Champion Power Equipment 6500-Watt Gasoline Powered Manual Start Portable Generator Owner's Manual
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OWNER’S MANUAL & OPERATING INSTRUCTIONS
8125 Starting Watts / 6500 Rated Watts
Recoil Start
PORTABLE GENERATOR
SAVE THESE INSTRUCTIONS
Important Safety Instructions are included in this manual.
MODEL NUMBER 100109
MADE IN CHINA
REV 100109-20150127
12039 Smith Ave.
Santa Fe Springs CA 90670
USA / 1-877-338-0999 www.championpowerequipment.com
AN IMPORTANT MESSAGE ABOUT TEMPERATURE:
Your Champion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to
40°C (104°F). When your product is needed your product may be operated at temperatures ranging from -15°C (5°F) to
50°C (122°F) for short periods. If the product is exposed to temperatures outside this range during storage, it should be brought back within this range before operation. In any event, the product must always be operated outdoors, in a well-ventilated area and away from doors, windows and other vents.
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
WARNING:
The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
*We are always working to improve our products. Therefore, the enclosed product may differ slightly from the image on the cover.
100109
8125 Starting Watts / 6500 Rated Watts
Recoil Start
PORTABLE GENERATOR
TABLE Of CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Controls and Features . . . . . . . . . . . . . . . . . . . . . .
5
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Parts Included . . . . . . . . . . . . . . . . . . . . . . . . .
6
Wheel Kit . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Remove the Generator from the Shipping Carton . .
7
Install the Wheel Kit . . . . . . . . . . . . . . . . . . . . .
7
Install the Support Leg . . . . . . . . . . . . . . . . . . .
7
Install the Handle . . . . . . . . . . . . . . . . . . . . . . .
7
Add Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . .
8
Add Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Generator Location . . . . . . . . . . . . . . . . . . . . .
10
Surge Protection . . . . . . . . . . . . . . . . . . . . . . .
10
Starting the Engine . . . . . . . . . . . . . . . . . . . . .
10
Connecting Electrical Loads . . . . . . . . . . . . . . .
11
Stopping the Engine . . . . . . . . . . . . . . . . . . . .
11
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Do Not Overload Generator . . . . . . . . . . . . . . . .
11
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Power Management . . . . . . . . . . . . . . . . . . .
11
Operation at High Altitude . . . . . . . . . . . . . . . .
12
Maintenance and Storage . . . . . . . . . . . . . . . . . . .
13
Engine Maintenance . . . . . . . . . . . . . . . . . . . .
13
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . .
13
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Spark Arrester . . . . . . . . . . . . . . . . . . . . . .
14
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Adjustments . . . . . . . . . . . . . . . . . . . . . . . .
14
Maintenance Schedule . . . . . . . . . . . . . . . .
14
Generator Maintenance . . . . . . . . . . . . . . . . . .
15
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Generator Storage . . . . . . . . . . . . . . . . . . . .
15
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Engine Specifications . . . . . . . . . . . . . . . . . . .
16
Generator Specifications . . . . . . . . . . . . . . . . .
16
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Maintenance Valve Clearance . . . . . . . . . . . . . .
16
An Important Message About Temperature . . . .
16
Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . .
17
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Engine Parts Diagram . . . . . . . . . . . . . . . . . . .
19
Engine Parts List . . . . . . . . . . . . . . . . . . . . . .
20
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . .
21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
Warranty Qualifications . . . . . . . . . . . . . . . . . .
23
Repair/Replacement Warranty . . . . . . . . . . . . . .
23
Do Not Return The Unit To
The Place Of Purchase . . . . . . . . . . . . . . . . . .
23
Warranty Exclusions . . . . . . . . . . . . . . . . . . . .
23
Normal Wear . . . . . . . . . . . . . . . . . . . . . . .
23
Installation, Use and Maintenance . . . . . . . .
23
Other Exclusions . . . . . . . . . . . . . . . . . . . . .
23
Limits of Implied Warranty and Consequential Damage . . . . . . . . . . . . .
23
Contact Information . . . . . . . . . . . . . . . . . . . . . 23
Address . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
Customer Service . . . . . . . . . . . . . . . . . . . .
23
Technical Service . . . . . . . . . . . . . . . . . . . .
23
1
ENGLISH 100109
INTRODUCTION
Introduction
Congratulations on your purchase of a Champion Power Equipment product. Champion Power Equipment and
Champion Engine Technology designs, builds, and supports all of our products to strict specifications and guidelines.
With proper product knowledge, safe use, and regular maintenance, this product should bring years of satisfying service.
Every effort has been made to ensure the accuracy and completeness of the information in this manual, and we reserve the right to change, alter and/or improve the product and this document at any time without prior notice.
Since CPE/CET highly value how our products are designed, manufactured, operated and are serviced, and also highly value your safety and the safety of others, we would like you to take the time to review this product manual and other product materials thoroughly and be fully aware and knowledgeable of the assembly, operation, dangers and maintenance of the product before use. Fully familiarize yourself, and make sure others who plan on operating the product fully familiarize themselves too, with the proper safety and operation procedures before each use. Please always exercise common sense and always error on the side of caution when operating the product to ensure no accidents, property damage, or injury occurs. We want you to continue to use and be satisfied with your CPE/CET product for years to come.
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
100109
Serial Number
Date of Purchase
Purchase Location
For Oil Type see ‘Add Engine Oil‘ section. For Fuel Type see ‘Add Fuel‘ section.
100109 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
2
3
ENGLISH 100109
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 3 ft. (91.4 cm) of clearance on all sides to ensure adequate cooling.
Maintain at least 5 ft. (1.5 m) of clearance from combustible materials.
