Champion power equipment 41155 Manual

Congratulations on your purchase of a Champion Power Equipment generator. CPE designs and builds generators to strict specifications and with proper use and maintenance this generator should bring you years of satisfying service.

SAFETY PRECAUTIONS

WARNING

Read, study, and follow all instructions before operating this device. Failure to heed these instructions may result in personal injury and/or property damage.

Your generator can develop tremendous power forces and if used unsafely or improperly could result in property damage, serious injury, or death. Throughout this manual you will find the following symbols for caution, warning, and danger. Pay particular attention to the notes preceded by these symbols as they are written for your safety. Ultimately, safe operation of this device rests with you, the operator.

DANGER

Indicates a hazard which, if not avoided, will result in death or serious injury.

WARNING

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

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or equipment damage. This notation is also used to alert against unsafe practices.

SAFETY AND OPERATION INSTRUCTIONS

WARNING

Failure to follow these instructions and warnings may result in death, personal injury, or property damage.

DANGER

Gasoline engines produce toxic carbon monoxide exhaust fumes. Breathing exhaust fumes will cause serious injury or death.

WARNING No modifications, alterations, or deviation to the generator are authorized by the manufacturer and should not be made.

WARNING

Read, study, and understand the operator's manual prior to operation of this product. Read, study and understand the engine manual prior to operation. Follow all warnings and instructions.

WARNING

Know your equipment. Check the applications, limitations, and potential hazards with this unit and its placement or location.

WARNING

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

WARNING

Gasoline is flammable. Check for spilled fuel or fuel leaks. Stop engine and allow to cool at least 2 minutes before refueling.

WARNING

Equipment must be used on a hard, level surface, free from grease, fuel and other combustible materials.

WARNING Engine must not be run at excessive speeds. Operating an engine at excessive speeds increases the hazard of personal injury. Do not tamper with the parts which may increase or decrease the speed of the engine.

WARNING Do not operate this generator in the rain or unusually wet conditions.

WARNING

This generator is designed for outdoor use only; do not use this generator inside any building or enclosure including the generator compartment of a recreational vehicle (RV), garages, basements, crawl spaces and other locations where CO gas can collect and cause death or injury. Fire or an explosion may result.

WARNING

No user-performed modifications, including venting of exhaust and/or cooling ventilation are authorized by the manufacturer, Also, allow at least two feet of clearance on all sides of the generator even while operating the unit outdoors.

WARNING If this unit is used for backup power in the event of a utility power failure, the following step must be taken: Before connecting the generator to an electrical system, open the main circuit breaker or main switch serving the system, to isolate the generator system from the electric utility. Failure to isolate the generator and utility systems may result in damage to the generator and may also result in injury or death to electric utility workers, due to a back feed of electrical energy.

WARNING

This product is equipped with a spark-arresting muffler. If the product will be used around flammable materials, or on land covered with materials such as agricultural crops, forest, brush, grass, or other similar items, then the approved spark arrester must be installed. SPARK-ARRESTERS ARE REQUIRED IN THE STATE OF CALIFORNIA. Spark arresters are also required on some U.S. Forest Service land and may also be legally required under other statutes and ordinances.

WARNING Never step over a generator.

WARNING

Failure to heed these warnings may result in personal injury and/or property damage. No modifications, alterations, or deviations to the generator are authorized by the manufacturer and should not be made.

WARNING Engine speed has been factory set to provide safe operation. Tampering with the engine speed adjustment could result in overheating of attachments and could cause a fire. Never attempt to “speed up” the engine to obtain more performance.

Both the output voltage and frequency will be thrown out of standard by this practice, endangering attachments and the user.

1

WARNING Never refuel a generator while it is in operation. Make sure the generator is not running. (This is a severe risk of fire.)

WARNING Engine Exhaust, some of it’s constituents, and certain vehicle components contain or emit chemicals known to the State of

California to cause cancer and birth defects or other reproductive harm.”

This product contains chemicals, including lead, known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling .”

CAUTION This generator has been shipped from the factory without oil in the crankcase. Operating the unit without oil can ruin the engine.

CAUTION

You MUST unplug any load from the generator before starting. This will help to prevent permanent damage to any appliances.

