The Champion 3500-Watt Dual Fuel Portable Generator is a powerful and handy unit but does not come without its occasional issues. Below are listed the most common problems that can arise while running this generator:
Error – Generator Surges After Starting
Cause:
The generator that surges after starting can be suffering from several issues. The carburetor could be clogged and need cleaning. The idle jet may be dirty. The choke may also be too tight or too loose. A gasket within the carburetor or another area of the engine may also be dried out or cracked. The gas may be old and require draining and refilling. The oil level may be low or the oil is old.
Solution:
Remove old gasoline and refill the tank. Fill the oil, or drain and replace it entirely. Inspect the brushes and slip rings and replace them if needed. Use carburetor cleaner and spray inside and around the mounting area to clean it. Check the gasket between the engine and plate and replace it if it is cracked.
Adjust the throttle link to tighten up the RPMs. Increase the idle jet up one size and release the air screw to fine-tune the engine. If the main jet is broken or loose, consider replacing it. The rotor may be open and need adjusting. Allow the generator to warm up before connecting a load.
Error – The Generator Has Trouble Starting
Cause:
A generator may have trouble starting if there is a dirt or blocked air filter. The spark plug may also be dirty, damaged, or disconnected from the cord. Old, stale fuel may be the cause, as the unit may not have been run in a long time. Excess loads can also cause the generator to fail to start.
Solution:
Review the owner’s manual to find the location of the air filter. Clean or replace it if needed. Check the spark plug connection and tighten the cable if it is loose. Replace the spark plug with a new one if any damage is found. Replace old fuel by draining the fuel tank and filling it with new fuel. If the fuel is not old, then simply fill the tank to the proper level. If there are too many loads connected to the generator, disconnect them and try starting the unit again.
Error – Unit Shuts Down While Operating
Cause:
The unit may shut down while operating if it runs out of fuel, or the oil level drops too low. The unit may be overheated if the airflow is restricted. This can occur if the air filter is blocked or there is poor ventilation in the area.
Solution:
Check the fuel and oil levels. Refill either if needed. Move the unit to a well-ventilated area and allow it to cool down before restarting if it suffers overheating. Inspect the air filter and clean or replace it if needed. Only run the generator on a flat, level surface. If the problem continues, take it to a Champion dealer for assistance.
Error – Generator Runs Rough After Starting
Cause:
The generator can run rough if the oil level is low or the spark plug is loose. The choke may also cause this if it is in the wrong position. Running the generator on a sloped surface may cause it to run rough.
Solution:
Place the generator on a flat surface and start it again. If the problem continues, fill both the fuel and oil to the proper levels. Adjust the choke and make sure the spark plug is connected to the wire.
Error – Generator Overheating
Cause:
The generator can overheat if it has insufficient ventilation, or is connected to too many loads.
Solution:
Move the generator to a well-ventilated area and consider removing excess loads. See the “Power Management” section of the user manual for further clarification.
Error – No AC Output
Cause:
AC output may be unavailable if the AC output port is not functioning properly, a connected device is faulty, or the device is not well-connected to the port. A circuit breaker may also be open, a capacitor may be defective, and an AVR (auto-voltage regulator) or brush assembly may be faulty. The unit may also have loose wiring in or around the AC output port.
Solution:
Make sure all connections are secure and the devices are working properly. Reset the circuit breaker and install a new capacitor, brush assembly, or AVR. Inspect all wiring connections and tighten them if needed. If these fixes are too difficult to do on one’s own, contact the Champion Service Center for assistance.
Error – The Generator Gallops
Cause:
The generator can gallop while running if the engine governor is defective.
Solution:
Contact a Champion service center for assistance.
Error – Circuit Breaker Trips Repeatedly
Cause:
The circuit breaker may trip if there are faulty cords or connected devices. The unit may be overloaded from too many connected devices causing a circuit breaker trip.
Solution:
Remove excess connected loads and try running the generator again. Inspect all connected cords and devices. If there are broken or frayed wires, replace them. Review the “Power Management” section of the user manual. If the problem continues, contact the Champion Customer Service Center.
The Champion 3500 Watt Dual Fuel Portable Generator will require preventive maintenance on a regular basis to run properly. Check the oil levels once every 8 hours of use and clean the air filter and replace the oil after every 50 hours of run time. Do not let the generator sit without running for more than 30 days. Only use the generator on a smooth, flat surface in a well-ventilated area. Clean off dust residue from the outside of the unit and around cooling slots if it appears.
If any other problems arise not listed above, contact Champion Customer Support for help.