WARNING
Medical and Life Support Uses.
In case of emergency, call 911 immediately.
NEVER use this product to power life support devices or life support appliances.
NEVER use this product to power medical devices or medical appliances.
Inform your electricity provider immediately if you or anyone in your household depends on electrical euipment to live.
Inform your electrical provider immediately if a loss of power would cause you or anyone in your household to experience a medical emergency.
100109 ENGLISH
DANGER
Fuel and fuel vapors are highly flammable and extremely explosive.
Fire or explosion can cause severe burns or death.
Unintentional startup can result in entanglement, traumatic amputation or laceration.
When adding or removing fuel:
Turn the generator off and let it cool for at least two minutes before removing the fuel cap. Loosen the cap slowly to relieve pressure in the tank.
Only fill or drain fuel outdoors in a well-ventilated area.
DO NOT pump gas directly into the generator at the gas station. Use an approved container to transfer the fuel to the generator.
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
4
5
ENGLISH 100109
CONTROLS AND fEATURES
Read this owner’s manual before operating your generator. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference.
Generator
1
2
3
4
8
6 7
5
(1) Fuel Tank – 7.7 gal. (29 L) capacity fuel tank.
(2) Choke – Used to start the engine.
(3) 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) Power Panel – See “Power Panel” section.
(8) Handle
100109 ENGLISH
Power Panel
1 2 3
CONTROLS AND fEATURES
(1) Engine Switch – Used to turn the generator on and off.
(2) Intelligauge with Power Meter – Five mode digital meter for displaying running hours, total time, voltage, hertz and wattage output.
(3) Circuit Breakers – Protects the generator against electrical overloads. Push to reset breaker.
4 5 6
(4) Ground Terminal – Consult an electrician for local grounding regulations.
(5) 120/240 Volt AC, 30 Amp Twist-Lock Receptacle
(NEMA L14-30R) – May be used to supply electrical power for the operation of 120/240 Volt AC, single phase 60 Hz electrical loads.
(6) 120 Volt AC, 20 Amp Duplex (2)
(GFCI 5-20R) – May be used to supply electrical power for the operation of 120 Volt AC single phase
60 Hz electrical loads.
Parts Included
Your 100109 Gasoline Powered Generator ships with the following parts:
Wheel Kit
– 9.5 in. Wheel . . . . . . . . . . . . . . . . . . . . . . . . . .
2
– Flange Bolt (M10x110 for Wheel) . . . . . . . . . . . .
2
– Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
– Flat Washer
Ø
10 . . . . . . . . . . . . . . . . . . . . . . . .
2
– Lock Nut (M10) . . . . . . . . . . . . . . . . . . . . . . . .
2
– Support Leg (w/vibration mounts) . . . . . . . . . . . .
1
– Flange Bolt (M8x16 for Support Leg) . . . . . . . . . .
2
– Flange Lock Nut (M8) . . . . . . . . . . . . . . . . . . . .
2
Other
– Oil Funnel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
– Oil . . . . . . . . . . . . . . . . . . . . . . . .
1.2 qt. (1.1 L)
6
7
ENGLISH 100109
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 flange bolt (M8x16) and flange 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)
1. Before adding fuel and oil, tip the generator on it’s side.
2. Slide the M10x110 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 lock nut.
5. Repeat steps 2-4 to attach the second wheel.
100109 ENGLISH
Add Engine Oil
CAUTION
DO NOT attempt to crank or start the engine before it has been properly filled with the recommended type and amount of oil. Damage to the generator as a result of failure to follow these instructions will void your warranty.
NOTE
The generator rotor has a sealed, pre-lubricated ball bearing that requires no additional lubrication for the life of the bearing.
NOTE
The recommended oil type is 10W-30 automotive oil.
1. Place the generator on a flat, level surface.
ASSEMBLy
Add Engine Oil Cont’d.
NOTE
Check oil often during the break-in period. Refer to the
Maintenance section for recommended service intervals.
CAUTION
The engine is equipped with a low oil shut-off and will stop when the oil level in the crankcase falls below the threshold level.
NOTE
We consider the first 5 hours of run time to be the break-in period for the unit. During the break in period stay at or below 50% of the running watt rating and vary the load occasionally to allow stator windings to heat and cool. Adjusting the load will also cause engine speed to vary and help seat piston rings. After the 5 hour break-in period, change the oil.
Degrees Celsiusº (Outside)
Full Synthetic 5W-30
2. Remove oil fill cap/dipstick to add oil.
3. Add up to 1.2 qt. (1.1 L) of oil (included) and replace oil fill cap/dipstick. DO NOT OVERFILL.
4. Check engine oil level daily and add as needed.
NOTE
Once oil has been added, a visual check should show oil about 1-2 threads from running out of the fill hole.
If using the dipstick to check oil level, DO NOT screw in the dipstick while checking.
Degrees Fahrenheitº (Outside)
NOTE
Weather will affect engine oil and engine performance. Change the type of engine oil used based on weather conditions to suit the engine needs.
NOTE
Synthetic oil may be used after the 5 hour initial break-in period. Using synthetic oil does not increase the recommended oil change interval.
8
9
ENGLISH 100109
ASSEMBLy
Add fuel
1. Use clean, fresh, regular unleaded fuel with a minimum octane rating of 85 and an ethanol content of less than 10% by volume.
2. DO NOT mix oil with fuel.
3. Clean the area around the fuel cap.
4. Remove the fuel cap.
5. Slowly add fuel to the tank. DO NOT OVERFILL.
Fuel can expand after filling. A minimum of
¼ in. (6.4 mm) of space left in the tank is required for fuel expansion, more than ¼ in. (6.4 mm) is recommended. Fuel can be forced out of the tank as a result of expansion if it is overfilled, and can affect the stable running condition of the product. When filling the tank, it is recommended to leave enough space for the fuel to expand.
