Owner's manual | Category 5 41535 Owner`s manual

OWNER’S MANUAL & OPERATING INSTRUCTIONS

9375 Starting Watts / 7500 Running Watts

Wireless Remote Electric Start

PORTABLE GENERATOR

MODEL NUMBER 41535

SAVE THESE INSTRUCTIONS

Important Safety Instructions are included in this manual.

MADE IN CHINA

REV 41535-20110701

10006 Santa Fe Springs Road

Santa Fe Springs CA 90670

USA / 1-877-338-0999 www.championpowerequipment.com

Have questions or need assistance?

Do not return this product to the store!

WE ARE HERE TO HELP!

Visit our website:

www.championpowerequipment.com

for more info:

• Product Info & Updates

• Frequently Asked Questions

• Tech Bulletins

• Product Registration

– or –

Call our Customer Care Team Toll-Free at:

1-877-338-0999

24/7 Tech Support: (562) 204-1188

41535

9375 Starting Watts / 7500 Running Watts

Wireless Remote Electric Start

PORTABLE GENERATOR

TABLE Of CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Portable Power Generator . . . . . . . . . . . . . . . . . .

1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

This Booklet . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Controls and Features . . . . . . . . . . . . . . . . . . . . . .

5

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Wireless Remote Control . . . . . . . . . . . . . . . . . .

7

Remote Control Power Consumption . . . . . . . .

7

Power Panel Load Management . . . . . . . . . . .

7

Parts Included . . . . . . . . . . . . . . . . . . . . . . . . .

8

Wheel Kit . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Remove the Generator from the Shipping Carton . .

9

Install the Wheel Kit . . . . . . . . . . . . . . . . . . . . .

9

Install the Support Leg . . . . . . . . . . . . . . . . . . .

9

Connect the Battery . . . . . . . . . . . . . . . . . . . . .

9

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

10

Add Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Generator Location . . . . . . . . . . . . . . . . . . . . .

12

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Surge Protection . . . . . . . . . . . . . . . . . . . . . . .

12

Wireless Remote Start . . . . . . . . . . . . . . . . . . .

12

Starting the Engine without Remote . . . . . . . . . .

12

Connecting Electrical Loads . . . . . . . . . . . . . . .

13

Stopping the Engine . . . . . . . . . . . . . . . . . . . .

13

Do Not Overload Generator . . . . . . . . . . . . . . . .

13

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Power Management . . . . . . . . . . . . . . . . . . .

13

Wattage Reference Chart . . . . . . . . . . . . . . . . .

14

Operation at High Altitude . . . . . . . . . . . . . . .

14

Maintenance and Storage . . . . . . . . . . . . . . . . . . .

15

Engine Maintenance . . . . . . . . . . . . . . . . . . . .

15

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . .

15

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Spark Arrester . . . . . . . . . . . . . . . . . . . . . .

16

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Adjustments . . . . . . . . . . . . . . . . . . . . . . . .

16

Maintenance Schedule . . . . . . . . . . . . . . . .

16

Generator Maintenance . . . . . . . . . . . . . . . . . .

17

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Generator Storage . . . . . . . . . . . . . . . . . . . .

17

Disconnect the Battery . . . . . . . . . . . . . . . .

17

Charge the Battery . . . . . . . . . . . . . . . . . . .

17

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Engine Specifications . . . . . . . . . . . . . . . . . . .

18

Generator Specifications . . . . . . . . . . . . . . . . .

18

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Valve Clearance . . . . . . . . . . . . . . . . . . . . . . .

18

FCC Statement for Remote Control Device . . . . .

18

Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . .

19

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

Engine Parts Diagram . . . . . . . . . . . . . . . . . . .

21

Engine Parts List . . . . . . . . . . . . . . . . . . . . . .

22

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . .

23

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Warranty Qualifications . . . . . . . . . . . . . . . . . .

25

Repair/Replacement Warranty . . . . . . . . . . . . . .

25

Do Not Return The Unit To

The Place Of Purchase . . . . . . . . . . . . . . . . . .

25

Warranty Exclusions . . . . . . . . . . . . . . . . . . . .

25

Normal Wear . . . . . . . . . . . . . . . . . . . . . . .

25

Installation, Use and Maintenance . . . . . . . .

25

Other Exclusions . . . . . . . . . . . . . . . . . . . . .

25

Limits of Implied Warranty and Consequential Damage . . . . . . . . . . . . .

25

Contact Information . . . . . . . . . . . . . . . . . . . . . 25

Address . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Customer Service . . . . . . . . . . . . . . . . . . . .

25

Technical Service . . . . . . . . . . . . . . . . . . . .

25

Emission Control System Warranty . . . . . . . . . .

26

ENGLISH 41535

INTROdUCTION

Introduction

Congratulations on your purchase of a Champion

Power Equipment generator . CPE designs and builds generators to strict specifications . With proper use and maintenance, this generator will bring years of satisfying service .

Portable Power Generator

This unit is a gasoline engine driven, alternating current

(AC) generator . It is designed to supply electrical power for lighting, appliances, tools and similar equipment .

Accessories

Champion Power Equipment manufactures and sells accessories designed to help you get the most from your purchase . To find out more about our covers, power cables and storm kits, please visit our web site at:

www.championpowerequipment.com

This Booklet

Every effort has been made to ensure the accuracy and completeness of the information in this manual . We reserve the right to change, alter and/or improve the product and this document at any time without prior notice .

Record the model and serial numbers as well as date and place of purchase for future reference . Have this information available when ordering parts and when making technical or warranty inquiries .

Champion Power Equipment Support

1-877-338-0999

Model Number

41535

Serial Number

Date of Purchase

Purchase Location

For Oil Type see ‘Add Engine Oil‘ section . For Fuel Type see ‘Add Fuel‘ section .

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41535 ENGLISH

MANUAL CONVENTIONS

This manual uses the following symbols to help differentiate between different kinds of information . The safety symbol is used with a key word to alert you to potential hazards in operating and owning power equipment .

Follow all safety messages to avoid or reduce the risk of serious injury or death .

dANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury .

CAUTION

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage .

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury .

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury .

NOTE

If you have questions regarding your generator, we can help . Please call our help line at 1-877-338-0999

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ENGLISH 41535

SAfETy RULES

WARNING

Read this manual thoroughly before operating your generator . Failure to follow instructions could result in serious injury or death .

WARNING

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm .

dANGER

Generator exhaust contains carbon monoxide, a colorless, odorless, poison gas . Breathing carbon monoxide will cause nausea, dizziness, fainting or death . 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 .

WARNING

Sparks can result in fire or electrical shock .

When servicing the generator:

Disconnect the spark plug wire and place it where it cannot contact the plug .

DO NOT check for spark with the plug removed .

Use only approved spark plug testers .

WARNING

Running engines produce heat . Severe burns can occur on contact .

Combustible material can catch fire on contact .

DO NOT touch hot surfaces .

Avoid contact with hot exhaust gases .

Allow equipment to cool before touching .

Maintain at least three feet of clearance on all sides to ensure adequate cooling .

Maintain at least five feet of clearance from combustible materials .

