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P O W E R G E N E R A T O R
OWNER’S MANUAL & OPERATING INSTRUCTIONS
3500 Starting Watts / 3000 Rated Watts
Recoil Start
PORTABLE GENERATOR
SAVE THESE INSTRUCTIONS
Important Safety Instructions are included in this manual.
MODEL NUMBER 46599
MADE IN CHINA
REV 46599-20120703
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
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.
46599
3500 Starting Watts / 3000 Rated Watts
Recoil 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
Parts Included . . . . . . . . . . . . . . . . . . . . . . . .
7
Wheel Kit . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Spark Arrester Kit . . . . . . . . . . . . . . . . . . . .
7
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Remove the Generator from the Shipping Carton .
8
Install the Wheel Kit . . . . . . . . . . . . . . . . . . . .
8
Install the Support Leg . . . . . . . . . . . . . . . . . .
8
Install the Handle . . . . . . . . . . . . . . . . . . . . . .
8
Install the Spark Arrester . . . . . . . . . . . . . . . . .
9
Add Engine Oil . . . . . . . . . . . . . . . . . . . . . . . .
9
Add Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Generator Location . . . . . . . . . . . . . . . . . . . .
11
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Surge Protection . . . . . . . . . . . . . . . . . . . . . .
11
Starting the Engine . . . . . . . . . . . . . . . . . . . .
11
Connecting Electrical Loads . . . . . . . . . . . . . .
12
Stopping the Engine . . . . . . . . . . . . . . . . . . .
12
Do Not Overload Generator . . . . . . . . . . . . . . .
12
Capacity . . . . . . . . . . . . . . . . . . . . . . . . .
12
Power Management . . . . . . . . . . . . . . . . . .
12
Operation at High Altitude . . . . . . . . . . . . . . .
13
Maintenance and Storage . . . . . . . . . . . . . . . . . .
14
Engine Maintenance . . . . . . . . . . . . . . . . . . .
14
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . .
14
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . .
14
Spark Arrester . . . . . . . . . . . . . . . . . . . . .
15
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . .
15
Adjustments . . . . . . . . . . . . . . . . . . . . . . .
15
Maintenance Schedule . . . . . . . . . . . . . . . .
15
Generator Maintenance . . . . . . . . . . . . . . . . .
16
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Generator Storage . . . . . . . . . . . . . . . . . . .
16
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Engine Specifications . . . . . . . . . . . . . . . . . .
17
Generator Specifications . . . . . . . . . . . . . . . .
17
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . .
17
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . .
17
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . .
18
Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . .
19
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
Engine Parts Diagram . . . . . . . . . . . . . . . . . .
21
Engine Parts List . . . . . . . . . . . . . . . . . . . . .
22
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .
23
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
Warranty Qualifications . . . . . . . . . . . . . . . . .
24
Repair/Replacement Warranty . . . . . . . . . . . . .
24
Do Not Return The Unit To
The Place Of Purchase . . . . . . . . . . . . . . . . . .
24
Warranty Exclusions . . . . . . . . . . . . . . . . . . . . 24
Normal Wear . . . . . . . . . . . . . . . . . . . . . .
24
Installation, Use and Maintenance . . . . . . . .
24
Other Exclusions . . . . . . . . . . . . . . . . . . . .
24
Limits of Implied Warranty and Consequential Damage . . . . . . . . . . . .
24
Contact Information . . . . . . . . . . . . . . . . . . . .
24
Address . . . . . . . . . . . . . . . . . . . . . . . . . .
24
Customer Service . . . . . . . . . . . . . . . . . . .
24
Technical Service . . . . . . . . . . . . . . . . . . .
24
ENGLISH 46599
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
46599
Serial Number
Date of Purchase
Purchase Location
For Oil Type see ‘Add Engine Oil‘ section . For Fuel Type see ‘Add Fuel‘ section .
1 REV 46599-20120703
46599 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 46599-20120703
2
ENGLISH 46599
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 .
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 .
3 REV 46599-20120703
46599 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
REV 46599-20120703
4
ENGLISH 46599
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
9
2
3
4
8
7
6
5
(1) Fuel Tank – 3 .8 gal . (14 .4 L) capacity fuel tank .
(2) Choke – Used to start the engine .
(3) Fuel Valve – Used to turn fuel supply on and off to engine .
(4) Air Filter – Protects the engine by filtering dust and debris from the intake air .
(5) Recoil Starter – Used to manually start the engine .
