CPG6500E2 - Generator Champion - Free user manual and instructions

USER MANUAL CPG6500E2 Champion

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Important Safety Instructions are included in this manual. PORTABLE GENERATOR Frame Type Two Y

ENGLISH SVENSKA NORSK DEUTSCH SUOMEN KIELI EESTI FRANÇAIS POLSKI2 INTRODUCTION 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 Model Number Serial Number Date of Purchase Purchase Location For Oil Type see ‘Add Engine Oil‘ section. For Fuel Type see ‘Add Fuel‘ section. Introduction Congratulations on purchasing your generator. Please follow these instructions and maintain it correctly. Portable Power Generator This unit is a petrol engine driven AC generator used for supply electrical power. Accessories CPE manufactures and supplies a series of accessories. See local dealer for more information. This Booklet We reserve the right to change, alter or improve the product and this manual without prior notice.3 MANUAL CONVENTIONS Please familiarize yourself with the following symbols. The safety symbol and key words are safety warnings. Follow all safety messages to avoid accidents or injury. 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. CAUTION DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. DANGER WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. WARNING If you have questions regarding your generator, we can help. Please contact yor local dealer. NOTE EN4 SAFETy RULES Generator exhaust contains carbon monoxide, a colorless, odorless, poison gas. Breathing carbon monoxide will cause nausea, dizziness, fainting or death. If you start to feel dizzy or weak, get to fresh air immediately. Operate generator outdoors only in a well ventilated area. DO NOT operate the generator inside any building, including garages, basements, crawlspaces and sheds, 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 CARBON MONOXIDE: using a generator indoors CAN KILL YOU IN MINUTES. 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. DANGER 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 3 ft. (91.4 cm) of clearance on all sides to ensure adequate cooling. Maintain at least 5 ft. (1.5 m) of clearance from combustible materials. WARNING Medical and Life Support Uses. In an emergency, call emergency services immediately. NEVER use this product to power life support devices or life support appliances. NEVER use this product to power medical devices or medical appliances. Inform your electricity provider immediately if you or anyone in your household depends on electrical equipment to live. Inform your electrical provider immediately if a loss of power would cause you or anyone in your household to experience a medical emergency. WARNING The engine exhaust from this product contains chemicals that are known to cause serious health problems and even death. WARNING Read this manual thoroughly before operating your generator. Failure to follow instructions could result in serious injury or death. WARNING5 SAFETy RULES 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 CAUTION 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 serious injury. 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. WARNING 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 before stopping the generator.DO NOT tamper with the governed speed. DO NOT modify the generator in any way. CAUTION 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 or regulations relating to fire prevention requirements. WARNING 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. 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 pump gas directly into the generator at the gas station. Use an approved container to transfer the fuel to the generator.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. 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. When storing the generator: Store away from sparks, open flames, pilot lights, heat and other sources of ignition. DANGER EN6 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, contact yor local dealer. 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

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 (Optional Extra) You will need the following tools to install the wheels:

• 17 mm wrench OR adjustable wrench (not included)

• Socket wrench with a 16 mm socket (not included)

• Pliers (not included)

1. Before adding fuel and oil, tip the generator on it’s side.

2. Slide the M10x120 flange bolt through the washer,

3. Slide the bolt through the mount point on the frame.

4. Fasten securely with the M10 lock nut.

5. Repeat steps 2-4 to attach the second wheel.

Install the Support Leg

1. Attach the vibration mounts to the support leg with

a flange bolt M8 x 25 and flange lock nuts.

2. Attach the support leg to the generator frame with

flange bolts M8 x 16 and flange lock nuts and fasten securely. DO NOT over tighten the lock nuts.

3. Tip the generator slowly so that it rests on the

wheels and support leg. The wheel kit is not intended for over-the-road use. CAUTION Connect the Battery (Electric Start Models only)

1. Remove the protective cover from the red (+) lead on

2. Attach the red (+) lead to the red (+) terminal on the

battery with the cap screw (M5x10) and secure with the lock washer (M5).