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41535 ENGLISH dANGER

Fuel and fuel vapors are highly flammable and extremely explosive .

Fire or explosion can cause severe burns or death .

Unintentional startup can result in entanglement, traumatic amputation or laceration .

When adding or removing fuel:

Turn the generator off and let it cool for at least two minutes before removing the fuel cap . Loosen the cap slowly to relieve pressure in the tank .

Only fill or drain fuel outdoors in a well-ventilated area .

DO NOT overfill the fuel tank .

Always keep fuel away from sparks, open flames, pilot lights, heat and other sources of ignition .

DO NOT light or smoke cigarettes .

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 .

WARNING

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 .

SAfETy RULES

WARNING

Rapid retraction of the starter cord will pull hand and arm towards the engine faster than you can let go .

Unintentional startup can result in entanglement, traumatic amputation or laceration .

Broken bones, fractures, bruises or sprains could result .

When starting engine, pull the starter cord slowly until resistance is felt and then pull rapidly to avoid kickback .

DO NOT start or stop the engine with electrical devices plugged in .

CAUTION

Exceeding the generator’s running capacity can damage the generator and/or electrical devices connected to it .

DO NOT overload the generator .

Start the generator and allow the engine to stabilize before connecting electrical loads .

Connect electrical equipment in the off position, and then turn them on for operation .

Turn electrical equipment off and disconnect before stopping the generator .

DO NOT tamper with the governed speed .

DO NOT modify the generator in any way .

CAUTION

Improper treatment or use of the generator can damage it, shorten its life and void your warranty .

Use the generator only for intended uses .

Operate only on level surfaces .

DO NOT expose generator to excessive moisture, dust, or dirt .

DO NOT allow any material to block the cooling slots .

If connected devices overheat, turn them off and disconnect them from the generator .

DO NOT use the generator if:

– Electrical output is lost

– Equipment sparks, smokes or emits flames

– Equipment vibrates excessively

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ENGLISH 41535

CONTROLS ANd fEATURES

Read this owner’s manual before operating your generator . Familiarize yourself with the location and function of the controls and features . Save this manual for future reference .

Generator

1

2

3

9

4

8

5

6

7

(1) Fuel Tank – 5 .9 gallon (22 .4 L) capacity fuel tank .

(2) Auto-Choke – Used to start the engine . No manual adjustment required .

(3) Fuel Valve – Used to turn fuel supply on and off to engine .

(4) Air Cleaner – Protects the engine by filtering dust and debris from the intake air .

(5) Recoil Starter – Used to manually start the engine .

(6) Quick Drain Tube – Used to easily and quickly drain oil from the engine .

(7) Oil Filler Cap – Check and fill engine oil level .

(8) Battery – Used to start the engine . Provides 12V

DC to the electric starter and receiver control module .

(9) Power Panel – See “Power Panel” section .

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41535 ENGLISH

Power Panel

1

2


3

4

5 6

7

8

(1) Intelligauge – Three mode digital meter for displaying running hours, voltage and hertz .

(2) Battery Switch – Enables/disables starting electrically – via remotely or by Ignition Switch .

(3) Circuit Breakers – Protects the generator against electrical overloads . Push to reset breaker .

(4) Ignition Switch – Used to start or stop the generator .

(5) 120 Volt AC, 30 Amp Twist-Lock Receptacle

(NEMA L5-30R) – May be used to supply electrical power for the operation of 120 Volt AC, 30 Amp, single phase 60 Hz electrical loads .

(6) 120/240 Volt AC, 30 Amp Twist-Lock Receptacle

(NEMA L14-30R) – May be used to supply electrical power for the operation of 120 and/or 240 Volt AC, 30 Amp, single phase 60 Hz electrical loads .

(7) 120 Volt AC, 20 Amp Duplex (2)

(NEMA 5-20R) – May be used to supply electrical power for the operation of 120 Volt AC, 20 Amp, single phase 60 Hz electrical loads .

(8) Ground Terminal – Consult an electrician for local grounding regulations .

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ENGLISH 41535


Wireless Remote Control

This generator is equipped with a wireless remote control system for starting and stopping . The system consists of (4) main components:

1 . Receiver Control Module (RCM)

2 . Wireless Remote

3 . Battery Switch

4 . Ignition Switch

The Remote Control functions are enabled when:

1 . The Ignition Switch is in the “ON” position, AND

2 . The Battery Switch is in the “ON” position .

The Remote Control functions are disabled if either of the above conditions is not met .

To start the generator by Remote Control, press the

“START” button on the Remote one time . The engine will attempt to start (6) times . The RCM controls the Auto Choke during each attempt to start . If the generator does not start, call Champion Customer Care team for assistance at 1-877-338-0999 .

To stop the generator by Remote Control, press the

“STOP” button on the Remote one time .

Remote Control Power Consumption

While the Ignition Switch is in the “ON: position, the

RCM is active and waiting for a remote signal . This function requires electrical current from the battery .

If the Ignition Switch is left in the “ON” position for extended periods (several weeks), the battery can be completely drained .

Moving the Ignition Switch to the “OFF” position disables the Remote functions, but the RCM still consumes approximately 2 mA from the battery .

To prevent battery drain, press the Battery Switch to the

“OFF” position . This disconnects power to the RCM so there is no current draw on the battery .

Power Panel Load Management

When the generator initially starts by the Remote, no voltage is supplied to the Power Panel for approximately

15 seconds . This allows the engine to reach full speed before electrical loads are applied to the generator .

When the generator is stopped by the Remote, the voltage to the Power Panel is immediately turned off .

Then the engine stops after the “STOP” button on the

Remote is pressed . Turning the Power Panel voltage off before the engine shutdown protects connected appliances from being damaged by non-60 Hz voltage while the generator coasts to a stop .

Power Panel Load Management Cont’d.

The on/off voltage delay at startup and shut down only happen when the Remote Control is used. There is no voltage delay when the pushbutton electric start or recoil start method is used.

When the pushbutton electric start or recoil start method is used, the operator must be sure all electrical loads (appliances) are turned OFF during startup and shutdown . Damage to the generator or the attached appliances can be caused by starting or stopping the generator while appliances are plugged in and turned ON .

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41535 ENGLISH

Parts Included

Your 41535 Gasoline Powered Generator ships with the following parts:

Wheel Kit

– 10” Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

– Flange Bolt (M10x120 for Wheel) . . . . . . . . . . . .

2

– Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

– Flat Washer 10 . . . . . . . . . . . . . . . . . . . . . . . . .

2

– Nut (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

– Support Leg w/Vibration Mounts . . . . . . . . . . . . .

1

– Flange Bolt (M8x16 for Support Leg) . . . . . . . . . .

2

– Nut (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Other

– Oil Funnel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

– Oil . . . . . . . . . . . . . . . . . . . . . . .

1 .16 qt . (1 .1 L)

– Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

– Spark Plug Socket . . . . . . . . . . . . . . . . . . . . . . .

1

– Cap Screw (M5x12 for Battery Terminals) . . . . . . .

2

– Nut (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

– 25ft . Power Distribution Cord . . . . . . . . . . . . . . .