CAUTION

Do not exceed rated capacity of current draw. Current load must be kept within rating on the generator label. Overloading will damage the unit and/or shorten its life.

CAUTION

For starting, grasp the starter grip and pull slowly until you feel resistance. Then pull firmly. Repeat if necessary with choke opened slightly. When engine starts, open the choke gradually until the engine is warm.

INCLUDED WITH YOUR GENERATOR

1. Generator

2. 6 ft Battery Cable

3. Wheel Kit

(1 Axle, 2 Wheels, 2 Vibration Mounts, 1 Handle Assembly, (1 Support Leg)

4. Bolt Kit

(2 Wheel Retaining Pins, 2 Flat Washers, 10 Cap Screws and Nuts)

5. Spark Arrestor, Cover Plate and 2 Screws w/ Lock Wahsers

1 set

1 set

1 set

1 set

1 set

2 3 4

NOT INCLUDED WITH YOUR GENERATOR

5

1 2

1. NEMA L14-30P

2. NEMA L5-30P

3. Standard 120V 3-Prong Plug

2

3

CONTROL PANEL COMPONENTS

1.AC Voltmeter

Use the voltmeter as a visual aid. It indicates the AC voltage. The normal voltage meter reading is 230 to 250 volts resulting in proper distribution of voltage to the receptacles. Excessive meter voltage could result in damage to appliances.

CAUTION Engine speed has been adjusted at the factory and establishes the proper electrical frequency output (60 Hz). Do not attempt to increase the speed of the engine for higher output. Serious damage could occur to the generator or engine.

2.120 Volt AC Outlet, Locking Receptacle

The outlet is protected by a 25 Amp push-to-reset circuit breaker. This receptacle powers 120 Volt AC, 60 Hz, Single Phase loads requiring up to 25 Amps or 3000 Watts of power.

3.120 / 240 Volt AC Outlet, Locking Receptacle

This outlet is protected by 25 Amp push-to-reset circuit breakers on each 120 Volt leg of the receptacle. This receptacle powers 240 Volt AC, 60

Hz, Single Phase loads requiring up to 23 Amps or 5500 Watts of power. If an L14-30P plug is wired for only one 120 Volt leg (3-wire connection) then this receptacle powers 120 Volt AC, 60 HZ, Single Phase loads requiring up to 25 Amps or 3000 Watts of power.

4.120 Volt AC, Duplex Receptacle

Each receptacle is protected against overload by a 20 Amp push-to-reset circuit breaker. Use each receptacle to operate 120 Volt AC, singlephase 60 Hz electrical loads requiring up to 20 Amps or 2,400 Watts of power.

5.Note:

Combined amperage of the receptacle is not to exceed circuit breaker limits.

6.12 VOLT, 10 Amp DC Outlet

This receptacle allows you to recharge a 12 Volt automotive or utility style storage battery with the battery charge cables provided. This receptacle cannot charge 6 Volt batteries and cannot be used to crank an engine. It is also not recommended for charging deep cycle batteries. Do not charge any batteries for extended periods without checking.

STARTING WATTAGE REQUIREMENTS

1. Some appliances and tools are listed below with starting and running voltage and amperage requirements. Use the following formula to

convert voltage and amperage to wattage: a. FORMULA: VOLTS X AMPS = WATTS b. EXAMPLE(Voltage and amperage for 1/3 HP furnace fan):

120 Volts X 10 Amps = 1200 Running Watts

2. To determine the approximate starting wattage requirement for most appliances and tools with inductive type motors, multiply the wattage

that was calculated by 3 times to assure adequate generator capacity. If the nameplate information is not available, use the values on the

following page as a guide.

3. Remember that the starting and running wattage for resistive loads are the same. (Example: a 100-watt light bulb requires only 100 Watts to

start.) Most resistive loads will be listed in wattage.

4.Use the chart on the next page as a reference guide.

CAUTION Let the engine stabilize and warm up for about five minutes after starting and before using.

CAUTION DO NOT OVERLOAD THE GENERATOR. Add up the rated watts (or amps) of all loads to be connected at one time.

This total should not be greater than the rated wattage/amperage capacity of the generator.