Add fuel Cont’d.
NOTE
Our engines work well with 10% or less ethanol blend fuels. When using blended fuels there are some issues worth noting:
– Ethanol-gasoline blends can absorb more water than gasoline alone.
– These blends can eventually separate, leaving water or a watery goo in the tank, fuel valve and carburetor.
– With gravity-fed fuel supplies, this compromised fuel can be drawn into the carburetor and cause damage to the engine and/or potential hazards.
– There are only a few suppliers of fuel stabilizer that are formulated to work with ethanol blend fuels.
– Any damages or hazards caused by using improper fuel, improperly stored fuel, and/ or improperly formulated stabilizers, are not covered by manufacture’s warranty.
It is advisable to always shut off the fuel supply, run the engine to fuel starvation and drain the tank when the equipment is not in use for more than 30 days.
6. Screw on the fuel cap and wipe away any spilled fuel.
CAUTION
Use regular unleaded gasoline with a minimum octane rating of 85.
Do not mix oil and gasoline.
Fill tank to approximately ¼ in. (6.4 mm) below the top of the tank to allow for fuel expansion.
DO NOT pump gas directly into the generator at the gas station. Use an approved container to transfer the fuel to the generator.
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.
WARNING
Pouring fuel too fast through the fuel screen may result in blow back of fuel at the operator while filling.
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.
100109 ENGLISH
OPERATION
Generator Location
NEVER operate the generator inside any building, including garages, basements, crawlspaces and sheds, enclosure or compartment, including the generator compartment of a recreational vehicle. 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. Generators should be on a flat, level surface at all times. (Even while not in operation) Generators must have at least 5 ft. (1.5 m) of clearance from all combustible material. In addition to clearance from all combustible material, generators must also have at least 3 ft. (91.4 cm) of clearance on all sides to allow for adequate cooling, maintenance and servicing.
Generators should never be started or operated in the back of a SUV, camper, trailer, in the bed of a truck
(regular, flat or otherwise), under staircases/stairwells, next to walls or buildings, or in any other location that will not allow for adequate cooling of the generator and/or the muffler. DO NOT contain generators during operation. Allow generators to properly cool before transport or storage.
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.
Failure to follow proper safety precautions may void manufacturer’s warranty.
WARNING
Do not operate or store the generator in rain, snow, or wet weather.
Using a generator or electrical appliance in wet conditions, such as rain or snow, or near a pool or sprinkler system, or when your hands are wet, could result in electrocution.
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.
Starting the Engine
1. Make certain the generator is on a flat, level surface.
2. Disconnect all electrical loads from the generator.
Never start or stop the generator with electrical devices plugged in or turned on.
3. Turn the fuel valve to the “ON” position.
4. Flip the engine switch to the “ON” position.
5. Move the choke lever to the “CHOKE” position.
6. Pull the starter cord slowly until resistance is felt and then pull rapidly
7. Do not over-choke. As as soon as engine starts, move the choke lever to the “RUN” position.
NOTE
Keep choke lever in “Choke” position for only 1 pull of the recoil starter. After first pull, move choke lever to the “Run” position for up to the next 3 pulls of the recoil starter. Too much choke leads to sparkplug fouling/engine flooding due to the lack of incoming air. This will cause the engine not to start.
WARNING
During operation the muffler and exhaust fumes produced will become hot. If adequate cooling and breathing space are not supplied, or if the generator is blocked or contained, temperatures can become extremely heated and may lead to fire.
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.
10
11
ENGLISH 100109
OPERATION
Connecting Electrical Loads
1. Let the engine stabilize and warm up for a few minutes after starting
2. Plug in and turn on the desired 120/240 Volt AC single phase, 60 Hz electrical loads.
– DO NOT connect 3-phase loads to the generator.
– DO NOT connect 50 Hz loads to the generator.
– DO NOT overload the generator.
NOTE
Connecting a generator to your electric utility company’s power lines or to another power source may be against the law. In addition this action, if done incorrectly, could damage your generator and appliances and could cause serious injury or even death to you or a utility worker who may be working on nearby power lines. If you plan to run a portable electric generator during an outage, please notify your electric utility company immediately and remember to plug your appliances directly into the generator. Do not plug the generator into any electric outlet in your home. Doing so could create a connection to the utility company power lines. You are responsible for ensuring that your generator’s electricity does not feed back into the electric utility power lines.
If the generator will be connected to a building electrical system, consult your local utility company or a qualified electrician. Connections must isolate generator power from utility power and must comply with all applicable laws and codes.
Stopping the Engine
1. Turn off 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. Turn the fuel valve to the “OFF” position.
4. Let the engine run until fuel starvation has stopped the engine. This usually takes a few minutes.
5. Press the engine switch to the “OFF” position.
Important: Always ensure that the fuel valve and the engine switch are in the “OFF” position when the engine is not in use.
NOTE
If the engine will not be used for a period of two (2) weeks or longer, please see the Storage section for proper engine and fuel storage.
Grounding
The generator system ground connects the frame to the ground terminals on the power panel. The system ground is connected to the AC neutral wire.
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.
100109 ENGLISH
OPERATION
Operation at High Altitude
The density of air at high altitude is lower than at sea level. Engine power is reduced as the air mass and airfuel ratio decrease. Engine power and generator output will be reduced approximately 3½% for every 1000 feet of elevation above sea level. This is a natural trend and cannot be changed by adjusting the engine. At high altitudes increased exhaust emissions can also result due to the increased enrichment of the air fuel ratio.
