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OWNER’S MANUAL & OPERATING INSTRUCTIONS
4000 Peak Watts / 3500 Running Watts
Wireless Remote Electric Start
PORTABLE GENERATOR
2 yEAR
LIMITED WARRANTY
MODEL NUMBER
46539
SAvE THESE INSTRuCTIONS
Important Safety Instructions are included in this manual.
MADE IN CHINA
REV 46539-20101109
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
46539
4000 Peak Watts / 3500 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
Vacuum Fuel Valve . . . . . . . . . . . . . . . . . . . . . .
7
Starting with a “Dry Fuel Line” . . . . . . . . . . . .
7
Starting with a “Primed Fuel Line” . . . . . . . . .
7
Parts Included . . . . . . . . . . . . . . . . . . . . . . . . .
8
Wheel Kit . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Spark Arrester Kit . . . . . . . . . . . . . . . . . . . . .
8
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Remove the Generator from the Shipping Carton . .
9
Install the Wheel Kit . . . . . . . . . . . . . . . . . . . . .
9
Install the Support Leg . . . . . . . . . . . . . . . . . . .
9
Install the Handles . . . . . . . . . . . . . . . . . . . . . .
9
Connect the Battery . . . . . . . . . . . . . . . . . . . .
10
Install the Spark Arrester . . . . . . . . . . . . . . . . .
10
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 . . . . . . . . . . . . . . . .
14
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Power Management . . . . . . . . . . . . . . . . . . .
14
Wattage Reference Chart . . . . . . . . . . . . . . . . .
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
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
46539
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
46539
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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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
REV 46539-20101109
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46539
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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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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46539
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
4
2
3
8
5
6
7
(1) Fuel Tank – 3 .8 gallon (14 .4 L) capacity fuel tank .
(2) Auto-Choke – Used to start the engine . No manual adjustment required .
(3) Vac Fuel Valve – Turn this valve to the “On” position to supply fuel to the engine .
(4) Air Cleaner – Protects the engine by filtering dust and debris from the intake air .
(5) Recoil Starter – Used to start the engine .
(6) Oil Filler Cap – Check and fill engine oil level .
(7) Battery – Used to start the engine . Provides 12V
DC to the electric starter and receiver control module .
(8) Power Panel – See “Power Panel” section .
5
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ENGLISH
Power Panel
1 2
CONTROLS ANd fEATuRES
3
4
5 6 7 8
(1) Intelligauge – Three mode digital meter for running hours, voltage and hertz .
(2) Ignition Switch
(3) Circuit Breaker(s) – Protects the generator against electrical overload .
(4) Battery Switch – Enables/disables starting electrically – via remotely or by Ignition Switch .
(5) Ground Terminal – Consult an electrician for local grounding regulations .
(6) 120V / 30A Twist-Lock – Protected by a 25 Amp push-to-reset circuit breaker . This receptacle powers 120 Volt AC, 60 Hz, single phase loads requiring up to 29 .2 Amps or 3500 Watts of power .
(7) 120V / 30A Recreational Vehicle (RV) Receptacle –
This receptacle powers 120 Volt AC, 60 Hz, single phase loads requiring up to 29 .2 Amps or 3500
Watts of power .
(8) 120V / 20A Duplex – Protected by a 20 Amp push-to-reset circuit breaker . Use each recepticle to operate 120 Volt AC, single phase, 60 Hz loads requiring up to 20 Amp 0r 2400 Watts of power .
REV 46539-20101109
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46539
CONTROLS ANd fEATuRES
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 approximately 5 seconds 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 .
The on/off voltage delay at startup and shut down only happen when the Remote Control is used. There is no
7
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Power Panel Load Management Cont’d.
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 .
vacuum fuel valve
This generator is equipped with a Vacuum Fuel Valve .
The Vac Fuel Valve functions similar to a standard on/ off fuel valve with the addition of a vacuum sensor that can open and close the fuel valve based on whether the engine is running or not .
The Vac Fuel valve has (3) selectable positions:
OFF
RUN PRIME
1. OFF (pointing up) a . Valve is switched CLOSED so no fuel passes through the valve .
2. RUN (pointing left) a . Turns on the Vac feature of the valve . The valve only opens to allow fuel to flow when the engine is running which provides vac pressure to the valve .
b . Valve stays OPEN while engine is running .
c . Valve automatically CLOSES when the engine stops .