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Air Conditioner (12,000 BTU)

Air Conditioner (20,000 BTU)

Battery Charger 20 AMP

Battery Charger 12V DC

Belt Sander 3”

Bench Grinder 6”

Chain Saw

Circular Saw (6-12”)

Clothes Washer

Coffee Maker

Compressor (1HP)

Compressor (½ HP)

Compressor (3/4 HP)

Curling Iron

Demolition Hammer

Disc Sander (9”)

Edge Trimmer

Electric Blanket

Electrical Nail Gun

Electric Range - One Element

Electric Skillet

Freezer

Furnace Fan (1/3 HP)

Hair Dryer

Hand Drill (1”)

Hand Drill (½”)

Hand Drill (1/4”)

Hand Drill (3/8”)

Hedge Trimmer

Home Security

Impact Wrench

Jet Pump

Jigsaw

Lawn Mower

Light Bulb

Microwave

Milk Cooler

Oil Burner on Furnace

Oil Fired Space Heater (140,000 BTU)

Oil Fired Space Heater (30,000 BTU)

Oil Fired Space Heater (85,000 BTU)

Paint Sprayer, Airless (1/3 HP)

Paint Sprayer, Airless (handheld)

Portable Heater (5,000 BTU)

Radio

Refrigerator

Refrigerator/Freezer

Slow Cooker

Small Refrigerator

Submersible Pump (1 HP)

Submersible Pump (½ HP)

Submersible Pump (1-1/2 HP)

Sump Pump

Table Saw

Television

Toaster Oven

Water Heater

Weed Trimmer

0

RUNNING WATTAGE GUIDE

500 1000 1500 2000 2500

1700

500

110

1000

700

1200

800

1200

1000

2000

1400

700

1300

1200

500

230

1200

1250

1500

500

750

100

250

500

450

500

550

800

1200

1200

1100

1200

100

700

1100

300

150

225

400

600

150

1550

50

600

1200

200

500

1800

2000

1500

600

1750

400

1500

2800

500

3000 3500

3300

4000

4000

Starting loads may need as much as 3 times the Running Wattage for Electrical Motors. Check your appliance rating before using generator.

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GENERATOR ASSEMBLY AND MOUNTING

1. If your generator was delivered with two L-shaped metal shipping brackets mounted underneath the engine, these brackets must be removed. These brackets were installed temporarily on some generators for shipping only and prevent the rubber isolation mounts beneath the engine and generator from functioning properly.

2. Your Champion Generator is supplied with a wheel kit. If you want to install the wheel kit on your unit, please follow the following instructions.

a. Place the bottom of the generator cradle on a flat, even surface. Temporarily place unit on blocks to ease assembly.

b. Slide axle through both mounting braces on the cradle frame as shown (Fig 1).

c. Slide a wheel and a flat washer over the axle (Fig 2), and then secure the wheel with a retaining pin.(Fig 3) d. Install the other wheel in the same manner.

3. Secure each vibration mount to the support leg with a lock nut (M8), and a cap screw (M8 x 30) (Fig 4)

4. Secure the support leg to the cradle with cap screws (M8 x 20) and lock nuts (M8) (Fig 5).

5. Position the handles on the cradle and attach with plastic flat washer, cap screws (M8 x 50) and lock nuts (M8) (Fig 6)

6. Loop handle locking pin lanyards around main frame above handle bracket. Use to lock handle in upright position.(Fig 7)

7. Check that all fasteners are tight.

8. If the included spark arrester insert is to be used, installation should be performed as follows. Insert the spark arrester screen into the muffler outlet. Secure the spark arrester by placing the cover plate over the end of the screen, with lettering facing outward. Secure the cover plate with the two screws and lock washers providing with the spark arrester kit.

FIG. 1 FIG. 2

FIG. 4 FIG. 5

FIG. 3

FIG. 6

5

FIG. 7

Running Watts

Max Watts

AC Voltage

DC Voltage

Frequency

Phase

Power Factor

Engine

Fuel Tank Capacity

Running Hours

Noise Level

Overall dimensions

Gross Weight (with package)

Net Weight (without gas)

MODEL # C41155

Generator Specifications

5500 Watts

6800 Peak Watts

120/240 V

12V

60 Hz

Single

1.0

11.0 HP OHV Champion Engine (EPA & CARB Certified)

6.5 gallons (25L)

12 Hours at 50% Load

74 dB (from 7 meters)

32.68” (L) x 22.44” (W) x 23.23” (H) - 83cm (L) x 57cm (W) x 59cm (H)

199 lbs. (90.5 kg)

154 lbs. (70 kg)

Grounding the generator provides extra safety.