1


(Battery Bolts)

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8

ENGLISH 41535

ASSEMBLy

Your generator requires some assembly . This unit ships from our factory without oil . It must be properly serviced with fuel and oil before operation .

If you have any questions regarding the assembly of your generator, call our help line at 1-877-338-0999 . Please have your serial number and model number available .

Install the Support Leg

1 . Attach the support leg to the generator frame with cap screws (M8x16) and nuts (M8) .

2 . Tip the generator slowly so that it rests on the wheels and support leg .

Remove the Generator from the Shipping Carton

1 . Set the shipping carton on a solid, flat surface .

2 . Remove everything from the carton except the generator .

3 . Carefully cut each corner of the box from top to bottom . Fold each side flat on the ground to provide a surface area to install the wheel kit and support leg .

Install the Wheel Kit

CAUTION

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

You will need the following tools to install the wheels:

• 17 mm wrench OR adjustable wrench (not included)

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

• Pliers (not included)

Connect the Battery

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

2 . Attach the red (+) lead to the red (+) terminal on the battery with the cap screw (M5x12) and secure with the lock washer (M5) .

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

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

2 . Slide the M10x120 wheel bolt through the washer, sleeve and wheel .

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

4 . Fasten securely with the M10 nut .

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

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41535 ENGLISH

Add Engine Oil

CAUTION

DO NOT attempt to crank or start the engine before it has been properly filled with the recommended type and amount of oil . Damage to the generator as a result of failure to follow these instructions will void your warranty .

NOTE

The recommended oil type is 10W-30 4-cycle automotive oil .

1 . Place the generator on a flat, level surface .

ASSEMBLy

Add Engine Oil Cont’d.

CAUTION

The engine is equipped with a low-oil-shutoff and will stop when the oil level in the crankcase falls below the threshold level .

NOTE

Check oil often during the break-in period . Refer to the

Maintenance section for recommended service intervals .

NOTE

The generator rotor has a sealed, pre-lubricated ball bearing that requires no additional lubrication for the life of the bearing .

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

3 . Add 1 .16 qt (1 .1 L) of oil (included) and replace oil fill cap/dipstick . See “Specifications” pages for oil recommendations based on operating conditions .

4 . Check engine oil level daily and add as needed .

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ENGLISH 41535

ASSEMBLy

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 . Allow approximately ¼ inch of space for fuel expansion .

Grounding

Your generator must be properly connected to an appropriate ground to help prevent electric shock .

WARNING

Failure to properly ground the generator can result in electric shock .

A ground terminal connected to the frame of the generator has been provided on the power panel . For remote grounding, connect of a length of heavy gauge (12 AWG minimum) copper wire between the generator ground terminal and a copper rod driven into the ground . We strongly recommend that you consult with a qualified electrician to ensure compliance with local electrical codes .

6 . Screw on the fuel cap and wipe away any spilled fuel .

CAUTION

Use regular unleaded gasoline with a minimum octane rating of 85 .

DO NOT mix oil and gasoline .

Fill tank to approximately ¼ inch below the top of the tank to allow for fuel expansion .

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 .

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41535 ENGLISH

OPERATION

Generator Location

Please consult your local authority . In some areas, generators must be registered with the local utility .

Generators used at construction sites may be subject to additional rules and regulations .

This generator must have at least five feet of clearance from combustible material . Leave at least three feet of clearance on all sides of the generator to allow for adequate cooling, maintenance and servicing .

Place the generator in a well-ventilated area . DO NOT place the generator near vents or intakes where exhaust fumes could be drawn into occupied or confined spaces . Carefully consider wind and air currents when positioning generator .

Grounding

The generator system ground connects the frame to the ground terminals on the power panel .

The generator (stator winding) is isolated from the frame and from the AC receptacle ground pin . Electrical devices that require a grounded receptacle pin connection may not function properly .

Surge Protection

CAUTION

Voltage fluctuation may impair the proper functioning of sensitive electronic equipment .

Electronic devices, including computers and many programmable appliances use components that are designed to operate within a narrow voltage range and may be affected by momentary voltage fluctuations .

While there is no way to prevent voltage fluctuations, you can take steps to protect sensitive electronic equipment .

1. Install UL1449, CSA-listed, plug-in surge suppressors on the outlets feeding your sensitive equipment.

Surge suppressors come in single- or multi-outlet styles . They’re designed to protect against virtually all short-duration voltage fluctuations .

Wireless Remote Start

Wireless remote starting is only possible within 80 feet of the generator .

Do not attempt to adjust the carburetor choke . The remote system will automatically close and open the choke .

1 . Make certain the generator is on a flat, level surface .

2 . Press the Ignition Switch to “ON” .

3 . Press the Battery Switch to “ON” .

4 . Turn the Fuel Valve to the “ON” position .

5 . To start the engine, press and release the “START” button on the handheld Remote Control device . DO

NOT hold the button down, only press the button once . The engine will attempt to start 6 times .

6 . A safety feature is provided which delays the electrical power availability during starting mode .

The delay lasts for approximately 15 seconds . The delay is provided to prevent damage to the generator if electrical loads are inadvertently turned on during engine startup .

7 . If the generator fails to start, check the battery condition and cable connections .

Starting the Engine without Remote

1 . Make certain the generator is on a flat, level surface .

2 . Turn off all electrical loads connected to the generator .

Never start or stop the generator with electrical devices plugged in and turned on .

3 . Turn the Fuel Valve to the “ON” position .

4 . Press the Battery Switch to “ON” .

5 . ELECTRIC START: Press the switch to the “START” position .

6 . RECOIL START: Pull the starter cord slowly until resistance is felt and then pull rapidly .

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 .

REV 41535-20110701

12

ENGLISH 41535

OPERATION

Connecting Electrical Loads

1 . Let the engine stabilize and warm up for a few minutes after starting

2 . Plug in and turn on the desired 120/240 Volt AC single phase, 60 Hz electrical loads .

– DO NOT connect 3-phase loads to the generator .

– DO NOT connect 50 Hz loads to the generator .

– DO NOT overload the generator .

NOTE

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 .

Stopping the Engine

1 . Turn off all electrical loads connected to the generator . Never start or stop the generator with electrical devices plugged in and turned on .

2 . Press and release the STOP button on the Remote

Control device OR turn the Ignition Switch to the

“OFF” position .

3 . Turn the Fuel Valve to the “OFF” position .

Important: If the generator will be moved or stored turn the Fuel Valve to the “OFF” position, press the Ignition

Switch and the Battery Switch on the power panel to the

“OFF” position .

do Not Overload Generator

Capacity

Follow these simple steps to calculate the running and starting watts necessary for your purposes .

1 . Select the electrical devices you plan on running at the same time .

2 . Total the running watts of these items . This is the amount of power you need to keep your items running .

3 . Identify the highest starting wattage of all devices identified in step 1 . Add this number to the number calculated in step 2 . Surge wattage is the extra burst of power needed to start some electric driven equipment . Following the steps listed under “Power

Management” will guarantee that only one device will be starting at a time .

