OPERATOR'S MANUAL
MODEL #100559
3500W PORTABLE GENERATOR
Made in China - REV 20180919 Champion Power Equipment, Inc., Santa Fe Springs, CA USA
or visit championpowerequipment.com
SAVE THESE INSTRUCTIONS. This manual contains important safety precautions which should be read and understood before operating the product. Failure
to do so could result in serious injury. This manual should remain with the product.
Specifications, descriptions and illustrations in this manual are as accurate as known at the time of publication, but are subject to change without notice.
This product is rated in accordance with PGMA (Portable Generator Manufacturers’ Association) standard ANSI/PGMA G300 (Safety and Performance of
Portable Generators).
REGISTER YOUR PRODUCT ONLINE
at championpowerequipment.com
100559 - 3500W PORTABLE GENERATOR
TABLE OF CONTENTS
2
TABLE OF CONTENTS
Introduction ................................................ 3
Safety Definitions
....................................... 3
Important Safety Instructions
.................... 4
Fuel Safety ...................................................... 6
Safety Labels .................................................... 7
Safety Symbols .................................................. 8
Operation Symbols .............................................. 9
Quickstart Label Symbols......................................10
Controls and Features ...............................11
Generator .......................................................11
Control Panel ...................................................12
Intelligauge .....................................................13
Assembly ...................................................14
Unpacking ......................................................14
Remove Shipping Support Brackets ...........................14
Add Engine Oil ..................................................14
Add Fuel ........................................................15
Grounding ......................................................16
Operation ...................................................17
Generator Location .............................................17
Surge Protection ...............................................17
Starting the Engine .............................................17
Connecting Electrical Loads ...................................18
Do Not Overload Generator ....................................19
Stopping the Engine ............................................19
Maintenance ............................................. 20
Cleaning the Generator ........................................20
Changing the Engine Oil .......................................20
Cleaning and Adjusting the Spark Plug ........................20
Cleaning the Air Filter ..........................................21
Cleaning the Spark Arrestor ...................................21
Adjusting the Governor .........................................21
Maintenance Schedule .........................................21
Storage ..................................................... 22
Short Term Storage (up to 30 days) ...........................22
Mid Term Storage (30 days – 1 year) .........................22
Long Term Storage (over 1 year) ..............................23
Removing from Storage ........................................23
Specifications ........................................... 24
Generator Specifications .......................................24
Engine Specifications ..........................................24
Oil Specifications ...............................................24
Fuel Specifications .............................................24
Temperature Specifications ....................................24
Parts Diagram ..................................................25
Parts List .......................................................26
Engine Parts Diagram ..........................................28
Engine Parts List ...............................................29
Wiring Diagram .................................................31
Troubleshooting ........................................ 32
100559 - 3500W PORTABLE GENERATOR
INTRODUCTION
3
INTRODUCTION
Congratulations on your purchase of a Champion Power
Equipment (CPE) product. CPE designs, builds, and supports
all of our products to strict specifications and guidelines. With
proper product knowledge, safe use, and regular maintenance,
this product should bring years of satisfying service.
Every effort has been made to ensure the accuracy and
completeness of the information in this manual at the time
of publication, and we reserve the right to change, alter and/
or improve the product and this document at any time without
prior notice.
CPE highly values how our products are designed,
manufactured, operated, and serviced as well as providing
safety to the operator and those around the generator.
Therefore, it is IMPORTANT to review this product manual
and other product materials thoroughly and be fully aware
and knowledgeable of the assembly, operation, dangers
and maintenance of the product before use. Fully familiarize
yourself, and make sure others who plan on operating the
product fully familiarize themselves too, with the proper safety
and operation procedures before each use. Please always
exercise common sense and always err on the side of caution
when operating the product to ensure no accident, property
damage, or injury occurs. We want you to continue to use and
be satisfied with your CPE product for years to come.
When contacting CPE about parts and/or service, you will
need to supply the complete model and serial numbers of your
product. Transcribe the information found on your product’s
nameplate label to the table below
CPE TECHNICAL SUPPORT TEAM
1-877-338-0999
MODEL NUMBER
100559
SERIAL NUMBER
DATE OF PURCHASE
PURCHASE LOCATION
SAFETY DEFINITIONS
The purpose of safety symbols is to attract your attention to
possible dangers. The safety symbols, and their explanations,
deserve your careful attention and understanding. The safety
warnings do not by themselves eliminate any danger. The
instructions or warnings they give are not substitutes for proper
accident prevention measures.
! DANGER
DANGER indicates a hazardous situation which,if not
avoided, will result in death or serious injury.
! WARNING
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
! CAUTION
CAUTION indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
"
NOTICE
NOTICE indicates information considered important, but
not hazard-related (e.g., messages relating to property
damage).
100559 - 3500W PORTABLE GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
4
IMPORTANT SAFETY INSTRUCTIONS
! WARNING
Cancer and Reproductive Harm – www.P65Warnings.ca.gov
! DANGER
Generator exhaust contains carbon monoxide, a colorless,
odorless, poisonous 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 AND POINT EXHAUST AWAY.
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
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a
poison you cannot see or smell.
NEVER use inside a home or garage, EVEN IF doors and
windows are open.
ONLY use OUTSIDE and far away from windows, doors,
and vents.
Install battery-operated carbon monoxide alarms or plug-in
carbon monoxide alarms with battery back-up according to
the manufacturer’s instructions.
! WARNING
Although the generator contains a spark arrester, maintain
a minimum distance of 5 ft. (1.5 m) from dry vegetation to
prevent fires.
! DANGER
Operate equipment with guards in place.
Rotating parts can entangle hands, feet, hair, clothing and/
or accessories. Traumatic amputation or severe laceration
can result.
Keep hands and feet away from rotating parts.
Tie up long hair and remove jewelry.
DO NOT wear loose-fitting clothing, dangling drawstrings or
items that could become caught.
! DANGER
Generator produces powerful voltage.
DO NOT touch bare wires or receptacles.
DO NOT use electrical cords that are worn, damaged or
frayed. Use only Champion electrical cords for proper
application.
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.
Connection to your home’s electrical system requires a
listed 30A transfer switch installed by a licensed electrician
and approved by the local authority having jurisdiction. The
connection must isolate the generator from the utility power
and must comply with all applicable laws and electrical
codes.
! WARNING
Do not use generator for medical and life support uses.
In case of emergency, call 911 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.
100559 - 3500W PORTABLE GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
5
! WARNING
Spark from removed spark plug wire 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 or any other metal object.
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
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 and turned on.
! CAUTION
Exceeding the generator’s running capacity can damage the
generator and/or electrical devices connected to it.
DO NOT overload the generator.
DO NOT tamper with the governed speed.
DO NOT modify the generator in any way.
! CAUTION
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.
! CAUTION
Improper treatment or use of the generator can damage it,
shorten its life or void the 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.
100559 - 3500W PORTABLE GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
6
Fuel Safety
! DANGER
GASOLINE AND GASOLINE VAPORS ARE HIGHLY
FLAMMABLE AND EXPLOSIVE.