BEFORE OPERATION

The National Electric Code requires that this product 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 front panel for this purpose. For remote grounding, connect a length of heavy gauge (12 AWG min.) copper wire between the generator Ground Terminal and a copper rod driven into the ground. This should provide a suitable ground connection. CPE recommends that you consult with a local electrician to insure that local codes are being adhered to.

OPERATION

Add oil:

1) Place generator on a level surface.

2) Follow the oil grade recommendations and oil fill instructions given in the maintenance section of this manual.

CAUTION Any attempt to crank or start the engine before it has been properly filled with the recommended oil may result in engine failure.

Add gasoline:

1. Use regular UNLEADED gasoline with the generator engine. Do not use premium gasoline. Do not mix oil with gasoline.

2. Clean area around fuel fill cap, remove cap.

3. Slowly add unleaded regular gasoline to fuel tank. Be careful not to overfill. Allow about ½” of tank space for fuel expansion.

4. Install fuel cap and wipe up any spilled gasoline.

WARNING Never fill fuel tank indoors.

WARNING Never fill fuel tank when Engine is running or hot.

WARNING Do not overfill the fuel tank.

WARNING Do not light cigarettes or smoke when filling the fuel tank.

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Start the generator:

1.Disconnect all electrical loads from the generator when starting the engine

2.Turn the fuel valve to the “On” position (Fig 8).

3.Set the On/Off switch to the “On” position (Fig 9).

4.Place the choke lever in the “Full” choke position by pulling it out as indicated in the illustration (Fig 10).

5.Grasp the recoil handle and pull slowly until slight resistance is felt. Then pull rapidly one time to start engine (Fig 11).

6.Move the choke to the “Run” position (In). If engine falters, move choke lever to “Half” choke position until the engine runs smoothly. When engine is at operating temperature, move the choke to “Run” position (In).

7.Let the engine stabilize and warm up for a few minutes after starting. Plug in the desired 120 and/or 240 Volt AC, single phase, 60 Hz electrical loads.

8.For initial operation of a new generator, allow the engine to operate for 20 to 30 minutes before applying any electrical load

FIG. 8 FIG. 9 FIG. 10 FIG.11

WARNING The choke should be used for both cold and warm engines.

WARNING Do not attempt to connect 240 Volt loads to the 120 Volt receptacles.

WARNING Do not connect 50 Hz loads to the generator.

Stopping the Engine:

1. Unplug all electrical loads from generator panel receptacles. Never start or stop engine with electrical devices plugged in and turned on.

2. Let engine run at no-load for 30 seconds to stabilize the internal temperatures of engine and generator.

3. Move On/Off switch to “OFF”.

4. Close the fuel shut-off valve.

MAINTENANCE

WARNING Improper maintenance or operating a defective generator could result in death or serious injury

1. Generator maintenance includes keeping the unit clean and dry.

2. Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust, dirt, moisture, or any corrosive vapors.

Cooling air slots in the generator must not become clogged with snow, leaves or any other foreign material.

3. Check the cleanliness of the generator frequently and clean when dust, dirt, oil, moisture or other foreign substances are visible on its

exterior surface.

4. Check the oil level and air cleaner cleanliness at each use.

5. Initial oil change at 1 month or 5 hours whichever comes first. Subsequent oil changes at 6 months or 100 hour increments, whichever

comes first.

6. Clean the air cleaner element every 50 hours (every 10 hours under dusty conditions.) Wash in high flash-point solvent. Squeeze dry, then

dip in clean engine oil and squeeze out excess oil.

7. Check and adjust the spark plug every 6 months or 100 hours, whichever comes first.

8. Replace the spark plug every year or 300 hours, whichever comes first.

9. Check and if necessary adjust the intake and exhaust valve clearances initially at the first 10 hours of operation and subsequently at every 6

months or 100 hours of operation.

10.If used, clean the spark arrester every 6 months or 100 hours, whichever comes first.

