Champion Power Equipment 46539 Owners Manual 46539_manual English_02 18 2013

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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

4000 Starting Watts/3500 Running Watts

PORTABLE GENERATOR

SAVE THESE INSTRUCTIONS

Important Safety Instructions

are included in this manual.

MADE IN CHINA

REV 46539-20130218

Wireless Remote, Electric Start

46539

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.

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.

46539

Wireless Remote, Electric Start

PORTABLE GENERATOR

4000 Starting Watts/3500 Running 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

Wireless Remote Control .................. 7

Remote Control Power Consumption ........ 7

Power Panel Load Management ........... 7

Parts Included ......................... 8

Wheel Kit .......................... 8

Other ............................. 8

Assembly ............................... 9

Remove the Generator from the Shipping Carton .. 9

Install the Wheel Kit ..................... 9

Install the Support Leg ................... 9

Install the Handles ...................... 9

Connect the Battery ..................... 9

Add Engine Oil ........................ 10

Add Fuel ............................ 11

Grounding ........................... 11

Operation .............................. 12

Generator Location ..................... 12

Grounding ........................... 12

Surge Protection ....................... 12

Wireless Remote and Electric Start .......... 13

Recoil Start .......................... 13

Connecting Electrical Loads ............... 14

Stopping the Engine .................... 14

Do Not Overload Generator ................ 15

Capacity .......................... 15

Power Management ................... 15

Operation at High Altitude ................ 15

Maintenance and Storage ................... 16

Engine Maintenance .................... 16

Oil .............................. 16

Spark Plugs ........................ 16

Air Filter .......................... 16

Spark Arrester ...................... 17

Cleaning .......................... 17

Adjustments ........................ 17

Maintenance Schedule ................ 17

Generator Maintenance .................. 17

Storage ............................. 18

Generator Storage .................... 18

Battery ........................... 18

Charge the Battery ................... 18

Disconnect the Battery ................ 18

Remote Control Battery ................ 18

Specifications ........................... 19

Engine Specifications ................... 19

Generator Specifications ................. 19

Fuel ............................... 19

Oil ................................ 19

Spark Plugs .......................... 19

Maintenance Valve Clearance .............. 19

FCC Statement for Remote Control Device ..... 19

Wiring Diagram ........................ 20

Parts Diagram ........................ 21

Parts List ............................ 22

Engine Parts Diagram ................... 23

Engine Parts List ...................... 24

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 25

Warranty .............................. 26

Warranty Qualifications .................. 26

Repair/Replacement Warranty .............. 26

Do Not Return The Unit To

The Place Of Purchase .................. 26

Warranty Exclusions .................... 26

Normal Wear ....................... 26

Installation, Use and Maintenance ........ 26

Other Exclusions ..................... 26

Limits of Implied Warranty

and Consequential Damage ............. 26

Contact Information. . . . . . . . . . . . . . . . . . . . . 26

Address ........................... 26

Customer Service .................... 26

Technical Service .................... 26

1 REV 46539-20130218

ENGLISH 46539

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

46539

For Oil Type see ‘Add Engine Oil‘ section. For Fuel Type see ‘Add Fuel‘ section.

INTRODUCTION

REV 46539-20130218 2

46539 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 46539-20130218

ENGLISH 46539

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 46539-20130218 4

46539 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

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

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

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

5 REV 46539-20130218

ENGLISH 46539

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 – 3.8 gal. (14.4 L) capacity fuel tank.

(2) Auto-Choke – Used to start the engine. No manual

adjustment required.

(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 start the engine.

(6) Oil Filler Cap – Check and fill engine oil level.

(7) Battery – Used to start the engine. Provides 12V

DC to the electric starter and receiver control

module.

(8) Power Panel – See “Power Panel” section.

1

5

3

2

4

7

6

8

Generator

CONTROLS AND FEATURES

REV 46539-20130218 6

46539 ENGLISH

Power Panel

1

5 6 7 8

3

(1) Intelligauge™ – Three mode digital meter for

running hours, voltage and hertz.

(2) Ignition Switch

(3) Circuit Breaker(s) – Protects the generator against

electrical overload.

(4) Battery Switch – Enables/disables starting

electrically – via remotely or by Ignition Switch.