Fire or explosion can cause severe burns or death.
Gasoline and gasoline vapors:
– Gasoline is highly flammable and explosive.
– Gasoline can cause a fire or explosion if ignited.
– Gasoline is a liquid fuel but it’s vapors can ignite.
– Gasoline is a skin irritant and needs to be cleaned up
immediately if spilled on skin or clothes.
– Gasoline has a distinctive odor, this will help detect potential
leaks quickly.
– In any petroleum gas fire, flames should not be extinguished
unless by doing so the fuel supply valve can be turned OFF.
This is because if a fire is extinguished and a supply of
fuel is not turned OFF, then an explosion hazard could be
created.
– Gasoline expands or contracts with ambient temperatures.
Never fill the gasoline tank to full capacity, as gasoline
needs room to expand if temperatures rise.
When adding or removing gasoline:
DO NOT light or smoke cigarettes.
Turn the generator off and let it cool for at least two minutes
before removing the gasoline cap. Loosen the cap slowly to
relieve pressure in the tank.
Only fill or drain gasoline outdoors in a well-ventilated area.
DO NOT pump gasoline directly into the generator at the gas
station. Use an approved container to transfer the fuel to the
generator.
DO NOT overfill the gasoline tank.
Always keep gasoline away from sparks, open flames, pilot
lights, heat and other sources of ignition.
When starting the generator:
DO NOT attempt to start a damaged generator.
Make certain that the gasoline cap, air filter, spark plug, fuel
lines and exhaust system are properly in place.
Allow spilled gasoline 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 valve is in the OFF position and the
gasoline 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.
Do not store generator or gasoline near furnaces, water heaters,
or any other appliances that produce heat or have automatic
ignitions.
! WARNING
Never use a gasoline container, gasoline tank, or any other
fuel item that is broken, cut, torn or damaged.
100559 - 3500W PORTABLE GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
7
Top
Safety Labels
These labels warn you of potential hazards that can cause serious injury. Read them carefully.
If a label comes off or becomes hard to read, contact Technical Support Team for possible replacement.
Alternator Side
LABEL DESCRIPTION
A
144 8-L-SF -A
El uso de un generador en interiores PUEDE MATARLO EN MINUTOS. El escape del generador contiene
monóxido de carbono. Éste es un veneno que no se puede ver ni oler. NUNCA lo use dentro del hogar ni el garaje,
INCLUSO SI las puertas y ventanas están abiertas. Úselo SÓLO a la INTEMPERIE lejos de ventanas, puertas, y
orificios de ventilación.
ONLY use OUTSIDE
and far away from
windows, doors,
and vents.
NEVER use inside
a home or garage,
EVEN IF doors and
windows are open.
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
! DANGER
! PELIGRO
CO Danger
B
1161-L-SF-A
Safety Symbols
C
UNLEADED FUEL ONLY. Minimum octane rating
of 85. Maximum 10% ethanol.
GASOLINA REGULAR SOLAMENTE. 85 octanos
como mínimo. Máximo de etanol de 10%.
ESSENCE SANS PLOMB SEULEMENT. Indice
d’octane minimal de 85. Maximum 10 % d'éthanol.
1032-L-OP-A
Fuel
D
! WARNING
DO NOT TOUCH!
Exhaust gases, muffler
and engine components
are extremely HOT and
cause burns.
Operation of this equipment may create sparks that can start
fires around dry vegetation. A spark arrestor may be
required. The operator should contact local fire agencies for
laws and regulations relating to fire prevention requirements.
If installed, clean every 100 hours or every season.
! ADVERTENCIA
¡NO TOCAR! Los gases de
escape, el silenciador y los
compnonentes del motor están
extremadamente CALIENTES y
causan quemaduras.
La operación de este equipo puede producir chispas que pueden provocar
incendios alrededor de la vegetación seca. Un supresor de chispas puede que
sea necesario. El operador debe comunicarse con las agencias locales de
bomberos para las leyes y reglamentos relativos a los requisitos de prevención
de incendios. Si está instalado, limpie cada 100 horas o cada temporada.
1291- L-SF-A
Hot Surface
B
A
C
D
100559 - 3500W PORTABLE GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
8
Safety Symbols
Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of
these symbols will allow you to more safely operate the product.
SYMBOL MEANING
Read Operator’s Manual. To reduce the risk of injury, user must read and understand operator’s
manual before using this product.
Clearance. Keep all objects at least 5 feet from generator. Heat from the muffler and exhaust gas
can ignite combustible objects.
Ground. Consult with local electrician to determine grounding requirements before operation.
Electric Shock. Failure to use in dry conditions and to observe safe practices can result in electric
shock. Improper connections to a building can allow current to backfeed into utility lines, creating an
electrocution hazard. A transfer switch must be used when connecting to a building.
Fire/Explosion. Fuel and its vapors are extremely flammable and explosive. Fire or explosion
can cause severe burns or death. Keep generator at least 5 ft (1.5m) from all objects to prevent
combustion.
Hot Surface. To reduce the risk of injury or damage, avoid contact with any hot surface.
Open Flame Alert. Fuel and its vapors are extremely flammable and explosive. Keep fuel away from
smoking, open flames, sparks, pilot lights, heat, and other ignition sources.
Wet Conditions Alert. Do not expose to rain or use in damp locations.
100559 - 3500W PORTABLE GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
9
Operation Symbols
Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of
these symbols will allow you to more safely operate the product.
SYMBOL MEANING
ON
STOP or OFF
Locking Receptacle
RV Ready Receptacle
Circuit Breaker Reset: Push
SYMBOL MEANING
Neutral Floating. Neutral circuit IS
NOT electrically connected to the frame/
ground of the generator.
Fuel/Gasoline Valve ON/OFF
Choke
Run
Ground Terminal
100559 - 3500W PORTABLE GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
10
Quickstart Label Symbols
Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of
these symbols will allow you to more safely operate the product.
Starting the Engine
! DANGER
Move generator outside and far away from windows,
doors and intake ventilation covers.
1. Check oil level.
Recommended oil is 10W-30.
2. Check gasoline level.
When adding gasoline, use a minimum octane rating of 85
and an ethanol content of 10% or less by volume.
3. Turn the fuel valve to “ON” position.
4. Press engine switch to the “ON” position.
5. Move choke lever to “CHOKE” position.
6. Pull the recoil starter.
7. Move the choke lever to “RUN” position.
8. Plug in desired device.
Stopping the Engine
1. Turn off and unplug all connected electrical loads.
2. Press the engine switch to the “OFF” position.
3. Turn the fuel valve to the “OFF” position.
1500-L-OP-A
31 1 22 3 4 5
10W-30
!
76 8
!
K 376 186 152 CG1
ColorsLPN 1500-L-OP
Rev A
Size 220 x 23 mm
Artwork Notes
2mm safe margin;
to be printed on white substrate
Revision Changes
---
This artwork belongs to Champion Power Equipment. The contents are confidential and privileged and shall not be disclosed to or used by or for
outside parties without the explicit consent of Champion Power Equipment.
