41115
Rev 41115-­20101217
10006 Santa Fe Springs Road
Santa Fe Springs, CA 90670 USA
Made in China
Owner’s Manual and Operating Instructions
SAVE THESE INSTRUCTIONS
Important Safety
Instructions are included in
this manual
6000 Starting Watts / 5000 Running Watts
PORTABLE GENERATOR
Table of Contents
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!
Parts Included...........................................7!
Assembly.......................................... 8!
Remove the Generator from the Shipping
Carton........................................................8!
Install the Wheel Kit .................................8!
Install the Support Leg .............................8!
Attach the Handle .....................................8!
Install the Spark Arrester .........................9!
Add Engine Oil..........................................9!
Add Fuel ....................................................9!
Grounding ...............................................10!
Operation........................................ 11!
Generator Location ..................................11!
Surge Protection ......................................11!
Starting the Engine ..................................11!
Connecting Electrical Loads ....................11!
Stopping the Engine ............................... 12!
Do Not Overload Generator.................... 12!
Capacity ............................................... 12!
Power Management ............................ 12!
Wattage Reference Chart ........................ 13!
Maintenance ................................... 14!
Engine Maintenance ............................... 14!
Oil ........................................................ 14!
Spark Plugs.......................................... 14!
Air Filter .............................................. 15!
Spark Arrester ..................................... 15!
Cleaning............................................... 15!
Adjustments ........................................ 15!
Maintenance Schedule ........................ 15!
Generator Maintenance .......................... 15!
Storage ............................................17!
Engine Storage ........................................ 17!
Generator Storage ................................... 17!
Specifications ................................. 18!
Engine Specifications..............................18!
Generator Specifications.........................18!
Fuel..........................................................18!
Oil ............................................................18!
Spark Plugs..............................................18!
Valve Clearance .......................................18!
Parts Diagram .........................................19!
Parts List ................................................ 20!
Wiring Diagram ..................................... 22!
Troubleshooting ............................. 23!
Warranty ........................................ 24!
Warranty Qualifications......................... 24!
Repair/Replacement Warranty ............. 24!
Do not return the unit to the place of
purchase ................................................. 24!
Warranty Exclusions.............................. 24!
Normal Wear ...................................... 24!
Installation, Use and Maintenance .... 24!
Other Exclusions ................................ 24!
Limits of Implied Warranty and
Consequential Damage .......................... 24!
Contact Information .............................. 24!
Address ............................................... 24!
Customer Service................................ 24!
Technical Service................................ 24!
Notes .............................................. 28!
Introduction
Introduction
Accessories
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.
This Owner’s Manual contains important
safety instructions and information. SAVE
THESE INSTRUCTIONS FOR FUTURE
REFERENCE.
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.
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
41115
Serial Number
Date of Purchase
Purchase Location
Rev 41115-20100317-E
1
Manual Conventions
Manual Conventions
CAUTION
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.
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
Follow all safety messages to avoid or reduce
the risk of serious injury or death.
CAUTION
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
NOTE
WARNING
If you have questions regarding your generator,
we can help. Please call our help line at 1-877338-0999.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
2
Rev 41115-20100317-E
Safety Rules
Safety Rules
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.
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.
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.
Traumatic amputation or severe laceration can
result.
Rev 41115-20100317-E
3
Safety Rules
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.
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.
4
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
Rev 41115-20100317-E
Controls and Features
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) Fuel Tank – 6.5 gallon capacity fuel
tank.
(2) Fuel Valve – Turn this valve to the
“On” position to supply fuel to the engine.
(3) Choke Lever – Used to start the
engine.
(4) Air Cleaner – Protects the engine by
filtering dust and debris from the intake air.
(6) Serial Number – Please have this
number available when calling for
assistance.
(7) Low Oil Sensor – Senses the level of
oil in the crankcase and shuts the engine
down if the level falls too low.
(8) Oil Filler Cap – Check and fill engine
oil level.
(9) Power Panel – See “Power Panel”.
(5) Recoil Starter – Used to start the
engine.
Rev 41115-20100317-E
5
Controls and Features
Power Panel
(1) Ignition Switch – Flip switch to the
“On” position to start the generator. Flip to
the “Off” position to turn off the generator.
(2) Circuit Breakers – Protects the
generator against electrical overload.
(3) Voltmeter – Displays the output
voltage of the generator.