(5) Ground Terminal – Consult an electrician for local

grounding regulations.

(6) 120 Volt AC, 30 Amp Twist-Lock Receptacle

(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.

(7) 120 Volt AC, 30 Amp Receptacle (NEMA TT-30R)

– May be used to supply electrical power for the

operation of 120 Volt AC, 30 Amp, single phase

60 Hz electrical loads.

(8) 120 Volt AC, 20 Amp 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.

2

CONTROLS AND FEATURES

4

7 REV 46539-20130218

ENGLISH 46539

CONTROLS AND FEATURES

Wireless Remote Control

This generator is equipped with a wireless remote

control system for starting and stopping. The system

consists of (4) main components:

1. Receiver Control Module (RCM)

2. Wireless Remote

3. Battery Switch

4. Ignition Switch

The Remote Control functions are enabled when:

1. The Ignition Switch is in the “ON” position, AND

2. The Battery Switch is in the “ON” position.

The Remote Control functions are disabled if either of

the above conditions is not met.

To start the generator by Remote Control, press the

“START” button on the Remote one time. The engine

will attempt to start (6) times. The RCM controls

the Auto Choke during each attempt to start. If the

generator does not start, call Champion Customer Care

team for assistance at 1-877-338-0999.

To stop the generator by Remote Control, press the

“STOP” button on the Remote one time.

Remote Control Power Consumption

While the Ignition Switch is in the “ON: position, the

RCM is active and waiting for a remote signal. This

function requires electrical current from the battery.

If the Ignition Switch is left in the “ON” position for

extended periods (several weeks), the battery can be

completely drained.

Moving the Ignition Switch to the “OFF” position

disables the Remote functions, but the RCM still

consumes approximately 2 mA from the battery.

To prevent battery drain, press the Battery Switch to the

“OFF” position. This disconnects power to the RCM so

there is no current draw on the battery.

Power Panel Load Management

When the generator initially starts by the Remote, no

voltage is supplied to the Power Panel for approximately

15 seconds. This allows the engine to reach full speed

before electrical loads are applied to the generator.

When the generator is stopped by the Remote, the

voltage to the Power Panel is immediately turned off.

Then the engine stops approximately 5 seconds after

the “STOP” button on the Remote is pressed. Turning

the Power Panel voltage off before the engine shutdown

protects connected appliances from being damaged by

non-60 Hz voltage while the generator coasts to a stop.

The on/off voltage delay at startup and shut down only

happen when the Remote Control is used. There is no

voltage delay when the pushbutton electric start or recoil

start method is used.

When the pushbutton electric start or recoil start

method is used, the operator must be sure all electrical

loads (appliances) are turned OFF during startup and

shutdown. Damage to the generator or the attached

appliances can be caused by starting or stopping the

generator while appliances are plugged in and turned ON.

Power Panel Load Management Cont’d.

REV 46539-20130218 8

46539 ENGLISH

Parts Included

CONTROLS AND FEATURES

Your 46539 Gasoline Powered Generator ships with the

following parts:

Wheel Kit

– 8 in. Wheel ...........................2

– Bushing ..............................2

– Nut (M10) ............................ 2

– Flat Washer 10 ......................... 2

– Support Leg (w/vibration mounts) ............1

– Handle ..............................1

– Flange Bolt (M10x105 for Wheel) ............2

– Flange Bolt (M8x45 for Handle) .............2

– Flange Bolt (M8x16 for Support Leg) ..........2

– Nut (M8) ............................4

Other

– Oil Funnel ............................1

– Oil ............................ 0.63 qt.

– Spark Plug Socket ....................... 1

– Remote ..............................1

9 REV 46539-20130218

ENGLISH 46539

ASSEMBLY

Install the Handles

1. Place the handle over the mounting channel on the

frame.

2. Secure the handle to the frame using the two handle

bolts (M8x45).

3. Place a lock nut (M8) on the end of each bolt and

fasten securely. DO NOT over tighten the lock nuts.

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 M10x105 wheel bolt through the washer,

sleeve and wheel.

3. Slide the bolt through the mount point on the frame.

4. Fasten securely with the M10 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

cap screws (M8x16) and 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

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 (M5x12) and secure with

the lock washer (M5).