Other high altitude issues can include hard starting, increased fuel consumption and spark plug fouling.
To alleviate high altitude issues other than the natural power loss, Champion Power Equipment can provide a high altitude carburetor main jet. The alternative main jet and installation instructions can be obtained by contacting Customer Support. Installation instructions are also available in the Technical Bulletin area of the
Champion Power Equipment internet site.
The part number and recommended minimum altitude for the application of the high altitude carburetor main jet is listed in the table below.
In order to select the correct high altitude main jet it is necessary to identify the carburetor model. For this purpose, a code is stamped on the side of the carburetor. Select the correct main jet part number corresponding to the carburetor code found on your particular carburetor.
Carburetor
Code
Main Jet Part Number
P27-2-H
P27-2-Z
Standard
Altitude
Standard
Altitude
46.131017.20.H
46.131017.20.01.H
46.131017.20.Z
46.131017.20.01.Z
Altitude
5000 Feet
(1524 Meters)
WARNING
Operation using the alternative main jet at elevations lower than the recommended minimum altitude can damage the engine. For operation at lower elevations, the standard main jet must be used. Operating the engine with the wrong engine configuration at a given altitude may increase its emissions and decrease fuel efficiency and performance.
GfCI
Your generator is equipped with two (2) Ground Fault
Circuit Interrupter (GFCI) duplexes. In the event of a ground fault, a GFCI trips automatically to stop the flow of electricity and prevent serious injury. The green indicating light on the receptacle will also turn off. Press the reset button located on the front of the receptacle to restore flow of electricity. (A) The green indicating light will also turn back on. GFCI does not protect against circuit overloads.
A
To ensure proper operation of the GFCI duplex, perform this test monthly:
1. With the generator running, plug a lamp into the
GFCI receptacle. Turn the lamp on.
2. Press the “Test” button located on the front of the receptacle to trip the device. (A) This should immediately stop the flow of electricity and shut off the lamp. If the electricity is not stopped, do not use this receptacle until is has been serviced or replaced.
3. Press the “Reset” button located on the front of the receptacle to restore the flow of electricity. If the indicator light does not go out and come back on or if the GFCI cannot be reset then it must be replaced.
WARNING
For the GFCI receptacles to work properly the neutral wire must be bonded to ground or to the generator frame. Your
Champion generator comes with the neutral wire already bonded to the frame. If the bonding wire is removed then the GFCI receptacles will no longer function as designed.
If the neutral bonding wire is removed to accommodate a transfer switch installation for connection to a house or building, then the transfer switch must not switch off the neutral connection to ground within the building.
Champion Power Equipment recommends that you consult with a licensed, local electrician. Due to the variety of local codes, we cannot specifically advise you regarding modifications to the wiring of your portable generator.
12
ENGLISH 100109
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 fill 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.
13
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 (not included) 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 - 0.8 mm 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 specification 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 fill cap/dipstick to add oil.
5. Add up to 1.2 qt. (1.1 L) of oil and replace oil fill cap/dipstick. DO NOT OVERFILL.
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 (not included) to firmly install the plug.
8. Attach the spark plug wire to the plug.
Air filter
1. Remove the snap-on cover holding the air filter 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 filter in the assembly.
7. Reattach the air filter cover and snap in place.
100109 ENGLISH
MAINTENANCE AND STORAGE
Spark Arrester
1. Allow the engine to cool completely before servicing the spark arrester.
2. Remove the three (3) screws holding the cover plate which retains the end of the spark arrester to the muffler.
3. Remove the spark arrester screen.
4. Carefully remove the carbon deposits from the spark arrester screen with a wire brush.
5. Replace the spark arrester if it is damaged.
6. Position the spark arrester in the muffler and attach with the three (3) screws.
CAUTION
Failure to clean the spark arrester will result in degraded engine performance.
NOTE
Federal and local laws and administrative requirements indicate when and where spark arresters are required. When ordered, spark arresters are required for operation of this generator in National Forest lands. In California, this generator must not be used on any forest-covered land, brush-covered land, or grass-covered land unless the engine is equipped with a spark arrester.
Cleaning
CAUTION
DO NOT spray engine with water.
Water can contaminate the fuel system.
Use a damp cloth to clean exterior surfaces of the engine.
Use a soft bristle brush to remove dirt and oil.
Use an air compressor (25 PSI) to clear dirt and debris from the engine.
Adjustments
The air-fuel mixture is not adjustable. Tampering with the governor can damage your generator and your electrical devices and will void your warranty. CPE recommends that you contact our service line at
1-877-338-0999 for all other service and/or adjustment needs.
Maintenance Schedule
Follow the service intervals indicated in the following maintenance schedule.
Service your generator more frequently when operating in adverse conditions.
Contact our helpline at 1-877-338-0999 to locate the nearest Champion Power Equipment certified service dealer for your generator or engine maintenance needs.
Every 8 hours or daily
Check oil level
Clean around air intake and muffler
First 5 Hours
Change oil
Every 50 hours or every season
Clean air filter
Change oil if operating under heavy load or in hot environments
Every 100 hours or every season
Change oil
Clean/Adjust spark plug
Check/Adjust valve clearance*
Clean spark arrester
Clean fuel tank and filter*
Every 250 hours
Clean combustion chamber*
Every 3 years
Replace fuel line
*To be performed by knowledgeable, experienced owners or
Champion Power Equipment certified dealers.
14
15
ENGLISH 100109
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. Add a properly formulated fuel stabilizer to the tank.