100559 - 3500W PORTABLE GENERATOR
CONTROLS AND FEATURES
11
CONTROLS AND FEATURES
Read this operator’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. Gasoline Tank – 4.7 gal. (17.8 L)
2. Choke – Used to start the engine.
3. Fuel Valve – Used to turn fuel supply on and off to engine.
4. Air Filter – Protects the engine by filtering dust and debris
from the intake air
5. Recoil Starter – Used to manually start the engine
6. Oil Fill Cap/Dipstick – Used to check and fill oil level.
7. Control Panel – See “Control Panel” section.
8. Fuel Gauge – Indicates the amount of gasoline in the fuel
tank.
9. Ground Terminal – Consult an electrician for local
grounding regulations.
1
3
4
5
6
7
9
2
8
100559 - 3500W PORTABLE GENERATOR
CONTROLS AND FEATURES
12
Control Panel
1. Engine Switch – Used to put in START mode or STOP the
generator.
2. Intelligauge – Four mode digital meter for displaying
voltage, frequency (hertz), run time, and total run time.
3. Circuit Breakers (Push Reset) – Protects the generator
against electrical overloads.
1
2
3
A
B
C
Parts Included
Accessories
Oil Funnel ..............................................................................1
RECEPTACLES
A
W
120V AC, 30A Locking (NEMA L5-30R)
May be used to supply electrical power for
operation of 120 Volt AC, 30 Amp, single
phase, 60 Hz electrical loads.
B
t
120V AC, 30A RV (NEMA TT-30R)
May be used to supply electrical power for
operation of 120 Volt AC, 30 Amp, single
phase, 60 Hz electrical loads.
C
A
(2×) 120V AC, 20A (NEMA 5-20R)
May be used to supply electrical power for
operation of 120 Volt AC, 20 Amp, single
phase, 60 Hz electrical loads.
100559 - 3500W PORTABLE GENERATOR
CONTROLS AND FEATURES
13
MODE DESCRIPTION
Voltage (V)
Output voltage of the generator.
Example: 120 volts
Frequency (F)
Output frequency in hertz.
Example: 60.0 hertz
Run Time (R)
Run time of the generator for the current session
Example: 6 hours
Total Run Time
Total run time of the generator since first operation
Example: 16 hours
Intelligauge
Four mode digital meter for displaying voltage, frequency
(hertz), run time, and total run time.
The LCD displays each mode by pressing the button below the
display.
MODE BUTTON
100559 - 3500W PORTABLE GENERATOR
ASSEMBLY
14
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 Technical Support Team at 1-877-338-0999.
Please have your serial number and model number available.
Unpacking
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 work with the generator.
Remove Shipping Support Brackets
To protect the generator during shipping, support brackets have
been installed between the engine and frame. These brackets
MUST BE REMOVED BEFORE adding oil or gasoline to the
generator.
"
NOTICE
DO NOT attempt to run generator without removing the
support brackets. Damage to the generator as a result of not
following these instructions will void the warranty.
1. BEFORE filling the engine with oil or gasoline, tip the
generator onto it’s recoil end. Tip onto the flattened
cardboard box the generator came in or other protective
surface so as to not scratch the frame.
2. Remove the bolts from the orange support brackets. Bolts
and brackets can be discarded.
3. Tip the generator upright.
Add Engine Oil
! 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 failing to follow
these instructions will void your warranty.
"
NOTICE
The generator rotor has a sealed, pre-lubricated ball bearing
that requires no additional lubrication for the life of the bearing.
"
NOTICE
The recommended oil type for typical use is 10W-30
automotive oil.
If running generator in extreme temperatures, refer to the
following chart for recommended oil type.
-20 0 20 40 60
Ambient temperature
Recommended Oil Type
80 100 120
-28.9
°F
°C -17.8 -6.7 4.4 15.6 26.7 37.8 48.9
10W-30
5W-30 Synthetic
10W-405W-30
1. Place the generator on a flat, level surface.
2. Remove oil fill cap/dipstick to add oil.
3. Using a funnel, add up to 18.6 fl. oz. / 0.6 qt. (0.6 L) of
oil (no included) and replace oil fill cap/dipstick. DO NOT
OVERFILL.
4. Check engine oil level at every use and add as needed.
100559 - 3500W PORTABLE GENERATOR
ASSEMBLY
15
"
NOTICE
Once oil has been added, a visual check should show oil
about 1-2 threads from running out of the fill hole.
When using the dipstick to check oil level, DO NOT screw in
the dipstick while checking.
MAX
MIN
OIL DIP STICK
"
NOTICE
Check oil level often during the break-in period. Refer to the
Maintenance section for recommended service intervals.
! CAUTION
This engine is equipped with a low oil shut-off and will stop
when the oil level in the crankcase falls below the threshold
level.
"
NOTICE
The first 5 hours of run time are 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 slightly and help seat piston
rings. After the 5 hour break-in period, change the oil.
"
NOTICE
Synthetic oil may be used after the 5 hour initial break-in
period. Using synthetic oil does not increase the
recommended oil change interval. Full synthetic 5W-30
oil will aid in starting in cold ambient < 41º F (5º C)
temperatures.
Add Fuel
Use clean, fresh, regular unleaded gasoline with a minimum
octane rating of 85 and an ethanol content of 10% or less by
volume. ybc
DO NOT mix oil with gasoline.
1. Remove the gasoline cap.
2. Slowly add gasoline to the tank. Tank is full when gasoline
reaches red circle on screen. DO NOT OVERFILL. Gasoline
can expand after filling. A minimum of ¼ in. (6.4 mm) of
space left in the tank is required for gasoline expansion,
although more than ¼ in. (6.4 mm) is recommended.
Gasoline can be forced out of the tank as a result of
expansion if overfilled, and can affect the stable running
condition of the generator.
3. The approximate fuel level is shown on the fuel gauge on
top of the fuel tank.
EMPTY FULL
4. Screw on the gasoline cap and wipe away any spilled fuel.
100559 - 3500W PORTABLE GENERATOR
ASSEMBLY
16
! CAUTION
Use unleaded gasoline with a minimum octane rating of 85
and an ethanol content of 10% or less by volume.
DO NOT light cigarettes or smoke when filling the tank.
DO NOT mix oil and gasoline.
DO NOT overfill the tank. Fill tank to approximately ¼ in.
(6.4 mm) below the top of the tank to allow for gasoline
expansion.
DO NOT pump gasoline directly into the generator at the
pump. Use an approved container to transfer the gasoline to
the generator.
DO NOT fill tank indoors.
DO NOT fill tank when the engine is running or hot.
! WARNING
Pouring gasoline too fast through the fuel screen may result
in gasoline splashing over the generator and operator while
filling.
"
NOTICE
The generator engine works well with 10% or less ethanol
blend gasoline. When using ethanol-gasoline blends there
are some issues worth 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. The
compromised gasoline can be drawn into the carburetor
and cause damage to the engine and/or potential
hazards.