3. Repeat steps 1-2 for the black (–) battery lead.7

1. Place the generator on a flat, level surface.2. Remove oil fill cap/dipstick to add oil.3. Add oil and replace oil fill cap/dipstick. DO NOT OVERFILL.4. Check engine oil level daily and add as needed.The recommended oil type is 10W-30 automotive oil. NOTE The engine is equipped with a low oil shut-off and will stop when the oil level in the crankcase falls below the threshold level. CAUTION Add Engine Oil 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. CAUTION ASSEMBLy 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. NOTE Add Engine Oil Cont’d.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 <5ºC (41ºF) NOTE We consider the first 5 hours of run time to be the break-in period for the unit. During the break in period stay at or below 50% of the running watt rating and vary the load occasionally to allow stator windings to heat and cool. Adjusting the load will also cause engine speed to vary and help seat piston rings. After the 5 hour break-in period, change the oil. NOTE Weather will affect engine oil and engine performance. Change the type of engine oil used based on weather conditions to suit the engine needs. NOTE Once oil has been added, a visual check should show oil about 1-2 threads from running out of the fill hole.If using the dipstick to check oil level, DO NOT screw in the dipstick while checking. NOTE Full Synthetic 5W-30Degrees Celsiusº(Outside)(Outside)Degrees Fahrenheitº EN8 ASSEMBLy Add Fuel Cont’d. Grounding Your generator must be properly connected to an appropriate ground to help prevent 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.Failure to properly ground the generator can result in electric shock. WARNING Our engines work well with 10% or less ethanol blend fuels. When using blended fuels there are some issues worth noting: – Ethanol-gasoline blends can absorb more water than gasoline alone. – These blends can eventually separate, leaving water or a watery goo in the tank, fuel valve and carburetor. – With gravity-fed fuel supplies, this compromised fuel can be drawn into the carburetor and cause damage to the engine and/or potential hazards. – There are only a few suppliers of fuel stabilizer that are formulated to work with ethanol blend fuels. – Any damages or hazards caused by using improper fuel, improperly stored fuel, and/or improperly formulated stabilizers, are not covered by manufacture’s warranty. It is advisable to always shut off the fuel supply, run the engine to fuel starvation and drain the tank when the equipment is not in use for more than 30 days. NOTE Add Fuel 1. Use clean, fresh, regular unleaded fuel with a minimum octane rating of 85 and an ethanol content of less than 10% by volume.2. DO NOT mix oil with fuel.3. Clean the area around the fuel cap. 4. Remove the fuel cap.5. Slowly add fuel to the tank. DO NOT OVERFILL. Fuel can expand after filling. A minimum of ¼ in. (6.4 mm) of space left in the tank is required for fuel expansion, more than ¼ in. (6.4 mm) is recommended. Fuel can be forced out of the tank as a result of expansion if it is overfilled, and can affect the stable running condition of the product. When filling the tank, it is recommended to leave enough space for the fuel to expand.6. Screw on the fuel cap and wipe away any spilled fuel.Use regular unleaded gasoline with a minimum octane rating of 85.Do not mix oil and gasoline.Fill tank to approximately ¼ in. (6.4 mm) below the top of the tank to allow for fuel expansion.DO NOT pump gas directly into the generator at the gas station. Use an approved container to transfer the fuel to the generator.DO NOT fill fuel tank indoors.DO NOT fill fuel tank when the engine is running or hot.DO NOT overfill the fuel tank.DO NOT light cigarettes or smoke when filling the fuel tank. CAUTION Pouring fuel too fast through the fuel screen may result in blow back of fuel at the operator while filling. WARNING9 OPERATION Generator Location Never operate the generator inside any building! (See safety warnings section). In some areas generators must be registered with the local utility company. Generators used on construction sites may be subject to local rules and regulations. Keep on a flat, level surface. Generators must have at least 5 ft (1.5m) clearance from all combustible material. In addition they must have at least 3 ft (91.4cm) of clearance on all sides to allow for adequate cooling, maintenance and servicing. Generators should never be started or operated in ant location that will not allow for adequate cooling of the generator and/or the muffler. Allow generators to cool before storage or transportation. Do not place the generator near any vents or intakes. Carefully consider wind and air currents when placing generator.Failure to follow proper safety precautions may void manufacturer’s warranty.