(6) Never Flat Tires
(7) Oil Filler Cap – Check and fill engine oil level .
(8) Power Panel – See “Power Panel” section .
(9) Handle
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46599 ENGLISH
Power Panel
1 2
CONTROLS ANd fEATURES
3 4 5
(1) Engine Switch – Used to start or stop the generator .
(2) 120 Volt AC, 20 Amp Duplex (2)
(NEMA 5-20R) – May be used to supply electrical power for the operation of 120 Volt AC, 20 Amp, single phase 60 Hz electrical loads .
(3) Circuit Breakers – Protects the generator against electrical overloads . Press button reset .
(4) AC Output Indicator – Indicates when power is being delivered to receptacle .
(5) Ground Terminal – Consult an electrician for local grounding regulations .
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6
CONTROLS ANd fEATURES
Parts Included
Your 46599 Gasoline Powered Generator ships with the following parts:
Wheel Kit
– 8” Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
– Flange Bolt (M10x105 for Wheel) . . . . . . . . . . . .
2
– Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
– Flat Washer 10mm . . . . . . . . . . . . . . . . . . . . . .
2
– Nut (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
– Flange Bolt (M8x25 for Vibration Mounts) . . . . . .
2
– Flange Bolt (M8x16 for Support Leg) . . . . . . . . . .
2
– Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
– Flange Bolt (M8x45 for Handle) . . . . . . . . . . . . .
2
– Nut (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Spark Arrester Kit
– Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . .
1
– Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
– Screw with Lock Washer . . . . . . . . . . . . . . . . . . .
2
Other
– Oil Funnel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
– Spark Plug Socket . . . . . . . . . . . . . . . . . . . . . . .
1
ENGLISH 46599
7 REV 46599-20120703
46599 ENGLISH
ASSEMBLy
Your generator requires some assembly . This unit ships from our factory without oil . It must be properly serviced with fuel and oil before operation .
If you have any questions regarding the assembly of your generator, call our help line at 1-877-338-0999 . Please have your serial number and model number available .
Install the Support Leg
1 . Attach the support leg to the generator frame with cap screws (M8x16) and nuts (M8) .
2 . Tip the generator slowly so that it rests on the wheels and support leg .
Remove the Generator from the Shipping Carton
1 . Set the shipping carton on a solid, flat surface .
2 . Remove everything from the carton except the generator .
3 . Carefully cut each corner of the box from top to bottom . Fold each side flat on the ground to provide a surface area to install the wheel kit and support leg .
Install the Wheel Kit
CAUTION
The wheel kit is not intended for over-the-road use .
You will need the following tools to install the wheels:
• 17 mm wrench OR adjustable wrench (not included)
• Socket wrench with a 16 mm socket (not included)
• Pliers (not included)
Install the Handle
1 . Place the handle over the mounting channel on the frame .
2 . Secure the handle to the frame using the two handle bolts (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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ENGLISH 46599
ASSEMBLy
Install the Spark Arrester
1 . Insert the spark arrester screen into the muffler outlet .
2 . Secure the spark arrester by placing the cover plate over the end of the screen, with the lettering facing outward .
Add Engine Oil Cont’d.
1 . Place the generator on a flat, level surface .
2 . Remove oil fill cap/dipstick to add oil .
3 . Add up to 0 .63 qt . (0 .6 L) of oil and replace oil fill cap/dipstick .
3 . 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 .
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 .
9 REV 46599-20120703
4 . Check engine oil level daily and add as needed .
CAUTION
The engine is equipped with a low-oil-shutoff and will stop when the oil level in the crankcase falls below the threshold level .
NOTE
Check oil often during the break-in period . Refer to the
Maintenance section for recommended service intervals .
NOTE
The generator rotor has a sealed, pre-lubricated ball bearing that requires no additional lubrication for the life of the bearing .
46599 ENGLISH
ASSEMBLy
Add fuel
1 . Use clean, fresh, regular unleaded fuel with a minimum octane rating of 85 and an ethanol content of less than 10% by volume .
2 . DO NOT mix oil with fuel .
3 . Clean the area around the fuel cap .
4 . Remove the fuel cap .
5 . Slowly add fuel to the tank . DO NOT overfill . Allow approximately ¼ inch of space for fuel expansion .
6 . Screw on the fuel cap and wipe away any spilled fuel .
CAUTION
Use regular unleaded gasoline with a minimum octane rating of 85 .
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 .
Do not mix oil and gasoline .
Fill tank to approximately ¼” 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 .
