Champion Power Equipment 100107 Owners Manual

2015-08-26

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OWNER’S MANUAL & OPERATING INSTRUCTIONS
12039 Smith Ave.
Santa Fe Springs CA 90670
USA / 1-877-338-0999
www.championpowerequipment.com
SAVE THESE INSTRUCTIONS
Important Safety Instructions
are included in this manual.
MADE IN CHINA
REV 100107-20140923
100107
MODEL NUMBER
7800 Starting Watts / 6500 Rated Watts
PORTABLE GENERATOR
Electric start
*We are always working to improve our products. Therefore, the enclosed product may differ slightly from the image on the cover.
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
AN IMPORTANT MESSAGE ABOUT TEMPERATURE:
Your Champion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to
40°C (104°F). When your product is needed your product may be operated at temperatures ranging from -15°C (5°F) to
50°C (122°F) for short periods. If the product is exposed to temperatures outside this range during storage, it should be
brought back within this range before operation. In any event, the product must always be operated outdoors, in a
well-ventilated area and away from doors, windows and other vents.
100107
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
Other ............................ 7
Assembly .............................. 8
Remove the Generator from the Shipping Carton . 8
Install the Wheel Kit .................... 8
Install the Support Leg .................. 8
Connect the Battery .................... 8
Add Engine Oil ........................ 9
Add Fuel ........................... 10
Grounding .......................... 10
Operation ............................. 11
Generator Location .................... 11
Grounding .......................... 11
Surge Protection ...................... 11
Starting the Engine .................... 12
Connecting Electrical Loads .............. 12
Stopping the Engine ................... 13
Do Not Overload Generator ............... 13
Capacity ......................... 13
Power Management .................. 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 ................. 15
Storage ............................ 16
Generator Storage ................... 16
Disconnect the Battery ............... 16
Charge the Battery .................. 16
Specifications .......................... 17
Engine Specifications .................. 17
Generator Specifications ................ 17
Fuel .............................. 17
Oil ............................... 17
Spark Plugs ......................... 17
Maintenance Valve Clearance ............. 17
An Important Message About Temperature .... 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
PORTABLE GENERATOR
7800 Starting Watts / 6500 Rated Watts
Electric Start
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ENGLISH 100107
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.
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.
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 and power
cables, 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.
Champion Power Equipment Support
Model Number
Serial Number
Date of Purchase
Purchase Location
1-877-338-0999
100107
For Oil Type see ‘Add Engine Oil‘ section. For Fuel Type see ‘Add Fuel‘ section.
INTRODUCTION
REV 100107-20140923 2
100107 ENGLISH
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.
MANUAL CONVENTIONS
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury.
CAUTION
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which, if
not avoided, may result in property damage.
CAUTION
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
DANGER
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
WARNING
If you have questions regarding your generator, we can
help. Please call our help line at 1-877-338-0999
NOTE
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ENGLISH 100107
SAFETY RULES
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.
DANGER
Sparks can result in fire or electrical shock.
When servicing the generator:
Disconnect the spark plug wire and place it where it
cannot contact the plug.
DO NOT check for spark with the plug removed.
Use only approved spark plug testers.
WARNING
Running engines produce heat. Severe burns can
occur on contact.
Combustible material can catch fire on contact.
DO NOT touch hot surfaces.
Avoid contact with hot exhaust gases.
Allow equipment to cool before touching.
Maintain at least 3 ft. (91.4 cm) of clearance on all
sides to ensure adequate cooling.
Maintain at least 5 ft. (1.5 m) of clearance from
combustible materials.
WARNING
Medical and Life Support Uses.
In case of emergency, call 911 immediately.
NEVER use this product to power life support
devices or life support appliances.
NEVER use this product to power medical devices
or medical appliances.
Inform your electricity provider immediately if you
or anyone in your household depends on electrical
equipment 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.
WARNING
The engine exhaust from this product contains
chemicals known to the state of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
Read this manual thoroughly before operating your
generator. Failure to follow instructions could result
in serious injury or death.
WARNING
REV 100107-20140923 4
100107 ENGLISH
SAFETY RULES
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
CAUTION
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.
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.
WARNING
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 before stopping the
generator.
DO NOT tamper with the governed speed.
DO NOT modify the generator in any way.
CAUTION
Fuel and fuel vapours 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.
DANGER
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ENGLISH 100107
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.
(1) Fuel Tank – 6.1 gallon (23 L) capacity fuel tank.
(2) Choke Lever – Used to start the engine.
(3) Fuel Valve – Turn this valve to the “ON” position to
supply fuel to the engine.
(4) Air Filter – Protects the engine by filtering dust
and debris from the intake air.
(5) Recoil Starter – Used to start the engine.
(6) Low Oil Sensor – Senses the level of oil in the
crankcase and shuts the engine down if the level
falls too low.
(7) Oil Filler Cap – Check and fill engine oil level.
(8) Battery – Used to start the engine.
(9) Power Panel – See “Power Panel”.
Generator
CONTROLS AND FEATURES
1
5
6
3
2
4
78
9
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100107 ENGLISH
Power Panel
(1) Ignition Switch – Press the switch to the “START”
position to start the generator, or to the “ON”
position to start the generator manually. Flip to the
“OFF” position to turn off the generator.