– If a fuel stabilizer is used, confirm that it is formulated to
work with ethanol-gasoline blends.
– Any damages or hazards caused by using improper
gasoline, improperly stored gasoline, and/or
improperly formulated stabilizers, are not covered by
manufacturer’s warranty.
It is advisable to always shut off the gasoline supply and
run the engine to starvation after each use. See Storage
instructions for extended non-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 (see Controls and Features for terminal location).
For remote grounding, connect of a length of heavy gauge
(12 AWG minimum) copper wire between the generator ground
terminal and a copper rod driven into the ground. We strongly
recommend that you consult with a qualified electrician to
ensure compliance with local electrical codes.
Neutral Floating*
– Neutral circuit IS NOT electrically connected to the frame/
ground of the generator.
– The generator (stator winding) is isolated from the frame
and from the AC receptacle ground pin.
– Electrical devices that require a grounded receptacle pin
connection will not function if the receptacle ground pin is
not functional.
Neutral Bonded to Frame*
– Neutral circuit IS electrically connected to the frame/ground
of the generator.
– The generator system ground connects lower frame
cross-member below the alternator. The system ground is
connected to the AC neutral wire.
* See your model’s control panel for specified type of grounding.
100559 - 3500W PORTABLE GENERATOR
OPERATION
17
OPERATION
Generator Location
NEVER operate the generator inside any building, including
garages, basements, crawlspaces and sheds, enclosure or
compartment, including the generator compartment of a
recreational vehicle. 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. Generators should be on
a flat, level surface at all times. (Even while not in operation)
Generators must have at least 5 ft. (1.5 m) of clearance from
all combustible material. In addition to clearance from all
combustible material, generators must also have at least 3 ft.
(91.4 cm) of clearance on all sides to allow for adequate cooling,
maintenance and servicing. Generators should never be started
or operated in the back of a SUV, camper, trailer, in the bed of
a truck (regular, flat or otherwise), under staircases/stairwells,
next to walls or buildings, or in any other location that will not
allow for adequate cooling of the generator and/or the muffler.
DO NOT contain generators during operation. Allow generators
to properly cool before transport or storage.
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.
Failure to follow proper safety precautions may void
manufacturer’s warranty.
! WARNING
Do not operate or store the generator in rain, snow, or wet
weather.
Using a generator or electrical appliance in wet conditions,
such as rain or snow, or near a pool or sprinkler system,
or when your hands are wet, could result in electrocution.
! WARNING
During operation the muffler and exhaust fumes will
become hot. If adequate cooling and breathing space are
not supplied, or if the generator is blocked or enclosed,
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.
– 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.
Starting the Engine
1. Make certain the generator is on a flat, level surface.
2. Disconnect all connected electrical loads from the
generator. Never start or stop the generator with electrical
devices plugged in or turned on.
3. Turn the gasoline fuel valve to the “ON” position.
4. Push the engine switch to the “ON” position.
100559 - 3500W PORTABLE GENERATOR
OPERATION
18
5. Move the choke to the CHOKE position. Note: for restarting
a warm engine, move the choke to 75% of the CHOKE
position.
6. Pull the starter cord slowly until resistance is felt and then
pull rapidly.
7. As soon as engine starts, move the choke to the “RUN”
position over a 2-5 second duration.
8. Connect electrical loads.
"
NOTICE
Keep choke in “CHOKE” position for only 1 pull of the recoil
starter. After first pull, move choke to “RUN” position for
up to 3 pulls of the recoil starter. Too much choke leads to
spark plug fouling/engine flooding due to lack of incoming
air. This will cause the engine not to start.
"
NOTICE
For gasoline restarts with hot engine in hot ambient
temperature > 86°F (30°C), keep choke in 75% of the
“CHOKE” position for only 1 pull of the recoil starter. After
first pull, move choke to “RUN” position for up to 3 pulls
of the recoil starter. Too much choke leads to spark plug
fouling/engine flooding due to lack of incoming air. This will
cause the engine not to start.
"
NOTICE
For gas starting in cold ambient temperature < 59°F
(15°C), the choke must be in 100% of the “CHOKE” position
for recoil start procedures. Do not over-choke. As soon as
engine starts, gradually move the choke lever to the “RUN”
position over a 2-5 second duration.
"
NOTICE
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
Let the engine stabilize and warm up for a few minutes after
starting.
Plug in and turn on the desired 120 or 240 (if applicable) Volt AC
single phase, 60 Hz electrical loads.
– DO NOT connect 3-phase loads to the generator.
– DO NOT overload the generator.
100559 - 3500W PORTABLE GENERATOR
OPERATION
19
! WARNING
Connecting a generator to your electric utility company’s
power lines or to another power source may be against
the law. In addition this action, if done incorrectly, could
damage your generator and appliances and could cause
serious injury or even death to you or a utility 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.
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. Starting wattage is the surge 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 × 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 get up to
temperature.
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.
"
NOTICE
Never exceed the specified capacity when adding loads to
the generator.
Stopping the Engine
1. Turn off and unplug all connected 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. Press the engine switch to the “OFF” position.
4. Turn the fuel valve to the “OFF” position.
Important: Always ensure that the fuel valve and the engine
switch are in the “OFF” position when the generator is not in
use.
"
NOTICE
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.
100559 - 3500W PORTABLE GENERATOR
MAINTENANCE
20
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.
! WARNING
Never operate a damaged or defective generator.
! WARNING
Improper maintenance will void your warranty.
"
NOTICE
For Emission control devices and systems, read and
understand your responsibilities for service as stated in the
Emission Control Warranty Statement of this manual.
The owner/operator is responsible for all periodic maintenance.
Complete all scheduled maintenance in a timely manner.
Correct any issue before operating the generator.
For service or parts assistance, contact our
Technical Support Team at 1-877-338-0999.
Cleaning the Generator
! CAUTION
DO NOT spray generator directly with water.
Water can enter the generator through the cooling slots and
damage the generator windings. It can also contaminate the
fuel system.
1. Use a damp cloth to clean exterior surfaces of the
generator.
2. Use a soft bristle brush to remove dirt and oil.
3. Use an air compressor (25 PSI) to clear dirt and debris
from the generator.
4. Inspect all air vents and cooling slots to ensure that they
are clean and unobstructed.
To prevent accidental starting, remove and ground the spark
plug wire before performing any service.
Changing the Engine Oil
Change oil when the engine is warm. Refer to the oil
specification to select the proper grade for your operating
environment.
1. Remove the oil drain bolt and washer with a 10 mm socket
(not included) and extension.
2. Allow the oil to drain completely into an appropriate
container.
DRAIN BOLT WASHER
3. Replace the oil drain bolt and washer.
4. Remove the oil fill cap/dipstick to add oil.
5. Add oil according to “Add Engine Oil” on Assembly
section. DO NOT OVERFILL. Oil not included for routine
maintenance.