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10
ENGLISH 46599
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 .
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 .
Grounding
The generator system ground connects the frame to the ground terminals on the power panel .
– The generator (stator winding) is isolated from the frame and from the AC receptacle ground pin .
– Electrical devices that require a grounded receptacle pin connection may not function properly .
Surge Protection
CAUTION
Voltage fluctuation may impair the proper functioning of sensitive electronic equipment .
Electronic devices, including computers and many programmable appliances use components that are designed to operate within a narrow voltage range and may be affected by momentary voltage fluctuations .
While there is no way to prevent voltage fluctuations, you can take steps to protect sensitive electronic equipment .
1. Install UL1449, CSA-listed, plug-in surge suppressors
on the outlets feeding your sensitive equipment.
Surge suppressors come in single- or multi-outlet styles . They’re designed to protect against virtually all short-duration voltage fluctuations .
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 ignition 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 spark plug fouling/engine flooding due to the lack of incoming air . This will cause the engine not to start .
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 .
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46599 ENGLISH
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 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 .
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 .
REV 46599-20120703
12
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
P19-2-Z
P19-2-H
Main Jet
Standard
Altitude
Standard
Altitude
Part Number Altitude
ST168FD-2-1131000-17Z
ST168F-2-1131000-17Z
ST168FD-2-1131000-17H
ST168F-2-1131000-17H
6000 Feet
(1800 Meters)
WARNING
Operation using the alternative main jet at elevations lower than the recommended minimum altitude can damage the engine . For operation at lower elevations, the standard main jet must be used . Operating the engine with the wrong engine configuration at a given altitude may increase its emissions and decrease fuel efficiency and performance .
13 REV 46599-20120703
ENGLISH 46599
46599 ENGLISH
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 a 13/16” or 21 mm socket 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 12 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 up to 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 .
REV 46599-20120703
14
ENGLISH 46599
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 .
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
Change fuel fliter
Clean/Adjust spark plug
Check/Adjust valve clearance *
Clean spark arrester
Clean fuel tank*
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 .
15 REV 46599-20120703
46599 ENGLISH
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 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 .
REV 46599-20120703
16
ENGLISH 46599
SPECIfICATIONS
Engine Specifications
– Model . . . . . . . . . . . . . . . . . . . . . . . . . . .
66534
– Displacement . . . . . . . . . . . . . . . . . . . . . . .
196cc
– Type . . . . . . . . . . . . . . . . . . . . . . . .
4-Stroke OHV
– Start Type . . . . . . . . . . . . . . . . . . . . . . . . .
Recoil
Generator Specifications
– Model . . . . . . . . . . . . . . . . . . . . . . . . . . .
46599
– Running Wattage . . . . . . . . . . . . . . . . .
3000 Watts
– Starting Wattage . . . . . . . . . . . . . . . . .
3500 Watts
– AC Load . . . . . . . . . . . . . . . . . . . . . . . . . .
120 V
– Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single
– Frequency . . . . . . . . . . . . . . . . . . . . . . . . .
60 Hz
– Fuel Capacity . . . . . . . . . . . . . . . .
3 .8 gal . (14 .4 L)
– Gross Weight . . . . . . . . . . . . . . .
105 .8 lbs (48 kg)
– Net Weight . . . . . . . . . . . . . . . . . . .
97 lbs (44 kg)
– Height . . . . . . . . . . . . . . . .
20 .3 inches (51 .5 cm)
– Width . . . . . . . . . . . . . . . . .
21 .9 inches (55 .6 cm)
– Length . . . . . . . . . . . . . . . . 26 .3 inches (66 .8 cm)
fuel
Fuel capacity is 3 .8 gal . (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 up to 0 .63 qt . (0 .6 L) .
Please reference the following chart for recommended oil types for use in the generator .
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 .