(2) 120V/30A Twist-Lock (NEMA L5-30R) – May be
used to supply electrical power for the operation
of 120 Volt AC, 30 Amp, single phase 60 Hz
electrical loads.
(3) 120/240V/30A Twist-Lock Receptacle
(NEMA L14-30R) – May be used to supply
electrical power for the operation of 120
and/or 240 Volt AC, 30 Amp, single phase 60 Hz
electrical loads.
(4) 120V/20A Duplex (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.
(5) Ground Terminal – Consult an electrician for local
grounding regulations.
(6) Circuit Breakers – Protects the generator against
electrical overload.
(7) Intelligauge – Tri-mode digital display for running
hours, voltage and hertz.
CONTROLS AND FEATURES
1 2 3 54
76
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ENGLISH 100107
Parts Included
Your 100107 Gasoline Powered Generator ships with the
following parts:
Wheel Kit
– 10 in. (25.4 cm) Wheel ...................2
– Bushing ..............................2
– Flange Bolt (M10x120 for Wheel) ............2
– Flat Washer ø10 ........................2
– Lock Nut (M10) ........................2
– Support Leg w/vibration mounts .............1
– Flange Bolt (M8x16 for Support Leg) ..........2
– Flange Lock Nut (M8) ....................2
Other
– Oil Funnel ............................1
– Spark Plug Socket ....................... 1
– Cap Screw (M5x10 for Battery Terminals) .......2
– Flange Nut (M5) ........................2
CONTROLS AND FEATURES
(Battery Bolts)
REV 100107-20140923 8
100107 ENGLISH
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.
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
You will need the following tools to install the wheels:
• 17 mm wrench OR adjustable wrench (not included)
• Socket wrench with a 16 mm socket (not included)
• Pliers (not included)
1. Before adding fuel and oil, tip the generator on it’s side.
2. Slide the flange bolt (M10x120) through the flat
washer, bushing and wheel.
3. Slide the bolt through the mount point on the frame.
4. Fasten securely with the M10 lock nut.
5. Repeat steps 2-4 to attach the second wheel.
Install the Support Leg
1. Attach the support leg to the generator frame with
flange bolts (M8x16) and flange lock nuts (M8).
2. Tip the generator slowly so that it rests on the
wheels and support leg.
The wheel kit is not intended for over-the-road use.
CAUTION
ASSEMBLY
Connect the Battery
1. Remove the protective cover from the red (+) lead on
the battery.
2. Attach the red (+)lead to the red (+) terminal on the
battery with the cap screw (M5x10) and secure with
the lock washer (M5)
3. Repeat steps 1-2 for the black (–) battery lead.
9 REV 100107-20140923
ENGLISH 100107
ASSEMBLY
Add Engine Oil 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 1.2 qt. (1.1 L) of oil and replace oil fill
cap/dipstick. DO NOT OVERFILL.
4. Check engine oil level daily and add as needed.
The engine is equipped with a low oil shut-off and
will stop when the oil level in the crankcase falls
below the threshold level.
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.
CAUTION
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.
NOTE
The recommended oil type is 10W-30 automotive oil.
NOTE
Synthetic oil may be used after the 5 hour initial
break-in period. Using synthetic oil does not
increase the recommended oil change interval.
NOTE
We consider the first 5 hours of run time to be
the break-in period for the unit. During the break
in period stay at or below 50% of the running
watt rating and vary the load occasionally to allow
stator windings to heat and cool. Adjusting the
load will also cause engine speed to vary and help
seat piston rings. After the 5 hour break-in period,
change the oil.
NOTE
Once oil has been added, a visual check should show
oil about 1-2 threads from running out of the fill hole.
If using the dipstick to check oil level, DO NOT screw
in the dipstick while checking.
NOTE Weather will affect engine oil and engine
performance. Change the type of engine oil used
based on weather conditions to suit the engine
needs.
NOTE
REV 100107-20140923 10
100107 ENGLISH
ASSEMBLY
Grounding
Your generator must be properly connected to an
appropriate ground to help prevent 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.
Failure to properly ground the generator can result in
electric shock.
WARNING
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.
NOTE
Add Fuel Cont’d.
Add Fuel
1. Use clean, fresh, regular unleaded fuel with a
minimum octane rating of 85 and an ethanol content
of less than 10% by volume.
2. DO NOT mix oil with fuel.
3. Clean the area around the fuel cap.
4. Remove the fuel cap.
5. Slowly add fuel to the tank. DO NOT OVERFILL. Fuel
can expand after filling. A minimum of 6.4 mm (¼ in.)
of space left in the tank is required for fuel expansion,
more than 6.4 mm (¼ in.) is recommended. Fuel can
be forced out of the tank as a result of expansion if it is
overfilled, and can affect the stable running condition of
the product. When filling the tank, it is recommended
to leave enough space for the fuel to expand.
6. Screw on the fuel cap and wipe away any spilled fuel.
Use regular unleaded gasoline with a minimum
octane rating of 85.
Do not mix oil and gasoline.
Fill tank to approximately 6.4 mm (¼ in.) 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.
