clip 4

47 CG500-020203 Rubber Tube 1

48 GB5781-B4-8 Bolt M4×8 2

49 GB93-LW-4 Lock Washer ø4 2

50 GB90-W-4 Washer ø4 2

51 CG500-020201 Middle Cover 1

52 CG500-040400 Fan FixerⅠ 1

53 CG500-040500 Fan Fixer Ⅱ 1

54 CG500-040600 Fan Fixer Ⅲ 1

55 CG500-040100A2 Cooling Fan 1

Specifications

Rev 70008-20071026 19

No Part Number Description Qty

56 ST188FD-1130001 Packing 2

57 C500B1-001115A Choke Lever Comp 1

58 C500B2-000016A Mixer 1

59 C500B1-000915A Packing 1

60 C500B1-000415A Separator 1

61 C500B2-000525A Separator Hose 1

62 C500B1-000715A Separator Hose Clip 2

63 ST188FD-1130003 Carburetor Insulator Packing 1

64 ST188FD-1010002 Bolt 2

65 GB41-N-6 Nut M6 10

66 ST188FD-1090006 Air Cleaner Stay 1

67 ST188FD-1090100 Air Cleaner Case Comp 1

68 ST188FD-1090002 Air Cleaner Seal 1

69 GB41-N-5 Nut M5 6

70 ST188FD-1090003 Separator 1

71 ST188FD-1090004 Element 1

72 ST188FD-1090200 Air Cleaner Cover Comp 1

73 ST188FD-1080200 Control Assembly 1

74 ST188FD-1010001 Bolt 2

75 GB90-W-8 Washer ø8 2

76 GB93-LW-8 Lock Washer ø8 2

77 GB41-N-8 Nut M8 2

78 ST188FD-1100001 Muffler Gasket 1

79 ST188FD-1730001 Exhaust Pipe 1

80 GB5781-B8-20 Bolt M8×20 7

81 ST188FD-1730100 Muffler Gasket 1

82 ST188FD-1732200-A Muffler Outer Protector 1

83 GB5781-B5-10 Bolt M5×10 2

84 GB93-LW-5 Lock Washer ø5 2

85 ST188FD-1100010-88 Spark Arrester Cover 1

86 ST188FD-1180121 Spark Arrester Assy 1

87 ST188FD-1731000A Muffler 1

88 ST188FD-1730002A Bushing ø8.5 1

89 ST188FD-1732101 Muffler Inner Protector 1

90 ST02FD-1151036 Brush Support Plate 1

91 ST182FD-1742203-UC Handle Sheath 1

92 ST182FD-1742201-UC Handle 1

93 ST182FD-1742202-UC Handle Underlay 2

94 GB896-86-8 Uncork Baffle 2

95 GB896-86-6 Uncork Baffle 2

96 ST182FD-1742002-UC Pin 2

97 ST02FD-1151207-M Grounding Wire 1

98 GB5781-B8-32 Bolt M8×32 2

99 ST188FD-1740004-C Vibration Mount 2

100 ST188FD-1743001-T Support Leg 1

101 ST188FD-1151102-D Fuel Tank Wing 2

102 ST29QXG-2000005 8" Wheel 2

103 GB90-W-16 Washer ø16 2

104 GBT93-CP3.2-40 Cotter Pin 2

105 GB5781-B6-90 Bolt M6×90 4

106 CG500-040700 Fan Cover 2

107 ST182FD-1152200-A Axle 1

108 CG500-600100A1 Gas Hose And Regulator 1

Specifications

20 Rev 70008-20071026

Wiring Diagram

Troubleshooting

Rev 70008-20071026 21

Troubleshooting

Problem Cause Solution

Generator will not start No fuel Add fuel

Faulty spark plug Replace spark plug

Unit loaded during start up Remove load from unit

Generator will not start;

Generator starts but runs roughly Low oil level Fill crankcase to the proper level

Place generator on a flat, level surface

Choke in the wrong position. Adjust choke.