17 REV 46599-20120703
46599 ENGLISH
Wiring diagram
SPECIfICATIONS
REV 46599-20120703
18
SPECIfICATIONS
Parts diagram
ENGLISH 46599
19 REV 46599-20120703
46599 ENGLISH
# Part Number Description
1 168FD-2-GC Engine
2 504 .191100 .04
Rotor Assembly
3 ST02FD-02100005-2 .5
Flange Bolt M8×233
4 GB96 8 Washerφ8
5 GB7244 8
6 504 .191200 .04
Lock Washer φ8
Stator Assembly
7 ST02FD-02100002
8 ST02FD-02100003
Stator Cover
End Housing
9 ST02FD-02100001-2 .5
Flange Bolt M6×158
10 GB97 .1 6 Washerφ6
11
12
GB93 6
ST02FD-02100009
13 ST02FD-02100008
14 GB93 5
Lock Washer φ6
Carbon Bursh
Pinch
Lock Washer φ5
15 GB5783 M5×16
16 GB97 .1 5
Bolt M5×16
Washer φ5
17 GB5783 M5×16 Bolt M5×16
18 ST02FD-02100007-CPE AVR
19 GB16674 M5X16 Flange Bolt M5×16
20 ST02FD-02100004( R) Generator End Cover
21 GB16674 M5X12
22 ST02FD-02100010
Flange Bolt M5×12
Terminal Block
23 GB818 M5X15
24 ST188FD-1100010-88
25 ST188FD-1180121
26 468 .101000 .05
Screw M5×15
Plate,Spark Arrester
Spark Arrester
Muffler
Flange Bolt M6×12 27 GB5789 M6X12
28
ST168FD-1100300-
CARB
29
ST168FD-1100003-
CARB
30 GB16674 M6X16
31 GB6175 M8
32 GB93 8
Secondary Air Intake Valve
Gasket,Air Supply Valve
Flange Bolt M6×16
Nut M8
Lock Washer φ8
Washer φ8
Muffler Gasket
33 GB848 8
34 ST168F-1100200-G
35 GB5789 M6x8
36 ST168FD-1090006-A
37 ST168FD-1160002-B
38 ST188FD-1070006A
39 ST02FD-04160000
40 504 .071000 .35( R)
41 ST02FD-04100010
42 ST02FD-04100014
43 GB93 6
44 GB5789 M6×20
45 ST168F-1070006A
Flange Bolt M6×8
Holder,Air Cleaner
Pipe,Fuel
Clip
Fuel Cock
Fuel Tank
Mount Vibration, Fuel Tank
Washer φ6
Lock Washer φ6
Flange Bolt M6×20
Fuel Tank Filter
Qty
1
1
2
2
2
5
1
1
1
1
1
1
1
4
6
10
1
1
1
1
2
1
1
1
2
1
2
1
1
4
1
4
4
1
4
2
1
1
1
1
1
2
2
2
2
# Part Number Description
46 168 .070100 .01
47 168 .070014 .01
48 ST160F-1070007
49
ST168FD-1070400-
CARB
50 GB819 M5×10
51
ST02FD-04120000-
CARB
52 ST188FD-1741002-C
53 ST182FD-1151110-B
Fuel Tank Cap
Pipe,Reversal Valve
Clamp
Reversal Valve
Screw M5×10
Fuel Meter Assembly
Cover,Handle
Handle
54 GB6177 M8
55 GB5789 M8×45
56
ST168FD-1070408-
CARB
57 ST02FD-0228
58 GB5782 M10×105
59 GB96 10
Nut M8
Flange Bolt M8×45
Clamp
Frame
Bolt M10×105
Flat Washer φ10
60 ST02FD-03621001
61 ST177FD-1152300(B)
62 GB6182 M10
63 504 .201200 .00
Bush φ10 .5×58 .5
8in Wheel
Nut M10
Motor Mount I
64 504 .201200 .01
65 GB6177 M6
Motor Mount II
Nut M6
66 ST02FD-02100013-2 .5
Grounding Line
67 GB5789 M8×16 Flange Bolt M8×16
68 ST05FD-03020301-60 Support Legφ2 .36φ
69 ST188FD-1743002-C Vibration Mount
70 GB5789 M8×25
71 ST02FD-05010703
Flange Bolt M8×25
Flange Bolt M5×13
72 2A105
73 ST02FD-05702004
74 ST02FD-05502023
75 GB823 M4×14
76 GB848 4
Control Panel
Ignition Switch
Receptacle 5-20R
Screw M4×14
Flat Washer φ4
77 GB859 4
78 GB6177 M4
Lock Washer φ4
Nut M4
79 ST02FD-05302001-L20 Circuit Breaker
80 ST02FD-05802001 pilot lamp
81 GB5783 M6×22
82 GB6175 M6
83 ST02FD-05212002
84 ST02FD-05202003
Bolt M6×22
Nut M6
Plug
Sheath,Wire
85 ST02FD-05212001
86 GB823 M5×14
87 OV01-00000000
88 GB6177 M5
89 ST02FD-05202014
Plug
Screw M5x14
Over Voltage Protector
Nut M5
Control box
Parts List
1
1
14
2
2
1
1
1
1
2
1
1
1
1
2
1
4
4
4
4
1
2
4
1
2
2
2
1
1
1
2
2
2
2
2
2
1
2
2
1
Qty
1
1
1
1
REV 46599-20120703
20
SPECIfICATIONS
Engine Parts diagram
56 5
7 5
8 5
ENGLISH 46599
21 REV 46599-20120703
46599 ENGLISH
# Part Number Description
1 GB5789-FB6-8 Flange Bolt 6 x 8
2 ST160F-1061200 Recoil Starter Knob
3 160 .061100 .32
4 ST160F-1061005
5 ST160F-1061009
6 ST160F-1061001-A
7 ST188F-1060006