Power Management

Use the following formula to convert voltage and amperage to watts:

Volts x Amps = Watts

To prolong the life of your generator and attached devices, follow these steps to add electrical load:

1 . Start the generator with no electrical load attached

2 . Allow the engine to run for several minutes to stabilize .

3 . Plug in and turn on the first item . It is best to attach the item with the largest load first .

4 . Allow the engine to stabilize .

5 . Plug in and turn on the next item .

6 . Allow the engine to stabilize .

7 . Repeat steps 5-6 for each additional item .

NOTE

Never exceed the specified capacity when adding loads to the generator .

13 REV 41535-20110701

41535 ENGLISH

Wattage Reference Chart

Use the chart to determine approximate wattage requirements for your equipment .

CAUTION

Exceeding specified load capacity can result in damage to the generator .

To determine total wattage necessary to power a device, ADD Running Watts to Starting Watts.

(A+B) . Starting watts can exceed three times the running watts . The values in the following table are approximate . Refer to your tool or appliance for actual wattage consumption .

Item

Light Bulb 100W

Refrigerator/Freezer

Freezer

Sump Pump

Well Pump 1 HP

Water Heater

Security System

AM/FM Radio

Garage Door Opener 1/2 HP

Running

Watts (A)

Essentials

100

1200

500

600

2000

4000

180

300

500

Battery Charger 12V DC 110

Air Conditioner 12000 BTU

Heating/Cooling

1700

Fan

Furnace Fan 1/3 HP

Microwave 1000W

Electric Range - One Element

Electric Skillet

300

1200

Home Appliances

1000

1500

1250

Coffee Maker

Clothes Washer

1500

1200

Entertainment

100 CD/DVD Player / VCR

Stereo Receiver

Television 27”

PC with 15” Monitor

450

500

800

Job Site

1000 Belt Sander 3”

Bench Grinder 6”

Circular Saw

Compressor 1 1/2 HP

700

1500

2500

Edge Trimmer

Hand Drill 1/2”

Lawn Mower

Paint Sprayer

Table Saw

500

1000

1200

600

2000

Starting

Watts (B)

2400

500

1800

4000

600

2500

600

2000

1500

1500

1500

2500

500

1000

1800

1200

2000

OPERATION

Operation at High Altitude

The density of air at high altitude is lower than at sea level . Engine power is reduced as the air mass and airfuel ratio decrease . Engine power and generator output will be reduced approximately 3½% for every 1000 feet of elevation above sea level . This is a natural trend and cannot be changed by adjusting the engine . At sufficiently high altitudes increased exhaust emissions can also result due to the increased enrichment of the air fuel ratio . Other high altitude issues can include hard starting, increased fuel consumption and spark plug fouling .

To alleviate high altitude issues other than the natural power loss, Champion Power Equipment can provide a high altitude carburetor main jet . The alternative main jet and installation instructions can be obtained by contacting Customer Support . Installation instructions are also available in the Technical Bulletin area of the

Champion Power Equipment internet site .

The part number and recommended minimum altitude for the application of the high altitude carburetor main jet is listed in the table below .

Part Number

Standard main jet ST190FD-2-1131000-17

Altitude main jet 490 .131017 .01

Altitude

6000 Feet

(1800 Meters)

WARNING

Operation using the alternative main jet at elevations lower than the recommended minimum altitude can damage the engine . For operation at lower elevations, the standard main jet must be used . Operating the engine with the wrong engine configuration at a given altitude may increase its emissions and decrease fuel efficiency and performance .

REV 41535-20110701

14

ENGLISH 41535

MAINTENANCE ANd STORAGE

The owner/operator is responsible for all periodic maintenance .

WARNING

Never operate a damaged or defective generator .

Oil Cont’d.

NOTE

Once oil has been added, a visual check should show oil about 1-2 threads from running out of the fi ll hole .

If using the dipstick to check oil level, DO NOT screw in the dipstick while checking .

WARNING

Tampering with the factory set governor will void your warranty .

WARNING

Improper maintenance will void your warranty .

NOTE

Maintenance, replacement, or repair of emission control devices and systems may be performed by any non-road engine repair establishment or individual .

Complete all scheduled maintenance in a timely manner .

Correct any issue before operating the generator .

NOTE

For service or parts assistance, contact our help line at 1-877-338-0999

Spark Plugs

1 . Remove the spark plug cable from the spark plug .

2 . Use the spark plug tool that shipped with your generator to remove the plug .

3 . Inspect the electrode on the plug . It must be clean and not worn to produce the spark required for ignition .

4 . Make certain the spark plug gap is 0 .7 - 0 .8mm or

(0 .028 - 0 .031 in .) .

0.7 - 0.8 mm

0.028 - 0.031 in.

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 specifi cation to select the proper grade of oil for your operating environment .

1 . Remove oil fi ll cap/dipstick .

2 . Use pliers to slide the spring clamp down the oil drain hose and pull the hose off the plug bracket .

3 . Point the hose into a drain pan and allow the oil to drain completely . Note: The hose end must be lower than the engine base to allow the oil to drain .

4 . Replace oil drain hose onto plug bracket and slide spring clamp back into position .

5 . Add 1 .16 qt (1 .1 L) of oil and replace oil fi ll cap/dipstick .

6 . Dispose of used oil at an approved waste management facility .

15 REV 41535-20110701

5 . Refer to the spark plug recommendation chart when replacing the plug .

6 . Carefully thread the plug into the engine .

7 . Use the spark plug tool to fi rmly install the plug .

8 . Attach the spark plug wire to the plug .

Air filter

1 . Remove the snap-on cover holding the air fi lter 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 fi lter in the assembly .

7 . Reattach the air fi lter cover and snap in place .

41535 ENGLISH

Spark Arrester

1 . Allow the engine to cool completely before servicing the spark arrester .

2 . Remove the three 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 .

CAUTION

Failure to clean the spark arrester will result in degraded engine performance .

NOTE

Federal and local laws and administrative requirements indicate when and where spark arresters are required . When ordered, spark arresters are required for operation of this generator in National Forest lands . In California, this generator must not be used on any forest- covered land, brush-covered land, or grass- covered land unless the engine is equipped with a spark arrester .


Cleaning

CAUTION

DO NOT spray engine with water .

Water can contaminate the fuel system .

Use a damp cloth to clean exterior surfaces of the engine .

Use a soft bristle brush to remove dirt and oil .

Use an air compressor (25 PSI) to clear dirt and debris from the engine .

Adjustments

The air-fuel mixture is not adjustable . Tampering with the governor can damage your generator and your electrical devices and will void your warranty . CPE recommends that you contact our service line at

1-877-338-0999 for all other service and/or adjustment needs .

Maintenance Schedule

Follow the service intervals indicated in the following maintenance schedule .

Service your generator more frequently when operating in adverse conditions .

Contact our helpline at 1-877-338-0999 to locate the nearest Champion Power Equipment certified service dealer for your generator or engine maintenance needs .

Every 8 hours or daily

Check oil level

Clean around air intake and muffler

First 5 Hours

Change oil

Every 50 hours or every season

Clean air filter

Change oil if operating under heavy load or in hot environments

Every 100 hours or every season

Change oil

Clean/Adjust spark plug

Check/Adjust valve clearance *

Clean spark arrester

Clean fuel tank and filter *

Every 250 hours

Clean combustion chamber*

Every 3 years

Replace fuel line

*To be performed by knowledgeable, experienced owners or

Champion Power Equipment certified dealers .

