Champion Power Equipment 42432 Owners Manual 42432_manual English_10 15 2012

2015-08-26

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OWNER’S MANUAL & OPERATING INSTRUCTIONS
10006 Santa Fe Springs Road
Santa Fe Springs CA 90670
USA / 1-877-338-0999
www.championpowerequipment.com
1800 Starting Watts / 1400 Rated Watts
PORTABLE GENERATOR
SAVE THESE INSTRUCTIONS
Important Safety Instructions
are included in this manual.
MADE IN CHINA
REV 42432-20121015
42432
MODEL NUMBER
warranty_badges.pdf 1 8/18/11 10:45 AM
*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
WARNING:
The Engine Exhaust from this product contains chemicals known to the State of California
to cause cancer, birth defects or other reproductive harm.
42432
PORTABLE GENERATOR
1800 Starting Watts / 1400 Rated Watts
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
Other ............................ 7
Assembly .............................. 8
Remove the Generator from the Shipping Carton . 8
Attaching the Engine Vibration Mounts ........ 8
Attaching the Alternator Vibration Mounts ...... 8
Add Engine Oil ........................ 8
Add Fuel ............................ 9
Grounding ........................... 9
Intalling the Spark Arrester ................ 9
Operation ............................. 10
Generator Location .................... 10
Grounding .......................... 10
Surge Protection ...................... 10
Starting the Engine .................... 10
Connecting Electrical Loads .............. 11
Stopping the Engine ................... 11
Do Not Overload Generator ............... 11
Capacity ......................... 11
Power Management .................. 11
Maintenance and Storage .................. 12
Engine Maintenance ................... 12
Oil ............................. 12
Spark Plugs ....................... 12
Air Filter ......................... 12
Spark Arrester ..................... 13
Cleaning ......................... 13
Adjustments ....................... 13
Maintenance Schedule .................. 13
Generator Maintenance ................. 14
Storage ............................ 14
Generator Storage ................... 14
Specifications .......................... 15
Engine Specifications .................. 15
Generator Specifications ................ 15
Fuel .............................. 15
Oil ............................... 15
Spark Plugs ......................... 15
Valve Clearance ....................... 15
Wiring Diagram ....................... 16
Parts Diagram ........................ 17
Parts List ........................... 18
Engine Parts Diagram .................. 19
Engine Parts List ..................... 20
Troubleshooting ......................... 21
Warranty ............................. 22
Warranty Qualifications ................. 22
Repair/Replacement Warranty ............. 22
Do Not Return The Unit To
The Place Of Purchase .................. 22
Warranty Exclusions. . . . . . . . . . . . . . . . . . . . 22
Normal Wear ...................... 22
Installation, Use and Maintenance ........ 22
Other Exclusions .................... 22
Limits of Implied Warranty
and Consequential Damage ............ 22
Contact Information .................... 22
Address .......................... 22
Customer Service ................... 22
Technical Service ................... 22
1 REV 42432-20121015
ENGLISH 42432
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, power
cables and storm kits, please visit our web site at:
www.championpowerequipment.com
This Booklet
Every effort has been made to ensure the accuracy and
completeness of the information in this manual. We reserve
the right to change, alter and/or improve the product and
this document at any time without prior notice.
Champion Power Equipment Support
Model Number
Serial Number
Date of Purchase
Purchase Location
1-877-338-0999
42432
For Oil Type see ‘Add Engine Oil‘ section. For Fuel Type see ‘Add Fuel‘ section.
INTRODUCTION
REV 42432-20121015 2
42432 ENGLISH
MANUAL CONVENTIONS
This manual uses the following symbols to help differentiate between different kinds of information. The safety symbol
is used with a key word to alert you to potential hazards in operating and owning power equipment.
Follow all safety messages to avoid or reduce the risk of serious injury or death.
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
3 REV 42432-20121015
ENGLISH 42432
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 three feet of clearance on all sides
to ensure adequate cooling.
Maintain at least five feet of clearance from
combustible materials.