2. Be sure all appliances are disconnected from the generator.
3. Run the generator for a few minutes so the treated fuel cycles through the fuel system and carburetor.
4. Turn the fuel valve to the “Off” position.
5. Let the generator run until fuel starvation has stopped the engine. This usually takes a few minutes.
6. The generator needs to cool completely before cleaning and storage.
7. Clean the generator according to the maintenance section.
8. Change the oil.
9. Remove the spark plug and pour about 1⁄2 ounce
(14.8 ml) of oil into the cylinder. Crank the engine slowly to distribute the oil and lubricate the cylinder.
10. Reattach the spark plug.
11. Store the unit in a clean, dry place out of direct sunlight.
Generator Storage Cont’d.
NOTE
Our engines work well with 10% or less ethanol blend fuels. When using blended fuels there are some issues worth noting:
– Ethanol-gasoline blends can absorb more water than gasoline alone.
– These blends can eventually separate, leaving water or a watery goo in the tank, fuel valve and carburetor.
– With gravity-fed fuel supplies, this compromised fuel can be drawn into the carburetor and cause damage to the engine and/or potential hazards.
– There are only a few suppliers of fuel stabilizer that are formulated to work with ethanol blend fuels.
– Any damages or hazards caused by using improper fuel, improperly stored fuel, and/ or improperly formulated stabilizers, are not covered by manufacture’s warranty.
It is advisable to always shut off the fuel supply, run the engine to fuel starvation and drain the tank when the equipment is not in use for more than 30 days.
DANGER
Generator exhaust contains odorless and colorless carbon monoxide gas.
To avoid accidental or unintended ignition of your generator during periods of storage, the following precautions should be followed:
– When storing the generator for short or extended
periods of time make sure that the Engine
Switch and the Fuel Valve are set in the OFF position.
100109 ENGLISH
SPECIfICATIONS
Engine Specifications
– Model . . . . . . . . . . . . . . . . . . . . . .
YF188FD-011
– Displacement . . . . . . . . . . . . . . . . . . . . . . .
389cc
– Type . . . . . . . . . . . . . . . . . . . . . . . .
4-Stroke OHV
– Start Type . . . . . . . . . . . . . . . . . . . . . . . . .
Recoil
Generator Specifications
– Model . . . . . . . . . . . . . . . . . . . . . . . . . . .
100109
– Rated Wattage . . . . . . . . . . . . . . . . . .
6500 Watts
– Starting Wattage . . . . . . . . . . . . . . . . .
8125 Watts
– AC Load . . . . . . . . . . . . . . . . . . . . . .
120/240 V
– Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single
– Frequency . . . . . . . . . . . . . . . . . . . . . . . . .
60 Hz
– Fuel Capacity . . . . . . . . . . . . . . . . .
7.7 gal. (29 L)
– Gross Weight . . . . . . . . . . . . . . .
185.2 lb. (84 kg)
– Net Weight . . . . . . . . . . . . . . . .
173.7 lb. (78.8 kg)
– Height . . . . . . . . . . . . . . . . . . .
26.6 in. (67.6 cm)
– Width . . . . . . . . . . . . . . . . . . .
27.6 in. (70.1 cm)
– Length . . . . . . . . . . . . . . . . . . . . .
27.6 in. (70 cm)
fuel
Fuel capacity is 7.7 gal. (29 L). Use regular unleaded gasoline with a minimum octane rating of 85 and an ethanol content of less than 10% by volume.
Oil
Use 10W-30 automotive oil.
Oil capacity is up to 1.2 qt. (1.1 L).
DO NOT OVERFILL.
Please reference the following chart for recommended oil types for use in the generator.
Degrees Celsiusº (Outside)
Spark Plugs
OEM spark plug: NHSP F6RTC
Replacement spark plug: NGK BPR6ES or equivalent
Make certain the spark plug gap is 0.7 - 0.8 mm or
(0.028 - 0.031 in.).
Maintenance Valve Clearance
– Intake: 0.13 – 0.17 mm (0.005 – 0.007 in.)
– Exhaust: 0.18 – 0.22 mm (0.007 – 0.009 in.)
Note: Tech bulletin regarding the valve adjustment procedure is on www.championpowerequipment.com.
An Important Message About Temperature
Your Champion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to 40°C (104°F). When your product is needed your product may be operated at temperatures ranging from -15°C (5°F) to 50°C (122°F) for short periods. If the product is exposed to temperatures outside this range during storage, it should be brought back within this range before operation. In any event, the product must always be operated outdoors, in a well-ventilated area and away from doors, windows and other vents.
Full Synthetic 5W-30
Degrees Fahrenheitº (Outside)
NOTE
Weather will affect engine oil and engine performance. Change the type of engine oil used based on weather conditions to suit the engine needs.
16
17
SPECIfICATIONS
Parts Diagram
9 10
25 26 27
ENGLISH 100109
100109 ENGLISH
31 1.9074.4.0510
32 1.16674.0825
33 152.190300.00
34 122.190004.01
35 1.93.05
36 1.5783.0520
37 122.190400.00
38 152.190003.00.48
39 1.16674.0512.2
40 1.5783.0516
41 1.97.1.05
42 1.16674.0516
43 153.190200.03
44 152.190002.00
45 2.08.032
46 1.97.1.06
47 2.08.035
48 1.6175.05
49 152.191002.00
50 152.191200.27
51 2.08.034
52 1.7244.10
53 1.96.10
# Part Number
1 2.06.006
2 2.05.001
3 152.070014.05
4 152.070013.03
5 2.06.004
6 1.5789.0608
7 152.070018.02
8 152.070702.06
9 152.070700.02
10 1.16674.0812
11 152.070702.05
12 122.070100.07
13 122.070300.03
14 24.070800.00
15 1.5789.0620.1
16 1.93.06
17 2.03.004.1
18 122.070015.01
19 152.071000.40.48
20 122.070400.05
21 2.06.007
22 152.070011.07
23 45.090006.20
24 1.6177.1.06
25 1.848.08
26 1.93.08
27 1.6175.08
28 46.100001.07
29 46.101000.00.2
30 46.101300.00
Description
Clamp ø7 x 1
Clamp ø8 x 6.5
Pipe, Reversal Valve 810 mm
Pipe, Air Cleaner, 135mm
Clamp ø8 x 1
Flange Bolt M6 x 8
Board, Heat Insulation
Support Arm, Top
Carbon Canister, 650cc
Flange Bolt M8 x 12
Support Arm, Bottom
Fuel Tank Cap
Fuel Filter Assembly
Reversal Valve
Flange Bolt M6 x 20, Black
Lock Washer ø6
Washer ø24 x ø6.5 x 1.5, Black
Mount Vibration, Fuel Tank
Fuel Tank, Yellow
Fuel Valve
Clamp ø8 x b6
Pipe, Fuel 7.6 in.
