46515 Rev 46515-20090319 10006 Santa Fe Springs Road Santa Fe Springs, CA 90670 USA Made in China Owner’s Manual and Operating Instructions SAVE THESE INSTRUCTIONS Important Safety Instructions are included in this manual 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. This Owner’s Manual contains important safety instructions and information. SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE. Portable Power Generator This unit is a gasoline engine driven, alternating current (AC) generator.
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 exhaust contains carbon monoxide, a colorless, odorless, poison gas. Breathing carbon monoxide will cause nausea, dizziness, fainting or death.
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 (1) Fuel Tank – 4.0 gallon capacity fuel tank. (2) Fuel Valve – Turn this valve to the “On” position to supply fuel to the engine. (6) Serial Number – Please have this number available when calling for assistance.
Controls and Features Power Panel (1) Ignition Switch – Flip switch to the “On” position to start the generator Flip to the “Off” position to turn off the generator. (2) Circuit Breakers – Protects the generator against electrical overload. (3) Voltmeter - Displays the output voltage of the generator. (4) 120 V 30 A Twist-Lock –This receptacle powers 120 Volt AC, 60 Hz, single phase loads requiring up to 25 A or 3500 Watts of power. Protected by a 25 A circuit breaker.
Controls and Features Parts Included Your 46515 Gasoline Powered Generator ships with the following parts: Spark Arrester Kit Spark Arrester Cover Plate Screws, Lock Washers Oil Funnel Spark Plug Socket Rev 46515-20090319 1 piece 1 piece 2 pieces 1 piece 1 piece 7
Assembly Assembly Your generator requires some assembly. This unit ships from our factory without oil. It must be properly serviced with fuel and oil before operation. If you have any questions regarding the assembly of your generator, call our help line at 1-877-338-0999. Please have your serial number and model number available. 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.
Assembly Add Fuel 1. 2. 3. 4. 5. Use clean, fresh, regular unleaded fuel with a minimum octane rating of 85. DO NOT mix oil with fuel. Clean the area around the fuel cap. Remove the fuel cap Slowly add fuel to the tank. DO NOT overfill. Allow approximately 1/4 inch of space for fuel expansion. DO NOT fill fuel tank indoors. DO NOT fill fuel tank when the engine is running or hot. DO NOT overfill the fuel tank. DO NOT light cigarettes or smoke when filling the fuel tank.
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 2. Let the generator run at no-load for several minutes to stabilize internal 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 Wattage Reference Chart Use the chart to determine approximate wattage requirements for your equipment. NOTE Starting watts can exceed three times the running watts. The values in the following table are approximate.
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 Plug WARNING Tampering with the factory set governor will void your warranty. 1. 2. 3. 4. 5. WARNING Improper maintenance will void your warranty. 6. 7. 8. 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 Generator Specifications Running Wattage Starting Wattage AC Load Phase Frequency Fuel Capacity Weight Height Width Length 3500 Watts 4000Watts 120 V Single 60 Hz 4.0 gallons (15 L) 98.1 lbs. (44.5 kg) 17.4 inches (44.2 cm) 17.5 inches (44.5 cm) 23.
Specifications Parts Diagram 16 Rev 46515-20090319
Specifications Parts List Item 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 Rev 46515-20090319 Part Number GB1667-S5-10 ST168FD-1160100 ST168FD-1160200 ST168FD-1160201 ST168F-1160500 GB5789-FB6-20 ST02FD-04100014 ST168FD-1163000 ST168FD-1160001A ST168FD-1160400 ST168FD-1160002A ST188FD-1070006A GB5789-FB6-12 GB5789-FB8-20 ST02FD-1150100 ST168FD-1100002B ST168FD-1150230 GB5789-FB5-12 ST02FD-1152002 GB5789-FB5
Specifications Item 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 18 Part Number ST168FD-1100000-G ST188FD-1180121 ST188FD-1100010-88 GB93-LW-5 GB5789-FB5-15 ST02FD-1152036 ST05FD-1170003-B ST05FD-1151209 ST02FD-1151201 GB1667-S5-38 GB90-W-5 OV01-00000000-1 GB6177-86-N4 GB818-85-S4-14 ST02FD-1151300 Description Muffler Spark Arrester Assembly Spark Arrester Cover Lock Washer ø5 Flange Bolt M5×15 Brush Support Plate Grommet Conduit Grommet Screw M5×38 Washer ø5 Tra
Specifications Wiring Diagram Rev 46515-20090319 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), and the United States Environment Protection Agency (U.S. EPA.) Emission Control System Warranty Your Champion Power Equipment (CPE) engine complies with U.S. EPA emission regulations. YOUR WARRANTY RIGHTS AND OBLIGATIONS: The US EPA AND CPE are pleased to explain the Federal Emission Control Systems Warranty on your 2009 small off-road engine. New engines must be designed, built and equipped, at the time of sale, to meet U.S.
Warranty EMISSION CONTROL SYSTEM WARRANTY The following are specific provisions relative to your Emission Control System Warranty Coverage. Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines): 1. APPLICABILITY: This warranty shall apply to 1997 and later model year engines). The ECS Warranty Period shall begin on the date the new engine or equipment is delivered to its original, end-use purchaser, and shall continue for 24 consecutive months thereafter. 2.
Warranty EMISSION-RELATED PARTS INCLUDE THE FOLLOWING: (using those portions of the list applicable to the engine) Systems covered by this warranty Fuel Metering System Air Induction System Ignition System Exhaust System Miscellaneous Parts Parts Description Fuel regulator, Carburetor and internal parts Air cleaner, Intake manifold Spark plug and parts, Magneto ignition system Exhaust manifold, catalytic converter Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed systems TO OBTAIN
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