3. Repeat steps 1-2 for the black (–) battery lead.

REV 46539-20130218 10

46539 ENGLISH

1. Place the generator on a flat, level surface.

2. Remove oil fill cap/dipstick to add oil.

3. Add 0.63 qt. (0.6 L) of oil (included) 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

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

ASSEMBLY

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

Add Engine Oil Cont’d.

The recommended oil type is 10W-30 automotive oil.

NOTE

11 REV 46539-20130218

ENGLISH 46539

ASSEMBLY

Add Fuel Cont’d.

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

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 ¼ in.

(0.64 cm) of space left in the tank is required

for fuel expansion, more than ¼ in. (0.64 cm) 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 ¼ in. (0.64 cm) 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

REV 46539-20130218 12

46539 ENGLISH

OPERATION

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.

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

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 will not function if the receptacle

ground pin is not functional.

13 REV 46539-20130218

ENGLISH 46539

OPERATION

Wireless Remote and Electric Start

Wireless remote starting is only possible within 80 feet

of the generator.

Do not attempt to adjust the carburetor choke. The

remote system will automatically close and open the

choke.

1. Make certain the generator is on a flat, level surface.

2. Turn off all electrical loads connected to the

generator. Never start or stop the generator with

electrical devices plugged in and turned on.

3. Turn the Fuel Valve to the “ON” position.

4. Press the Battery Switch to “ON”.

5. Press the Ignition Switch to “ON”.

6. WIRELESS REMOTE START: press and release the

“START” button on the handheld Remote Control

device. DO NOT hold the button down, only press

the button once. The engine will attempt to start six

times.

7. A safety feature is provided which delays the

electrical power availability during starting mode.

The delay lasts for approximately 15 seconds. The

delay is provided to prevent damage to the generator

if electrical loads are inadvertently turned on during

engine startup.

8. 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.

9. If the generator fails to start, check the battery

condition and cable connections.

Recoil Start

1. Make certain the generator is on a flat, level surface.

2. Turn off all electrical loads connected to the

generator. Never start or stop the generator with

electrical devices plugged in and turned on.

3. Turn the Fuel Valve to the “ON” position.

4. Press the Ignition Switch to “ON”.

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.

If the engine starts but does not continue to 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

When the battery switch is in the “ON” position,

the switch will light up if the battery is sending

out a charge. If the switch does not light up while

in the “ON” position, check that the battery

connection is still good.

NOTE

The supplied 12V 9AH battery does re-charge while

the engine is running, but it is also recommended

that the battery be fully charged at least once per

month.

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

spark plug fouling/engine flooding due to the lack of

incoming air. This will cause the engine not to start.

NOTE

REV 46539-20130218 14

46539 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 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

When the stop button on the remote is pressed,

power to the receptacles is turned off and the

engine will stop after 5 seconds.

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 engine switch to the “OFF” position.

6. Press the battery 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

15 REV 46539-20130218

ENGLISH 46539

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

OPERATION

Carburetor

Code Main Jet Part Number Altitude

P19-3-Z

Standard 2 6 .1 31 017. 2 0 . Z

3500 feet

(1067 meters)

Altitude 26.131017.20.01.Z

P19-3-H

Standard 2 6 .1 31 017. 2 0 . H

Altitude 26.131017.20.01.H

P19-3-R

Standard 2 6 .1 31 017. 2 0 . R

Altitude 26.131017.20.01.R

Operation at High Altitude

The density of air at high altitude is lower than at sea

level. Engine power is reduced as the air mass and air-

fuel ratio decrease. Engine power and generator output

will be reduced approximately 3½% for every 1000

feet of elevation above sea level. This is a natural trend

and cannot be changed by adjusting the engine. At high

altitudes increased exhaust emissions can also result

due to the increased enrichment of the air fuel ratio.

Other high altitude issues can include hard starting,

increased fuel consumption and spark plug fouling.

To alleviate high altitude issues other than the natural

power loss, Champion Power Equipment can provide a

high altitude carburetor main jet. The alternative main

jet and installation instructions can be obtained by

contacting Customer Support. Installation instructions

are also available in the Technical Bulletin area of the

Champion Power Equipment internet site.