Holder, Air Cleaner
Nut M6, Flange Lock
Washer ø8
Lock Washer ø8
Nut M8
Gasket, Exhaust
Muffler Assembly
Spark Arrester Assembly
Screw/Washer Assembly
M5 x 10
Flange Bolt M8 x 25
Carbon Brush Assembly
Brush Holder
Lock Washer ø5
Bolt M5 x 20
Terminal Block
Generator End Cover, Yellow
Flange Bolt M5 x 12
Bolt M5 x 16
Washer ø5
Flange Bolt M5 x 16
AVR, Large
End Housing
Flange Bolt M6 x 179
Washer ø6
Bolt M5 x 214
Nut M5
Stator Cover
Stator Assembly, Al, 140 mm,
NO DC , CSA
Flange Bolt M10 x 265
Lock Washer ø10
Washer ø10, Flat
Qty
2
2
2
2
2
1
1
1
2
1
1
1
4
1
8
4
1
4
1
1
1
1
1
3
1
2
1
2
1
1
3
4
2
1
4
2
1
3
1
2
4
1
2
1
1
1
5
2
1
1
1
1
3
# Part Number
54 152.191100.26
55 152.192300.01
56 152.190005.00
57 152.190005.01
58 46.401
59 5.1900.026
60 1.5789.0612
61 1.862.06
62 1.894.1.10
63 152.200703.04
64 1.894.1.08
65 152.200703.02
66 152.200701.02.2
67 152.200702.02
68 6.5.245.402.2
69 1.6177.1.10
70 152.201200.03
71 1.5782.10110
72 122.200016.01
73 152.201701.09.1
74 1.6182.10
75 152.201200.04
76 1.6177.1.08
77 1.5789.0816
78 152.200002.01.2
79 152.201400.00
80 1.5789.0825
81 152.20.1.2
82 1.5783.0622.3
83 1.6175.06.3
84 1.97.1.06.3
85 1.93.06.3
86 1.9074.4.0514.1
87 5.1120.050
88 5.1120.009
89 5.1870.005
90 5.1870.003
91 5.1000.004.3
92 5.1440.002
93 1.823.0514
94 5.1210.925
95 5.1210.920
96 1.6177.1.04.1
97 5.1810.001
98 152.210002.21
99 1.5789.0615.1
100 122.210003.01
101 5.1330.018
102 152.210003.02
103 100109.21.10
104 100109.21
Qty
1
2
2
2
1
1
2
2
2
1
2
8
2
2
2
2
4
2
1
1
2
1
2
2
2
2
1
1
1
1
1
1
5
Description
Rotor Assembly, Al, 140 mm,
NO DC , CSA
Air Guide
Rubber 1, Fore-Cover
Rubber 2, Fore-Cover
Engine
Grounding Line 150 mm
Flange Bolt M6 x 12
Lock Washer ø6
Circlip ø10
Long Pin, Handle
Circlip ø8
Pin, Handle
Handle, U Shape
Cover, Handle
Frame
Nut M10, Flange Lock
Motor Mount, I
Bolt M10 × 110
Bushing ø16 x 10.5 x 59
9.5 in. Wheel, Black
Lock Nut M10
Motor Mount, II
Nut M8, Flange Lock
Flange Bolt M8 x 16
Support Leg, 84MM
Rubber, Support
Flange Bolt M8 x 25
Control Panel, Black
Bolt 6 x 22, Green
Nut M6, Green
Washer ø6, Green
Lock Washer ø6, Green
Screw/Washer Assembly
M5 x 14, Black
Receptacle 5-20R Duplex,
GFCI
Receptacle L14-30R
Receptacle Cover, Receptacle
5-20R, Duplex, GFCI
Receptacle Cover, Receptacle
L14-30R
Ignition Switch, Red
Intelligauge, Power meter
Screw M5 x 14
25 Amp Circuit Breaker
20 Amp Circuit Breaker
Nut M4, Flange Lock, Black
Over Voltage Protector
Control Box
Flange Bolt M6 x 15, Black
Wire Jacket, Control Box
Sheath, Wire, ø16 x 250mm
Plug, Control Box
Wire Assembly
Control Panel Assembly
2
1
2
1
1
1
1
1
1
1
4
6
1
2
2
1
1
3
18
19
SPECIfICATIONS
Engine Parts Diagram
ENGLISH 100109
100109 ENGLISH
# Part Number
1 21.061300.00
2 1.5789.0608
28 1.276.6202
29 47.050006.00
30 45.050100.14
31 46.030008.00
32 2.04.001
33 46.080600.00
34 1.276.6207
35 46.031000.01.48
36 45.030007.00
37 1.5789.0840.0.8
38 2.03.021.1
39 45.110013.00
40 45.110100.00
41 21.110011.00
42 45.110012.00
43 47.050200.00
44 46.050005.00
45 2.09.004
46 45.050003.00
47 45.050303.00
48 46.050302.00
49 46.050301.00
50 2.04.004
51 46.030009.01
52 46.080400.00
53 46.010100.00
54 2.01.010
3 46.061100.00.2
4 45.060005.00
5 45.061102.00
6 2.10.003
7 45.060003.00
8 45.060002.00
9 45.060009.00
10 45.060007.00
11 45.060008.00
12 1.5789.0612
13 2.05.005
14 46.080100.01.48
15 2.02.007
16 1.5789.0629
17 45.060001.00
18 46.123000.03
19 45.080001.00
20 46.120100.03
21 2.11.007
22 2.05.050
23 45.030032.00
24 2.03.023
25 46.030100.01
26 45.127000.02
27 1.5789.0615
Description
Recoil Handle
Flange Bolt M6 x 8