REV 41535-20110701

16

ENGLISH 41535


Generator Maintenance

Make certain that the generator is kept clean and stored properly . Only operate the unit on a flat, level surface in a clean, dry operating environment . DO NOT expose the unit to extreme conditions, excessive dust, dirt, moisture or corrosive vapors .

CAUTION

DO NOT use a garden hose to clean the generator .

Water can enter the generator through the cooling slots and damage the generator windings .

Use a damp cloth to clean exterior surfaces of the generator .

Use a soft bristle brush to remove dirt and oil .

Use an air compressor (25 PSI) to clear dirt and debris from the generator .

Inspect all air vents and cooling slots to ensure that they are clean and unobstructed .

Storage

The generator should be started at least once every 14 days and allowed to run for at least 20 minutes . For longer term storage, please follow these guidelines .

Generator Storage

1 . Allow the engine to cool completely before storage .

2 . Clean the generator according to the instructions in the Maintenance section .

3 . Turn the Fuel Valve to the “OFF” position .

4 . Be sure all appliances are disconnected from the generator . Start the engine and let it run until the fuel in the line and the carburator is consumed and the engine dies .

5 . Press the Battery Switch to “OFF” .

6 . Add a fuel stabilizer into the fuel tank .

7 . Change the oil .

8 . Remove the spark plug and pour about ½ ounce of oil into the cylinder . Crank the engine slowly to distribute the oil and lubricate the cylinder .

9 . Reattach the spark plug .

10 . Store the unit in a clean, dry place out of direct sunlight .

dANGER

Generator exhaust contains odorless and colorless carbon monoxide gas .

To avoid accidental or unintended ignition of your remote start generator during periods of storage, the following precautions should be followed:

– When storing the generator for short periods of

time make sure that the Ignition Switch, the Fuel

Valve and the Battery Switch are set in the OFF position .

– When storing the generator for extended periods

of time make sure that the Ignition Switch, the

Fuel Valve and the Battery Switch are set in the the the OFF position and the battery leads have been disconnected from the battery .

disconnect the Battery

1 . Remove the protective cover from the black/negative battery lead .

2 . Disconnect the black/negative lead from the black/ negative terminal on the battery and store the cap screw (M5x12) and lock washer (M5) .

3 . Repeat steps 1-2 for the red/positive battery lead .

4 . Store the battery in a cool, dry place .

Charge the Battery

For generators equipped with batteries for electric starting, proper battery maintenance and storage should be followed . An automatic battery charger with automatic trickle charging capability should be used to charge the battery . Maximum charging rate should not exceed 1,5 amps . Follow the instructions included with the battery charger . The battery should be fully charged at least once per month .

17 REV 41535-20110701

41535 ENGLISH

SPECIfICATIONS

Engine Specifications

– Engine . . . .

439 cc OHV CPE (Remote/Electirc Start)

Generator Specifications

– Running Wattage . . . . . . . . . . . . . . . . .

7500 Watts

– Starting Wattage . . . . . . . . . . . . . . . . .

9375 Watts

– AC Load . . . . . . . . . . . . . . . . . . . . . .

120/240 V

– Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single

– Frequency . . . . . . . . . . . . . . . . . . . . . . . . .

60 Hz

– Fuel Capacity . . . . . . . . . . . . .

5 .9 gallons (22 .4 L)

– Gross Weight . . . . . . . . . . . . .

231 .6 lbs (107 .3 kg)

– Net Weight . . . . . . . . . . . . . . .

219 .3 lbs (99 .7 kg)

– Height . . . . . . . . . . . . . . . .

26 .0 inches (66 .1 cm)

– Width . . . . . . . . . . . . . . . .

27 .0 inches (68 .8 cm)

– Length . . . . . . . . . . . . . . . . .

27 .5 inches (69 .9 cm)

fuel

Fuel capacity is 5 .9 gallons (22 .4 L) . Use regular unleaded gasoline with a minimum octane rating of 85 and an ethanol content of less than 10% by volume .

Oil

Use 4-Cycle automotive oil .

Oil capacity is 1 .16 qt (1 .1 L) .

Please reference the following chart for recommended oil types for use in the generator .

Spark Plugs

Recommended replacement spark plug:

– NGK BR6ES or equivalent

Make certain the spark plug gap is 0 .7 – 0 .8 mm or

(0 .028 – 0 .031 in .) .

Valve Clearance

– Intake: 0 .13 – 0 .17 mm (0 .005 – 0 .007 in .)

– Exhaust: 0 .18 – 0 .22 mm (0 .007 – 0 .009 in .)

fCC Statement for Remote Control device

1 . This device complies with Part 15 of the FCC Rules .

Operation is subject to the following two conditions:

(1) This device may not cause harmful interference .

(2) This device must accept any interference received, including interference that may cause undesired operation .

2 . Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment .

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules . These limits are designed to provide reasonable protection against harmful interference in a residential installation .

This equipment generates uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications . However, there is no guarantee that interference will not occur in a particular installation . If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

– Reorient or relocate the receiving antenna .

– Increase the separation between the equipment and receiver .

– Connect the equipment into an outlet on a circuit different from that to which the receiver is connected .

Consult the dealer or an experienced radio/TV technician for help .

REV 41535-20110701

18

SPECIfICATIONS

Parts diagram

ENGLISH 41535

19 REV 41535-20110701

41535 ENGLISH

# Part Number Description

1 ST160F-1070007 Fuel Line Clip 7mm

2 ST05FD-04712003-CARB Air Cleaner Hose

3 ST168FD-1070408-CARB Clip

4 509 .070014 .00

5 GB5789-FB8-12

Rollover Valve Hose

Flange Bolt M8×12

6 ST05FD-04712100-CARB Charcoal Canister

7 ST05FD-04712005-CARB support arm

8 ST05FD-04712002-CARB 90o Elbow

9 ST188FD-1070006A Clip ø8

10 509 .070011 .01

11 ST02FD-04160000

Fuel tube(8 .9in)

Fuel Cock

12 509 .071000 .35(S)