CAUTION
Pouring fuel too fast through the fuel screen may
result in blow back of fuel at the operator while filling.
WARNING
11 REV 100107-20140923
ENGLISH 100107
Grounding
The generator system ground connects the frame to the
ground terminals on the power panel.
Surge Protection
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.
OPERATION
Voltage fluctuation may impair the proper
functioning of sensitive electronic equipment.
CAUTION
Generator Location
NEVER operate the generator inside any building,
including garages, basements, crawlspaces and sheds,
enclosure or compartment, including the generator
compartment of a recreational vehicle. Please consult
your local authority. In some areas, generators must
be registered with the local utility. Generators used at
construction sites may be subject to additional rules and
regulations. Generators should be on a flat, level surface
at all times. (Even while not in operation) Generators
must have at least 5 ft. (1.5 m) of clearance from all
combustible material. In addition to clearance from
all combustible material, generators must also have
at least 3 ft. (91.4 cm) of clearance on all sides to
allow for adequate cooling, maintenance and servicing.
Generators should never be started or operated in the
back of a SUV, camper, trailer, in the bed of a truck
(regular, flat or otherwise), under staircases/stairwells,
next to walls or buildings, or in any other location that
will not allow for adequate cooling of the generator
and/or the muffler. DO NOT contain generators during
operation. Allow generators to properly cool before
transport or storage.
Place the generator in a well-ventilated area. DO NOT
place the generator near vents or intakes where exhaust
fumes could be drawn into occupied or confined
spaces. Carefully consider wind and air currents when
positioning generator.
Failure to follow proper safety precautions may void
manufacturer’s warranty.
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.
WARNING
WARNING
During operation the muffler and exhaust fumes
produced will become hot. If adequate cooling and
breathing space are not supplied, or if the generator
is blocked or contained, temperatures can become
extremely heated and may lead to fire.
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100107 ENGLISH
Connecting Electrical Loads
1. Let the engine stabilize and warm up for a few
minutes after starting
2. Plug in and turn on the desired 120/240 Volt AC
single phase, 60 Hz electrical loads.
– DO NOT connect 3-phase loads to the generator.
– DO NOT connect 50 Hz loads to the generator.
– DO NOT overload the generator.
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.
NOTE
OPERATION
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. ELECTRIC START: Press and hold the ignition switch
to the “START” position. Release as the engine
begins to roll over. If the engine fails to start within
five seconds, release the switch and wait at least ten
seconds before attempting to start the engine again.
7. RECOIL START: Pull the starter cord slowly until
resistance is felt and then pull rapidly
8. Do not over-choke. As as soon as engine starts, move
the choke lever to the “RUN” position.
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.
NOTE
Keep choke lever in “Choke” position for only 1
pull of the recoil starter. After first pull, move choke
lever to the “Run” position for up to the next 3
pulls of the recoil starter. Too much choke leads to
sparkplug fouling/engine flooding due to the lack of
incoming air. This will cause the engine not to start.
NOTE
13 REV 100107-20140923
ENGLISH 100107
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.
Never exceed the specified capacity when adding
loads to the generator.
NOTE
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 ignition 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.
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.
NOTE
OPERATION
REV 100107-20140923 14
100107 ENGLISH
Air Filter
1. Remove the snap-on cover holding the air filter to
the assembly.
2. Remove the foam element.
3. Wash in liquid detergent and water. Squeeze
thoroughly dry in a clean cloth.
4. Saturate in clean engine oil.
5. Squeeze in a clean, absorbent cloth to remove all
excess oil.
6. Place the filter in the assembly.
7. Reattach the air filter cover and snap in place.
The owner/operator is responsible for all periodic
maintenance.
Complete all scheduled maintenance in a timely manner.
Correct any issue before operating the generator.
Never operate a damaged or defective generator.
Tampering with the factory set governor will void
your warranty.
Engine Maintenance
To prevent accidental starting, remove and ground spark
plug wire before performing any service.
Oil
Change oil when the engine is warm. Refer to the oil
specification to select the proper grade of oil for your
operating environment.
1. Remove the oil drain plug with a 15 mm socket and
extension.
2. Allow the oil to drain completely.
3. Replace the drain plug.
4. Remove oil fill cap/dipstick to add oil.
5. Add 1.2 qt. (1.1 L) of oil and replace oil fill
cap/dipstick. DO NOT OVERFILL.
6. Dispose of used oil at an approved waste
management facility.
Spark Plugs
1. Remove the spark plug cable from the spark plug.
2. Use the spark plug tool that shipped with your
generator to remove the plug.
3. Inspect the electrode on the plug. It must be clean and
not worn to produce the spark required for ignition.
4. Make certain the spark plug gap is 0.7 - 0.8 mm or
(0.028 - 0.031 in.).
5. Refer to the spark plug recommendation in
Specifications section when replacing the plug.
6. Carefully thread the plug into the engine.
7. Use the spark plug tool to firmly install the plug.
8. Attach the spark plug wire to the plug.
For service or parts assistance, contact our help
line at 1-877-338-0999
NOTE
Maintenance, replacement, or repair of emission
control devices and systems may be performed
by any non-road engine repair establishment or
individual.
