C46540 Rev C46540-20070615 Owner’s Manual and Operating Instructions 4000 Peak Watts / 3500 Running Watts PORTABLE GENERATOR
Table of Contents Introduction ..................................... 1 Portable Power Generator ........................ 1 Accessories................................................ 1 This Booklet .............................................. 1 Manual Conventions .........................2 Safety Rules ......................................3 Controls and Features....................... 5 Generator.................................................. 5 Power Panel .............................................
Introduction Introduction Accessories Congratulations on your purchase of a Champion Power Equipment generator. CPE designs and builds generators to strict specifications. With proper use and maintenance, this generator will bring years of satisfying service. 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.
Manual Conventions Manual Conventions CAUTION This manual uses the following symbols to help differentiate between different kinds of information. The safety symbol is used with a key word to alert you to potential hazards in operating and owning power equipment. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Follow all safety messages to avoid or reduce the risk of serious injury or death.
Safety Rules 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 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.
Safety Rules DANGER Fuel and fuel vapors are highly flammable and extremely explosive. Fire or explosion can cause severe burns or death. Unintentional startup can result in entanglement, traumatic amputation or laceration. When adding or removing fuel Turn the generator off and let it cool for at least two minutes before removing the fuel cap. Loosen the cap slowly to relieve pressure in the tank. Only fill or drain fuel outdoors in a well-ventilated area. DO NOT overfill the fuel tank.
Controls and Features Controls and Features Read this owner’s manual before operating your generator. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference. Generator Fuel Tank – 6.5 gallon capacity fuel tank. Oil Filler Cap – Check and fill engine oil level. Air Cleaner – Protects the engine by filtering dust and debris from the intake air. Fuel Valve – Turn this valve to the “On” position to supply fuel to the engine.
Controls and Features Power Panel Receptacles 120/240 V 20 A Twist-Lock – protected by a 15 A push-to-reset circuit breaker on each 120 Volt leg of the receptacle. This receptacle powers 240 Volt AC, 60 Hz, single phase loads requiring up to 14.6 A or 3500 Watts of power. If an L14-30P plug is wired for only one 120 Volt leg (3-wire connection) then this receptacle powers 120 Volt AC, 60 Hz, single phase loads requiring up to 15 A or 1800 Watts of power.
Controls and Features Parts Included Your C46540 Gasoline Powered Generator ships with the following parts: 6 foot Battery Cable Rev C46540-20070615 Spark Arrester Kit Spark Arrester Cover Plate Screws, Lock Washers 1 piece 1 piece 2 pieces Oil Funnel Wrench Spark Plug Socket 1 piece 1 piece 1 piece 7
Assembly Assembly CAUTION Your generator requires some assembly. This unit ships from our factory without oil. It must be properly serviced with fuel and oil before operation. The engine is equipped with a low-oil-shutoff and the will stop when the oil level in the crankcase falls below the threshold level. 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.
Assembly 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. Rev C46540-20070615 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.
Operation Operation Generator Location Please consult your local authority. In some areas, generators must be registered with the local utility. Generators used at construction sites may be subject to additional rules and regulations. This generator must have at least five feet of clearance from combustible material. Leave at least three feet of clearance on all sides of the generator to allow for adequate cooling, maintenance and servicing. Place the generator in a well-ventilated area.
Operation temperatures of the engine and generator. 3. Turn the ignition switch to the “Off” position. 4. Turn the fuel valve to the “Off” position. 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.
Maintenance Maintenance 6. Dispose of used oil at an approved waste management facility. The owner/operator is responsible for all periodic maintenance. WARNING Never operate a damaged or defective generator. Spark Plugs WARNING Tampering with the factory set governor will void your warranty. 1. 2. 3. 4. WARNING Improper maintenance will void your warranty. 5. 6. 7. Complete all scheduled maintenance in a timely manner. Correct any issue before operating the generator.