(4) 120 /240 V 30 A Twist-Lock –
Protected by a 25 A flip-to-reset circuit
breaker on each 120 Volt leg of the
receptacle. This receptacle powers 240 Volt
AC, single phase loads requiring up to 5000
watts. 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 20.8 A or
2500 Watts of power.
(5) 120 V 20 A Duplex – Each duplex is
protected by a 20 A flip-to-reset circuit
breaker to operate 120 Volt AC, single phase,
60 Hz loads requiring up to 20 A 0r 2400
Watts of power.
(6) Ground Bolt – Consult an electrician
for local grounding regulations.
6
Rev 41115-20100317-E
Controls and Features
Parts Included
Your Model 41115 Gasoline Powered Generator ships with the following parts:
Wheel Kit
Handle Assembly
8” Solid Wheel
Axle Assembly
Support Leg
Vibration Mounts
Support Leg Hardware
1
2
2
1
2
1
Oil Funnel
Spark Plug Socket
1 piece
1 piece
Spark Arrester Kit
Spark Arrester
Cover Plate
Screws, Lock Washers
1 piece
1 piece
2 pieces
Oil
Rev 41115-20100317-E
set
piece
sets
piece
piece
set
1 piece
7
Assembly
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.
Remove the Generator from
the Shipping Carton
Attach the rubber vibration mount to
the support leg with a cap screw
(M8x25) and lock nut (M8).
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
Pliers (not included)
Before adding oil to the engine, tip the
generator slowly so that the engine side
is up.
2. Slide the M10x105 wheel bolt through
the washer, sleeve and wheel.
3. Slide the bolt through the mount point
on the frame.
4. Fasten securely with the 10mm nut.
5. Repeat steps 2-4 to attach the second
wheel.
2. Attach the support leg to the generator
frame with cap screws (M8x16) and lock
nuts (M8).
3. Tip the generator slowly so that it rests
on the wheels and support leg.
Attach the Handle
1.
Place the handle over the mounting
channel on the frame.
2. Secure the handle to the frame using the
two handle bolts.
1.
8
3. Place a lock nut (M8) on the end of each
bolt and fasten securely. DO NOT over
tighten the lock nuts.
Rev 41115-20100317-E
Assembly
2. Remove oil fill cap/dipstick to add oil.
Install the Spark Arrester
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 the lettering facing outward.
Secure the cover plate with the two screws
and lock washers provided with the spark
arrester kit.
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 forestcovered land, brush-covered land, or grasscovered land unless the engine is equipped with
a spark arrester.
3. Add 1.16 qt (1.1 L) of oil and replace oil
fill cap/dipstick. See “Specifications”
page in the manual for oil
recommendations based on operating
conditions.
4. Check engine oil level daily and add as
needed.
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.
CAUTION
Failure to install the spark arrester may result in
an increased risk of fire.
NOTE
The generator rotor has a sealed, pre-lubricated
ball bearing that requires no additional lubrication
for the life of the bearing.
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.
1.
Add Fuel
1.
Use clean, fresh, regular unleaded fuel
with a minimum octane rating of 85.
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 ! inch of
space for fuel expansion.
Place the generator on a flat, level
surface.
Rev 41115-20100317-E
9
Assembly
Grounding
Your generator must be properly connected
to an appropriate ground to help prevent
electric shock.
WARNING
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 !” 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.
10
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.
Rev 41115-20100317-E
Operation
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.
Surge Protection
Starting the Engine
1.
2.
3.
4.
5.
6.
7.
Make certain the generator is on a flat,
level surface.
Disconnect all electrical loads from the
generator. Never start or stop the
generator with electrical devices plugged
in or turned on.
Turn the fuel valve to the “On” position.
Move the choke lever to the “Choke”
position.
Flip the ignition switch to the “On”
position.
Pull the starter cord slowly until
resistance is felt and then pull rapidly
As engine warms up, move the choke
lever to “Run”.
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.
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.
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.
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 shortduration voltage fluctuations.
2. Obtain an Uninterruptible Power
Supply (UPS) device.
Most UPS devices come with a
rechargeable battery between the
electronic equipment and power supply
source. The device buffers the voltage
and protects against virtually all shortduration voltage fluctuations.
Rev 41115-20100317-E
11
Operation
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 and unplug all electrical loads.
Never start or stop the generator with
electrical devices plugged in or turned
on.
2. Let the generator run at no-load for
several minutes to stabilize internal
temperatures of the engine and
generator.
3. Flip the ignition switch to the “Off”
position.
4. Turn the fuel valve to the “Off” position.
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 generator capacity when
adding loads.
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
12
Rev 41115-20100317-E
Operation
Wattage Reference Chart
Use the chart to determine approximate
wattage requirements for your equipment.
NOTE
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.