3. PRIME (pointing down) a . Valve is switched OPEN to allow fuel to flow freely to the carburator .
Starting with a “dry fuel Line”
When there is no residual fuel in the carburetor, the
Vacuum Fuel Valve must be in the “PRIME” position in order to start the generator . This case occurs when the unit is:
– Brand new out of the box, OR
– The fuel line and carburetor have been drained for long term storage .
When the engine starts and reaches full speed, the Vac
Fuel Valve can be turned to the “RUN” position .
Starting with a “Primed fuel Line”
When residual fuel is present in the fuel line and carburetor, the Vacuum Fuel Valve may be turned to the
“PRIME” or “RUN” position to start the generator .
46539
ENGLISH
Parts Included
Your 46539 Gasoline Powered Generator ships with the following parts:
Wheel Kit
– 8” Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
– Vibration Mounts . . . . . . . . . . . . . . . . . . . . . . . .
2
– Support Leg . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
– Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
– Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
– Flange Bolt (M10x105 for Wheel) . . . . . . . . . . . .
2
– Flange Bolt (M8x45 for Handle) . . . . . . . . . . . . .
2
– Flange Bolt (M8x25 for Vibration Mounts) . . . . . .
2
– Flange Bolt (M8x16 for Support Leg) . . . . . . . . . .
2
– Nut (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
– Flat Washer 10 . . . . . . . . . . . . . . . . . . . . . . . . .
2
– Nut (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Spark Arrester Kit
– Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . .
1
– Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
– Screw with Lock Washer
. . . . . . . . . . . . . . . . . . . .
2
Other
– Oil Funnel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
– Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0 .6 L
– Spark Plug Socket . . . . . . . . . . . . . . . . . . . . . . .
1
– Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
– Cap Screw (M6x10 for Battery Terminals) . . . . . . .
2
– Nut (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
CONTROLS ANd fEATuRES
(Battery Bolts)
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46539
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 lock 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)
Install the Handles
1 . Place the handle over the mounting channel on the frame .
2 . Secure the handle to the frame using the two handle bolts (M8x45) .
3 . Place a lock nut (M8) on the end of each bolt and fasten securely . DO NOT over tighten the lock nuts .
1 . Before adding fuel and oil, tip the generator on it’s side .
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 M10 nut .
5 . Repeat steps 2-4 to attach the second wheel .
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ASSEMBLy
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 (M6x10) and secure with the lock washer (M6) .
3 . Repeat steps 1-2 for the black (–) battery lead .
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 .
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 . Please see “Specifications” section for more information on oil types .
1 . Place the generator on a flat, level surface .
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 forest- covered land, brush-covered land, or grass- covered land unless the engine is equipped with a spark arrester .
CAuTION
Failure to install the spark arrester may result in an increased risk of fire .
2 . Remove oil fill cap/dipstick to add oil .
3 . Add 0 .63 qt (0 .6 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 .
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 .
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46539
ASSEMBLy
Add Engine Oil Cont’d.
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 .
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 ½ 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 ½ 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 .
11
REV 46539-20101109
46539
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 .
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 .
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 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 “PRIME” 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 . Turn the vac fuel valve to the “RUN” position .
7 . 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 .
8 . 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 “PRIME” 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 .
7 . After starting the engine, turn the fuel valve to the
“RUN” position .
REV 46539-20101109
12
ENGLISH
46539
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 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 .
NOTE
When the stop button on the remote is pressed, power to the receptacles is turned off and the engine will stop after 5 seconds .
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 .
13
REV 46539-20101109
46539
ENGLISH
OPERATION
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 .
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
Battery Charger 12V DC
500
110
Air Conditioner 12000 BTU
Heating/Cooling
1700
Fan
Furnace Fan 1/3 HP
300
1200
Home Appliances
Microwave 1000W
Electric Range - One Element
1000
1500
Electric Skillet 1250
Coffee Maker
Clothes Washer
1500
1200
CD/DVD Player / VCR
Stereo Receiver
Television 27”
PC with 15” Monitor
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
Running
Watts (A)
Essentials
100
1200
Entertainment
100
450
500
800
Job Site
1000
700
1500
2500
500
1000
1200
600
2000
500
600
2000
4000
180
300
Starting
Watts (B)
2400
500
1800
4000
600
2500
600
2000
1500
1500
1500
2500
500
1000
1800
1200
2000
REV 46539-20101109
14
ENGLISH
46539
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 the oil drain plug with a 15 mm socket and extension .