13 GB1667-S5-10

14 ST05FD-04711200-CARB Fuel Meter Assembly

15 ST168F-1070400-K Rollover Valve, KELCH

16 168 .070100 .01

17 ST168F-1070006A

Fuel Tank

Screw M5×10

Fuel Tank Cap

Fuel Filter

Flange Bolt M6×20 18 GB5789-FB6-20

19 GB93-LW-6

20 ST02FD-04100014

21 ST02FD-04100010

Lock Washer ø6

Washer ø6 .5

Tank Rubber

Air Cleaner Stay 22 ST188FD-1090006

23 GB41-N-6

24 GB90-W-8

25 GB93-LW-8

26 GB41-N-8

27 ST188FD-1100001-G

28 188 .101000 .06

29 GB1667-S5-12

Nut M6

Washer ø8

Lock Washer ø8

Nut M8

Muffler Gasket

Muffler

Screw M5×12

30 188 .101500 .31

31 GB5789-FB8-20

Spark Arrester Assy

Flange Bolt M8×20

32 GB5789-FB6-12 Flange Bolt M6×12

33 ST168FD-1100003-CARB SAI Valve Washer

34 ST168FD-1100300-CARB SAI Valve

35 GB41-N-5 Nut M5

36 GB90-W-5

37 GB93-LW-5

Washer ø5

Lock Washer ø5

Flange Bolt M5×229 38 ST07FD-02010003

39 GB90-W-6

40 GB93-LW-6

41 ST05FD-1152035

Washer ø6

Lock Washer ø6

Brush Assembly

Brush Support Plate 42 ST02FD-02100008

43 GB5781-B5-20

44 GB5789-FB5-12

45 ST05FD-1152001(S)

46 GB5781-B5-16

47 ST02FD-02100010

48 GB5789-FB5-16

49 509 .190200 .01

Bolt M5×20

Flange Bolt M5×12

Generator End Cover

Bolt M5×16

Terminal

Flange Bolt M5×16

AVR

50 ST05FD-1152002

51 ST07FD-02010002

52 ST07FD-02011001

53 ST07FD-02010001

54 ST07FD-02011100

55 GB93-LW-10

56 GB90-W-10

End Cover

Flange Bolt M6×194

Stator cover

Flange Bolt M10×1 .25×280

Stator assembly

Lock Washer ø10

Washer ø10

57 ST07FD-02011200

58 GB5789-FB6-8

59 ST05FD-1151600

60 ST05FD-1152008

61 ST05FD-1152009

62 190FDE-2-GC1

Rotor comp

Flange Bolt M6×8

Cover

Plug-A

Plug-B

Engine

2

1

1

2

1

1

1

1

1

1

1

1

1

1

4

1

2

1

2

1

1

2

6

1

2

6

2

5

5

1

1

1

2

1

3

1

2

1

2

4

4

1

3

4

4

1

4

1

1

1

1

2

1

1

1

1

1

4

1

2

Qty

2

1

# Part Number

63 ST182FD-1742203-UC

64 509 .200701 .07

65 ST05FD-03161202

66 GB896-B-6

67 27 .001

68 GB896-B-8

69 GB5789-FB8-35

70 GB96 8×24×3

71 ST182FD-1742003-UC

72 GB5789-FB6-12

73 ST02FD-1152010-5

74 ST05FD-1151400-1

75 GB41-N-8

76 ST05FD-1151300-1

77 GB41-LN-10

78 GB41-N-10

79 ST05FD-192(F)

80 ST188FD-1744002-T

81 ST36QXG-03000002

82 GB96-FW-10

83 GB5781-B10-120

84 GB41-N-5

85 FM12180

86 509 .200904 .00

87 ST168FD-1750002-C7

88 ST168FD-1750002-C6

89 ST05FD-03011112

90 GB5789-FB8-16

91 ST05FD-03020301-84

92 ST188FD-1743002-C

93 GB5789-FB8-25

94 5P15E(F)

95 29 .001 .00

96 ST02FD-05502020

97 ST02FD-05502022

98 ST02FD-05502023

99 GB1667-S4-14

100 GB93-LW-4

101 GB90-W-4

102 GB41-N-4

103 GB5781-B6-22

104 GB41-N-6

105 GB90-W-6

106 ST05FD-05215001

107 ST05FD-05215009

108 ST05FD-05215003

109 ST02FD-05302001-L20

110 ST02FD-05302001-L30

111 DP03-00000000-2

112 21 .001000 .02

113 ST188FD-1020001

114 0V01-00000000

115 GB1667-S5-14

116 BG01-00000000

117 GB1667-S5-38

118 ST05FD-05205011

119 ST02FD-05302010

120 WR05-00000000

121 ST02FD-05612005

122 ST02FD-05612004

123 ST05FD-05205012

124 EC02

Parts List

Qty

1

2

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

3

1

2

1

10

8

1

1

2

10

8

1

1

1

2

2

2

1

1

1

3

1

1

2

2

2

2

2

2

1

1

2

1

1

8

2

6

2

2

2

2

1

1

2

2

Description

Handle Cover

Handle

Handle underlay

Baffle ø6

Switch

Receptacle L5-30R

Receptacle L14-30R

Receptacle 5-20R

Screw M4×14

Lock Washer ø4

Washer ø4

Nut M4

Bolt M6×22

Nut M6

Washer ø6

Grommet

Conduit

Grommet

20 Amp Circuit Breaker

30 Amp Circuit Breaker

Intelligauge

Switch

Grommet

Transition

Screw M5×14

Rectifier

Screw M5×38

Muffler Inner Protector

FUSE(10A)

Remote control

Indicator light

Button

Control Box

Charger

Pin

Baffle ø8

Flange Bolt M8×35

Big washer ø8

Straight Bottom rubber

Flange Bolt M6×12

Grounding Wire

Bottom Rubber 2

Nut M8

Bottom Rubber 1

Lock Nut M10

Nut M10

Frame

10in Wheel

Bushing ø10 .5×69 .5

Flat Washer ø10

Bolt M10×120

Nut M5

Battery12V15AH

Rubber Battery Tie Down

Battery Wire, Negative

Battery Wire, Positive

Battery Gromet

Flange Bolt M8×16

Support leg

Vibration mount

Flange Bolt M8×25

Control Panel 41535

REV 41535-20110701

20

SPECIfICATIONS

Engine Parts diagram

ENGLISH 41535

21 REV 41535-20110701

41535 ENGLISH

# Part Number

1 GB5789-FB6-8

2 ST188F-1060100-G

6

7

8

3

4

5

ST188F-1060009

ST188F-1060008

ST160F-1061200

ST188F-1060007

ST188F-1060006

ST188F-1060004

9 ST188F-1060005

10 ST188F-1060003

11 ST188F-1060002

12 ST160FD-1070408-CARB

13 GB5789-FB6-12

14 ST188FD-1081000-G(S)

15 ST188FD-1030003-A

16 ST188FD-1030014

17 GB5789-FB8-40

18 ST188F-1030200

19 ST188F-1050004

20 ST188F-1050005

21 ST190F-2-1050200

22 ST190F-2-1050001

ST190F-1050100

23 ST190F-1050003

ST190F-1050002

24 ST188F-1080002-G

25 ST190F-2-1040011

26 ST190F-2-1040003

27 ST188F-1040004

28 ST188F-1040006

29 ST188F-1040007

30 ST188F-1040008

31 ST188F-1040002

32 ST188F-1040009

33 ST188F-1020003-CPE

34 ST190F-2-1020100

35 ST190F-2-1020006

36 ST188FD-1020002

37 ST160F-1040025

38 GB41-N-6

39 ST160F-1040024

40 GB90-W-6

41 ST188F-1040022

42 ST188F-1040023

43 ST188F-1040026

44 ST188F-1040021

45 ST188F-1040028

46 ST168F-1040027

47 ST188F-1080001-G

48 ST190F-2-1011000-G

49 ST188F-1010001

50 ST188F-1030009

51 ST188F-1040010-II

52 ST190F-2-1040012

53 139FMD-1003101

54 139FMD-1003102

55 ST188F-1030013

56 ST190F-1030008-G

57 ST188FD-1010002

58 F6RTC

59 ST188F-1122000-G

60 GB5789-FB6-29

Qty.