Spark Arrestor Cleaning Procedure: a.If the generator has been running, allow it to cool before cleaning the spark arrester.

b.Remove the (2) screws holding the cover plate which retains the end of the spark arrester.

c.Remove the spark arrester screen.

d.Carefully remove carbon deposits from the spark arrester screen using a wire brush.

e.Replace the spark arrester if it is damaged.

CAUTION We DO NOT recommend using a garden hose to clean the generator. Water can enter the fuel system and cause problems. In addition, if water enters the generator through cooling air slots, some of the water will be retained in voids and cracks of the rotor and stator winding insulation. Water and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings.

7

SERVICE INFORMATION

A = Intermittent use (less than 1 hour) or colder temperatures, below 60°F

B = Medium use (less than 3 hours) or seasonal temperatures 50°F 80°F

C = Extreme use (continuous use) or hot climates 80°F-100°F

Spark Plug, NGK or equivalent A B6ES B B7ES C B8ES

Spark Plug Gap

Valve Clearance, Cold

0.70 / 0.80mm (.028 / .031 in.)

Intake 0.13 / 0.17mm (.005 / .007 in.)

Exhaust 0.18 / 0.22mm (.007 / .009 in.)

ADDING / CHECKING OIL LEVEL

1)Remove oil fill cap / dipstick to add oil

2)Add 1.6 qts. (1.1 L) oil and replace cap / dipstick

3)To check oil level - remove cap/dipstick and wipe it clean. Insert

cap/dipstick into the filler, but do NOT screw it in. Oil should

appear on dipstick.

4)If more oil is required add slowly

5)Oil should be filled at least to the bottom of the threads but not above the

top of the threads when on a level surface.

MAX IMUM FILL

MIN IMUM FILL

DIP STICK

DRAIN PLUG

CAUTION This engine is equipped with a “low oil shut-off” and the engine will stop when engine oil falls below the minimum safe level. Add oil immediately then restart engine.

CHECK ENGINE OIL LEVEL DAILY AND ADD AS NEEDED!

30

5W-30

10W-30

°F-20 0 20 40 60 80 100 120

MAINTENANCE SCHEDULE:

REGULAR SERVICE PERIOD : Perform at every indicated month or operating hour interval, whichever comes first.

ITEM

EACH USE

FIRST

MONTH OR

5 HOURS

FIRST 10

HOURS

EVERY

3 MONTHS

OR 50 HOURS

EVERY

6 MONTHS

OR 100 HRS

Engine Oil

Air Cleaner

Sediment cup

Spark plug

Valve clearence*

Spark Arrester

Fuel tank and filter*

Fuel Line

Check level

Change

Check

Clean

Clean

Clean-Readjust

Check-Readjust

Clean

Clean

Replace if necessary Every 3 years

* Recommended for experienced owner or service center.

• Tampering with the factory set governor could void your warranty.

• Improper maintenance will void your warranty.

8

TROUBLE SHOOTING GUIDE

PROBLEM CAUSE

Engine will not start Low on fuel or oil

Ignition switches in off position

Faulty spark plug

Choke in wrong position

Fuel shut-off valve in closed position

Unit loaded during start-up

Spark plug wire loose

No electrical output Faulty receptacle

Circuit breaker kicked out

Defective capacitor

Faulty brush assembly

Faulty power cord

Faulty AVR

Loose wiring

Repeated circuit breaker tripping

Overload

Faulty cords or equipment

Generator overheating Generator overloaded

Insufficient ventilation

CORRECTION

Add fuel or oil

Turn to “ON” position

Replace spark plug

Adjust choke accordingly

Open fuel shut-off valve

Remove load from unit

Attach wire to spark plug

Have Service Center replace

Depress and reset

Have Service Center replace capacitor

Replace brush assembly

Replace cord

Have Service Center replace AVR

Inspect and tighten wiring connections

Reduce load. Depress and reset

Check for damage, bare, or frayed wires. Replace

Reduce load

Move to adequate supply of fresh air, check for air restriction

CHAMPION POWER EQUIPMENT

1 YEAR LIMITED WARRANTY

Warranty Qualifications:

Champion Power Equipment (CPE) will activate this warranty on receipt of your Warranty Registration Card and proof of purchase such as a copy of your sales receipt from one of CPE's retail customers.