2 . Allow the oil to drain completely .
3 . Replace the drain plug .
4 . Remove oil fi ll cap/dipstick to add oil .
5 . Add 0 .63 qt (0 .6 L) of oil and replace oil fi ll cap/dipstick .
6 . Dispose of used oil at an approved waste management facility .
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 .
15
REV 46539-20101109
46539
ENGLISH
MAINTENANCE ANd STORAGE
Spark Arrester
1 . Allow the engine to cool completely before servicing the spark arrester .
2 . Remove the two 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 two screws .
CAuTION
Failure to clean the spark arrester will result in degraded engine performance .
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 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 dealers .
REV 46539-20101109
16
ENGLISH
46539
MAINTENANCE ANd STORAGE
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 vac 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 (M6x10) and lock washer (M6) .
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 46539-20101109
46539
ENGLISH
SPECIfICATIONS
Engine Specifications
– Engine . . . . . . . . . .
196 cc OHV CPE (Electirc Start)
Generator Specifications
– Running Wattage . . . . . . . . . . . . . . . . .
3500 Watts
– Starting Wattage . . . . . . . . . . . . . . . . .
4000 Watts
– AC Load . . . . . . . . . . . . . . . . . . . . . .
120/240 V
– Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single
– Frequency . . . . . . . . . . . . . . . . . . . . . . . . .
60 Hz
– Fuel Capacity . . . . . . . . . . . . .
3 .8 gallons (14 .4 L)
– Weight . . . . . . . . . . . . . . .
G .W . 139 .7 lbs (63 .5 kg)
. . . . . . . . . . . . . . . . . . . .
N .W . 129 .8 lbs (59 kg)
– Height . . . . . . . . . . . . . . . . . .
23 .6 inches (60 cm)
– Width . . . . . . . . . . . . . . . .
24 .2 inches (61 .5 cm)
– Length . . . . . . . . . . . . . . . . . .
27 .2 inches (69 cm)
fuel
Fuel capacity is 3 .8 gallons (14 .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 0 .63 qt (0 .6 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 46539-20101109
18
SPECIfICATIONS
Parts diagram
ENGLISH
46539
19
REV 46539-20101109
46539
ENGLISH
Description
Engine
Build Up B
Muffler Stay II
Flange Bolt M6×12
Screw M5×15
Spark Arrester Cover
Spark Arrester Assembly
Muffler
Muffler Cover
Air Fill Clique
Air Fill Clique Washer
Flange Bolt M6×16
Nut M8
Lock Washer 8 mm
Washer 8 mm
Muffler Gasket
Air Cleaner Stay-LPG
Flange Bolt M6×8
Fuel Cock
Clip
Minus Press Pipe
Fuel Line
Clip
Fuel Tank
Tank Rubber
Washer 6 mm
Flange Bolt M6×20
Tank Filter
Fuel Tank Cap
Rollover Valve Hose
Rollover Valve
Screw M5×10
Fuel Meter Assembly
Handle Sheath
Build Up A
Rotor Comp
Flange Bolt M8×233
Washer 8 mm
Lock Washer 8 mm
Stator Assembly
Stator Cover
End Cover
Flange Bolt M6×158
Washer 6 mm
Lock Washer 6 mm
Brush Assembly
Plate Pinch
Lock Washer 5 mm
Bolt M5×16
Washer 5 mm
Bolt M5×16
AVR
Flange Bolt M5×16
Generator End Cover
Flange Bolt M5×12
Terminal
Muffler Stay I
Flange Bolt M8×20
# Part Number
1
168FDE-2-GC3
2
3
4