8 ST188F-1060005
9 GB5789-FB6-12
10 ST188F-1060003
11 ST188F-1060004
12 ST188F-1060002
13 ST168F-1080100-G
14 ST160F-1050010
15 ST160F-1060001-A
16 ST168F-1080001
17 ST168F-1120100
18 ST168F-1080200
19 ST168F-1030100
20 GB5789-FB6-15
21 ST160F-1030003
22 ST160F-1030004
23 ST168F-2-1030012-G
24 GB276-BB-6205-UU
25 ST160F-1127000-A
26 ST160F-1110108
Oil Seal
Flange Bolt M6x15
Drain Bolt
Washer, Drain Bolt
Crankcase
Radial ball bearing 6205
Oil Level Sensor
Washer, Governor φφφ
27 ST160F-1110101
28 ST160F-1110102
29 ST160F-1110104
30 ST160F-1110103
31 ST160F-1110107
32 ST02FD-1151201A
Governor Weight
Choke Lever
33 ST160F-1110105-A Bushing, Governor
34 ST168FD-2-1050001-A Crankshaft Assembly
35 ST168F-1030008-G
36 ST160F-1030001-B
37 ST160F-1030002
38 GB5789-FB8-32
Governor Gear
Pin, Weight
Shaft, Governor Gear
Circlip, Governor Gear
Gasket, Crankcase
Oil Dipstick
Gasket, Oil Dipstick
Flange Bolt 8 x 32
Spring, Throttle Return
Spring, Governor
39 ST168F-1110005
40 ST168F-1110007
41 ST160F-1110003
42 GB41-N-6
43 ST160F-1110008
44 ST160F-1110001
45 ST168F-1110006
46 ST160F-1110004
Arm, Governor
Nut M6
Pin, Shaft
Shaft, Governor Arm
Rod, Governor
Bolt, Governor Arm
47 GB5789-FB6-25
48 ST160F-1123000-G
49 152FMD-1001007
50 GB5789-FB8-55
51 ST168FD-1090005-G
52 ST168FD-1090004
Recoil Starter Assembly
Recoil Starter Spring
Recoil Starter Rope
Recoil Starter Reel
Spring, Ratchet
Starter RatchetφMetalφ
Flange Bolt M6 x 12
Ratchet Guide
Ratchet Guide Spring
Screw, Ratchet guide
Fan Cover Assembly
Nut M14
Start Hub
Cooling Fan
Flywheel
Air Guideφφφ
Flange Bolt 6 x 25
Ignition Coil
Dowel Pin 10 x 16
Flange Bolt 8 x 55
Cover, Air Cleaner
Element
Qty
5
1
1
1
1
1
2
2
1
1
1
2
1
2
1
4
2
1
2
1
1
1
1
1
1
2
2
1
1
9
1
1
1
1
1
4
1
1
2
1
1
2
1
1
3
1
1
1
6
1
1
2
# Part Number
53 ST168FD-1090003
54 ST168FD-1090002
55
ST168FD-1091000-
CARB
56 ST160F-1130003-CPE
57 ST168F-1130001
58 ST168F-1130002-CPE
59 ST160F-1010001
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 ST168FD-1030007-G
67
ST168FD-1080200-
CARB
68 GB1099-79
69 ST168FD-1030007-G
70 ST168F-1050100
71 ST168F-1050003
72 ST168F-1050004
73 ST168F-2-1050005
ST168F-1050007
Description
Separator
Air Cleaner Seal
Base, Air Cleaner
Gasket, Carburetor
Insulator, Carburetor
Gasket, Insulator
Stud Bolt 6 x 110
Cylinder Head
Gasket, Cylinder Head
Valve, Intake
Valve, Exhaust
Lifter,Valve
Camshaft Assembly
Dowel Pin 9 x 14
Air Shroud, Cylinder
Key
Crankcase Cover
Connecting Rod Assembly
Wrist Pin
Circlip, Wrist Pin
Piston
Ring, First
74 ST168F-1050006
ST168F-1050200
Ring, Second
Ring, Oil
75 ST168F-1080002-GC
76 GB900-SB8-35
77 ST168F-1040005
78 ST168F-1040014-A
79 ST168F-1040027
80 168 .040201 .34
81 GB41-N-6
82 168 .040004 .34
83 ST168FD-1020011-A
84 ST168F-1020100-C
85 ST160F-1020002-A
86 ST160F-1040024
87 ST160F-1040025
88 ST160F-1040022
89 168 .040202 .34
90 ST160F-1040008
91 ST160F-1040001
Shroud, Cylinder Head
Stud Bolt 8 x 35
Push Rod
Oil Seal, Valve
Stud Bolt, Rocker Arm
Retainer, Rocker Arm
Nut M6
Guide, Push Rod
Breather Tube
Cylinder Cover Assembly
Gasket, Cylinder Cover
Screw, Valve Adjustment
Locknut
Rocker Arm
Shaft, Rocker Arm
Rotator, Exhaust Valve
Retainer, Intake Valve
92 ST160F-1040007
93 ST160F-1040003
94 F6RTC
95
ST168FD-2-1131000-
CPE
Retainer, Exhaust Valve
Spring, Valve
Spark Plug
Carburetor
96 ST168FD-1130005-CPE Gasket, Carburetor
97 GB90-W-6 Washer φ6
98
ST168FD-2-1131000-17 Standard Main Jet
ST168F-2-1131000-17 Altitude Main Jet
2
1
2
2
1
1
1
1
1
2
1
1
1
1
2
2
2