Warranty registration and your receipt must be submitted within ten (10) days from the date of purchase.

Champion Power Equipment Repair/Replacement Warranty:

CPE warrants to the original purchaser that the mechanical and electrical components will be free of defects in material and workmanship for a period of one (1) year from the original date of purchase (90 days for commercial & industrial use). 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 Department and CPE will troubleshoot any problem with you over the phone or via 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 will not apply to parts and/or labor if this generator is deemed to have been misused, neglected, involved in an accident, abused, overloaded the generator limits, unauthorized modifications, improper installation or improper connection to any electrical components. Painted surfaces are also excluded from this warranty. *Warranty is Limited to 90-days from purchase for Commercial users, including Rentals.

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 written warranty is the only warranty and any implied warranty will be limited by these terms.

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.

An exchanged unit will continue the warranty from the purchase date of the original unit.

9

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 2005 and later, small off-road engine. In California, new, small off-road engines must be designed, built and equipped to meet the

State's stringent anti smog standards. In the other states, new engines must be designed, built and equipped, at the time of sale, to meet U.S.

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

Your emission control system may include parts such as the carburetor, fuel-injection system, the ignition system, 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 off-road engine, but CPE cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

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

You are responsible for presenting your small off-road engine to an Authorized CPE service outlet, CPE dealer or CPE, Santa Fe Springs, Ca. as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact:

Champion Power Equipment, Inc.

Customer Service

10006 Santa Fe Springs Road

Santa Fe Springs, CA 90670

Tel: (562) 236-9422

The emission warranty is a defects warranty. Defects are judged on normal engine performance. The warranty is not related to an inuse 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 offroad 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.

10

d. Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a

CPE Authorized Service Outlet.

e. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in fact defective, provided that such diagnostic work is performed at a CPE Authorized Service Outlet.

f. CPE shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of an emission-related part covered by the ECS Warranty.

g. Throughout the ECS Warranty Period, CPE shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand for such emission-related parts.

h. Any CPE Authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty maintenance or repair and will be provided without charge to the owner. Such use shall not reduce CPE's warranty obligation.

i. Unapproved add-on or modified parts may not be used to modify or repair a CPE engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. CPE shall not be liable hereunder for failures of any warranted parts of a CPE engine caused by the use of such an unapproved add-on or modified part.

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

Air Induction System

Ignition System

Exhaust System

Miscellaneous Parts

Evaporative Emissions

Fuel regulator, Carburetor and internal parts

Air cleaner, Intake manifold

Spark plug and parts, Magneto ignition system

Exhaust manifold, catalytic converter

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. Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used.

If you have any questions regarding your warranty rights and responsibilities, or to obtain warranty service, please write or call the

Customer service of Champion Power Equipment, Inc.

Champion Power Equipment, Inc.

10006 Santa Fe Springs Road

Santa Fe Springs, CA 90670

(562) 236-9422

Attn: Customer Service

Customer Service: Mon. - Fri. 8:30 am - 5:00 pm (Pacific Standard Time)

Toll Free : 1 - 877 - 338 - 0999

Fax no. : 1 - 562-236-9429 (weekdays only)

Technical Service: Mon. - Fri. 8:30 am - 5:00 pm (Pacific Standard Time)

Toll Free : 1 - 877 - 338 - 0999

24hr. Voicemail: 1 - 626 - 230 - 5248 or E-mail: [email protected]