ST02FD-02100011
ST02FD-02100012
ST02FD-02110000-2 .5
5
6
7
ST02FD-02100005-2 .5
GB96 8
GB7244 8
8
9
ST02FD-02120000-2 .5
ST02FD-02100002-2 .5
10
ST02FD-02100003
11
ST02FD-02100001-2 .5
12
GB97 .1 6
13
GB93 6
14
ST02FD-02100009
15
ST02FD-02100008
16
GB93 5
17
GB5783 M5×16
18
GB97 .1 5
19
GB5783 M5×16
20
AVR02-00000000
21
GB16674 M5X16
22
ST02FD-02100004
23
GB16674 M5X12
24
ST02FD-02100010
25
ST02FD-1150200
26
GB5789 M8X20
27
ST02FD-1150100
28
GB5789 M6X12
29
GB818 M5X15
30
ST188FD-1100010-88
31
ST188FD-1180121
32
ST168FD-1100000-GC
33
ST02FD-03030400
34
ST168FD-1100300-CARB
35
ST168FD-1100003-CARB
36
GB16674 M6X16
37
GB6175 M8
38
GB93 8
39
GB848 8
40
ST168F-1100200-G
41
ST168FD-1090006-A
42
GB5789 M6x8
43
168 .070400 .01
44
ST160F-1070001
45
168 .070900 .01
46
ST168FD-1160002B
47
ST188FD-1070006A
48
504 .071000 .35
49
ST02FD-04100010
50
ST02FD-04100014
51
GB5789 M6×20
52
ST168F-1070006A
53
168 .070100 .01
54
168 .070014 .01
55
ST168FD-1070400-CARB
56
GB819 M5×10
57
ST02FD-04120000-CARB
58
ST188FD-1741002-C
Qty
1
1
1
4
4
1
1
3
1
1
1
2
1
1
1
1
2
1
1
4
1
1
2
2
2
1
1
1
1
1
1
1
14
2
1
1
3
2
1
2
7
2
1
1
5
1
6
10
1
1
1
4
1
1
1
1
1
1
Parts List
# Part Number
59
ST182FD-1151110-B
60
GB6177 M8
61
GB5789 M8×45
62
ST02FD-0183
63
ST02FD-04001001-CARB
64
ST02FD-04001003-CARB
65
ST168FD-1070408-CARB
66
ST02FD-1151300C-1
67
ST02FD-1151300D-1
68
GB6182 M10
69
ST177FD-1152300
70
ST02FD-03621001
71
GB96 10
72
GB5782 M10×105
73
504 .200904 .00
74
FM1290
75
ST188FD-1750002-C3
76
ST05FD-03011112
77
ST168FD-1751002-A
78
ST188FD-1750002-C7
79
GB5789 M8×16
80
ST05FD-03020301-60
81
ST188FD-1743002-C
82
GB5789 M8×25
83
ST02FD-02100013-2 .5
84
GB6177 M6
85
GB862 6
86
ST188FD-1020001
87
GB823 M5×38
88
504 .210002 .10
89
ST02FD-05612005
90
ST02FD-05612004
91
WR05-00000000
92
GB823 M5×14
93
EC02
94
ST02FD-05302010
95
2P6
96
DP03-00000000
97
GB823 M4×14
98
GB848 4
99
GB859 4
100 29 .001 .00
101 21 .001000 .02
102 GB5781 M6×22
103 GB6175 M6
104 ST02FD-05502020
105 GB6177 M4
106 ST02FD-05502029
107 ST02FD-05502023
108 ST02FD-05302001-L25
109 ST02FD-05302001-L20
110 OV01-00000000-1
111 504 .210002 .00
112 ST02FD-05212001
113 ST02FD-05212007
114 ST02FD-05212002
115 ST160F-1070007
1
1
1
2
1
6
1
1
1
8
8
8
1
1
1
2
1
1
3
1
1
1
1
4
1
1
1
1
1
2
5
2
1
1
2
1
2
1
2
1
1
1
1
2
2
2
2
2
2
1
2
2
2
1
1
Qty
1
14
Description
Handle
Nut M8
Flange Bolt M8×45
Frame
Canister
Air Cleaner Hose
Clip
Bottom Rubber II
Bottom Rubber I
Nut M10
8” Wheel
Bush 10 .5×58 .5
Flat Washer 10
Bolt M10×105
Rubber Belt
9AH Battery
Battery Red Wire (+)
Jacket
Battery Terminal Cover
Battery Black Wire (–)
Flange Bolt M8×16
Support Leg
Vibration Mount
Flange Bolt M8×25
Earth Line
Nut M6
Washer 6
Grommet
Screw M5×38
Control Box
Indicator Light
Button
Remote Control
Screw M5x14
Charger
FUSE(10A)
Control Panel
Intelliguage
Screw M4x14
Washer 4 mm
Lock Washer 4 mm
Ignition Switch
Battery Switch
Bolt M6×22
Nut M6
Receptacle L5-30R
Nut M4
RV Receptacle
5-20R Receptacle
AC .25A CIRCUIT BREAKERS
AC .20A CIRCUIT BREAKERS
Transition
Control Box