6. Dispose of used oil at an approved waste management
facility.
"
NOTICE
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.
Cleaning and Adjusting the Spark Plug
1. Remove the spark plug cable from the spark plug.
2. Use a spark plug socket tool (not included), or a
13/16 in. (21 mm) socket (not included) 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
0.024-0.031 in. (0.6-0.8 mm).
100559 - 3500W PORTABLE GENERATOR
MAINTENANCE
21
SPARK PLUG GAP
5. Refer to the spark plug types in Specifications when
replacing the plug.
6. Firmly re-install the plug.
7. Attach the spark plug cable to the spark plug.
Cleaning the 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.
Cleaning the Spark Arrestor
1. Allow the engine to cool completely before servicing the
spark arrestor.
2. Remove the two or three screws (varies by model) holding
the cover plate which retains the spark arrestor to the
muffler.
3. Remove the spark arrestor screen.
4. Carefully remove the carbon deposits from the spark
arrestor screen with a wire brush.
Type 1 Type 2
* See your model’s parts list for specified type of spark arrestor.
5. Replace the spark arrestor if it is damaged.
6. Position the spark arrestor on the muffler and attach with
the screws removed in step 2.
! CAUTION
Failure to clean the spark arrestor will result in degraded
engine performance.
"
NOTICE
Federal and local laws and administrative requirements
indicate when and where spark arrestors are required.
When ordered, spark arrestors are required for operation
of this generator in National Forest lands. In California,
this generator must not be used on any forest-covered
land, brush-covered land, or grass-covered land unless the
engine is equipped with a spark arrestor.
Adjusting the Governor
! WARNING
Tampering with the factory set governor will void your
warranty.
The air-fuel mixture is not adjustable. Tampering with
the governor can damage your generator and your
electrical devices and will void your warranty. Contact our
Technical Support Team at 1-877-338-0999 for all other
service and/or adjustment needs.
Maintenance Schedule
Follow the service intervals indicated in the following
maintenance schedule.
Service your generator more frequently when operating in
adverse conditions.
Contact our Technical Support Team at 1-877-338-0999
to locate the nearest CPE certified service dealer for your
generator or engine maintenance needs.
EVERY 8 HOURS OR PRIOR TO EACH USE
# Check oil level
# Clean around air intake and muffler
FIRST 5 HOURS (BREAK IN)
# Change oil
EVERY 50 HOURS OR ANNUALLY
# Clean air filter
# Change oil if operating under heavy load or in hot
environments
DELETE "NATIONAL FOREST" NOTICE IF CANADA ONLY ITEM
100559 - 3500W PORTABLE GENERATOR
STORAGE
22
EVERY 100 HOURS OR ANNUALLY
# Change oil
# Clean/adjust spark plug
# Check/adjust valve clearance*
# Clean spark arrestor
# Clean fuel tank and filter*
EVERY 250 HOURS
# Clean combustion chamber**
EVERY 3 YEARS
# Replace fuel line*
* To be performed by knowledgeable, experienced owners or CPE certified
service centers.
STORAGE
! DANGER
Gasoline vapors are highly flammable and extremely
explosive.
Fire or explosion can cause severe burns or death. Only
fill or drain fuel outdoors in a well-ventilated area. DO NOT
pump gasoline directly into the generator. Use an approved
container to transfer the fuel to the generator. Never use
a gasoline container, gasoline tank, or any other fuel item
that is damaged or appears damaged. DO NOT overfill the
gasoline tank. Always keep fuel away from sparks, open
flames, pilot lights, heat and other sources of ignition.
DO NOT light or smoke cigarettes.
Short Term Storage (up to 30 days)
Gasoline may gum up and clog the carburetor if the generator is
not run or carburetor drained within 4 weeks.
1. Be sure all appliances are disconnected from the generator.
2. Start the generator as instructed in “Starting the Engine”
section.
3. Turn the fuel valve to the “OFF” position.
4. Let the engine run until fuel starvation has stopped the
engine. This usually takes a few minutes.
5. Move the engine switch to the “OFF” position.
Mid Term Storage (30 days – 1 year)
Gasoline in the tank has a maximum shelf life of up to 1 year
with the addition of a properly formulated fuel stabilizer and
stored in a cool, dry place.
1. Be sure all appliances are disconnected from the generator.
2. Add a properly formulated fuel stabilizer to the gasoline
tank.
3. Turn the fuel valve to the “ON” position.
4. Start and run the generator for 10 minutes so the treated
gasoline cycles through the fuel system.
5. Option 1: Drain Gasoline from Carburetor
5a. Turn engine switch to the “OFF” position and allow
generator to cool completely before continuing.
5b. Turn the fuel valve to the “OFF”.
5c. Use the drain bolt on the carburetor to empty any
excess gasoline from the carburetor into an appropriate
container. Use a funnel (and appropriate hose if
necessary) under the carburetor drain bolt to avoid
spillage.
5d. When gasoline stops flowing from the carburetor,
replace and tighten the carburetor drain bolt and
be sure to properly dispose of the drained gasoline
according to local regulations or guidelines.
6. Option 2: Run Dry
6a. With the generator running, turn the fuel valve to the
“OFF” position and allow the generator to run until the
engine stops from complete fuel starvation. This may
take a few minutes.
6b. Turn engine switch to the “OFF” position and allow
generator to cool completely before continuing.
7. Remove the spark plug cap and spark plug and pour about
a tablespoon of oil into the cylinder.
8. Pull the recoil slowly to crank the engine to distribute the
oil and lubricate the cylinder.
9. Install the spark plug and spark plug cap.
100559 - 3500W PORTABLE GENERATOR
STORAGE
23
10. Clean the generator according to Cleaning the Generator.
11. Store the generator in a cool, dry place out of direct
sunlight.
Long Term Storage (over 1 year)
For storage over 1 year, the gasoline tank and carburetor must
be completely drained of gasoline.
1. Follow steps 1-4 according to Mid Term Storage.
1a. Turn engine switch to the “OFF” position and allow
generator to cool completely before continuing.
2. Use the drain bolt on the carburetor to empty any excess
gasoline from the gasoline tank and carburetor into an
appropriate container. Use a funnel (and appropriate hose if
necessary) under the carburetor drain bolt to avoid spillage.
3. When gasoline stops flowing from the carburetor, replace
and tighten the carburetor drain bolt and be sure to
properly dispose of the drained gasoline according to local
regulations or guidelines.
4. Turn the fuel valve to the “OFF” position.
5. Follow steps 8-11 according to Mid Term Storage.
Removing from Storage
If the generator has been improperly stored for a long period
of time with gasoline in the gasoline tank and/or carburetor, all
fuel must be drained and the carburetor must be thoroughly
cleaned. This process involves technically advanced tasks.
For assistance please call our Technical Support Team at
1-877-338-0999.
If the gasoline tank and carburetor were properly emptied of all
gasoline prior to the generator being stored, follow the below
steps when removing from storage.