NOTE
Once oil has been added, a visual check should show
oil about 1-2 threads from running out of the fill hole.
If using the dipstick to check oil level, DO NOT screw
in the dipstick while checking.
NOTE
WARNING
WARNING
Improper maintenance will void your warranty.
WARNING
Oil Cont’d.
MAINTENANCE AND STORAGE
0.7-0.8 mm
0.028-0.031 in.
15 REV 100107-20140923
ENGLISH 100107
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.
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.
Cleaning
DO NOT spray engine with water.
CAUTION
Water can contaminate the fuel system.
MAINTENANCE AND STORAGE
Maintenance Schedule
Follow the service intervals indicated in the following
maintenance schedule.
Service your generator more frequently when operating
in adverse conditions.
Contact our help line at 1-877-338-0999 to locate the
nearest Champion Power Equipment certified service
dealer for your generator or engine maintenance needs.
Spark Arrester
1. Allow the engine to cool completely before servicing
the spark arrester.
2. Remove the screws (3) 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 screws (3).
Failure to clean the spark arrester will result in
degraded engine performance.
CAUTION
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.
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.
DO NOT use a garden hose to clean the generator.
Water can enter the generator through the cooling
slots and damage the generator windings.
CAUTION
*To be performed by knowledgeable, experienced owners or
Champion Power Equipment certified dealers.
Every 8 hours or daily
Check oil level
Clean around air intake and muffler
First 5 hours
Change oil
Every 50 hours or every season
Clean air filter
Change oil if operating under heavy load or in hot
environments
Every 100 hours or every season
Change oil
Clean/Adjust spark plug
Check/Adjust valve clearance*
Clean spark arrester
Clean fuel tank and filter*
Every 250 hours
Clean combustion chamber*
Every 3 years
Replace fuel line
REV 100107-20140923 16
100107 ENGLISH
MAINTENANCE AND STORAGE
Disconnect the Battery
1. Remove the protective cover from the black/negative
battery lead.
2. Disconnect the black/negative lead from the black/
negative terminal on the battery and store the cap
screw (M5x10) and lock washer (M5).
3. Repeat steps 1-2 for the red/positive battery lead.
4. Store the battery in a cool, dry place.
Charge the Battery
Proper battery maintenance and storage should be
followed. A 12V automatic battery charger (not included)
with automatic trickle charging capability should be used
to charge the battery. Maximum charging rate should not
exceed 2 amps. Follow the instructions included with
the battery charger. The battery should be fully charged
at least once per month.
Generator exhaust contains odorless and colorless
carbon monoxide gas.
To avoid accidental or unintended ignition of your
electric start generator during periods of storage,
the following precautions should be followed:
– When storing the generator for short periods of
time make sure that the Ignition Switch and the
Fuel Valve are switched to the OFF position.
– When storing the generator for extended periods
of time make sure that the Ignition Switch
and the Fuel Valve are switched to the the
OFF position and the battery leads have been
disconnected from the battery.
DANGER
A Float Charger will maintain the battery condition
over long storage periods.
NOTE
Storage
The generator should be started at least once every 14
days and allowed to run for at least 20 minutes. For
longer term storage, please follow these guidelines.
Generator Storage
1. Add a properly formulated fuel stabilizer to the tank.
2. Be sure all appliances are disconnected from the
generator.
3. Run the generator for a few minutes so the treated
fuel cycles through the fuel system and carburetor.
4. Turn the fuel valve to the “Off” position.
5. Let the generator run until fuel starvation has
stopped the engine. This usually takes a few minutes.
6. The generator needs to cool completely before
cleaning and storage.
7. Clean the generator according to the maintenance section.
8. Change the oil.
9. Remove the spark plug and pour about 1⁄2 ounce
(14.8 mL) of oil into the cylinder. Crank the engine
slowly to distribute the oil and lubricate the cylinder.
10. Reattach the spark plug.
11. Store the unit in a clean, dry place out of direct
sunlight.
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.
NOTE
Generator Storage Cont’d.
17 REV 100107-20140923
ENGLISH 100107
Fuel
Fuel capacity is 6.1 gallons (23 L). Use regular
unleaded gasoline with a minimum octane rating of 85
and an ethanol content of less than 10% by volume.
Generator Specifications
– Model ...........................100107
– Rated Wattage ..................6500 Watts
– Starting Wattage .................7800 Watts
– AC Voltage ..................... 120/240 V
– Phase ............................Single
– Frequency .........................60 Hz
– Fuel Capacity ...............6.1 gallons (23 L)
– Gross Weight ..............212.7 lb. (96.5 kg)
– Net Weight .................200.6 lb. (91 kg)
– Height .................... 26 in. (66.1 cm)
– Width ................... 27.3 in. (69.3 cm)
– Length. . . . . . . . . . . . . . . . . . . 27.8 in. (70.5 cm)
SPECIFICATIONS
Engine Specifications
– Model .....................YF190FD-2-110
– Displacement .......................439cc
– Type ........................4-Stroke OHV
– Start Type ....................Electric Start
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.
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.).
Oil
Use 10W-30 automotive oil.
Oil capacity is up to 1.2 qt. (1.1 L).
DO NOT OVERFILL.
Please reference the following chart for recommended
oil types for use in the generator.