Build Up
Conduit
Build Up
Clip
REV 46539-20101109
20
SPECIfICATIONS
Engine Parts diagram
ENGLISH
46539
21
REV 46539-20101109
46539
ENGLISH
# Part Number Description
1
GB5789--86-FB6-8
2
3
4
ST160F--1061200
ST160F--1061100-Q
ST160F--1061005
5
6
7
ST160F--1061009
ST160F--1061001-A
ST188F--1060006
8
9
ST188F--1060005
GB5789--86-FB6-12
10
ST188F--1060003
11
ST188F--1060004
12
ST188F-1060002
13
168 .080100 .06
14
ST160F--1050010
15
ST160F--1060001
16
ST168F--1080001
17
ST168F--1120100-A
18
ST168F--1080200-A
19
ST168F--1030100
20
GB5789--86-FB6-15
21
ST160F--1030003
22
ST160F--1030004
23
ST168F-2-1030012-G-E
24
GB/T—276--94
25
ST160F--1127000-A
26
ST160F--1110108
27
ST160F--1110101
28
ST160F--1110102
29
ST160F--1110104
30
ST160F--1110103
31
ST160F--1110107
32
ST188FD-1130004
33
ST160F--1110105-A
34
ST168FD-2-1050001-A
35
ST168F--1030008-G
36
ST160F--1030001-B
37
ST160F--1030002
38
GB5789--86-FB8-32
39
ST168F--1110005
40
ST168F--1110007
41
ST160F--1110003
42
GB6177--86
43
ST160F--1110008
Flange Bolt 6X8
Recoil Starter Knob
Recoil Startercomp
Recoil Starter Spring
Recoil Starter Rope
Recoil Starter Reel
Return Spring
Starter Ratchet (Metal)
Flange Bolt M6X12
Ratchet Guide
Ratchet Guide Spring
Setting Screw
Fan Cover Comp
Nut M14
Start Hub
Cooling Fan
Fly Wheel
Side Place (Ii)
Oil Seal
Flange Bolt M6X15
Drain Plug Bolt
Drain Bolt Washer
Crankcase (For Usa)
Radial Ball Bearing 6205
Oil Level Switch Assembly
Governor Washer (Ii)
Governor Weight Holder
Governor Weight Pin
Governor Shaft
Governor Holder Clip
Governor Weight
Clip, String
Governor Cover
Crankshaft Comp
Case Over Packing (No Asbestos)
Oil Filler Cap Assembly
Oil Filler Cap Packing
Flange Bolt 8X32
Throttle Return Spring
Governor Spring
Governor Arm
Nut M6
Lock Pin
44
ST160F--1110001
45
ST168F--1110006
46
ST160F--1110004
47
GB5789--86-FB6-25
48
ST160F--1123000-G
49
152FMD--1001007
50
GB5789--86-FB8-55
51
ST168FD--1090200-G
Governor Arm Shaft
Governor Rod
Governor Arm Bolt
Flange Bolt 6X25
Ignition
Dowel Pin 10X16
Flange Bolt 8X55
Air Cleaner Cover Comp
52
ST168FD--1090004
53
ST168FD--1090003
54
ST168FD--1090002 Air Cleaner Seal
55
ST168FD-1090004-CARB Air Cleaner Case Comp
56
ST160F--1130003-CPE
57
ST168F--1130001-LPG
Element
Separator
Carburetor Packing (No Asbestos)
Carburetor Insulator
58
ST168F--1130002-CPE Insulator Packing (No Asbestos)
1
2
4
1
1
5
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
6
1
1
1
1
2
2
1
2
1
2
1
1
2
2
1
1
2
4
1
1
1
1
1
1
8
1
1
1
2
2
1
1
1
Qty
5
1
# Part Number Description
59
ST168FD--1010001-A
60
ST168F-2-1010100-G
61
ST168F-2-1030009-G
62
ST168F--1040002
63
ST168F--1040006
64
ST168F-2-1040013
65
ST168F-2-1041000
66
ST168F--1030015-G
Stud Bolt 6X95
Cylinder Head Comp
Cylinder Head Gasket
Intake Valve
Exhaust Valve
Valve Lifter
Camshaft Assembly
Dowel Pin 9X14
67
ST168FD-1080200-CARB Shroud Comp
68
GB1099--79 Key
69
ST168FD--1030007-G
70
ST168F--1050100
Crankcase Cover
Connecting Rod Comp
Piston Pin
71
ST168F--1050003
72
ST168F--1050004
73
ST168F-2-1050005
74
ST168F--1050007