Rev 41115-20100317-E
Item
Running
Watts
Essentials
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
Battery Charger 12V DC
Heating/Cooling
Air Conditioner 12000 BTU
Fan
Furnace Fan 1/3 HP
Home Appliances
Microwave 1000W
Electric Range - One Element
Electric Skillet
Coffee Maker
Clothes Washer
Entertainment
CD/DVD Player
VCR
Stereo Receiver
Television 27"
PC with 15" Monitor
Job Site
Belt Sander 3"
Bench Grinder 6"
Circular Saw
Compressor 1 1/2 HP
Edge Trimmer
Hand Drill 1/2"
Lawn Mower
Paint Sprayer
Table Saw
Starting
Watts
100
1200
500
600
2000
4000
180
300
500
110
2400
500
1800
4000
600
1700
300
1200
2500
600
2000
1000
1500
1250
1500
1200
100
100
450
500
800
1000
700
1500
2500
500
1000
1200
600
2000
1500
1500
1500
2500
500
1000
1800
1200
2000
13
Maintenance
1.
Maintenance
The owner/operator is responsible for all
periodic maintenance.
NOTICE
2.
3.
4.
5.
6.
Maintenance, replacement, or repair of the
emission control devices and systems may be
performed by any non-road engine repair
establishment or individual.
Remove the oil drain plug with a 15 mm
socket and extension.
Allow the oil to drain completely.
Replace the drain plug.
Remove oil fill cap/dipstick to add oil.
Add 1.16 qt (1.1 L) of oil and replace oil
fill cap/dipstick.
Dispose of used oil at an approved waste
management facility.
WARNING
Never operate a damaged or defective generator.
Spark Plugs
1.
WARNING
Tampering with the factory set governor will void
your warranty.
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.
WARNING
Improper maintenance will void your warranty.
Complete all scheduled maintenance in a
timely manner. Correct any issue before
operating the generator.
NOTE
4. Make certain the spark plug gap is 0.7 0.8mm (0.028 - 0.031 in.).
For service or parts assistance, contact our help
line at 1-877-338-0999.
Engine Maintenance
To prevent accidental starting, remove and
ground spark plug wire before performing
any service.
Oil
Change oil when the engine is warm. Refer
to the oil specification to select the proper
grade of oil for your operating environment.
14
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 firmly install
the plug.
8. Attach the spark plug wire to the plug.
Rev 41115-20100317-E
Maintenance
Air Filter
1.
2.
3.
4.
5.
6.
7.
Remove the snap-on cover holding the
air filter to the assembly.
Remove the foam element.
Wash in liquid detergent and water.
Squeeze thoroughly dry in a clean cloth.
Saturate in clean engine oil.
Squeeze in a clean, absorbent cloth to
remove all excess oil.
Place the filter in the assembly.
Reattach the air filter cover and snap in
place.
Spark Arrester
1.
2.
3.
4.
5.
6.
Allow the engine to cool completely
before servicing the spark arrester.
Remove the two screws holding the
cover plate which retains the end of the
spark arrester to the muffler.
Remove the spark arrester screen.
Carefully remove the carbon deposits
from the spark arrester screen with a
wire brush.
Replace the spark arrester if it is
damaged.
Position the spark arrester in the
muffler and attach with the two screws.
CAUTION
Failure to clean the spark arrester will result in
degraded engine performance.
Cleaning
CAUTION
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
schedule below.
Service your generator more frequently
when operating in adverse conditions.
Contact our help line 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 3 years
Replace fuel line
*
To be performed by knowledgeable,
experienced owners or Champion Power
Equipment certified service dealers
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.
Rev 41115-20100317-E
15
Maintenance
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.
16
Rev 41115-20100317-E
Storage
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.
Engine Storage
1.
2.
3.
4.
5.
6.
7.
Generator Storage
1.
Allow the generator to cool completely
before storage.
2. Turn off the fuel supply at the fuel valve.
3. Clean the generator according to the
instructions in the Maintenance section.
4. Store the unit in a clean, dry area.
5. Store in a clean, dry place out of direct
sunlight.
Allow the engine to cool completely
before storage.
Clean the engine according to the
instructions in the Maintenance section.
Drain all fuel completely from the fuel
line and carburetor to prevent gum from
forming.
Add a fuel stabilizer into the fuel tank.
Change the oil.
Remove the spark plug and pour about
" ounce of oil into the cylinder. Crank
the engine slowly to distribute the oil
and lubricate the cylinder.
Reattach the spark plug.