The part number and recommended minimum altitude

for the application of the high altitude carburetor main

jet is listed in the table below.

In order to select the correct high altitude main jet

it is necessary to identify the carburetor model. For

this purpose, a code is stamped on the side of the

carburetor. Select the correct main jet part number

corresponding to the carburetor code found on your

particular carburetor.

Operation using the alternative main jet at elevations

lower than the recommended minimum altitude can

damage the engine. For operation at lower elevations, the

standard main jet must be used. Operating the engine

with the wrong engine configuration at a given altitude

may increase its emissions and decrease fuel efficiency

and performance.

WARNING

REV 46539-20130218 16

46539 ENGLISH

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

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 0.63 qt. (0.6 L) of oil and replace oil fi ll

cap/dipstick. DO NOT OVERFILL.

6. Dispose of used oil at an approved waste

management facility.

Air Filter

1. Remove the snap-on cover holding the air fi lter 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 fi lter in the assembly.

7. Reattach the air fi lter cover and snap in place.

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 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.

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

Oil Cont’d.

0.7 - 0.8 mm

0.028 - 0.031 in.

MAINTENANCE AND STORAGE

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

17 REV 46539-20130218

ENGLISH 46539

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.

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

MAINTENANCE AND STORAGE

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

*To be performed by knowledgeable, experienced owners or

Champion Power Equipment certified dealers.

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

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 46539-20130407 18

46539 ENGLISH

MAINTENANCE AND STORAGE

Storage

The generator should be started at least once every 14

days and allowed to run for at least 20 minutes. For

longer term storage, please follow these guidelines.

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 acompletely 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.

Remote Control Battery

Generator Battery

This product is equipped with an automatic battery

charging circuit. The battery will receive charging

voltage when the engine is running. The battery will

maintain a proper charge if the unit is used on a regular

basis (about once every two weeks). If it is used less

frequently, the battery should be connected to a trickle

charger or battery maintainer to keep the battery

properly charged. If the battery is not able to start the

engine, it can be started by manually pulling the engine

recoil cord. If the battery voltage is extremely low,

the charging circuit may not be able to re-charge the

battery. In this case, the battery must be connected

to a standard automotive style battery charger for re-

charging before it can be used.

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 (M5x12) and lock washer (M5).

3. Repeat steps 1-2 for the red/positive battery lead.

4. Store the battery in a cool, dry place.

A Float Charger will maintain the battery condition

over long storage periods.

NOTE

– Always purchase the correct size and grade of

battery most suitable for the intended use.

– Clean the battery contacts and also those of the

device prior to battery installation.

– Remove batteries from equipment which is not to

be used for an extended period of time.

– Remove batteries if consumed or if product is to

be left unused for a long time.

NOTE

Charge the Battery

For a generator equipped with batteries for electric

starting, proper battery maintenance and storage

should be followed. An automatic battery charger with

automatic trickle charging capability should be used to

charge the battery. Maximum charging rate should not

exceed 1.5 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

remote 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, the Fuel

Valve and the Battery Switch are set in the OFF

position.

– When storing the generator for extended periods

of time make sure that the Ignition Switch, the

Fuel Valve and the Battery Switch are set in the

the the OFF position and the battery leads have

been disconnected from the battery.

DANGER

19 REV 46539-20130218

ENGLISH 46539

Engine Specifications

– Model .....................YF168FD-2-211

– Displacement .......................196cc

– Type ........................4-Stroke OHV

– Start Type ..................Wireless Remote

FCC Statement for Remote Control Device

1. This device complies with Part 15 of the FCC Rules.

Operation is subject to the following two conditions:

(1) This device may not cause harmful interference.

(2) This device must accept any interference

received, including interference that may cause

undesired operation.

2. Changes or modifications not expressly approved by

the party responsible for compliance could void the

user’s authority to operate the equipment.

NOTE: This equipment has been tested and found to

comply with the limits for a Class B digital device,

pursuant to Part 15 of the FCC Rules. These limits

are designed to provide reasonable protection against

harmful interference in a residential installation.