Recoil Starter Cover, Black
Recoil Starter Spring
Recoil Starter Reel
Rope ø5 x 1550
Spring, Ratchet
Starter Ratchet (Iron)
Spring Guide, Ratchet
Ratchet Guide
Screw, Ratchet Guide
Flange Bolt M6 x 12
Clamp ø6
Cover, Fan, Yellow
Nut M16 x 1.5
Flange Bolt M6 x 29
Pulley, Starter
Ignition Coil
Cooling Fan
Flywheel ( EPA)
Oil Seal ø35 x ø52 x 8
Wire Clip, 100 mm
Sheath, Wire
Washer ø12.5 x ø20 x 2
Crankcase
Oil Level Sensor
Flange Bolt M6 x 15
Bearing, 6202
Weight Balancer
Crankshaft
Gasket, Crankcase Cover
Dowel Pin, ø9 x 14
Air Guide, Right Side
Bearing, 6207
Oil Dipstick Assembly, Yellow
Cover, Crankcase
Flange Bolt M8 x 40
Washer ø6.4 x ø13 x 1, Black
Shaft, Governor Gear
Gear, Governor
Clip, Governor Gear
Bushing, Governor Gear
Connecting Rod
Piston
Circlip ø21 x 1
Pin, Piston
Ring, Oil
Ring, Second Piston
Ring, First Piston
Dowel Pin, ø12 x 20
Gasket, Cylinder Head
Air Guide, Lower
Cylinder Head
Stud Bolt M8 x 35
Qty
1
2
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
7
1
1
1
1
1
2
2
1
1
2
1
2
1
1
2
1
1
1
4
1
2
1
1
1
1
12
2
2
1
4
1
1
1
1
# Part Number
81 1.6177.1.06
82 21.040021.00
83 2.01.008
84 46.130002.20
85 45.130001.00
86 46.130003.20
46.131000.20
87
46.131000.24
88 46.130004.20
89 1.6177.06
90 46.091100.03
91 45.091002.20
92 45.091001.20
93 45.091003.20
94 46.091200.04
95 45.110001.00
96 2.03.019
97 2.11.006
98 45.110008.00
99 45.110003.00
100 2.08.040
101 45.110006.00
102 45.110005.00
103 45.110007.00
104 46.080300.20
46.131017.20
105
46.131017.20.01
55 2.15.002(F6RTC)
56 2.08.014
57 46.020002.00
58 46.021000.00
59 45.020001.02
60 45.020100.00
61 2.08.039
62 46.041000.00
63 45.040013.00
64 45.040002.00
65 45.040006.00
66 46.040005.00
67 45.040015.00
68 45.040017.00
69 45.040003.00
70 23.040010.00
71 45.040001.00
72 45.040007.00
73 45.040008.00
74 46.040004.00
75 46.040016.00
76 46.040201.00
77 46.040009.00
78 46.040018.00
79 1.97.1.06
80 22.040012.00
106 46.091000.03
107 46.061000.00
Parts List
Description
Spark Plug (F6RTC)
Flange Bolt M10 x 80
Gasket, Cylinder Head Cover
Cylinder Head Cover
Breather Tube
Bolt, Cylinder Head Cover
Bolt, Drain, 12 x 1.5 x 15
Camshaft
Lifter, Valve
Valve, Intake
Valve, Exhaust
Push Rod
Retainer, Valve Spring
Oil Seal, Valve
Spring, Valve
Bolt, Rocker Arm
Retainer, Intake Valve Spring
Retainer, Exhaust Valve Spring
Rotator, Exhaust Valve
Guide Plate Push Rod
Shaft, Rocker Arm
Retainer, Rocker Arm
Rocker Arm, Intake Valve
Rocker Arm, Exhaust Valve
Washer ø6
Screw, Valve Adjustment
Flange Lock Nut M6
Nut, Lock M6 x 0.5
Stud Bolt M6 x M8 x 105
Gasket, Insulator
Insulator, Carburetor
Gasket, Carburetor
Qty
1
2
2
2
1
1
1
1
1
1
1
1
2
2
1
1
2
2
1
2
2
2
2
1
1
2
1
1
1
4
1
1
Carburetor
Gasket, Air Cleaner
Flange Nut M6
Base, Air Cleaner
Seal, Air Cleaner
Separator, Air Cleaner
Element, Air Cleaner
Cover, Air Cleaner
Shaft, Governor Arm
Washer ø8.2 x ø17 x 0.8
Oil Seal ø7 x ø14 x 5
Pin, Shaft
Arm, Governor
Bolt, Governor Arm, 6 x 21
Rod, Governor
Spring, Throttle Return
Spring, Governor
Air Guide, Upper
Standard Main Jet
Altitude Main Jet
Air Cleaner Assembly
Recoil Assembly
1
1
/
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
20
21
SPECIfICATIONS
Wiring Diagram
R 20A
Y Y L L
Y W L L
ENGLISH 100109
100109 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 [email protected]
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
22
ENGLISH 100109
WARRANTy
23
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 two years (parts and labor) from the original date of purchase (180 days (parts and labor) 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