WARNING
Medical and Life Support Uses.
In case of emergency, call 911 immediately.
NEVER use this product to power life support
devices or life support appliances.
NEVER use this product to power medical devices
or medical appliances.
Inform your electricity provider immediately if you
or anyone in your household depends on electrical
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 42432-20121015 4
42432 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
Fuel and fuel vapors are highly flammable and
extremely explosive.
Fire or explosion can cause severe burns or death.
Unintentional startup can result in entanglement,
traumatic amputation or laceration.
When adding or removing fuel:
Turn the generator off and let it cool for at least two
minutes before removing the fuel cap. Loosen the
cap slowly to relieve pressure in the tank.
Only fill or drain fuel outdoors in a well-ventilated area.
DO NOT pump gas directly into the generator at the
gas station. Use an approved container to transfer
the fuel to the generator.
DO NOT overfill the fuel tank.
Always keep fuel away from sparks, open flames,
pilot lights, heat and other sources of ignition.
DO NOT light or smoke cigarettes.
When starting the generator:
DO NOT attempt to start a damaged generator.
Make certain that the gas cap, air filter, spark plug,
fuel lines and exhaust system are properly in place.
Allow spilled fuel to evaporate fully before
attempting to start the engine.
Make certain that the generator is resting firmly on
level ground.
When operating the generator:
DO NOT move or tip the generator during operation.
DO NOT tip the generator or allow fuel or oil to spill.
When transporting or servicing the generator:
Make certain that the fuel shutoff valve is in the off
position and the fuel tank is empty.
Disconnect the spark plug wire.
When storing the generator:
Store away from sparks, open flames, pilot lights,
heat and other sources of ignition.
DANGER
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
5 REV 42432-20121015
ENGLISH 42432
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
CONTROLS AND FEATURES
(1) Fuel Tank – 1.45 gal. (5.5 L) capacity fuel tank.
(2) Choke – Used to start the engine.
(3) Fuel Valve – Turn this valve to the “ON” position to
supply fuel to the engine.
(4) Air Cleaner – Protects the engine by filtering dust
and debris from the intake air.
(5) Recoil Starter – Used to manually start the engine.
(6) Oil Filler Cap – Check and fill engine oil level.
(7) Power Panel – See “Power Panel” section.
3
2
4
765
1
REV 42432-20121015 6
42432 ENGLISH
Power Panel
CONTROLS AND FEATURES
1 2 3
4 5
(1) Engine Switch – Used to turn the generator on and
off.
(2) Voltmeter – Used to display alternator output
voltage.
(3) Circuit Breaker – Protects the generator against
electrical overloads. Push to reset breaker.
(4) 120 Volt AC, 20 Amp Receptacle (NEMA 5-20R)
– May be used to supply electrical power for the
operation of 120 Volt AC, 10 Amp, single phase
60 Hz electrical loads.
(5) Ground Terminal – Consult an electrician for local
grounding regulations.
7 REV 42432-20121015
ENGLISH 42432
CONTROLS AND FEATURES
Parts Included
Your 42432 Gasoline Powered Generator ships with the
following parts:
Spark Arrester Kit
– Spark Arrestor ......................... 1
– Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
– Screw with Lock Washer .................... 2
Other
– Vibration Mount (Engine Side) ............... 2
– Vibration Mount (Alternator Side) .............2
– Nut (M8) ............................. 4
– Flange Bolt M8x20 ...................... 2
– Oil Funnel ............................ 1
– Spark Plug Socket .......................1
Engine Side Mount
Alternator Side Mount
REV 42432-20121015 8
42432 ENGLISH
ASSEMBLY
Your generator requires some assembly. This unit ships
from our factory without oil. It must be properly serviced
with fuel and oil before operation.
If you have any questions regarding the assembly of your
generator, call our help line at 1-877-338-0999. Please
have your serial number and model number available.
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.