Maintenance Spark Arrester Every 8 hours or daily 1. Check oil level Clean around air intake and muffler First 5 Hours 2. 3. 4. 5. 6. Allow the engine to cool completely before servicing the spark arrester. Remove the two screws holding the cover plate which retains the end of the spark arrester to the muffler. Remove the spark arrester screen. Carefully remove the carbon deposits from the spark arrester screen with a wire brush. Replace the spark arrester if it is damaged.
Storage Storage The generator should be started at least once every 14 days and allowed to run for at least 20 minutes. For longer term storage, please follow these guidelines. 5. Change the oil. 6. Remove the spark plug and pour about ½ ounce of oil into the cylinder. Crank the engine slowly to distribute the oil and lubricate the cylinder. 7. Reattach the spark plug. Generator Storage Engine Storage 1. Allow the engine to cool completely before storage. 2.
Specifications Specifications Engine Specifications Engine 196 cc OHV CPE EPA & CARB certified Generator Specifications Running Wattage Starting Wattage AC Load DC Load Phase Frequency Fuel Capacity Weight Height Width Length 3500 Watts 4000Watts 120/240 V 12 V Single 60 Hz 4 gallons (15 L) 99.2 lbs. (45 kg) 18.1 inches (46 cm) 18.1 inches (46 cm) 24.2 inches (61.5 cm) Fuel Fuel capacity is 4 US gallons (15 L). Use regular unleaded gasoline with a minimum octane rating of 85.
Specifications Parts Diagram 16 Rev C46540-20070615
Specifications Parts List No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Parts# ST168FD-1160100 GB1667-S5-6 ST168FD-1160200 ST168FD-1160200A ST168F-1160500 ST168FD-1160001A GB5781-B6-16 ST168FD-1163000 ST168FD-1160400 ST168FD-1160002 ST168FD-1100200N GB41-N-6 GB5781-B6-20 ST168FD-1100002B ST02FD-1152035 ST02FD-1152002 GB5781-B5-10 GB5781-B5-16 ST168FD-1150230 GB5781-B5-15 ST168FD-1152031 ST168FD-
Specifications No 56 57 58 59 60 61 62 63 64 65 18 Parts# ST02FD-1151204A ST02FD-1151200B ST02FD-1151201M ST02FD-1151202M ST02FD-1151203M ST02FD-1151200D ST05FD-1151202-10A ST168FD-1100201A ST168FD-1100201B ST168FD-1100201C Description Volt Meter 120/240v. Receptacle Voltage Selector RV Receptacle 120v. AC Receptacle DC Receptacle 10 Amp Circuit Breaker Spark Arrester Comp.
Specifications Wiring Diagram 19
Troubleshooting Troubleshooting Problem Generator will not start Generator will not start; Generator starts but runs roughly Generator shuts down during operation Generator cannot supply enough power or overheating Cause No fuel Faulty spark plug Unit loaded during start up Low oil level Choke in the wrong position.
Warranty Warranty CHAMPION POWER EQUIPMENT 1 YEAR LIMITED WARRANTY Effective September 1, 2006. Replaces all undated warranties and all warranties dated before September 1, 2006. 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.
Warranty Champion Power Equipment, Inc (CPE), The California Air Resources Board (CARB) and the United States Environment Protection Agency (U.S. EPA.) Emission Control System Warranty Your Champion Power Equipment (CPE) engine complies with both the U.S. EPA and state of California Air Resources Board (CARB) emission regulations.
Warranty EMISSION CONTROL SYSTEM WARRANTY The following are specific provisions relative to your Emission Control System Warranty Coverage. Emission Control System Warranty (ECS Warranty) for 1995 and later model year California small off-road engines (for other states, 1997 and later model year engines): 1. APPLICABILITY: This warranty shall apply to 1995 and later model year California small offroad engines (for other states, 1997 and later model year engines).
Warranty i. Unapproved add-on or modified parts may not be used to modify or repair a CPE engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. CPE shall not be liable hereunder for failures of any warranted parts of a CPE engine caused by the use of such an unapproved add-on or modified part.
Notes Notes Rev C46540-20070615 25
1-877-338-0999 10006 Santa Fe Springs Road Santa Fe Springs, CA 90670 USA Made in China © 2007 Champion Power Equipment, Inc.