12039 Smith Ave.
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 [email protected]
Fax no.: 1-562-236-9429
Technical Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999 [email protected]
24/7 Tech Support: 1-562-204-1188
Champion Power Equipment, Inc. (CPE),
The United States Environment Protection Agency (U.S. EPA.) and the California Air Resources Board (CARB)
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 US EPA, California Air Resources Board, and CPE are pleased to explain the Federal and California Emission
Control Systems Warranty on your 2015 small off-road engine and engine powered equipment. In California, new, small off-road engines and new equipment that use small off-engines must be designed, built and equipped to meet the State’s stringent anti smog standards. In the other states, new engines and equipment must be designed, built and equipped, at the time of sale, to meet U.S. EPA regulations for small non-road engines. CPE warrants the emission control system on your small off-road engine and equipment for the period of time listed below, provided there has been no abuse, neglect, unapproved modification, or improper maintenance of your equipment.
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. For engines less than or equal to 80cc, only the fuel tank and fuel line is subject to the evaporative emission control warranty requirements of this section.
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
This emission control system is warranted for two years, subject to provisions set forth below. If, during the warranty period, emission related part on your engine is defective in materials or workmanship, the part will be repaired or replaced by CPE.
OWNER WARRANTY RESPONSIBILITIES:
As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in your Owner’s Manual. CPE recommends that you retain all your receipts covering maintenance on your small offroad engine, but CPE cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
As the small off-road engine owner, you should however be aware that CPE may deny you warranty coverage if your small, off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
You are responsible for presenting your small off-road engine to an Authorized CPE service outlet or alternate service outlet as described in (3)(f.) below, CPE dealer or CPE, Santa Fe Springs, Ca. as soon as a problem exists.
The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding your warranty rights and responsibilities, you should contact:
Champion Power Equipment, Inc.
Customer Service
12039 Smith Ave.
Santa Fe Springs, CA 90670
1-877-338-0999 [email protected]
EMISSION CONTROL SYSTEM WARRANTY
The following are specific provisions relative to your Emission Control System (ECS) Warranty Coverage.
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 to U.S. EPA emissions standards for spark-ignited engines at or below 19 kilowatts and all applicable regulations adopted by the California Air Resources Board and b. Free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to the part as described in the engine manufacturer’s application for certification for a period of two years.
3. THE WARRANTY ON EMISSION-RELATED PARTS WILL BE INTERPRETED AS FOLLOWS: a. Any warranted part that is not scheduled for replacement as required maintenance in the Owners
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by CPE according to Subsection “d” below. Any such part repaired or replaced under the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period. b. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the
Owners Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary”, shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period. c. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by CPE according to Subsection “d” below. Any such emissions-related part repaired or replaced under the ECS Warranty, shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part. d. Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a CPE Authorized Service Outlet. e. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in fact defective, provided that such diagnostic work is performed at a CPE Authorized
Service Outlet. f. CPE shall pay for covered emissions warranty repairs at non-authorized service outlets under the following circumstances: i. The service is required in a population center with a population over 100,000 according to U.S.
Census 2000 without a CPE Authorized Service Outlet AND ii. The service is required more than 100 miles from a CPE Authorized Service Outlet. The 100 mile limitation does not apply in the following states: Alaska, Arizona, Colorado, Hawaii, Idaho, Montana, Nebraska,
Nevada, New Mexico, Oregon, Texas, Utah and Wyoming. g. CPE shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of an emission-related part covered by the ECS Warranty. h. Throughout the ECS Warranty Period, CPE shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand for such emission-related parts. i. Any CPE Authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty maintenance or repair and will be provided without charge to the owner. Such use shall not reduce CPE’s warranty obligation. j. Unapproved add-on or modified parts may not be used to modify or repair a CPE engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. CPE shall not be liable hereunder for failures of any warranted parts of a CPE engine caused by the use of such an unapproved add-on or modified part.
EMISSION-RELATED PARTS INCLUDE THE FOLLOWING: (using those portions of the list applicable to the engine)
Systems covered by this warranty
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
Evaporative Emissions
Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed systems.
Fuel Tank, Fuel Cap, Fuel Line, Fuel Line Fittings, Clamps, Pressure
Relief Valves, Control Valves, Control Solenoids, Electronic Controls,
Vacuum Control Diaphragms, Control Cables, Control Linkages, Purge
Valves, Vapor Hoses, Liquid/Vapor Separator, Carbon Canister, Canister
Mounting Brackets, Carburetor Purge Port Connector
TO OBTAIN WARRANTY SERVICE:
You must take your CPE engine or the product on which it is installed, along with your warranty registration card or other proof of original purchase date, at your expense, to any Champion Power Equipment dealer who is authorized by Champion Power Equipment, Inc. to sell and service that CPE product during his normal business hours. Alternate service locations defined in Section (3)(f.) above must be approved by CPE prior to service. Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used.
If you have any questions regarding your warranty rights and responsibilities, or to obtain warranty service, please write or call Customer Service at Champion Power Equipment, Inc.
Champion Power Equipment, Inc.
12039 Smith Ave.
Santa Fe Springs, CA 90670
1-877-338-0999
Attn.: Customer Service [email protected]
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