11

PARTS DIAGRAM

12

No

1

2

3

29

30

31

32

25

26

27

28

18

19

20

21

22

23

24

11

12

13

14

15

16

17

7

8

9

10

4

5

6

40

41

42

43

44

45

46

33

34

35

36

37

38

39

47

48

49

ST05FD-1151204

ST188FD-1710001-C

ST188FD-1710002-C

ST188FD-1710003-C

ST188FD-1710004-C

ST05FD-1151207

GB5789-86

ST05FD-1152002

GB5789-86

ST168F-1152032

ST168F-1152004A

ST05F-1152031A

ST02FD-1152035

ST05FD-1152032

GB5789-86

ST04FD-1152001

GB5787-88

ST04FD-1152020

ST04FD-1152010

ST05FD-1151600

ST188FD-1030011

ST1P60F-1030004

ST188F-1030003

ST182FD-100000

ST188FD-1740008-C

ST188FD-1740007-C

ST188FD-1740200-C

ST188FD-1740006-C

GB6177-86

ST05FD-1151300A

ST05FD-1151300B

GB6177-86

ST188FD-1740001

ST188FD-1151100-C

ST160F-1070001

ST188FD-1160002

ST168FD-1160400

ST188FD-1160001

ST168F-1160500

ST168FD-1160200

GB819-85

ST168FD-1160100

GB5789-86

GB287-86

ST188FD-1160300-C

ST188FD-1131001

Part #

ST188FD-1712000

ST188FD-1710100-C

PARTS LIST

Description

Switch

Control Panel

A.C 25A Circuit Breaker

ST05FD-1151202 A.C 20A Circuit Breaker

D.C 10A Breaker

Voltmeter

120V (30 A) Receptacle

120V/240 (30 A) Receptacle

120V (20 A) Duplex Receptacle

12V DC Receptacle

Wiring Control Cover

Bolt M5 x 10

Generator end cover

Bolt M6 x 10

Terminal

Diode assembly

AVR

Brush assembly

End cover

Flange bolt M6 x 164

Stator cover

Flange bolt M10 x 1.25 x 250

Stator assembly

Rotor comp

Filter cover

Crankcase cover

O-Ring

Oil filler cap

Engine

Handle bar end cover

Handle bar

Pin

Flat washer

Nut M8

Bottom rubber 1

Bottom rubber2

Nut M10

Axle

Frame

Clip

Fuel tube

Fuel cock

Fuel tank

Fuel filter

Fuel tank cap

Screw M5 x 6

Fuel meter assembly

Bolt M6 x 25

Washer Φ6

Rubber

Spacer

13

1

1

1

1

6

4

1

4

12

2

2

2

2

2

4

4

4

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

1

1

1

2

1

7

1

1

1

1

Qty

1

1

2

1

1

2

1

69

70

71

72

73

74

75

62

63

64

65

66

67

68

55

56

57

58

59

60

61

No

50

51

52

53

54

84

85

86

87

88

80

81

82

83

76

77

78

79

Part #

ST188FD-1131015

ST188FD-1131100

ST188FD-1131002

GB818-85

ST188FD-1031200

ST182FD-1130002

ST188FD-1131000

ST188F-1020001

ST182FD-1133000

ST188FD-1134000

ST182FD-1130003

ST188FD-1010002

ST188FD-1090006

ST188FD-1090100

ST188FD-1090002

GB6177-86

ST188FD-1090003

ST188FD-1090004

ST188FD-1090200

GB6177-86

ST188FD-1080200

ST188FD-1010001

ST188FD-1100001

ST188FD-1100100

GB5781-86

ST188FD-1100002

ST188FD-1100105

GB5789-86

ST188FD-1100104

ST188FD-1100103

GB5789-86

ST188FD-1100006

GB5789-86

ST188FD-1740004-C

ST188FD-1740005-C

ST188FD-1740100-C

GB97.1-85

GB/T91-2000

GB5789-86

PARTS LIST

Description

Clip

Valve

Rubber tube

Screw M5 x 10

Diaphram assembly

Packing

Stay assembly

Grommet

Carburetor

Carburetor insulator

Carburetor insulator packing

Bolt

Air cleaner stay

Air cleaner case comp

Ari cleaner seal

Nut M5

Separator

Element

Air cleaner cover comp

Nut M6

Control assembly

Bolt

Muffler gasket

Ex pipe

Bolt M8 x 25

Muffler

Muffler outer protector

Bolt M6 x 12

Muffler life protector

Muffler inner protector

Bolt M8 x 20

Muffler stay

Bolt M8 x 30

Vibration mount

Support leg

Wheel

Washer Φ16

Retain pin 3.2 x 40

Bolt M8 x 50

1

1

10

1

2

1

2

1

2

1

4

1

1

1

6

2

1

1

1

1

1

1

Qty

1

1

1

3

1

2

1

1

2

2

2

1

5

1

2

2

2

14

2/06 -1