4

1

1

1

2

1

1

2

1

1

1

2

2

2

1

1

2

1

1

1

2

1

1

2

2

1

1

1

2

1

1

4

1

2

2

4

2

2

1

1

1

1

1

1

2

2

1

1

1

7

2

12

1

2

1

1

1

2

1

1

1

1

Description

Flange Bolt M6×8

Recoil Starter Case Comp

Starter Return Spring

Recoil Starter Pulley

Recoil Starter Knob

Recoil Starter Rope

Return Spring

Ratchet Guide Spring

Starter Ratchet

Ratchet Guide

Ratchet Guide Bolt

Wire clip

Flange Bolt M6×12

Fan Cover (Silver)

Oil Filler Cap

Oil Filler Cap Packing

Flange Bolt M8×40

Oil Seal

Piston Pin Clip

Piston Pin

Connecting Rod Assembly

Piston

Oil Ring Set

Second Ring Set

First Ring Set

Shroud

Exhaust Valve

Intake Valve

Valve Stem Seal

Valve Spring Washer

Valve Spring

Exhaust Valve Spring Retainer

Intake Valve Spring Retainer

Valve Rotator

Head Cover Gasket

Head Cover

Valve Cover Bolt Comp .

Breather Tube

Pivot Adjusting Nut

Nut M6

Rocker Arm Bolt

Washer ø6

Intake Valve Rocker

Exhaust Valve Rocker

Valve Rocker Arm

Rocker Axis

Push Rod Guide Plate

Pivot Bolt

Shroud

Cylinder Head

Exhaust Stud

Cylinder Head Bolt

Push Rod

Valve Lifter

Drain Plug Bolt

Drain Plug Washer

Dowel Pin

Cylinder Head Gasket G-Style

Intake Stud

Spark plug

Ignition Coil

Flange Bolt M6×29

# Part Number

61 ST188FD-1130003-CPE

62 ST188F-1134000

63 ST188F-1130002-CPE

64 490 .131000 .01

65 188 .130005 .01

66 ST188FD-1130001-CPE

67 ST188FD-1090100-CARB

68 GB41-N-6

69 ST188FD-1090003

70 ST188FD-1090004

71 ST188FD-1090200-G

72 ST188F-1110002

73 ST188F-1110001

74 ST188FD-1081000-G

75 ST188F-1110006

76 ST160F-1110004

77 ST188F-1110004

78 ST188F-1110007

79 ST188F-1110005

80 ST188F-1110003

81 ST188F-1050006

82 ST188F-1060001

83 ST190F-2-1080002

84 ST188F-1121000-A

85 ST188F-1030012

86 ST190F-2-1030006-G

87 ST188F-1030100

88 ST188F-1030001

89 ST168F-1030015-G

90 GB276-BB-6207-UU

91 ST188F-1030010-G

92 ST188FD-1127000-A

93 GB5789-FB6-15

94 GB276-BB-6202-UU

95 ST190F-2-1041000

96 ST190F-2-1050303

97 ST188F-1050304

98 ST190FD-2-1050301

99 ST160F-1110108

100 ST188F-1110101

101 ST188F-1110103

102 ST188F-1110102

103 ST188F-1110009

104 ST160F-1110103

105 ST188F-1110008

106 ST188F-1125000

107 GB5789-FB8-35

108 ST188F-1126000

GB5789-FB5-20

109

GB93-LW-5

110 ST188F-1123000

111 ST188F-1030002

112 ST190FD-2-1131000-17

113 ST188FD-1031011-G

114 0902 .132001 .00

115 GB1667-S4-8

116 188 .132200 .00

117 0902 .130010 .00

118 168 .130015 .01

119 190 .032000 .00

120 190 .030200 .00

121 06 .135015 .10

Camshaft Comp

Balance gear

Key

Crankshaft comp

Governor Washer

Governor Weight Holder

Governor Weight

Governor Weight Pin

Governor Shaft

Governor Holder Clip

Governor Slider

Start Motor

Flange Bolt M8×35

Relay

Flange Bolt M5×20

Lock Washer ø5

Electric Charge Coil

Wire Flat

Main JET

Crankcase Cover

Stepper Motor Cover

Screw M4×8

Stepper Motor Comp .

Spring Conn .

Connector,Starter

Oil Drain Tube

Support

Clip

Description

Carburetor Insulator Packing

Carburetor Insulator

Carburetor Packing

Carburetor

Stepper Motor Support

Carburetor Packing

Air Cleaner Case

Nut M6

Separator

Element

Air Cleaner Cover

Governor Rod

Throttle Return Spring

Control Assembly

Governor Arm

Governor Arm Bolt

Governor Spring

Pin Clip

Washer8 .2×17×0 .8

Cover Arm Shaft

Flywheel Nut

Starter Pulley

Cooling Fan

Flywheel

Grommet

Crankcase

Oil Seal

Wire Clip

Dowel Pin 9×14

Radial Ball Bearing 6207 Unsealed

Case Cover Packing

Oil level switch Assembly

Flange Bolt M6×15

Radial Ball Bearing 6202 Unsealed

Qty.

1

2

2

1

1

2

3

1

1

1

3

1

1

1

1

1

1

2

2

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

3

1

1

1

2

1

1

1

1

1

REV 41535-20110701

22

SPECIfICATIONS

Wiring diagram

ENGLISH 41535

23 REV 41535-20110701

41535 ENGLISH

Problem

Generator will not start

Cause

No fuel

Faulty spark plug

Unit loaded during start up

Low oil level Generator will not start;

Generator starts but runs roughly

Generator shuts down during operation

Choke in the wrong position .

Spark plug wire loose

Out of fuel

Low oil level

Generator cannot supply enough power or overheating

Generator is overloaded

Insufficient ventilation

No AC output

Generator gallops

Repeated circuit breaker tripping

Cable not properly connected

Connected device is defective

Circuit breaker is open

Faulty brush assembly

Faulty AVR (auto voltage regulator)

Loose wiring

Other

Engine governor defective

Overload

Faulty cords or device

for further technical support:

Technical Service

Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)

Toll Free: 1-877-338-0999 tech@championpowerequipment .com

TROUBLESHOOTING

Solution

Add fuel

Replace spark plug

Remove load from unit

Fill crankcase to the proper level

Place generator on a flat, level surface

Adjust choke .

Attach wire to spark plug

Fill fuel tank

Fill crankcase to the proper level . Place generator on a flat, level surface

Review load and adjust . See “Power

Management”

Check for air restriction . Move to a well ventilated area

Check all connections

Replace defective device

Reset circuit breaker

Replace brush assembly (Service Center)

Replace AVR (Service Center)

Inspect and tighten wiring connections

Contact the help line .

Contact the help line

Review load and adjust . See “Power

Management”

Check for damaged, bare or frayed wires .