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 WARNING During operation the muffler and exhaust fumes produced will become hot. If adequate cooling and breathing space are not supplied, or if the generator is blocked or contained, temperatures can become extremely heated and may lead to fire. Surge Protection 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.Voltage fluctuation may impair the proper functioning of sensitive electronic equipment. CAUTION 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. Turn the Fuel Valve to the “ON” position.4. Move the choke lever to the “CHOKE” position.5. Flip the ignition switch to the “ON” position. 6. For models that have an ELECTRIC START: Press and hold the ignition switch to the “START” position. Release as the engine begins to roll over. If the engine fails to start within five seconds, release the switch and wait at least ten seconds before attempting to start the engine again.7. RECOIL START: Pull the starter cord slowly until resistance is felt and then pull rapidly8. Do not over-choke. As as soon as engine starts, move the choke lever to the “RUN” position. 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. EN10 Connecting Electrical Loads 1. Let the engine stabilize and warm up for a few minutes after starting2. Plug in and turn on the desired 220 Volt AC single phase, 50 Hz electrical loads. – DO NOT connect 3-phase loads to the generator. – DO NOT connect 60 Hz loads to the generator. – DO NOT overload the generator.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 worker who may be working on nearby power lines. If you plan to run a portable electric generator during an outage, please notify your electric utility company immediately and remember to plug your appliances directly into the generator. Do not plug the generator into any electric outlet in your home. Doing so could create a connection to the utility company power lines. You are responsible for ensuring that your generator’s electricity does not feed back into the electric utility power lines.If the generator will be connected to a building electrical system, consult your local utility company or a qualified electrician. Connections must isolate generator power from utility power and must comply with all applicable laws and codes. NOTE OPERATION 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.2. Let the generator run at no-load for several minutes to stabilize internal temperatures of the engine and generator.3. Turn the Fuel Valve to the “OFF” position.4. Let the engine run until fuel starvation has stopped the engine. This usually takes a few minutes.5. Press the Ignition Switch to the “OFF” position.Important: Always ensure that the Fuel Valve and the Ignition Switch are in the “OFF” position when the engine is not in use.If the engine will not be used for a period of two (2) weeks or longer, please see the Storage section for proper engine and fuel storage. 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. NOTE Keep choke lever in “Choke” position for only 1 pull of the recoil starter. After first pull, move choke lever to the “Run” position for up to the next 3 pulls of the recoil starter. Too much choke will cause the engine not to start. NOTE When the battery switch is in the “ON” position, the switch will light up if the battery is sending out a charge. If the switch does not light up while in the “ON” position, check that the battery connection is still good. NOTE The supplied 12V 15AH battery does re-charge while the engine is running, but it is also recommended that the battery be fully charged at least once per month. NOTE Starting the Engine Cont’d. Connecting Electrical Loads Cont’d.11 Do Not Overload Generator CapacityFollow 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 ManagementUse the following formula to convert voltage and amperage to watts:Volts x Amps = WattsTo prolong the life of your generator and attached devices, follow these steps to add electrical load:1. Start the generator with no electrical load attached2. 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.Never exceed the specified capacity when adding loads to the generator. NOTE OPERATION Operation at High Altitude Be aware that engine efficiency can reduce and exhaust emissions increase when working at high altitude. Other high altitude issues can include hard starting, increased fuel consumption and spark plug fouling. This is a natural trend and cannot be altered by engine adjustment. An Important Message About Temperature Your Champion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to 40°C (104°F). When your product is needed your product may be operated at temperatures ranging from -l5°C (5°F) to 50°C (122°F) for short periods. If the product is exposed to temperatures outside this range during storage, it should be brought back within this range before operation. In any event, the product must always be operated outdoors, in a well-ventilated area and away from doors, windows and other vents. EN12