Spark plug wire loose Attach wire to spark plug

Generator shuts down during

operation Out of fuel Fill fuel tank

Low oil level 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 “Power

Management”

Insufficient ventilation Check for air restriction. Move to a

well ventilated area

No AC output Cable not properly connected Check all connections

Connected device is defective Replace defective device

Circuit breaker is open Reset circuit breaker

Capacitor defective Replace capacitor (Service Center)

Faulty brush assembly Replace brush assembly (Service

Center)

Faulty AVR Replace AVR (Service Center)

Loose wiring Inspect and tighten wiring

connections

Other Contact the help line.

Generator gallops Engine governor defective Contact the help line

Repeated circuit breaker tripping Overload Review load and adjust. See “Power

Management”

Faulty cords or device Check for damaged, bare or frayed

wires. Replace defective device

Warranty

22 Rev 70008-20071026

Warranty

CHAMPION POWER EQUIPMENT

1 YEAR LIMITED WARRANTY

Effective September 1, 2006. Replaces all

undated warranties and all warranties dated

before September 1, 2006.

Warranty Qualifications

Champion Power Equipment (CPE) will register

this warranty upon receipt of your Warranty

Registration Card and a copy of your sales receipt

from one of CPE's retail locations as proof of

purchase.

Please submit your warranty registration and

your proof of purchase within ten (10) days of the

date of purchase.

Repair/Replacement Warranty

CPE warrants to the original purchaser that the

mechanical and electrical components will be free

of defects in material and workmanship for a

period of one (1) year from the original date of

purchase (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.

Do not return the unit to the place

of purchase

Contact CPE's Technical Service and CPE will

troubleshoot any issue via phone or e-mail. 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.

Warranty Exclusions

This warranty does not cover the following

repairs and equipment:

Normal Wear

Generators need periodic parts and service to

perform well. This warranty does not cover repair

when normal use has exhausted the life of a part

or the equipment as a whole.

Installation, Use and Maintenance

This warranty will not apply to parts and/or labor

if this generator is deemed to have been misused,

neglected, involved in an accident, abused, loaded

beyond the generator’s limits, modified, installed

improperly or connected incorrectly to any

electrical component. Normal maintenance such

as spark plugs, air filters, adjustments, fuel

system cleaning and obstruction due to buildup is

not covered by this warranty.

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.

Failure to use the factory supplied LPG regulator

and hose assembly (from the tank to the panel)

will void 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

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

Warranty

Rev 70008-20071026 23

Champion Power Equipment, Inc (CPE),

The California Air Resources Board (CARB) and

the United States Environment Protection Agency (U.S. EPA.)

Emission Control System Warranty

Your Champion Power Equipment (CPE) engine complies with both the U.S. EPA and state of

California Air Resources Board (CARB) emission regulations.

YOUR WARRANTY RIGHTS AND OBLIGATIONS:

The California Air Resources Board, US, EPA AND CPE are pleased to explain the Federal and

California Emission Control Systems Warranty on your 2007 small off-road engine. In California,

new, small off-road engines must be designed, built and equipped to meet the State’s stringent

anti smog standards. In the other states, 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 and catalytic converter. 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:

Emission control systems on 1995 and later model year California small off-road engines are

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.

Warranty

24 Rev 70008-20071026

EMISSION CONTROL SYSTEM WARRANTY

The following are specific provisions relative to your Emission Control System Warranty

Coverage.

Emission Control System Warranty (ECS Warranty) for 1995 and later model year California

small off-road engines (for other states, 1997 and later model year engines):

1. APPLICABILITY: This warranty shall apply to 1995 and later model year California small off-

road engines (for other states, 1997 and later model year 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. Designed, built and equipped so as to conform with all applicable regulations adopted

by the Air Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of

the Health and Safety Code, and

b. 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.

Warranty

Rev 70008-20071026 25

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 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.

Systems covered by this

warranty Parts Description

Fuel Metering System Fuel regulator, Mixer and internal parts

Air Induction System Air cleaner, Intake manifold

Ignition System Spark plug and parts, Magneto ignition system

Exhaust System Exhaust manifold

Miscellaneous Parts Tubing, Fittings, Seals, Gaskets, and Clamps associated with these

listed systems.

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

Notes

26 Rev 70008-20071026

Notes

1-877-338-0999

10006 Santa Fe Springs Road

Santa Fe Springs, CA 90670 USA

Made in China

Champion Power Equipment 70008 Users Manual

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