ST168F--1050006
Piston Pin Clip
Piston
First Ring Set
Second Ring Set
ST168F--1050200 Ring Comp
75
ST168F--1080002-GC
76
GB900--88
77
ST168F--1040005
78
ST168--1040014-A
79
ST168F--1040027
80
ST168F--1040026
81
GB6177--86-N6
82
ST168F--1040023
83
ST160F--1020001
84
ST168F--1020100-C
85
ST160F--1020002-A
86
ST168F--1040024
87
ST168F--1040025
88
ST168F--1040022
89
ST168F--1040021
90
ST160F--1040008
Shroud Comp (I)
Stud Bolt
Push Rod
Oil Seal
Pivot Bolt
Valve Rocker Arm
Nut M6
Exhaust Rocker
Breather Tube
Head Over Comp
Head Over Packing
Rectify Bolt
Locknut
Entrance Rocker
Rocker Axes
Valve Rotator
91
ST160F--1040001
92
ST160F--1040007
93
ST160F--1040003
94
F6RTC
Intake Valve Spring Retainer
Exhaust Valve Spring Retainer
Valve Spring
Spark Plug
95
468 .131000 .02
96
0902 .130010 .00
Carburetor
Spring
97
168 .130015 .01
Connector, Starter
98
ST168FD--1130005-CPE Packing
99
168 .130005 .01
Support,Stepper Motor
Stepper Motor Comp
100 188 .132200 .00
101 GB818 M4×8
102 0902 .132001 .00
Screw M4×8
Cover, Stepper Motor
Electrify Coil
103 ST188F-1123000
104 ST168F-1180104
105 ST168F-1180002
Grommet
Wire Flat
Flange Bolt 6X29
106 GB5789--86-FB6-29
107 ST168F-1180001
108 ST168F-1181100
Dowel Pin 8×10
Start Motor
109 GB29 .2-88-FB5-16
GB93-87-SW5
Flange Bolt M5×16
Spring Washer 5 mm
Relay
110 168 .125200 .01
111 ST188FD-1070006-A
112 168 .070900 .01
Clip
Pipe
2
2
2
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
2
1
1
1
1
2
2
1
1
1
1
1
2
1
2
2
2
1
1
2
1
1
1
1
1
1
1
1
2
2
1
2
1
1
1
Qty
2
1
REV 46539-20101109
22
SPECIfICATIONS
Wiring diagram
ENGLISH
46539
23
REV 46539-20101109
46539
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 46539-20101109
24
ENGLISH
46539
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
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free:1 (877) 338-0999
Fax no .: 1 (562) 236-9429
Technical Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1 (877) 338-0999 tech@championpowerequipment .com
24/7 Tech Support: (562) 204-1188
25
REV 46539-20101109
46539
ENGLISH
WARRANTy
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 2010 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 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.
ATTN: 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 46539-20101109
26
ENGLISH
46539
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 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 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 .
27
REV 46539-20101109
46539
ENGLISH
WARRANTy
EMISSION-RELATEd PARTS INCLudE THE fOLLOWING
(using those portions of the list applicable to the engine)
:
Systems covered by this warranty
Fuel Metering System
Air Induction System
Ignition System
Exhaust System
Miscellaneous Parts
Evaporative Emissions
Parts Description
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.
ATTN: Customer Service
10006 Santa Fe Springs Road
Santa Fe Springs, CA 90670
Tel: 1-877-338-0999
REV 46539-20101109
28
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