MAINTENANCE AND STORAGE

The owner/operator is responsible for all periodic maintenance.Complete all scheduled maintenance in a timely manner. Correct any issue before operating the generator.Never operate a damaged or defective generator.Tampering with the factory set governor will void your warranty. 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 (not included). 2. Allow the oil to drain completely.3. Replace the drain plug.4. Remove oil fill cap/dipstick to add oil.5. Add oil and replace oil fill cap/dipstick. DO NOT OVERFILL.6. Dispose of used oil at an approved waste management facility. Spark Plugs 1. Remove the spark plug cable from the spark plug.2. 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. Refer to spark plug information located in the “specification” page for this model.5. Carefully thread the plug into the engine.6. Use the spark plug tool (not included) to firmly install the plug.7. Attach the spark plug wire to the plug.Maintenance, replacement, or repair of emission control devices and systems may be performed by any non-road engine repair establishment or individual. NOTE WARNING WARNING Improper maintenance will void your warranty. WARNING Oil Cont’d. Once oil has been added, a visual check should show oil about 1-2 threads from running out of the fill hole.If using the dipstick to check oil level, DO NOT screw in the dipstick while checking. NOTE Maintenance Valve Clearance OEM spark plug: F6RTC Replacement spark plug: NGK BPR6ES or equivalent Make certain the *spark plug gap is 0.7 - 0.8 mm or (0.028 - 0.031 in.). - Intake: 0.13 - 0.17 mm (0.005 - 0.007 in.) - Exhaust: 0.18 - 0.22 mm (0.007 - 0.009 in.) Note: Tech bulletin regarding the valve adjustment procedure is on www.championpowerequipment.com0.7-0.8 mm0.028-0.031 in.13 AdjustmentsThe 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 your local dealer for all other service and/or adjustment needs.Maintenance ScheduleFollow the service intervals indicated in the following maintenance schedule. Service your generator more frequently when operating in adverse conditions. 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.CleaningDO NOT spray engine with water. CAUTION Water can contaminate the fuel system.Spark Arrester1. Allow the engine to cool completely before servicing the spark arrester.2. Remove the 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 three screws.Failure to clean the spark arrester will result in degraded engine performance. CAUTION Federal and local laws and administrative requirements indicate when and where spark arresters are required. NOTE *To be performed by knowledgeable, experienced owners or Champion Power Equipment certified dealers.

MAINTENANCE AND STORAGE

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.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.DO NOT use a garden hose to clean the generator.Water can enter the generator through the cooling slots and damage the generator windings. CAUTION Every 8 hours or dailyCheck oil levelClean around air intake and mufflerFirst 5 HoursChange oilEvery 50 hours or every seasonClean air filterChange oil if operating under heavy load or in hot environmentsEvery 100 hours or every seasonChange oilClean/Adjust spark plugCheck/Adjust valve clearance*Clean spark arresterClean fuel tank and filter*Every 250 hoursClean combustion chamber*Every 3 yearsReplace fuel lineAir Filter1. 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. EN14

REMARQUE When the battery switch is in the “ON” position, the switch will light up if the battery is sending out a charge. If the switch does not light up while in the “ON” position, check that the battery connection is still good.

REMARQUE The supplied 12V 15AH battery does re-charge while the engine is running, but it is also recommended that the battery be fully charged at least once per month.

Oil Seal, Valve, Iron

122.070011.05 Pipe,Fuel(5.5in) 1 83 1.9074.4.0414.2 Bolt and Washer Assembly M4 x 14 2

Screw Valve Adjustment

Bolt M6×21 Governor Arm

Screw Valve Adjustment

Bolt M6×21 Governor Arm

CHARGE COILBATTERYSTARTER