1. Place the generator on a flat, level surface.
2. Remove oil fill cap/dipstick to add oil.
3. Add 0.42 qt. (0.4 L) of oil and replace oil fill cap/
dipstick. Once oil has been added, a visual check
should show oil about 1-2 threads from running out of
the fill hole.
4. Check engine oil level daily and add as needed.
The recommended oil type is 10W-30 automotive oil.
NOTE
Add Engine Oil
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
The engine is equipped with a low-oil-shutoff and will
stop when the oil level in the crankcase falls below the
threshold level.
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
Attaching the Engine Vibration Mounts
1. Thread the vibration mount bolt through the frame
(engine side).
2. Firmly secure the bolt to the frame with the M8 nut.
Tighten. DO NOT over tighten.
3. Repeat steps 1-2 for the remaining mount (2 total).
Attaching the Alternator Vibration Mounts
1. Thread the flange bolt (M8x20) through the vibration
mount and then through the frame (alternator side).
2. Firmly secure the bolt to the frame with the M8 nut.
Tighten. DO NOT over tighten.
3. Repeat steps 1-2 for the remaining mount (2 total).
9 REV 42432-20121015
ENGLISH 42432
ASSEMBLY
Add Fuel
1. Use clean, fresh, regular unleaded fuel with a
minimum octane rating of 85 and an ethanol content
of less than 10% by volume.
2. DO NOT mix oil with fuel.
3. Clean the area around the fuel cap.
4. Remove the fuel cap.
5. Slowly add fuel to the tank. DO NOT overfill. Allow
approximately ¼ inch of space for fuel expansion.
6. Screw on the fuel cap and wipe away any spilled fuel.
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
Use regular unleaded gasoline with a minimum
octane rating of 85.
Do not mix oil and gasoline.
Fill tank to approximately ¼” below the top of the
tank to allow for fuel expansion.
DO NOT pump gas directly into the generator at the
gas station. Use an approved container to transfer
the fuel to the generator.
DO NOT fill fuel tank indoors.
DO NOT fill fuel tank when the engine is running or hot.
DO NOT overfill the fuel tank.
DO NOT light cigarettes or smoke when filling the
fuel tank.
CAUTION
Pouring fuel too fast through the fuel screen may
result in blow back of fuel at the operator while filling.
WARNING
Failure to install the spark arrester may result in an
increased risk of fire.
CAUTION
Installing 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.
Secure the cover plate with the two screws and lock
washers provided with the spark arrester kit.
Federal and local laws and administrative
requirements indicate when and where spark
arresters are required. When ordered, spark arresters
are required for operation of this generator in
National Forest lands. In California, this generator
must not be used on any forest- covered land, brush-
covered land, or grass- covered land unless the
engine is equipped with a spark arrester.
NOTE
REV 42432-20121015 10
42432 ENGLISH
OPERATION
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.
Voltage fluctuation may impair the proper
functioning of sensitive electronic equipment.
CAUTION
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
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 engine switch to the “ON” position.
5. Move the choke lever to the “CHOKE” position.
6. Pull the starter cord slowly until resistance is felt and
then pull rapidly
7. Do not over-choke. As as soon as engine starts, move
the choke lever to the “RUN” position.
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
Grounding
The generator system ground connects the frame to the
ground terminals on the power panel.
– The generator (stator winding) is isolated from the
frame and from the AC receptacle ground pin.
– Electrical devices that require a grounded receptacle
pin connection may not function properly.
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 five feet of clearance from all
combustible material. In addition to clearance from all
combustible material, generators must also have at least
three feet 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.
11 REV 42432-20121015
ENGLISH 42432
OPERATION
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.
2. Allow the engine to run for several minutes to stabilize.
3. Plug in and turn on the first item. It is best to turn
on the item with the largest load first.
4. Allow the engine to stabilize.
5. 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
Connecting Electrical Loads
1. Let the engine stabilize and warm up for a few
minutes after starting
2. Plug in and turn on the desired 120 Volt AC single
phase, 60 Hz electrical loads.
– DO NOT connect 3-phase loads to the generator.
– DO NOT connect 50 Hz loads to the generator.