1. Be sure the engine switch is in the “OFF” position.
2. Add gasoline to the generator according to Add Fuel:
Gasoline.
3. Turn the fuel valve to the “ON” position.
4. After 5 minutes check the carburetor and air filter areas for
any leaking gasoline. If any leaks are found, the carburetor
will need to be disassembled and cleaned or replaced. If no
gasoline leaks are found, turn the fuel valve to the “OFF”
position.
5. Check engine oil level and add clean, fresh oil if needed.
See Oil Specifications for proper oil type.
6. Check and clear air filter of any obstructions such as bugs
or cobwebs. If necessary, clean air filter according to
Cleaning the Air Filter.
7. Start the generator according to Starting the Engine.
100559 - 3500W PORTABLE GENERATOR
SPECIFICATIONS
24
SPECIFICATIONS
Generator Specifications
Generator Model ........................................ 100559
Start Type ................................................ Manual
Watts (Starting/Running) ........................... 4375/3500
AC Volts ....................................................... 120
AC Amps @ 120V ........................................... 29.2
Frequency .................................................. 60 Hz
Phase .......................................................Single
Weight ........................................ 102.1 lb. (46.3 kg)
Length ...........................................23.2 in. (59 cm)
Width ......................................... 18.3 in. (46.4 cm)
Height .......................................... 19.9 in. (50.6 cm)
Engine Specifications
Model ...................................................... FH210
Displacement ..............................................208 cc
Type ................................................ 4-Stroke OHV
Spark Plug
OEM Type ........................................... NHSP F6RTC
Replacement Type ................... NGK BPR6ES or equivalent
Gap ...............................0.024-0.031 in. (0.6-0.8 mm)
Valve
Intake Clearance .............. 0.004-0.006 in. (0.10-0.15 mm)
Exhaust Clearance ............0.006-0.008 in. (0.15-0.20 mm)
"
NOTICE
A technical bulletin regarding valve adjustment procedures
is available at www.championpowerequipment.com.
Oil Specifications
DO NOT OVERFILL.
Type ............................................ *See chart below
Capacity ..............................18.6 fl. oz. / 0.6 qt. (0.6 L)
-20 0 20 40 60
Ambient temperature
Recommended Oil Type
80 100 120
-28.9
°F
°C -17.8 -6.7 4.4 15.6 26.7 37.8 48.9
10W-30
5W-30 Synthetic
10W-405W-30
"
NOTICE
Temperature will affect engine oil and engine performance.
Change the type of engine oil used based on the
temperature to suit the engine needs.
Fuel Specifications
Use unleaded gasoline with a minimum octane rating of 85 and
an ethanol content of 10% or less by volume. DO NOT USE E15
or E85. DO NOT OVERFILL.
Gasoline Capacity ............................... 4.7 gal. (17.8 L)
Temperature Specifications
Starting Temperature Range (°F/°C) ........ 5 to 104/-15 to 40
"
NOTICE
An important message about temperature: Your product
is designed and rated for continuous operation at ambient
temperatures up to 104°F (40°C). When needed, it may be
operated at temperatures ranging from 5°F (-15°C) to 122°F
(50°C) for short periods of time. If 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 vents.