An Important Message About Temperature
Your Champion Power Equipment product is designed
and rated for continuous operation at ambient
temperatures up to 40°C (104°F). When your product is
needed your product may be operated at temperatures
ranging from -15°C (5°F) to 50°C (122°F) for short
periods. If the product is exposed to temperatures
outside this range during storage, it should be brought
back within this range before operation. In any event,
the product must always be operated outdoors, in a
well-ventilated area and away from doors, windows and
other vents.
Weather will affect engine oil and engine
performance. Change the type of engine oil used
based on weather conditions to suit the engine
needs.
NOTE
REV 100107-20140923 18
100107 ENGLISH
Wiring Diagram
SPECIFICATIONS
AVR
L
W
G
B
Y
R
YELLOW
BLACK
BLUE
GREEN
RED
WHITE
Br
WHITE BLUE
GREEN YELLOW
WHITE GREEN
BROWN
BLACK WHITE
B/W
W/L
G/Y
W/G
B
W
R
G/Y
G/Y
Y
Y
W
L
L
R
W
+
MW1
FW
EXW
In INDIGO
ENGINE BLOCK
GENERATOR BLOCK
EARTH
TERMINAL
SPARKING PLUG
IGNITION COILFUEL CUT
SOLENOIL
OIL LEVEL
SW
MW2
B
L14-30R
CONTROL BOX BLOCK
COMBINATION SW
L
Y
Y
L
L
L5-30R
B
W
R
R
L
B
R
M
Br
W
W
L
G/Y
CHARGE COIL BATTERY STARTER
DIODE
Br
B/G
B/G
R
B
34
2
16
5
OFF
ON
ST
COMBINATION SWITCH
R
B
R
B
B
W
G/Y
WW
Br
Br
DCW
6
5
4
3
2
1
B/W
B/W
B
ST
OFF
ON
multi-purpose meter
FUSE
10A
BNO USE
W/G
W/G
B
W
B
G/Y
B
Transition
R
W
YB
5-20R
W
CIRCUIT BREAKER
20A
G/Y
250V 25A
DOUBLE POLE
19 REV 100107-20140923
ENGLISH 100107
Parts Diagram
SPECIFICATIONS
16
17
18
19
20
28 29 30 3 1 32
33
34
30 3536
373837
39
40
41
42
43
44
45
46
47
48
30
36
49
51
52
53
54
84
73
76
77
78
79
81
82
83
85
55
58
17
59 60 61
62
63
64
65
66
67
68
69
71 72 7419
80
75
75
86
21 2223
24
2556
50
50
57
48
1
2
3456 8
9
10
11
12
13
14
15
878889 9091 9293
57 94 9 5 96 97
9899
105106107
108
110
111
102
103
104
9
56
70
7
100
101
26
27
109
113
112
REV 100107-20140923 20
100107 ENGLISH Parts List
#Part Number Description Qty
1122.070100.07 Fuel Tank Cap 1
2122.070300.03 Fuel Filter 1
324.070800.00 Reversal Valve 1
42.06.006 Clamp (Ø7×Ø1) 1
524.070030.00 Hole, Breather Tube 1
6152.070014.06 Pipe, Reversal Valve, 730
mm 1
72.05.001 Clamp (Ø8×6.5) 2
81.5789.0620.2 Flange Bolt M6×20 4
91.93.06 Lock Washer Ø6 8
10 2.03.004 Washer (Ø24×Ø6.5×1.5) 4
11 122.070015.01 Mount Vibration, Fuel Tank 4
12 152.071000.31.48 Fuel Tank, Yellow 1
13 122.070400.05 Fuel Cock 1
14 2.06.007 Clamp (Ø8×b6) 2
15 152.070011.07 Pipe, Fuel, 195 mm 1
16 45.090006.20 Holder, Air Cleaner 1
17 1.6177.1.06 Flange Lock Nut M6 2
18 1.848.08 Washer Ø8 2
19 1.93.08 Lock Washer Ø8 2
20 1.6175.08 Nut M8 2
21 46.100001.07 Muffler Gasket 1
22 46.101000.01.2 Muffler Assembly 1
23 1.9074.4.0510 Screw/Washer Assembly
M5×10 3
24 46.101300.00 Spark Arrester Assembly 1
25 1.16674.0820 Flange Bolt M8×20 1
26 2.13.009 Bushing (Ø9× Ø13×16) 1
27 1.16674.08 35 Flange Bolt M8×35 1
28 152.190300.00 Carbon Bursh Assembly 1
29 122.190004.01 Pinch, Carbon Brush 1
30 1.93.05 Lock Washer Ø5 5
31 1.5783.0520 Bolt M5×20 1
32 122.190400.00 Terminal Block 1
33 152.190003.00.48 Generator End Cover, Yellow 1
34 1.16674.0512.2 Flange Bolt M5×12 2
35 1.5783.0516 Bolt M5×16 2
36 1.97.1.05 Washer Ø5 4
37 1.16674.0516 Flange Bolt M5×16 3
38 153.190200.04 AVR (6KW CSA) 1
39 152.190002.00 End Housing 1
40 2.08.032 Flange Bolt M6×179 4
41 1.97.1.06 Washer Ø6 4
42 2.08.035 Bolt M5 ×214 2
43 1.6175.05 Nut M5 2
44 152.191002.00 Stator Cover 1
45 152.191200.27 Stator Assembly, Al, 140
mm, NO DC , CSA 1
46 2.08.034 Flange Bolt M10×265 1
47 1.7244.10 Lock Washer Ø10 1
48 1.96.10 Washer Ø10 3
49 152.191100.26 Rotor Assembly, Al, 140 mm,
NO DC , CSA 1
50 1.5789.0608 Flange Bolt M6×8 2
51 152.192300.01 Air Guide 1
52 152.190005.00 Rubber, Fore-Cover, A 1
53 152.190005.01 Rubber, Fore-Cover, B 1
54 47. 6 0 5 Engine 1
55 5.1900.029 Grounding Line 150 mm 1
56 1.5789.0612 Flange Bolt M6×12 5
57 1.862.06 Lock Washer Ø6 2