– DO NOT overload the generator.
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
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
REV 42432-20121015 12
42432 ENGLISH
MAINTENANCE AND STORAGE
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.
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
WARNING
WARNING
Improper maintenance will void your warranty.
WARNING
Once oil has been added, a visual check should show
oil about 1-2 threads from running out of the fi ll hole.
If using the dipstick to check oil level, DO NOT screw
in the dipstick while checking.
NOTE
Engine Maintenance
To prevent accidental starting, remove and ground spark
plug wire before performing any service.
Oil
Change oil when the engine is warm. Refer to the oil
specifi cation to select the proper grade of oil for your
operating environment.
1. Remove the oil drain plug with a 12 mm socket and
extension.
2. Allow the oil to drain completely.
3. Replace the drain plug.
4. Remove oil fi ll cap/dipstick to add oil.
5. Add 0.42 qt. (0.4 L) of oil and replace oil fi ll
cap/dipstick.
6. Dispose of used oil at an approved waste
management facility.
Air Filter
1. Using your fi ngers, unscrew the thumb screws of the
top and bottom holes of the air fi lter cover.
2. Remove the plastic outer casing.
3. Remove the foam element.
4. Wash in liquid detergent and water. Squeeze
thoroughly dry in a clean cloth.
5. Saturate in clean engine oil.
6. Squeeze in a clean, absorbent cloth to remove all
excess oil.
7. Place the fi lter in the assembly.
8. Reattach the air fi lter cover and using your fi ngers,
insert the thumb screws into the top and bottom
holes of the air fi lter cover. Screw until tight. Be sure
not to over tighten.
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 - 0.8mm or
(0.028 - 0.031 in.).
5. Refer to the spark plug recommendation chart when
replacing the plug.
6. Carefully thread the plug into the engine.
7. Use the spark plug tool to fi rmly install the plug.
8. Attach the spark plug wire to the plug.
0.7 - 0.8 mm
0.028 - 0.031 in.
Oil Cont’d.
13 REV 42432-20121015
ENGLISH 42432
Adjustments
The air-fuel mixture is not adjustable. Tampering with
the governor can damage your generator and your
electrical devices and will void your warranty. CPE
recommends that you contact our service line at
1-877-338-0999 for all other service and/or adjustment
needs.
Maintenance Schedule
Follow the service intervals indicated in the following
maintenance schedule.
Service your generator more frequently when operating
in adverse conditions.
Contact our helpline at 1-877-338-0999 to locate the
nearest Champion Power Equipment certified service
dealer for your generator or engine maintenance needs.
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
*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 3 years
Replace fuel line
Spark Arrester
1. Allow the engine to cool completely before servicing
the spark arrester.
2. Remove the two screws holding the cover plate which
retains the end of the spark arrester to the muffler.
3. Remove the spark arrester screen.
4. Carefully remove the carbon deposits from the spark
arrester screen with a wire brush.
5. Replace the spark arrester if it is damaged.
6. Position the spark arrester in the muffler and attach
with the two screws.
Failure to clean the spark arrester will result in
degraded engine performance.
CAUTION
REV 42432-20121015 14
42432 ENGLISH
MAINTENANCE AND STORAGE
Generator Maintenance
Make certain that the generator is kept clean and stored
properly. Only operate the unit on a flat, level surface in
a clean, dry operating environment. DO NOT expose the
unit to extreme conditions, excessive dust, dirt, moisture
or corrosive vapors.
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.
Generator exhaust contains odorless and colorless
carbon monoxide gas.
To avoid accidental or unintended ignition of your
generator during periods of storage, the following
precautions should be followed:
– When storing the generator for short or extended
periods of time make sure that the Engine
Switch and the Fuel Valve are set in the OFF
position.
DANGER
Storage
The generator should be started at least once every 14
days and allowed to run for at least 20 minutes. For
longer term storage, please follow these guidelines.
Generator Storage
1. Add a properly formulated fuel stabilizer to the tank.
2. Be sure all appliances are disconnected from the
generator.