This equipment generates uses and can radiate radio

frequency energy and, if not installed and used in

accordance with the instructions, may cause harmful

interference to radio communications. However, there

is no guarantee that interference will not occur in a

particular installation. If this equipment does cause

harmful interference to radio or television reception,

which can be determined by turning the equipment

off and on, the user is encouraged to try to correct the

interference by one or more of the following measures:

– Reorient or relocate the receiving antenna.

– Increase the separation between the equipment and

receiver.

– Connect the equipment into an outlet on a

circuit different from that to which the receiver is

connected.

Consult the dealer or an experienced radio/TV technician

for help.

Oil

Use 10W-30 automotive oil.

DO NOT OVERFILL.

Oil capacity is 0.63 qt. (0.6 L).

Please reference the following chart for recommended

oil types for use in the generator.

Fuel

Fuel capacity is 3.8 gal. (14.4 L). Use regular unleaded

gasoline with a minimum octane rating of 85 and an

ethanol content of less than 10% by volume.

Generator Specifications

– Running Wattage .................3500 Watts

– Starting Wattage .................4000 Watts

– AC Load ..........................120 V

– Phase ............................Single

– Frequency .........................60 Hz

– Fuel Capacity ................3.8 gal. (14.4 L)

– Gross Weight ...............138.9 lbs (63 kg)

– Net Weight .................129 lbs (58.5 kg)

– Height ..................22.4 inches (57 cm)

– Width ................ 24.4 inches (62.1 cm)

– Length. . . . . . . . . . . . . . . . 26.3 inches (66.7 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 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.).

REV 46539-20130218 20

46539 ENGLISH

Wiring Diagram

SPECIFICATIONS

21 REV 46539-20130218

ENGLISH 46539

SPECIFICATIONS

Parts Diagram

123456789101112 1314 15 16 17 18192021 22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37 38