Rev 41115-20100317-E
17
Specifications
Specifications
Engine Specifications
Engine
338 cc OHV CPE
Generator Specifications
Running Wattage
Starting Wattage
AC Load
Phase
Frequency
Fuel Capacity
Weight
Height
Width
Length
5000 Watts
6000 Watts
120/240 V
Single
60 Hz
6.5 gallons (25 L)
171.7 lbs. (77.9 kg)
24.4 inches (62 cm)
24 inches (61 cm)
29.5 inches (75 cm)
Spark Plugs
Your generator comes equipped with a #”
long reach plug (19mm)
Intermittent use (less than 1 hour/month) or
colder temperatures (below 60°F)
NGK BR6ES or equivalent
Moderate use (less than 3 hours/month) or
seasonal temperatures (50-80°F)
NGK BR7ES or equivalent
Extreme use (continuous) or hot climates
(80-100°F)
NGK BR8ES or equivalent
Make certain the spark plug gap is 0.7 0.8mm (0.028 - 0.031 in.).
Fuel
Fuel capacity is 6.5 US gallons (25 L). Use
regular unleaded gasoline with a minimum
octane rating of 85.
Oil
Oil capacity is 1.16 qt (1.1 L).
Valve Clearance
Intake 0.13-0.17mm (0.005 – 0.007 in.)
Exhaust 0.18-0.22mm (0.007 – 0.009 in.)
18
Rev 41115-20100317-E
Specifications
Parts Diagram
Rev 41115-20100317-E
19
Specifications
Parts List
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
20
Part Number
ST05FD-05705001
5A97
ST02FD-05302001-L25
ST02FD-05302001-L20
ST02FD-05602010-D
ST02FD-05502022
ST02FD-05502023
GB5783 M6"22
GB97.1 6
GB93 6
GB6175 M6
GB5789 M6"12
ST05FD-05205009
ST05FD-05215001
ST05FD-05215009
ST05FD-05215003
GB16674 M5"12
ST05FD-1152001
GB16674 M5"16
ST02FD-02100010
ST05F-1152030-CPE
ST02FD-02100008
ST05FD-1152035
ST05FD-1152002
ST05FD-1152004-4
ST05FD-1152003-4
ST05FD-1152005-4
ST05FD-1152010-4
GB7244 10
GB96 10
ST05FD-1152020-4
GB5789 M6"8
ST05FD-1151600
ST182FD-1000000-G
ST05FD-0121-4
ST02FD-1152010-5
GB5789 M6"12
ST05FD-1151400-1
ST05FD-1151300-1
GB6177 M8
GB6182 M10
GB6177 M10
ST188FD-1070006A
ST188FD-1160002-CPE
ST02FD-04160000
ST05FD-04310000
ST02FD-04130000
ST02FD-04120000-A
GB819 M5"10
ST05FD-04120000
GB5789 M6"20
Description
Ignition Switch
Control panel
AC.25A CIRCUIT BREAKER
AC.20A CIRCUIT BREAKER
Volt Meter
Receptacle L14-30R
Receptacle 5-20R
Bolt M6"22
Washer 6
Spring Washer 6
Nut M6
Flange Bolt M6"12
Control panel cover
Grommet
Conduit
Grommet
Flange Bolt M5"12
Generator end cover
Flange Bolt M5"16
Terminal
AVR
Brush assembly cover board
Brush assembly
End cover
Flange bolt M6"165
Stator cover
Flange bolt M10"1.25"250
Stator assembly
Spring washer 10
Washer 10
Rotor comp
Flange Bolt M6"8
Cover
Engine
frame
Grounding line
Flange Bolt M6"12
Bottom rubber 2
Bottom rubber 1
Nut M8
Nut M10
Nut M10
Clip
Fuel tube
Fuel cock
Fuel tank
Fuel filter
Fuel tank cap
Screw M5"10
Fuel meter assembly
Flange Bolt M6"20
Qty.
1
1
2
2
1
1
2
1
2
2
2
11
1
1
1
1
2
1
5
1
1
1
1
1
4
1
1
1
1
1
1
6
1
1
1
1
1
2
2
8
2
4
2
1
1
1
1
1
2
1
4
Rev 41115-20100317-E
Specifications
No.
