46538 Rev 46538-20100614 www.championpowerequipment.
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. Champion Power Equipment manufactures and sells accessories designed to help you get the most from your purchase.
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 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. 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.
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 – 3.8 gallon capacity fuel tank. (5) Recoil Starter – Used to start the engine (2) Fuel Valve – Turn this valve to the “On” position to supply fuel to the engine. (6) Battery – Used to start the engine.
Controls and Features Power Panel (1) Ignition Switch (2) Intelligauge – Three mode digital meter for running hours, voltage and hertz. (3) Circuit Breakers – Protects the generator against electrical overload. (4) 120 V 20 A Duplex – each duplex is protected by a 20 A push-to-reset circuit breaker to operate 120 Volt AC, single phase, 60 Hz loads requiring up to 20 A 0r 2400 Watts of power.
Controls and Features Parts Included Your Model 46538 Gasoline Powered Generator ships with the following parts: Wheel Kit Handle 8” Wheel Support Leg Vibration Mounts Hardware Oil Funnel Spark Plug Socket 1 piece 1 piece Spark Arrester Kit Spark Arrester Cover Plate Screws, Lock Washers 1 piece 1 piece 2 pieces Wireless Remote Rev 46538-20100614 E 1 piece 2 pieces 1 piece 2 pieces 24 pieces 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. Install the Support Leg 1. Remove the Generator from the Shipping Carton Attach the rubber vibration mount to the support leg with a cap screw (M8x25) and lock nut (M8). 1.
Assembly Connect the Battery Remove the protective cover from the red battery lead. 2. Attach the red lead to the red terminal on the battery with the cap screw (M6x10) and secure with the lock washer (M6) 3. Repeat step 2 for the black battery lead. Add Engine Oil CAUTION 1. Install the Spark Arrester Insert the spark arrester screen into the muffler outlet. Secure the spark arrester by placing the cover plate over the end of the screen, with the lettering facing outward.
Assembly NOTE The generator rotor has a sealed, pre-lubricated ball bearing that requires no additional lubrication for the life of the bearing. Add Fuel 1. 2. 3. 4. 5. 6. 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 ¼ inch of space for fuel expansion. Screw on the fuel cap and wipe away any spilled fuel.
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 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. 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.
Operation 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.
Maintenance Maintenance The owner/operator is responsible for all periodic maintenance. WARNING 2. 3. 4. 5. Allow the oil to drain completely. Replace the drain plug. Remove oil fill cap/dipstick to add oil. Add 0.63 qt (0.6 L) of oil and replace oil fill cap/dipstick. 6. Dispose of used oil at an approved waste management facility. Never operate a damaged or defective generator. WARNING Tampering with the factory set governor will void your warranty. Spark Plugs 1.
Maintenance Spark Arrester 1. 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. Position the spark arrester in the muffler and attach with the two screws.
Storage Storage Generator 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. 2. 3. Engine Storage 1. 2. 3. 4. 5. 6. 7. 16 Allow the engine to cool completely before storage. Clean the engine according to the instructions in the Maintenance section. Drain all fuel completely from the fuel line and carburetor to prevent gum from forming. Add a fuel stabilizer into the fuel tank.
Specifications NGK BR8ES or equivalent Specifications Engine Specifications Engine 196 cc OHV CPE Electric Start Make certain the spark plug gap is 0.7 0.8mm (0.028 - 0.031 in.). Valve Clearance Intake 0.13-0.17mm (0.005 – 0.007 in.) Exhaust 0.18-0.22mm (0.007 – 0.009 in.) Generator Specifications Running Wattage Starting Wattage AC Load Phase Frequency Fuel Capacity Weight Height Width Length 3000 Watts 3500 Watts 120V Single 60 Hz 3.8 gallons (14.4 L) 127.6 lbs. (58 kg) 21.5 inches (54.5 cm) 23.
Specifications Parts Diagram 18 Rev 46538-20100614 E
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 Part Number ST02FD-04120000-CARB GB819 M5×10 ST168FD-1070400-CARB ST02FD-04001002-CARB 168.070100.01 ST168F-1070006A GB5789 M6×20 ST02FD-04100014 ST02FD-04100012 ST02FD-04100011 504.071000.
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 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 20 Part Number GB818 M5X15 ST188FD-1741002-C ST182FD-1151110-B GB6177 M8 GB5789 M8×45 GB5789 M8×35 GB93 8 GB96 8 ST182FD-1742003-UC ST02FD-1151300D-1 GB6177 M8 ST02FD-1151300C-1 ST02FD-0171-2.
Specifications Item 106 107 108 109 110 111 112 113 114 Part Number ST188FD-1750002-C7 ST168FD-1751002-A ST02FD-03030400 ST02FD-04001003 ST02FD-04001001-CARB ST168FD-1070408-CARB GB5789 M6×12 ST168FD-1100003-CARB ST168FD-1100300-CARB Rev 46538-20100614 E Description Battery black wire (-) Jacket Muffler Cover Air cleaner hose Canister Clip Flange bolt M6×12 Air fill clique washer Air fill clique Qty.
Specifications Wiring Diagram 22 Rev 46538-20100614 E
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 2 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 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.