3. Run the generator for a few minutes so the treated
fuel cycles through the fuel system and carburetor.
4. Turn the fuel valve to the “Off” position.
5. Let the generator run until fuel starvation has
stopped the engine. This usually takes a few minutes.
6. The generator needs to cool completely before
cleaning and storage.
7. Clean the generator according to the maintenance section.
8. Change the oil.
9. Remove the spark plug and pour about 1⁄2 ounce
of oil into the cylinder. Crank the engine slowly to
distribute the oil and lubricate the cylinder.
10. Reattach the spark plug.
11. Store the unit in a clean, dry place out of direct
sunlight.
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.
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
15 REV 42432-20121015
ENGLISH 42432
Oil
Use 10W-30 automotive oil.
Oil capacity is 0.42 qt. (0.4 L).
Please reference the following chart for recommended
oil types for use in the generator.
Fuel
Fuel capacity is 1.45 gal. (5.5 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 ........................... 42432
– Running Wattage ................. 1400 Watts
– Starting Wattage ................. 1800 Watts
– AC Load .......................... 120 V
– Phase ............................ Single
– Frequency ......................... 60 Hz
– Fuel Capacity ................ 1.45 gal. (5.5 L)
– Gross Weight ............... 66.14 lbs (30 kg)
– Net Weight ................. 59.52 lbs (27 kg)
– Height ................ 15.15 inches (38.5 cm)
– Width ............... 14.37 inches (36.5 cm)
– Length. . . . . . . . . . . . . . . . . 17.72 inches (45 cm)
SPECIFICATIONS
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 E6RTC
Replacement spark plug: NGK BPR6HS or equivalent
Make certain the spark plug gap is 0.7 - 0.8 mm or
(0.028 - 0.031 in.).
Engine Specifications
– Model ........................... 62422
– Displacement ........................ 80cc
– Type ........................ 4-Stroke OHV
– Start Type ......................... Recoil
REV 42432-20121015 16
42432 ENGLISH
SPECIFICATIONS
Wiring Diagram
17 REV 42432-20121015
ENGLISH 42432
SPECIFICATIONS
Parts Diagram
1
2
3
456789
10
1 1
1 2
1 3
14
1 5
16
1 7 18
19
20
21
22
23
24
25
2 6
2 7 282 9 3 0 3 1 3 2
3 4
35
3 6
37
38
39
3 1
40
41
4 2
43
44
4 5 4647
48
49
50
5 1 5 2
5 3
5 4 5 5
56
5 7 5 8 5 9 6 0 6 1
3 1
6 2 6 3 6 4 6 5 66
67
68
6 9
33
REV 42432-20121015 18
42432 ENGLISH Parts List
#Part Number Description Qty
1152FD-2-A1 Engine 1
2ST154FD-1100100 Muffler Gasket 1
3ST154FD-1110000 Muffler Assembly 1
4GB9 7.1 8 Washer Φ8 2
5GB93 8 Lock Washer Φ8 2
6GB6175 M8 Nut M8 2
7ST188FD-1180121 Spark Arrester 1
8ST188FD-1100010-88 Plate,Spark Arrester 1
9GB9074.4 M5×14 Combination Screw M5×14 2
10 ST02FD-04160000 Fuel Cock 1
11 ST152FD-1070006 Clip 1
12 ST154FD-1070002-CPE Pipe,Fuel 1
13 st188F-1070006-A Clip 1
14 504.070100.02 Fuel Tank Cap 1
15 ST02FD-04130000 Fuel Filter 1
16 GB819 M5×10 Screw M5×10 2
17 ST154FD-1070300 Fuel Meter Assembly 1
18 GB5789 M6×20 Flange Bolt M6×20 4