58 152.201200.00 Motor Mount 2
#Part Number Description Qty
59 1.894.1.10 Circlip Ø10 2
60 152.200703.04 Long Pin, Handle 2
61 1.894.1.08 Circlip Ø8 2
62 152.200703.02 Short Pin, Handle 2
63 152.200701.02.2 Handle, U Shape 1
64 152.200702.02 Cover, Handle 1
65 6.5.238.402.2 Frame 1
66 1.6177.1.10 Flange Lock Nut M10 2
67 152.201200.03 Motor Mount, I 1
68 1.5782.10120 Bolt M10 ×120 2
69 253.200016.00 Bushing (Ø16×Ø10.5×69.5) 2
70 152.201701.04.48 10 in. Wheel, Yellow 2
71 1.6182.10 Lock Nut M10 2
72 152.201200.04 Motor Mount, II 1
73 1.5789.0835 Flange Bolt M8×35 2
74 1.96.08 Washer Ø8 2
75 1.6177.1.08 Flange Lock Nut M8 8
76 1.5789.0816 Flange Bolt M8×16 2
77 152.200002.01.2 Support Leg, 84 mm 1
78 152.201400.00 Rubber, Support 2
79 1.5789.0825 Flange Bolt M8×25 2
80 1.9074.3.0510 Screw/Washer Assembly
M5×10 2
81 1.6177.1.05 Flange Lock Nut M5 2
82 9.1000.150 Battery 12V15AH 1
83 152.200904.00 Pinch, Rubber 1
84 5.1900.025 Black Wire, 320 mm, Battery 1
85 5.1900.024 Red Wire, 480 mm, Battery 1
86 152.200013.01 Jacket, Wire 3
87 152.159.20.2 Control Panel 1
88 5.1000.001.3 Ignition Switch 1
89 5.1120.023 Receptacle L5-30R, CSA 1
90 5.1120.026 Receptacle L14-30R, CSA 1
91 5.1120.027 Receptacle 5-20R Duplex,
CSA 1
92 1.9074.4.0414.1 Screw/Washer Assembly
M4×14, Black 8
93 1.6177.1.04.1 Flange Lock Nut M4, Black 8
94 1.5783.0622.3 Bolt M6×22, Green 1
95 1.6175.06.3 Nut M6, Green 2
96 1.97.1.06.3 Washer Ø6, Green 2
97 1.93.06.3 Lock Washer Ø6, Green 2
98 5.1430.002 Intelligauge 1
99 5.1240.925 AC 25A Breaker, Double
Pole, CSA 1
100 1.9074.4.0306.1 Screw/Washer Assembly
M3×6, Black 4
101 5.1210.920 AC 20A Breaker, Push
Button, CSA 1
102 152.210003.01 Wire Jacket, Control Box,
CSA 1
103 5.1310.004 Conduit (Metal, 180 mm)
CSA 1
104 152.210003.03 Plug, Control Box, CSA 1
105 5.1810.000 Over Voltage Protector, CSA 1
106 1.823.0514 Screw M5×14 2
107 5.1800.000 Rectifier 1
108 1.9074.1.0538.2 Screw/Washer Assembly
M5×38 3
109 5.1280.003 Fuse (10A) 1
110 122.210003.00 Grommet 1
111 152.210002.10 Control Box 1
112 100107.21.10 Wire Assembly 1
113 100107.21 Control Panel Assembly 1
21 REV 100107-20140923
ENGLISH 100107
Engine Parts Diagram
SPECIFICATIONS
45
64
40
102
103
104
105
91
106
107
110
109
108
85
10
1
2
345678911
12 13 14 15 16 17 18 19 20 16
24 25
26 27 28 29 30 31
33 34 35 12 36 30 37 38
23 39
41
42
43
44
46 47 48 49 50 51 52 53 12 54 55
57
58
59
60 61
62
65 66
68 69 70 71 72 73 74 75 76 77 78 79 80 81 82
86
87
88
67
83 84
56
94
95
96
111
89
97 98 99 100101
221 22 23
93
89
112
63
32
92
113
114
90
91
REV 100107-20140923 22
100107 ENGLISH Parts List
#Part Number Description Qty
121.061300.00 Recoil Handle 1
21.5789.0608 Flange Bolt M6×8 4
346.061100.00.2 Recoil Starter Cover, Black 1
445.060005.00 Recoil Starter Spring 1
545.061102.00 Recoil Starter Reel 1
62.10.003 Rope (Ø5×1550) 1
745.060003.00 Spring, Ratchet 2
845.060002.00 Starter Ratchet (Iron) 2
945.060009.00 Spring, Ratchet Guide 1
10 45.060007.00 Ratchet Guide 1
11 45.060008.00 Screw, Ratchet Guide 1
12 1.5789.0612 Flange Bolt M6×12 12
13 2.05.005 Clamp (Ø6) 2
14 47.080100.01.48 Fan Cover, Yellow 1
15 2.02.007 Nut (M16×1.5) 1
16 1.5789.0629 Flange Bolt M6×29 4
17 45.060001.00 Pulley, Starter 1
18 46.123000.01 Ignition Coil 1
19 47.080001.00 Cooling Fan 1
20 46.120100.04 Flywheel (Electric Start EPA) 1
21 45.030006.00 Plate, Coil 1
22 45.121000.00 Charging Coil 1
23 2.11.007 Oil Seal (Ø35×Ø52×8) 2
24 2.05.050 Wire Clip, 100 mm 1
25 45.030032.00 Sheath, Wire 1
26 2.03.023 Washer (Ø12.5×Ø20×2) 2
27 47.030100.01 Crankcase 1
28 45.127000.02 Oil Level Sensor 1
29 1.5789.0615 Flange Bolt M6×15 2
30 1.276.6202 Bearing 6202 2
31 47.050006.00 Weight Balancer 1
32 47.050100.01 Crankshaft 1
33 46.030008.00 Gasket, Crankcase Cover 1
34 2.04.001 Dowel Pin (Ø9×14) 2
35 46.080600.00 Air Guide, Right Side 1
36 1.276.6207 Bearing 6207 1
37 46.031000.01.48 Oil Dipstick Assembly, Yellow 1