100559 - 3500W PORTABLE GENERATOR
SPECIFICATIONS
25
Parts Diagram
1
2
28
29
30
32
33
31
26
38
27
25
24
24
21
22
22
23
49
50
51
52
53
54
55
56
57
60
61
62
63
46
45
59
58
64
42
41
48
47
70
69
35
34
72
71
73
74
75
76
43
43
43
26
20
44
44
44
44
51
51
45
46
65
66
67
1
17
16
18
19
58
39
68
7
14
13
12
15
9
10
11
5
4
6
3
37
8
36
40
100559 - 3500W PORTABLE GENERATOR
SPECIFICATIONS
26
# Part Number Description Qty.
1 100011261-0002
Flange Bolt M6 × 12,
Black Zinc
4
2 100095690-0001 Panel Assembly 1
3 100019772-0001 Switch 1
4 100095895 Control Panel 1
5 100095927 Intelligauge, VFT 1
6 100019751
30Amp Circuit Breaker,
Push Button
1
7 100019754
20Amp Circuit Breaker,
Push Button
1
8 100120180 Breaker Cover 2
9 100020005 Receptacle L5-30R 1
10 100020008 Receptacle TT-30R 1
11 100020029
Receptacle 5-20R,
Duplex
1
12 100088269
Receptacle Cover
L5-30R
1
13 100088268
Receptacle Cover
TT-30R
1
14 100098921
Receptacle Cover
5-20R, Duplex
1
15 100020100 Protect Panel 1
16 100011452-0003 Lock Nut M6, Flange 4
17 100095689-0001
Frame
590 × 464 × 504.5
1
18 100022335 Damping Support 4
19 100010964-0002 Screw M6 × 12 4
20 100009983
Grounding Line
165.5 mm
1
21 100011421-0003 Flange Nut M6 1
22 100010920-0002 Flat Washer Ø6 2
23 100010828-0002 Butterfly Type Nut M6 1
24 100010886-0004 Spring Washer Ø6 2
25 100011025-0001
Lock Washer Ø6,
Toothed
1
26 100011268-0002 Flange Bolt M6 × 25 5
27 100009075 Rubber Damper 1
28 100021153 Fuel Valve 1
29 100005138 Clamp Ø9.5 × 8 1
30 100095592-0001
Fuel Tank, 17.8 L,
Yellow
1
31 100093333 Fuel Tank Cap 1
32 100098838 Fuel Filter 1
33 100099571 Reversal Valve 1
34 100095894 Gauge, Fuel Level 1
# Part Number Description Qty.
35 100059920-0001
Label,
Fuel Level Gauge
1
36 100021118
Bushing,
Ø12 × Ø9 × 13
4
37 100032369
Vibration Mounting,
Fuel Tank
4
38 100010439-0001
Washer
Ø6.5 × 2 × Ø25, Black
4
39 100005148 Clamp Ø8 1
40 100086538
Connection Tube
654 mm
1
41 100000657 Cable Clamp 1
42 100020165 Support, End Cover 1
43 100011261-0004 Flange Bolt M6 × 12 3
44 100011453-0003 Lock Nut M8, Flange 8
45 100021000-0001
Vibration Mount,
Support 2
2
46 100020986-0001
Vibration Mount,
Support 1
2
47 1ZC7DF0N3 Engine, 208 cc 1
48 100021030 Holder, Air Cleaner 1
49 100011250-0002 Flange Bolt M5 × 14 2
50 100018658-0023
Generator End Cover,
Yellow
1
51 100011252-0001 Flange Bolt M5 × 18 6
52 100018603 AVR 1
53 100018592
Carbon Brush
Assembly
1
54 100018701 Terminal Block 1
55 100010885-0004 Spring Washer Ø5 1
56 100010919-0002 Flat Washer Ø5 1
57 100011297-0002 Flange Bolt M6 × 165 4
58 100011230-0002 Flange Bolt M8 × 16 2
59 100021068
Mounting Plate
Support Assembly
1
60 100018567 End Housing 1
61 100011375-0001
Flange Bolt
M8 × 1 × 220
1
62 100010887-0004 Spring Washer Ø8 1
63 100010899-0002 Washer Ø8 1
64 100095623
Alternator Assembly,
Al, Ø160 × 120 mm
1
65 100095943
Stator Cover,
112.5 mm
1
Parts List
100559 - 3500W PORTABLE GENERATOR
SPECIFICATIONS
27
# Part Number Description Qty.
66 100095944
Stator Assembly, Al,
Ø160 × 120 mm
1
67 100095942
Rotor Assembly, Al,
Ø95 × 120 mm
1
68 100011422-0004 Flange Nut M8 2
69 100006936 Gasket, Exhaust Pipe 1
70 100087308
Exhaust Muffler
Assembly
1
71 100097575-0001 Flange Bolt M6 × 10 4
72 100006811 Muffler Cover 1
73 100126717 Muffler 1
74 100006594
Spark Arrester
Assembly
1
75 100006999 Plate, Spark Arrester 1
76 100011247-0003 Flange Bolt M5 × 8 2
100559 - 3500W PORTABLE GENERATOR
SPECIFICATIONS
28
Engine Parts Diagram
1
2
16
17
36
37
38
39
41
42
46
47
49
18
19
20
21
33
26
27
28
30
31
40
48
52
54
53
55
56
57
59
58
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
51
80
81
83
84
85
86
87
88
89
90
91
78
77
3
7
75
1
32
29
24
4
5
6
8
9
10
11
12
13
14
15
25
34
35
52
78
77
79
82
43
44
45
50
76
35
35
35
35
22
23
92
100559 - 3500W PORTABLE GENERATOR
SPECIFICATIONS
29
Engine Parts List
# Part Number Description Qty.
1 100011264-0003
Flange Bolt M6 × 16,
GB5789
5
2 100002335
Cylinder Head
Cover(Cpe)
1
3 100031972 Breather Tube 1
4 100066138
Gasket, Cylinder Head
Cover
1
5 100011463-0002 Flange Nut M6 2
6 100004431 Rocker Arm Assembly 2
7 100004512 Shaft, Rocker Arm 1
8 100004506 Retainer, Rocker Arm 1
9 100004505 Bolt, Rocker Arm 2
10 100004478 Guide Plate, Push Rod 1
11 100004588
Valve Adjust Cap,
Exhaust
2
12 100004585
Valve Spring Seat,
Exhaust
2
13 100004564 Spring, Valve 2
14 100004600 Oil Seal, Valve 1
15 100002464-0001 Flange Bolt M8 × 60 4
16 100002389 Cylinder Head 1
17 100009378 Spark Plug F6RTC 1
18 100010389 Stud Bolt M8 × 35 2
19 100010354 Stud Bolt M6 × 96 2
20 100092295 Gasket, Insulator 1
21 100005599 Insulator, Carburetor 1
22 100078606 Gasket, Carburetor 1
23 100086220-0001 Carburetor 1
24 100066136 Gasket, Air Filter Base 1
25 100004745 Air Filter Assembly 1
26 100005023 Air Filter Base 1
27 100004894 Air Filter Clip 2
28 100004877 Air Filter Separator 1
29 100011250-0002 Flange Bolt M5 × 14 4
30 100004795 Gasket, Air Filter Cover 1
31 100004770 Air Filter Element 1
32 100004873 Air Filter Cover 1
33 100011452-0003 Lock Nut M6, Flange 2
34 100007111 Air Guide, Lower 1
35 100011261-0004
Flange Bolt M6 × 12,
GB5789
6
36 100010213 Gasket, Cylinder Head 1
37 100010558 Dowel Pin Ø10 × 16 2
38 100004408 Push Rod 2
# Part Number Description Qty.
39 100004550 Valve, Exhaust 1
40 100004524 Valve, Intake 1
41 100004263 Lifter, Valve 2
42 100003245 Piston Ring Set 1
43 100003150 1st Piston Ring 1
44 100003191 2nd Piston Ring 1
45 100003283 Oil Ring 1
46 100003221 Circlip, Wrist Pin 2
47 100003081 Piston 1
48 100003125 Wrist Pin 1
49 100003448 Connecting Rod 1
50 100003430 Bolt, Connecting Rod 2
51 100002664 Crankcase 1
52 100010787 Bearing TM6205 - P63 2
53 100003770 Crankshaft 1
54 100092356 Camshaft 1
55 100010025 Oil Level Sensor 1
56 100011217-0002 Flange Bolt M6 × 16 2
57 100010544 Dowel Pin Ø7 × 14 1
58 100010554 Dowel Pin Ø9 × 14 1
59 100092294
Gasket, Crankcase
Cover
1
60 100002990 Cover, Crankcase 1
61 100017651
Oil Seal
Ø25 × Ø41.25 × 6
1
62 100011319-0001 Flange Bolt M8 × 32 6
63 100004107-0001 Oil Dipstick Assembly 1
64 100008296 Gear, Governor 1
65 100011215-0001 Flange Bolt M6 × 12 4
66 100008186 Control Assembly 1
67 100007840 Spring, Governor 1
68 100007947 Rod, Governor 1
69 100007920 Spring, Throttle Return 1
70 100008417 Arm, Governor 1
71 100007986 Cotter, Governor Shaft 1
72 100017630 Oil Seal Ø6 × Ø11 × 4 1
73 100010113
Sealing Ring,
Ø5.2 × 1.9
1
74 100007975 Governor Shaft 1
75 100005138 Clamp Ø9.5 × 8 1
76 100017831
Fuel Pipe,
Ø4 × Ø10 × 126
1
77 100010272
Drain Bolt,
M10 × 1.25 × 15
2
100559 - 3500W PORTABLE GENERATOR
SPECIFICATIONS
30
# Part Number Description Qty.
78 100010459
Washer
Ø10 × 1.5 × Ø16
2
79 100017644
Oil Seal
Ø25 × Ø41.25 × 6,
Spiral Grain
1
80 100009288 Ignition Module 1
81 100011268-0003 Flange Bolt M6 × 25 2
82 100007062 Lower guard 1
83 100009533 Flywheel 1
84 100007028 Cooling Fan 1
85 100007550 Pulley, Starter 1
86 100011459-0003 Flange Nut M14 × 1.5 1
87 100099123-0001
Recoil Starter
Assembly
1
88 100007659-0002 Fan Cover, Yellow 1
89 100099122-0001 Recoil Starter, Black 1
90 100010894-0001 Washer Ø6 3
91 100011528-0004 Flange Bolt M6 × 10 3
92 100127017
Cylinder Head
Assembly
1
100559 - 3500W PORTABLE GENERATOR
SPECIFICATIONS
31
Wiring Diagram
100559 - 3500W PORTABLE GENERATOR
TROUBLESHOOTING
32
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.
Low oil level.