2
2
1
1
1
1
2
1
1
1
1
1
1
1
2
1
/
1
1
1
1
1
1
2
1
1
2
1
2
1
Qty
1
1
REV 46599-20120703
22
ENGLISH 46599
TROUBLESHOOTING
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
Generator cannot supply enough power or overheating
Generator is overloaded
Insufficient ventilation
No AC output
Choke in the wrong position .
Spark plug wire loose
Out of fuel
Low oil level
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
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
23 REV 46599-20120703
46599 ENGLISH
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 info@championpowerequipment .com
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: 1-562-204-1188
REV 46599-20120703
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Champion Power Equipment, Inc. (CPE), and the United States Environment Protection Agency (U.S. EPA.)
Emission Control System Warranty
Your Champion Power Equipment (CPE) engine complies with the U.S. EPA emission regulations.
YOUR WARRANTY RIGHTS AND OBLIGATIONS:
The US EPA AND CPE are pleased to explain the Federal Emission Control Systems Warranty on your 2012 small off-road engine and engine powered equipment. 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.
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
10006 Santa Fe Springs Road
Santa Fe Springs, CA 90670
1-877-338-0999
EMISSION CONTROL SYSTEM WARRANTY
The following are specific provisions relative to your Emission Control System Warranty Coverage.
1. APPLICABILITY: This warranty shall apply to 1997 and later model year small off-road engines. The ECS
Warranty Period shall begin on the date the new engine or equipment is delivered to its original, end-use purchaser, and shall continue for 24 consecutive months thereafter.
2. GENERAL EMISSIONS WARRANTY COVERAGE
CPE warrants to the original, end-use purchaser of the new engine or equipment and to each subsequent purchaser that each of its small off-road engines is: a. Designed, built and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act, as amended, 42 U.S.C. 7401 et seq. b. Free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to the part as described in the engine manufacturer’s application for certification for a period of two years.
3. THE WARRANTY ON EMISSION-RELATED PARTS WILL BE INTERPRETED AS FOLLOWS: a. Any warranted part that is not scheduled for replacement as required maintenance in the Owners
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by CPE according to Subsection “d” below. Any such part repaired or replaced under the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period. b. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the
Owners Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary”, shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period. c. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by CPE according to Subsection “d” below. Any such emissions-related part repaired or replaced under the ECS Warranty, shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part. d. Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a CPE Authorized Service Outlet. e. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in fact defective, provided that such diagnostic work is performed at a CPE Authorized
Service Outlet. f. CPE shall 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.
10006 Santa Fe Springs Road
Santa Fe Springs, CA 90670
1-877-338-0999
Attn.: Customer Service
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