38 45.030007.00 Crankcase Cover 1
39 1.5789.0840.0.8 Flange Bolt M8×40 7
40 2.03.021.1 Washer (Ø6.4×Ø13×1), Black 1
41 45.110013.00 Shaft, Governor Gear 1
42 45.110100.00 Governor Gear 1
43 21.110 011.00 Clip, Governor Gear 1
44 45.110012.00 Bushing, Governor Gear 1
45 47.050200.00 Connecting Rod 1
46 47.050005.01 Piston 1
47 2.09.004 Circlip (Ø21×Ø1) 2
48 45.050003.00 Pin, Piston 1
49 46.050303.02 Ring, Oil 1
50 46.050302.02 Ring, Second Piston 1
51 46.050301.02 Ring, First Piston 1
52 2.04.004 Dowel Pin (Ø12×20) 2
53 46.030009.02 Gasket, Cylinder Head 1
54 46.080400.00 Air Guide, Lower 1
55 47.010100.01 Cylinder Head 1
56 2.01.010 Stud Bolt M8×35 2
57 2.15.002(F6RTC) Spark Plug (F6RTC) 1
58 2.08.014 Flange Bolt M10×80 4
59 46.020002.00 Gasket, Cylinder Head Cover 1
60 47.021000.00 Cylinder Head Cover (CPE) 1
61 45.020001.02 Breather Tube 1
#Part Number Description Qty
62 47.020100.00 Bolt, Cylinder Head Cover 1
63 2.08.039 Drain Bolt (M12×1.5×15) 2
64 47.041000.01 Camshaft (EPA) 1
65 47.040004.00 Valve Lifter 2
66 47.040002.00 Intake Valve 1
67 47.040006.00 Exhaust Valve 1
68 46.040005.00 Push Rod 2
69 45.040015.00 Retainer, Valve Spring (Down) 2
70 45.040017.00 Oil Seal, Valve 2
71 45.040003.00 Valve Spring 2
72 23.040010.00 Bolt, Rocker Arm 2
73 45.040001.00 Retainer, Intake Valve Spring (Up) 1
74 45.040007.00 Retainer, Exhaust Valve Spring
(Up) 1
75 45.040008.00 Rotator, Exhaust Valve 1
76 46.040004.00 Guide Plate, Push Rod 1
77 46.040016.00 Shaft, Rocker Arm 1
78 46.040201.00 Retainer, Rocker Arm 1
79 46.040009.00 Rocker Arm, Intake Valve 1
80 46.040018.00 Rocker Arm, Exhaust Valve 1
81 1.97.1.06 Washer Ø6 2
82 22.040012.00 Screw, Valve Adjustment 2
83 1.6177.1.06 Flange Lock Nut M6 2
84 21.040021.00 Lock Nut (M6×0.5) 2
85 2.01.008 Stud Bolt (M6×M8×105) 2
86 46.130002.20 Insulator Gasket 1
87 45.130001.00 Carburetor Insulator 1
88 46.130003.20 Carburetor Gasket 1
89 47.131000.21 Carburetor 1
90 46.130004.20 Gasket, Air Cleaner 1
91 1. 617 7. 0 6 Flange Nut M6 3
92 46.091100.03 Base, Air Cleaner 1
93 45.091002.20 Seal, Air Cleaner 1
94 45.091001.20 Separator, Air Cleaner 1
95 45.091003.20 Element, Air Cleaner 1
96 46.091200.04 Cover, Air Cleaner 1
97 1.5789.0835 Flange Bolt M8×35 2
98 45.125100.00 Starter Motor Assembly 1
99 45.125200.03 Relay, Starter (Three Gear) 1
100 1.93.05 Lock Washer Ø5 2
101 1.16674.0516 Flange Bolt M5×16 2
102 45.110001.00 Shaft, Governor Arm 1
103 2.03.019 Washer (Ø8.2×Ø17×0.8) 1
104 2.11.006 Oil Seal (Ø7×Ø14×5) 1
105 45.110008.00 Pin, Shaft 1
106 45.110003.00 Governor Arm 1
107 2.08.040 Bolt (M6×21), Governor Arm 1
108 45.110006.00 Governor Rod 1
109 45.110005.00 Spring, Throttle Return 1
110 45.110007.00 Governor Spring 1
111 46.080300.20 Air Guide, Upper 1
112 47.131017.21 Standard Main Jet 1
113 46.091000.03 Air Cleaner Assembly 1
114 46.061000.00 Recoil Assembly 1
23 REV 100107-20140923
ENGLISH 100107
TROUBLESHOOTING
Problem Cause Solution
Generator will not start No fuel Add fuel
Faulty spark plug Replace spark plug
Unit loaded during start up Remove load from unit
Generator will not start;
Generator starts but runs roughly
Low oil level Fill crankcase to the proper level
Place generator on a flat, level surface
Choke in the wrong position Adjust choke.
Spark plug wire loose Attach wire to spark plug
Generator will not start electrically Generator battery is dead Recharge generator battery
Battery switch is in the “OFF”
position
Turn battery switch to “ON” position
Generator shuts down during operation Out of fuel Fill fuel tank
Low oil level Fill crankcase to the proper level.
Place generator on a flat, level surface
Generator cannot supply enough
power or overheating
Generator is overloaded Review load and adjust. See “Power
Management”
Insufficient ventilation Check for air restriction. Move to a
well ventilated area
No AC output Cable not properly connected Check all connections