19 GB93 6 Lock Washer Φ6 4
20 ST02FD-04100014 Washer Φ6 4
21 ST02FD- 04100010 Mount Vibration, Fuel Tank 4
22 ST154FD-1070100 (Y) Fuel Tank 1
23 ST154FD-3000005 Generator Front Bracket 1
24 GB5789 M8×20 Flange Bolt M8×20 4
25 502.091100.00 Rotor Assembly 1
26 ST154FD-3002001 Stator Cover 1
27 502.091200.00 Stator Assembly 1
28 GB96 8 Washer Φ8 3
29 GB7244 8 Lock Washer Φ8 3
30 ST154FD-3000007 Flange Bolt M8×175 1
31 GB5789 M6×12 Flange Bolt M6×12 7
32 ST154FD-1100400 Holder Muffler 1
33 ST154FD-3000004 End Housing 1
34 ST154FD-3000008 Flange Bolt M6×90 4
35 ST02FD-02100004(Y) Generator End Cover 1
#Part Number Description Qty
36 GB16674 M5×12 Flange Bolt M5×12 2
37 ST02FD-02100013-14 Grounding Line 1
38 GB6177 M6 Nut M6 1
39 GB862 6 Lock Washer Φ6 1
40 ST-QT-108 Frame 1
41 ST154FD-2000001 Motor Mount 1
42 ST168FD-1151400 Rubber Pad 2
43 ST154FD-2000002 Motor Mount 1
44 GB5789 M8×12 Flange Bolt M8×12 2
45 WP30-03110001 Rubber Pad 2
46 GB5783 M8×20 Flange Bolt M8×20 2
47 GB6177 M8 Nut M8 14
48 ST154FD-2000003 Motor Mount 2
49 ST154FD-2001000-
D1(Y) Ornament Plate 1
50 ST02FD-03221002 Flange Bolt M6×12 4
51 1I7 Control Panel 1
52 ST01FD-05701001 Switch 1
53 ST02FD-05602010-D Voltage Meter 1
54 ST02FD-05502024 ReceptacleΦ5-20RΦ 1
55 GB9074.8 Screw Combination M4×14 2
56 ST02FD-05302001-L10 Breaker 1
57 GB5783 M6×22 Bolt M6×22 1
58 GB6175 M6 Nut M6 2
59 GB93 6 Lock Washer Φ6 2
60 GB9 7.1 6 Washer Φ6 2
61 GB862 6 Lock Washer Φ6 1
62 ST01FD-05201001 Control Box 1
63 GB823 M5×12 Screw M5×12 2
64 GB6177 M4 NUT M4 1
65 ST01FD-05221001 Capacitance 1
66 GB823 M4×14 Screw M4×14 1
67 ST02FD-05212002 Plug 1
68 ST02FD-05212007 Sheath,wire 1
69 ST02FD-05212001 Plug 1
19 REV 42432-20121015
ENGLISH 42432
SPECIFICATIONS
Engine Parts Diagram
REV 42432-20121015 20
42432 ENGLISH
#Part Number Description Qty
1ST154F-1061005 Rope Handle 1
2ST154F-1061007 Rope 1
3GB5789 M6x12 Screw M6x12 5
4ST154F-1061100 Starter Case 1
5ST154F-1061004 Spiral Spring 1
6ST154F-1061001 Drum Sheave 1
7ST154F-1061002 Driving Pawl 2
8ST154F-1061008 Spring 1
9ST154F-1061006 Driving Pawl 1
10 ST154F-1061003 Lock Washer 1
11 G B 617 7. 2 Flywheel Nut 1
12 GB16674 M6x12 Bolt M6x12 8
13 ST154F-1080002( R) Fan Case 1
14 ST154F-1060001 Starter Bush 1
15 ST154F-1080001 Fan 1
16 ST15 4F-112010 0 Flywheel 1
17 ST154F-1080004 Air Shroud 1
18 ST154F-1080005 Air Shroud 1
19 ST160F-1030003 Drain Plug 2
20 ST160F-1030004 Drain Plug Seal 2
21 ST152F-II-1030200 Crankcase 1
22 139FMD -1001001 Dowel Pin 4
23 ST152FD -1030011 Oil Seal 1
24 GB276 6203 Ball Bearing 6203 1
25 ST154F-1050008 Governing Driving Gear 1
26 ST152FD-II-1050001 Crankshaft 1
27 ST15 4F-1110105 Governing Gear Shaft 1
28 ST160F-1110106 Washer 1
29 ST15 4F-1110104 Flyweight Pin 2
30 ST15 4F-1110101 Governing Gear 1
31 ST15 4F-1110103 Flyweight 2
32 ST15 4F-1110102 Collar 1
33 ST154F-1040100 Camshaft Assembly 1
34 ST154F-1030008-M Crankcase Gasket 1
35 ST154F-1030007 Crankcase Cover 1
36 GB5789 M6x25 Screw M6x25 6