Fill crankcase to the proper level.
Place generator on a flat, level surface.
Spark plug wire loose. Attach wire to spark plug.
Fuel valve is closed. Open fuel valve.
Engine switch OFF. Turn engine switch ON.
Generator starts but runs roughly.
Choke in the wrong position. Adjust choke.
Dirty air filter. Clean or replace air filter.
Dirty fuel valve. Clean the fuel valve.
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 “Connecting
Electrical Loads.”
Dirty air filter. Clean or replace air filter.
No AC output.
Power cord not properly connected. Check all connections.
Connected device is defective. Replace defective device.
Circuit breaker is open. Reset circuit breaker.
Faulty brush assembly. Replace brush assembly (Service Center).
Faulty AVR (auto voltage regulator). Replace AVR (Service Center).
Loose wiring. Inspect and tighten wiring connections.
Other. Contact the help line.
Generator hunts. Engine governor defective. Contact the help line.
Repeated circuit breaker tripping.
Overload.
Review load and adjust. See “Connecting
Electrical Loads.”
Faulty power cords or device.
Check for damaged, bare or frayed wires.
Replace defective device.
For further technical support:
Technical Support Team
Mon-Fri 8:30 AM-5:00 PM (PST/PDT)
Toll Free 1-877-338-0999
support@championpowerequipment.com
WARRANTY*
CHAMPION POWER EQUIPMENT
3 YEAR LIMITED WARRANTY
Warranty Qualifications
To register your product for warranty and FREE lifetime call center
technical support please visit:
https://www.championpowerequipment.com/ r egister
To complete registration you will need to include a copy of the
purchase receipt as proof of original purchase. Proof of purchase is
required for warranty service. Please register within ten (10) days
from 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 three years (parts and labor) from
the original date of purchase and 270 days (parts and labor) for
commercial and 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
Products with mechanical and electrical components 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 the product is
deemed to have been misused, neglected, involved in an accident,
abused, loaded beyond the product’s limits, modified, installed
improperly or connected incorrectly to any electrical component.
Normal maintenance is not covered by this warranty and is not required
to be performed at a facility or by a person authorized by CPE.
Other Exclusions
This warranty excludes:
– Cosmetic defects such as paint, decals, etc.
– Wear items such as filter elements, o-rings, etc.
– Accessory parts such as starting batteries, and storage covers.
– Failures due to acts of God and other force majeure events
beyond the manufacturer’s control.
– Problems caused by parts that are not original Champion Power
Equipment parts.
When applicable, this warranty does not apply to products used for
prime power in place of a utility.
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 product. THIS
WARRANTY AND THE ATTACHED U.S. EPA, CARB and/or ECCC
EMISSION CONTROL SYSTEM WARRANTIES (WHEN APPLICABLE)
ARE 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 or province to province. Your state or province 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
12039 Smith Ave.
Santa Fe Springs, CA 90670 USA
www.championpowerequipment.com
Customer Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free : 1-877-338-0999
info@championpowerequipment.com
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
24/7 Tech Support: 1-562-204-1188
* Except as otherwise stipulated in any of the following enclosed Emission Control System Warranties (when applicable) for the Emission Control System: U.S.
Environment Protection Agency (EPA), California Air Resources Board (CARB) and/or Environment and Climate Change Canada (ECCC). Whichever warranty applies
for the longer period, either this 3 year limited warranty or the applicable Emission Control System Warranty, shall supersede the other.
Champion Power Equipment, Inc. (CPE),
United States Environment Protection Agency (U.S. EPA)
Emission Control System Warranty
Your Champion Power Equipment (CPE) engine complies with 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 2018 small
off-road engine (SORE) and engine powered equipment. New engines and equipment must be designed, built and
equipped, at the time of sale, to meet U.S. EPA regulations for small off-road engines (SORE). CPE warrants the
emission control system on your small off-road engine (SORE) and equipment for the period of time listed below,
provided there has been no abuse, neglect, unapproved modification, or improper maintenance of your equipment.
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 (SORE) 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, an 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 (SORE) 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 (SORE) owner, you should however be aware that CPE may deny you warranty
coverage if your small, off-road engine (SORE) or a part has failed due to abuse, neglect, improper maintenance or
unapproved modifications.
You are responsible for presenting your small off-road engine (SORE) to an Authorized CPE service outlet or
alternate service outlet as described in (3)(f.) below, 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
12039 Smith Ave.
Santa Fe Springs, CA 90670
1-877-338-0999
tech@championpowerequipment.com
EMISSION CONTROL SYSTEM WARRANTY
The following are specific provisions relative to your Emission Control System (ECS) Warranty Coverage.
1. APPLICABILITY: This warranty shall apply to 1997 and later model year small off-road engines (SORE). 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 (SORE) is:
a. Designed, built and equipped so as to conform to U.S. EPA emissions standards for spark-ignited
engines at or below 19 kilowatts.
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 pay for covered emissions warranty repairs at non-authorized service outlets under the
following circumstances:
i. The service is required in a population center with a population over 100,000 according to U.S.
Census 2000 without a CPE Authorized Service Outlet AND
ii. The service is required more than 100 miles from a CPE Authorized Service Outlet. The 100 mile
limitation does not apply in the following states: Alaska, Arizona, Colorado, Hawaii, Idaho, Montana, Nebraska,
Nevada, New Mexico, Oregon, Texas, Utah and Wyoming.
g. 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.
h. 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.
i. 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.
j. 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.
EMISSION-RELATED PARTS INCLUDE THE FOLLOWING: (using those portions of the list applicable to the
engine)
Systems covered by this
warranty
Parts Description
Fuel Metering System
Fuel regulator, Carburetor and internal parts
Air Induction System
Air cleaner, Intake manifold
Ignition System
Spark plug and parts, Magneto ignition system
Exhaust System
Exhaust manifold, catalytic converter
Miscellaneous Parts
Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed
systems.
Evaporative Emissions
Fuel Tank, Fuel Cap, Fuel Line (for liquid fuel and fuel vapors), Fuel
Line Fittings, Clamps, Pressure Relief Valves, Control Valves, Control
Solenoids, Electronic Controls, Vacuum Control Diaphragms, Control
Cables, Control Linkages, Purge Valves, Gaskets, Vapor Hoses,
Liquid/Vapor Separator, Carbon Canister, Canister Mounting Brackets,
Carburetor Purge Port Connector
TO OBTAIN WARRANTY SERVICE:
You must take your CPE engine or the product on which it is installed, along with your warranty registration card or
other proof of original purchase date, at your expense, to any Champion Power Equipment dealer who is
authorized by Champion Power Equipment, Inc. to sell and service that CPE product during his normal business
hours. Alternate service locations defined in Section (3)(f.) above must be approved by CPE prior to service. 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 Customer Service at Champion Power Equipment, Inc.
Champion Power Equipment, Inc.
12039 Smith Ave.
Santa Fe Springs, CA 90670
1-877-338-0999
Attn.: Customer Service
tech@championpowerequipment.com