42

43

44

45

46

47

48

50

5152

53

54

55

56

59

60

61

62

63

64

65

66

67

68

69

70

71

7273

7475

76

77

78

79

80

81

82

83848586

87

88

89

90 91

92

93 809495

96

979899

100101 102103

104

105106

107 108109

27

55

55

16

27

13

39

40

41

27

49

17

22

27

5758 49

REV 46539-20130218 22

46539 ENGLISH Parts List

#Part Number Description Qty

126.601 Engine 1

2122.190005.00 Rubber, Fore-Cover 1

3122.190005.01 Rubber, Fore-Cover 1

4123.191100.19 Rotor Assembly 1

52.08.022 Flange Bolt M8×242 1

61.96.08 Washer Ø8 1

71.7244.08 Lock Washer Ø8 1

8123.191200.19 Stator Assembly 1

9123.191002.01 Stator Cover 1

10 122.190002.00 End Housing 1

11 2.08.065 Flange Bolt M6×168 4

12 1.97.1.06 Washer Ø6 4

13 1.93.06 Lock Washer Ø6 8

14 122.190300.00 Carbon Brush Assembly 1

15 122.190004.01 Pinch 1

16 1.93.05 Lock Washer Ø5 3

17 1.5783.0516 Bolt M5×16 3

18 1.97.1.05 Washer Ø5 2

19 122.190200.05 AVR 1

20 1.16674.0516 Flange Bolt M5×16 2

21 122.190003.00.48 Generator End Cover 1

22 1.16674.0512.2 Flange Bolt M5×12 3

23 122.190400.00 Terminal Block 1

24 122.190018.00 Bracket, Muffler 1

25 1.16674.0820 Flange Bolt M8×20 3

26 122.190018.01 Bracket, Muffler 1

27 1.5789.0612 Flange Bolt M6×12 13

28 1.9074.4 0514 Bolt And Washer Assembly

M5×14 2

29 46.101503.08 Plate, Spark Arrester 1

30 46.101300.08 Arrester Assembly,Spark 1

31 26.101000.00 Muffler Assembly 1

32 23.102000.03.2 Muffler Cover 1

33 1.6175.08 Nut M8 2

34 1.93.08 Lock Washer Ø8 2

35 1.848.08 Washer Ø8 2

36 26.100001.00 Muffler Gasket 1

37 23.090006.22 Holder, Air Cleaner 1

38 1.5789.0608 Flange Bolt M6×8 1

39 23.070011.04 Pipe, Fuel(6.1in) 1

40 2.06.007 Clamp 2

41 122.070400.05 Fuel Cock 1

42 122.071000.05.48 Fuel Tank 1

43 122.070015.01 Mount Vibration, Fuel Tank 4

44 2.03.004 Washer Ø6 4

45 1.5789.0620.2 Flange Bolt M6×20 4

46 23.070301.00 Fuel Filter 1

47 24.070100.00 Fuel Tank Cap 1

48 24.070014.03 Pipe, Reversal Valve 1

49 2.06.006 Clamp 3

50 24.070800.00 Reversal Valve 1

51 1.819.0510 Screw M5×10 2

52 122.072000.00 Fuel Meter Assembly 1

53 152.200702.00 Cover, Handle 1

54 122.200700.03.2 Handle 1

55 1.6177.1.08 Nut M8 14

#Part Number Description Qty

56 1.5789.0845 Flange Bolt M8×45 2

57 122.070700.00 Carbon Canister 1

58 122.070013.00 Pipe, Air Cleaner 1

59 6.2.246.318.2 Frame 1

60 2.05.001 Clamp 2

61 122.201200.05 Motor Mount 2

62 122.201200.04 Motor Mount 2

63 1.6182.10 Nut M10 2

64 122.201701.05.48 8in Wheel 2

65 122.200016.01 Bush Ø16×Ø10.5×58.5 2

66 1.96.10 Washer Ø10 2

67 1.5782.10105 Bolt M10 ×105 2

68 122.200904.00 Pinch, Rubber 1

69 9.1000.090 Battery 12V9AH 1

70 152.200013.01 Jacket 1

71 5.1900.010 Red Wire, Battery 1

72 122.200013.01 Jacket 2

73 5.1900.011 Black Wire, Battery 1

74 1.5789.0816 Flange Bolt M8×16 2

75 152.200002.00.2 Support Leg 1

76 152.201400.00 Rubber, Support 2

77 1.5789.0825 Flange Bolt M8×25 2

78 5.1900.026 Grounding Line 1

79 1.6177.1.06 Nut M6 1

80 1.862.06 Lock Washer Ø6 2

81 122.210003.00 Plug 2

82 1.9074.1.0538.2 Bolt And Washer Assembly

M5×38 5

83 122.210002.20 Control Box 1

84 5.1460.003 Indicator light 1

85 5.1040.004 Switch 1

86 5.1830.000 Remote Control 1

87 1.823.0514 Screw M5×14 4

88 5.1820.000 Charger 1

89 5.1280.003 Fush(10A) 1

90 122.159.006.2 Control Panel 1

91 5.1430.001 Intelligauge 1

92 5.1000.001.3 Switch 1

93 5.1000.000.3 Switch 1

94 1.5783.0622.3 Bolt M6×22 1

95 1.6175.06.3 Nut M6 2

96 1.97.1.06.3 Washer Ø6 2

97 1.93.06.3 Lock Washer Ø6 2

98 5.1120.008 Receptacle L5-30R 1