Connected device is defective Replace defective device
Circuit breaker is open Reset circuit breaker
Faulty brush assembly Replace brush assembly (Service
Center)
Faulty AVR (auto voltage regulator) Replace AVR (Service Center)
Loose wiring Inspect and tighten wiring connections
Other Contact the help line.
Generator gallops Engine governor defective Contact the help line
Repeated circuit breaker tripping Overload Review load and adjust. See “Power
Management”
Faulty cords or device Check for damaged, bare or frayed
wires. Replace defective 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
REV 100107-20140923 24
100107 ENGLISH
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 labour) and two years (parts) from the
original date of purchase (90 days (parts and labour)
and 180 days (parts) for commercial and 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 labour 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 province to province. Your province may
also have other rights you may be entitled to that are not
listed within this warranty.
Contact Information
Address
Champion Power Equipment, Inc.
Customer Service
12039 Smith Ave.
Santa Fe Springs, CA 90670
www.championpowerequipment.com
Customer Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
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
WARRANTY
Champion Power Equipment, Inc (CPE),
Emission Control System Warranty
Your Champion Power Equipment (CPE) engine complies with Environment Canada (EC) emission
regulations.
YOUR WARRANTY RIGHTS AND OBLIGATIONS:
CPE is pleased to explain the Emission Control Systems Warranty on your 2014 small off-road engine.
New engines must be designed, built and equipped, at the time of sale, to meet EC regulations for small
non-road engines. CPE must warrant the emission control system on your small off-road engine for the
period of time listed below, provided there has been no abuse, neglect, unapproved modification, or
improper maintenance of your small off-road engine.
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 off-road 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, CPE
dealer or CPE, Santa Fe Springs, CA., USA as soon as a problem exists. The warranty repairs should be
completed in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding your warranty rights and responsibilities, you should contact:
Champion Power Equipment, Inc.
Customer Service
12039 Smith Ave.
Santa Fe Springs, CA 90670
USA
Tel: 1-877-338-0999
tech@championpowerequipment.com
EMISSION CONTROL SYSTEM WARRANTY
The following are specific provisions relative to your Emission Control System Warranty
Coverage.
Emission Control System Warranty (ECS Warranty):
1. APPLICABILITY: 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 the Canadian Environmental Protection Act, 1999 (CEPA 1999).
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 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.
g. 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.
h. 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.
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.
EMISSION-RELATED PARTS INCLUDE THE FOLLOWING: (using those portions of the list
applicable to the engine)
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.
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. Claims for repair or adjustment found to be caused solely by
defects in material or workmanship will not be denied because the engine was not properly maintained
and used.
If you have any questions regarding your warranty rights and responsibilities, or to obtain
warranty service, please write or call Customer Service at Champion Power Equipment, Inc.
Champion Power Equipment, Inc.
12039 Smith Ave.
Santa Fe Springs, CA 90670
USA
1-877-338-0999
Attn: Customer Service
tech@championpowerequipment.com

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