Replace defective device

REV 41535-20110701

24

ENGLISH 41535

WARRANTy

WARRANTy

CHAMPION POWER EQUIPMENT

2 YEAR LIMITED WARRANTY

Warranty Qualifications

Champion Power Equipment (CPE) will register this warranty upon receipt of your Warranty Registration Card and a copy of your sales receipt from one of CPE’s retail locations as proof of purchase .

Please submit your warranty registration and your proof of purchase within ten (10) days of the date of purchase .

Repair/Replacement Warranty

CPE warrants to the original purchaser that the mechanical and electrical components will be free of defects in material and workmanship for a period of one year (parts and labor) and two years (parts) from the original date of purchase (90 days (parts and labor) and 180 days (parts) for commercial & industrial use) . Transportation charges on product submitted for repair or replacement under this warranty are the sole responsibility of the purchaser . This warranty only applies to the original purchaser and is not transferable .

do Not Return The Unit To The Place Of Purchase

Contact CPE’s Technical Service and CPE will troubleshoot any issue via phone or e-mail . If the problem is not corrected by this method, CPE will, at its option, authorize evaluation, repair or replacement of the defective part or component at a CPE Service Center .

CPE will provide you with a case number for warranty service . Please keep it for future reference . Repairs or replacements without prior authorization, or at an unauthorized repair facility, will not be covered by this warranty .

Warranty Exclusions

This warranty does not cover the following repairs and equipment:

Normal Wear

Generators need periodic parts and service to perform well .

This warranty does not cover repair when normal use has exhausted the life of a part or the equipment as a whole .

Installation, Use and Maintenance

This warranty will not apply to parts and/or labor if this generator is deemed to have been misused, neglected, involved in an accident, abused, loaded beyond the generator’s limits, modified, installed improperly or connected incorrectly to any electrical component .

Installation, Use and Maintenance Cont’d.

Normal maintenance such as spark plugs, air filters, adjustments, fuel system cleaning and obstruction due to buildup is not covered by this warranty .

Other Exclusions

This warranty excludes:

– Cosmetic defects such as paint, decals, etc .

– Wear items such as filter elements, o-rings, etc .

– Accessory parts such as starting batteries, and storage covers .

– Failures due to acts of God and other force majeure events beyond the manufacturer’s control .

– Problems caused by parts that are not original

Champion Power Equipment parts .

This warranty does not apply to generators used for prime power in place of a utility .

Limits of Implied Warranty and Consequential damage

Champion Power Equipment disclaims any obligation to cover any loss of time, use of this product, freight, or any incidental or consequential claim by anyone from using this generator . THIS WARRANTY IS IN LIEU OF

ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,

INCLUDING WARRANTIES OF MERCHANTABILITY OR

FITNESS FOR A PARTICULAR PURPOSE .

A unit provided as an exchange will be subject to the warranty of the original unit . The length of the warranty governing the exchanged unit will remain calculated by reference to the purchase date of the original unit .

This warranty gives you certain legal rights which may change from state to state . Your state may also have other rights you may be entitled to that are not listed within this warranty .

Contact Information

Address

Champion Power Equipment, Inc .

Customer Service

10006 Santa Fe Springs Rd .

Santa Fe Springs, CA 90670 www .championpowerequipment .com

Customer Service


Toll Free:1-877-338-0999 info@championpowerequipment .com

Fax no .: 1 (562) 236-9429

Technical Service


Toll Free: 1-877-338-0999 tech@championpowerequipment .com

24/7 Tech Support: (562) 204-1188

25 REV 41535-20110701

Champion Power Equipment Emissions Control Warranty Statement, engines greater than 80cc

Champion Power Equipment, Inc. (CPE),

The California Air Resources Board (CARB) and the United States Environment Protection Agency (U.S. EPA.)

Emission Control System Warranty

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

Resources Board (CARB) emission regulations.

YOUR WARRANTY RIGHTS AND OBLIGATIONS:

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

Control Systems Warranty on your 2011 small off-road engine. In California, new, small off-road engines must be designed, built and equipped to meet the State’s stringent anti smog standards. In the other states, new engines must be designed, built and equipped, at the time of sale, to meet U.S. EPA regulations for small non-road engines.

CPE must warrant the emission control system on your small off-road engine for the period of time listed below, provided there has been no abuse, neglect, unapproved modification, or improper maintenance of your small offroad engine.

Your emission control system may include parts such as the carburetor, fuel-injection system, the ignition system, catalytic converter and fuel lines. Also included may be hoses, belts, connectors and other emission related assemblies. Where a warrantable condition exits, CPE will repair your small off-road engine at no cost to you including diagnosis, parts and labor.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

This emission control system is warranted for two years, subject to provisions set forth below. If, during the warranty period, emission related part on your engine is defective in materials or workmanship, the part will be repaired or replaced by CPE.

OWNER WARRANTY RESPONSIBILITIES:

As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in your Owner’s Manual. CPE recommends that you retain all your receipts covering maintenance on your small offroad engine, but CPE cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the small off-road engine owner, you should however be aware that CPE may deny you warranty coverage if your small, off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

You are responsible for presenting your small off-road engine to an Authorized CPE service outlet 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


Santa Fe Springs, CA 90670

1-877-338-0999

The emission warranty is a defects warranty. Defects are judged on normal engine performance. The warranty is not related to an in-use emission test.

EMISSION CONTROL SYSTEM WARRANTY

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

Emission Control System Warranty (ECS Warranty) for 1995 and later model year California small off-road engines

(for other states, 1997 and later model year engines):

1. APPLICABILITY: This warranty shall apply to 1995 and later model year California small off-road engines (for other states, 1997 and later model year engines). The ECS Warranty Period shall begin on the date the new engine or equipment is delivered to its original, end-use purchaser, and shall continue for 24 consecutive months thereafter.

2. GENERAL EMISSIONS WARRANTY COVERAGE

CPE warrants to the original, end-use purchaser of the new engine or equipment and to each subsequent purchaser that each of its small off-road engines is: a. Designed, built and equipped so as to conform with all applicable regulations adopted by the Air

Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code, and b. Free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to the part as described in the engine manufacturer’s application for certification for a period of two years.

3. THE WARRANTY ON EMISSION-RELATED PARTS WILL BE INTERPRETED AS FOLLOWS: a. Any warranted part that is not scheduled for replacement as required maintenance in the Owners

Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by CPE according to Subsection “d” below. Any such part repaired or replaced under the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period. b. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the

Owners Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary”, shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period. c. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by CPE according to Subsection “d” below. Any such emissions-related part repaired or replaced under the ECS Warranty, shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part. d. Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a CPE Authorized Service Outlet. e. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in fact defective, provided that such diagnostic work is performed at a CPE Authorized

Service Outlet. f. CPE shall 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

Evaporative Emissions

Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed systems.

Fuel Tank, Fuel Cap, Fuel Line, Fuel Line Fittings, Clamps, Pressure

Relief Valves, Control Valves, Control Solenoids, Electronic Controls,

Vacuum Control Diaphragms, Control Cables, Control Linkages, Purge

Valves, 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.


Santa Fe Springs, CA 90670

1-877-338-0999

Attn.: Customer Service

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