99 1.9074.4.0414.1 Bolt And Washer Assembly

M4×14 6

100 1.6177.1.04.1 Nut M4 6

101 5.1120.034 Receptacle TT-30R 1

102 5.1120.010 Receptacle 5-20R 1

103 5.1210.925 AC.25A Breaker 1

104 5.1210.920 AC.20A Breaker 1

105 5.1810.001 Over Voltage Protector 1

106 122.210002.14 Control Box 1

107 122.210003.01 Grommet 1

108 5.1330.001 Sheath, Wire 1

109 122.210003.03 Grommet 1

23 REV 46539-20130408

ENGLISH 46539

SPECIFICATIONS

Engine Parts Diagram

1

2345678910

12 13

14

2526 27 29 30 32 35 37

38 12 40 41

42

43 44

46

47

21 22

23 24

108

107 106 104 103

53

52

117

51

50

49 55

56

57

58

54

60 62

61

63

65

66

67

68

69

7071

72

74

25

75 1

93

94

95

92

91

90

97

78

79

80

82

83

84

85

86

87

88

76

59

77

96

105

81

73

19 54

3931，28 16

48

36

1

33

15

20

34

102 116

101

51

100

98

45

64

109

110

111

112

113

115

114

99

89

108

11

18

17

REV 46539-20130408 24

46539 ENGLISH

#Part Number Description Qty

11.5789.0608 Flange Bolt M6×8 7

222.061100.00.2 Recoil Starter Cover 1

321.061005.00 Recoil Starter Spring 1

42.10.003 Rope (Ø5×1550) 1

521.061001.01 Recoil Starter Reel 1

645.060003.00 Spring,Ratchet 2

745.060002.00 Starter Ratchet (Iron) 2

845.060009.00 Spring,Ratchet Guide 1

945.060007.00 Ratchet Guide 1

10 45.060008.00 Screw, Ratchet Guide 1

11 24.040004.00 Guide Plate Push Rod 1

12 1.5789.0612 Flange Bolt M6×12 8

13 24.080100.00.48 Fan Cover 1

14 2.05.005 Clamp (Ø6) 2

15 21.061300.00 Handle (soft) 1

16 23.125200.01 Relay, Starter (Remote Control) 1

17 22.061000.00 Recoil Assembly 1

18 24.091000.21 Air Cleaner Assembly 1

19 1.5789.0629 Flange Bolt M6×29 1

20 2.03.016 Washer, Drain Bolt

(Ø10×Ø16×1.5) 2

21 2.02.006 Nut (M14×1.5) 1

22 21.060001.01 Pulley, Starter 1

23 23.080001.00 Cooling Fan 1

24 24.120100.03 Flywheel (Electric Start ) 1

25 2.11.001 Oil Seal (Ø25×Ø41.3×6) 2

26 2.03.020.1 Washer (Ø6.2×Ø15×0.5) 1

27 21.110100.00 Gear, Governor 1

28 1.93.05 Lock Washer Ø5 2

29 21.110013.00 Shaft, Governor, Gear 1

30 21.110 011.00 Clip, Governor, Gear 1

31 1.16674.0516 Flange Bolt M5×16 2

32 21.110012.01 Bushing, Govorner Gear (Iron) 1

33 45.121000.00 Coil, Charging 1

34 23.030006.00 Plate, Coil 1

35 23.080600.02 Air Guide, Right Side 1

36 45.030032.00 Sheath, Wire 1

37 26.030100.00 Crankcase (200) 1

38 21.127000.01 Oil Level Sensor 1

39 23.125100.00 Starter Motor Assembly 1

40 23.050200.00 Connecting Rod 1

41 25.050100.11 Crankshaft (A 200Engine For

Equipment) 1

42 1.276.6205 Bearing 6205 2

43 24.030008.00 Gasket, Crankcase Cover (No

Asbestos) 1

44 22.031000.00.48 Oil Dipstick Assy. 1

45 23.070011.04 Pipe, Fuel (155) 1

46 23.030007.01 Cover, Crankcase (Engine For

Equipment) 1

47 1.5789.0832.0.8 Flange Bolt 8×32 6

48 2.04.005 Dowel Pin (Ø8×10) 2

49 23.110006.00 Rod Governor 1

50 21.110003.00 Arm, Governor 1

51 1. 617 7. 0 6 Flange Nut M6 3

52 21.110001.00 Shaft, Governor Arm 1

53 22.123000.02 Ignition Coil (Shield EPA ) 1

54 1.5789.0625 Flange Bolt M6×25 5

55 23.110005.01 Spring, Throttle Return 1

56 23.110007.00 Spring, Governor 1

57 2.08.040 Bolt,Governor Arm (M6×21) 1

58 21.110008.00 Pin, Shaft 1

59 24.080300.00 Control Assembly (Engine For

Equipment) 1

#Part Number Description Qty

60 25.040013.00 Lifter, Valve 2

61 2.04.001 Dowel Pin (Ø9×14) 2

62 26.041000.00 Camshaft (200 EPA) 1

63 2.14.012 Sem.Key (4×7.5×19) 1

64 2.08.037 Bolt, Drain (M10×1.25×25) 2

65 26.050005.00 Piston 1

66 23.050003.00 Wrist Pin 1

67 2.09.001 Circlip (Ø18 ×Ø1) 2

68 26.050303.00 Ring, Oil 1

69 26.050302.00 Ring, Second Piston 1