37 ST154F-1030002 Oil Gauge Seal 2
38 ST154F-1030001 Oil Gauge 2
39 GB276 6303 Ball Bearing 6303 1
40 ST154F-1050002 Timing Gear 1
41 GB1099 5x16 Key 5x16 2
42 ST154F-1080003 Air Shroud 1
43 ST152F-II-1030009 Cylinder Gasket 1
44 GB16674 M6x20 Bolt M6x20 2
45 ST154F-1121000 T.C.I 1
46 GB896-86 Circlip 1
47 ST15 4F-1110001 Governing Shaft 1
48 ST15 4F-111000 6 Clip 1
49 ST15 4F-1110005 Governing Spring 1
50 ST15 4F-111000 4 Governing Lever 1
51 ST15 4F-1110002 Carburetor Connecting Rod 1
#Part Number Description Qty
52 ST15 4F-1110003 Carburetor Spring 1
53 GB6177-86 Nut M6 2
54 GB5789 M8x55 Screw M8x55 4
55 ST154F-1040007 Valve Lifter 2
56 ST154F-1040005 Push Rod 2
57 GB5787-86 Connecting Rod Screw M6x28 2
58 ST154F-1050101 Connecting Rod Cap 1
59 ST154F-1050102 Connecting Rod Body 1
60 ST154F-1050004 Piston Pin Circlip 2
61 ST152F-II-1050003 Piston Pin 1
62 ST152F-II-1050005 Poston 1
63 ST154F-1040006 Exhaust Valve 1
64 ST152F-II-1050200 Third Piston Ring 1
65 ST152F-II-1050006 Second Piston Ring 1
66 ST154F-1040002 Intake Valve 1
67 ST152F-II-1050007 First Piston Ring 1
68 ST152F-II-1020100 Cylinder Head Assembly 1
69 ST154F-1040004 Guide Plate 1
70 ST154F-1040001 Valve Retainer 2
71 ST154F-1040003 Valve Spring 2
72 ST154F-1041001 Rocker Arm Seat 1
73 GB16674 M6x16 Bolt M6x16 5
74 ST154F-1041004 Valve Clearance Adjusting
screw 2
75 ST154F-1041100 Rocker Arm (B) 1
76 ST154F-1010001-A Head Cover Gasket 1
77 ST154F-1010100-A Cylinder Head Cover Assembly 1
78 E6RTC Spark Plug 1
79 ST154F-1041003 Circlip 2
80 ST154F-1041002 Rocker Arm Shaft 2
81 ST15 4F-10 41200 Rocker Arm(A) 1
82 ST154F-1041005 Valve Clearance Adjusting Nut 2
83 ST160F-1020001 Tube 1
84 ST154F-1010002 Baffle 1
85 ST154F-1020001 Intake Bolt 2
86 ST154F-1130001 Carburetor Gasket 2
87 ST154F-1130002 Carburetor Connector 1
88 ST152FD-2-1131000 Carburetor 1
89 ST154F-1090100 Air Cleaner Base 1
90 GB6177 M6 Nut M6 2
91 ST154F-1090003 Element Seat 1
92 ST154F-1090004 Air Cleaner Element 1
93 ST154F-1090002 Air Leaner Cover 1
94 ST154F-1090001 Cover Screw 2
95 GB822 M5x35 Screw M5x35 1
96 ST160F-1111006 Spring 1
97 GB5789 M6x8 Bolt M6x8 3
98 ST15 4FD-111100 0 Governing Rack 1
99 ST160F-1126000 Diode Comp 1
100 ST154F-1030300-A Oil Level Sensor 1
101 GB16674 M6 ×18 Bolt M6x18 1
102 ST154F-1040008 Oil Seal 1
21 REV 42432-20121015
ENGLISH 42432
TROUBLESHOOTING
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
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 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 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
Loose wiring Inspect and tighten wiring connections
Other 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
REV 42432-20121015 22
42432 ENGLISH
WARRANTY
WARRANTY
CHAMPION POWER EQUIPMENT
2 YEAR LIMITED WARRANTY
Warranty Qualifications
Champion Power Equipment (CPE) will register this
warranty upon receipt of your Warranty Registration Card
and a copy of your sales receipt from one of CPE’s retail
locations as proof of purchase.