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
Part Number
ST02FD-04100014
ST02FD-04100010
ST188FD-1100001-G
ST188FD-1100100-G
GB16674 M8"25
ST188FD-1090006
GB6177 M6
GB848 8
GB93 8
GB6175 M8
ST188FD-1101300-A
ST188FD-1100103
ST188FD-1100104
ST188FD-1180121
ST188FD-1100010-88
GB818 M5"14
GB93 5
ST188FD-1100107-G
GB5789 M8"20
ST188FD-1101200
GB5789 M8"35
GB97.1 6
GB93 6
BG01-00000000
GB818 M5"14
GB818 M4"14
GB6177 M4
GB818 M5"38
GB97.1 5
GB5789 M8"16
ST05FD-03020301-60
ST188FD-1743002-C
GB5789 M8"25
GB5789 M8"45
GB6177 M8
ST182FD-1151110-B
ST188FD-1741002C
ST177FD-1152300
ST02FD-03621001
GB96 10
GB5782 M10"105
ST188FD-1100106-G
ST05FD-1152007-4
GB6175 M5
OV01-00000000
Rev 41115-20100317-E
Description
Washer 6
Tank rubber
Muffler gasket
Exhaust pipe
Flange Bolt M8"25
Air cleaner stay
Nut M6
Washer 8
Spring washer 8
NutM8
Muffler
Muffler outer protector
Muffler life protector
Spark arrester assembly
Spark arrester cover
Flange Bolt M5"14
Spring washer 5
Muffler inner protector
Flange Bolt M8"20
Muffler stay
Flange Bolt M8"35
Washer 6
Spring washer 6
Rectifier
Screw M5x14
Screw M4x14
Nut M4
Screw M5"38
Washer 5
Flange Bolt M8"16
Support leg
Vibration mount
Flange Bolt M8"25
Flange Bolt M8"45
Nut M8
Handle
Handle sheath
8in Wheel
Bush 10.5"58.5
Flat washer 10
Bolt M10"105
Cover
Flange bolt M5"201
Nut M5
Transition
Qty.
4
4
2
1
2
1
2
2
2
2
1
1
1
1
1
2
4
1
3
1
1
4
8
1
1
7
7
3
5
2
1
2
2
2
2
1
1
2
2
2
2
1
2
2
1
21
Specifications
Wiring Diagram
22
Rev 41115-20100317-E
Troubleshooting
Troubleshooting
Problem
Generator will not start
Generator will not start or
generator starts but runs roughly
Generator shuts down during
operation
Generator cannot supply enough
power or overheating
Cause
No fuel
Faulty spark plug
Unit loaded during start up
Low oil level
Choke in the wrong position
Spark plug wire loose
Out of fuel
Low oil level
Generator is overloaded
Insufficient ventilation
No AC output
Cable not properly connected
Connected device is defective
Circuit breaker is open
Capacitor defective
Faulty brush assembly
Faulty AVR
Loose wiring
Generator gallops
Repeated circuit breaker tripping
Other
Engine governor defective
Overload
Faulty cords or device
Rev 41115-20100317-E
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 capacitor (Service Center)
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
23
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
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 cause 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.
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.
Limits of Implied Warranty and
Consequential Damage
Do not return the unit to the place
of purchase
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.
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.
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
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
This warranty does not cover the following
repairs and equipment:
Champion Power Equipment, Inc.
Customer Service
10006 Santa Fe Springs Rd.
Santa Fe Springs, CA 90670
Normal Wear
Customer Service
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.
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
Fax no.: 1-562-236-9429
Installation, Use and Maintenance
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
tech@championpowerequipment.com
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, loaded
beyond the generator’s limits, modified, installed
improperly or connected incorrectly to any
electrical component. Normal maintenance such
24
Technical Service
Rev 41115-20100317-E
Warranty
Champion Power Equipment, Inc (CPE),
and the United States Environment Protection Agency (U.S. EPA.)
Emission Control System Warranty
Your Champion Power Equipment (CPE) engine complies with U.S. EPA emission regulations.
YOUR WARRANTY RIGHTS AND OBLIGATIONS:
The US EPA AND CPE are pleased to explain the Federal Emission Control Systems Warranty
on your 2010 small off-road engine. 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: 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.
Rev 41115-20100317-E
25
Warranty
EMISSION CONTROL SYSTEM WARRANTY
The following are specific provisions relative to your Emission Control System
Warranty Coverage.
Emission Control System Warranty (ECS Warranty) for 1997 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 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 at the time of sale with applicable
regulations under section 213 of the Clean Air Ac, as amended, 42 U.S.C. 7401 et seq.
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 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
26
Rev 41115-20100317-E
Warranty
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
Fuel Metering System
Parts Description
Fuel regulator, Carburetor and internal parts
Air Induction System
Air cleaner, Intake manifold
Ignition System
Spark plug and parts, Magneto ignition system
Exhaust System
Exhaust manifold, catalytic converter
Miscellaneous Parts
Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed systems.
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
1-877 338-0999
Attn: Customer Service
Rev 41115-20100317-E
27
Notes
Notes
28
Rev 41115-20100317-E