Please submit your warranty registration and your proof
of purchase within ten (10) days of the date of purchase.
Repair/Replacement Warranty
CPE warrants to the original purchaser that the
mechanical and electrical components will be free of
defects in material and workmanship for a period of
one year (parts and labor) and two years (parts) from
the original date of purchase (90 days (parts and
labor) and 180 days (parts) for commercial & industrial
use). Transportation charges on product submitted
for repair or replacement under this warranty are the
sole responsibility of the purchaser. This warranty only
applies to the original purchaser and is not transferable.
Do Not Return The Unit To The Place Of Purchase
Contact CPE’s Technical Service and CPE will
troubleshoot any issue via phone or e-mail. If the
problem is not corrected by this method, CPE will, at its
option, authorize evaluation, repair or replacement of the
defective part or component at a CPE Service Center.
CPE will provide you with a case number for warranty
service. Please keep it for future reference. Repairs
or replacements without prior authorization, or at an
unauthorized repair facility, will not be covered by this
warranty.
Warranty Exclusions
This warranty does not cover the following repairs and
equipment:
Normal Wear
Generators need periodic parts and service to perform well.
This warranty does not cover repair when normal use has
exhausted the life of a part or the equipment as a whole.
Installation, Use and Maintenance
This warranty will not apply to parts and/or labor if this
generator is deemed to have been misused, neglected,
involved in an accident, abused, loaded beyond the
generator’s limits, modified, installed improperly or
connected incorrectly to any electrical component.
Installation, Use and Maintenance Cont’d.
Normal maintenance such as spark plugs, air filters,
adjustments, fuel system cleaning and obstruction due
to buildup is not covered by this warranty.
Other Exclusions
This warranty excludes:
– Cosmetic defects such as paint, decals, etc.
– Wear items such as filter elements, o-rings, etc.
– Accessory parts such as starting batteries, and
storage covers.
– Failures due to acts of God and other force majeure
events beyond the manufacturer’s control.
– Problems caused by parts that are not original
Champion Power Equipment parts.
This warranty does not apply to generators used for
prime power in place of a utility.
Limits of Implied Warranty and Consequential Damage
Champion Power Equipment disclaims any obligation to
cover any loss of time, use of this product, freight, or
any incidental or consequential claim by anyone from
using this generator. THIS WARRANTY IS IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
A unit provided as an exchange will be subject to the
warranty of the original unit. The length of the warranty
governing the exchanged unit will remain calculated by
reference to the purchase date of the original unit.
This warranty gives you certain legal rights which may
change from state to state. Your state may also have
other rights you may be entitled to that are not listed
within this warranty.
Contact Information
Address
Champion Power Equipment, Inc.
Customer Service
10006 Santa Fe Springs Rd.
Santa Fe Springs, CA 90670
www.championpowerequipment.com
Customer Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free:1-877-338-0999
info@championpowerequipment.com
Fax no.: 1 (562) 236-9429
Technical Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
tech@championpowerequipment.com
24/7 Tech Support: (562) 204-1188

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