70 26.050301.00 Ring,First Piston 1

71 26.030009.00 Gasket, Cylinder Head (168-2) 1

72 2.04.003 Dowel Pin (Ø10×14) 2

73 23.040002.00 Valve, Intake 1

74 23.040006.00 Valve, Exhaust 1

75 Air Guide, Lower ( 200 G) 1

76 2.15.002 (F6RTC) Spark Plug (F6RTC) 1

77 1.5789.0855 Flange Bolt M8×55 4

78 23.040017.00 Oil Seal, Valve (Iron) 2

79 21.040003.00 Spring, Valve 2

80 21.040007.00 Retainer, Exhaust Valve Spring

(up) 1

81 21.040001.00 Retainer, Intake Valve Spring

(up) 1

82 21.040008.00 Rotator, Exhaust Valve 1

83 24.040202.00 Shaft, Rocker Arm 1

84 22.040009.00 Rocker Arm, Intake Valve 2

85 22.040012.00 Screw, Valve Adjustment 2

86 21.040021.00 Nut,Lock 2

87 1.97.1.06 Washer 6 2

88 1.6177.1.06 Flg.Nut M6 2

89 26.131017. 2 0 Standard Main Jet 1

26.131017.20.01 Altitude Main Jet /

90 24.040201.00 Retainer, Rocker Arm 1

91 23.040010.00 Bolt, Rocker Arm 2

92 23.040005.00 Push Rod 2

93 21.020002.01 Gasket, Cylinder Head Cover 1

94 24.021000.00 Cylinder Head Cover (CPE) 1

95 23.020001.02 Breather Tube 1

96 1.5789.0615 Flange Bolt M6×15 4

97 2.01.010 Stud.Bolt (M8×35) 2

98 2.06.007 Clip (Ø8×b6) 2

99 24.091200.20 Cover, Air Cleaner 1

100 23.091003.21 Element, Air Cleaner 1

101 23.091001.21 Separator, Air Cleaner 1

102 23.091002.21 Seal, Air Cleaner 1

103 26.010100.00 Cylinder Head (168-2) 1

104 2.01.003 Stud Bolt 6×90 2

105 24.130002.00 Gasket, Insulator (No Asbestos) 1

106 23.130001.00 Insulator, Carburetor 1

107 22.130003.00 Gasket ,Carb. (No Asbestos) 1

108 26.131000.24 Carburetor 1

109 81.130010.00 Spring,Connecter 1

110 26.130015.24 Connecter,Choke Valve Axis 1

111 24.130004.20 Gasket, Air Cleaner (No

Asbestos) 2

112 26.130005.24 Support, Stepper Motor 1

113 45.132200.01 Stepper Motor 1

114 1.823.0408 Screw M4×8 2

115 81.132001.00 Cover, Stepper Motor 1

116 24.0 91100.21 Base, Air Cleaner 1

117 2.03.021.1 Washer (Ø6.4×Ø13×1) 1

26.080400. 01

25 REV 46539-20130218

ENGLISH 46539

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 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 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

REV 46539-20130218 26

46539 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

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

Champion Power Equipment, Inc. (CPE),

The United States Environment Protection Agency (U.S. EPA.) and the California Air Resources Board (CARB)

Emission Control System Warranty

Your Champion Power Equipment (CPE) engine complies with both the U.S. EPA and state of California Air

Resources Board (CARB) emission regulations.

YOUR WARRANTY RIGHTS AND OBLIGATIONS:

The US EPA, California Air Resources Board, and CPE are pleased to explain the Federal and California Emission

Control Systems Warranty on your 2013 small off-road engine and engine powered equipment. In California, new,

small off-road engines and new equipment that use small off-engines must be designed, built and equipped to meet

the State’s stringent anti smog standards. In the other states, new engines and equipment must be designed, built

and equipped, at the time of sale, to meet U.S. EPA regulations for small non-road engines. CPE warrants the

emission control system on your small off-road engine and equipment for the period of time listed below, provided

there has been no abuse, neglect, unapproved modification, or improper maintenance of your equipment.

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. For engines less than or equal to 80cc, only the fuel tank and fuel line is

subject to the evaporative emission control warranty requirements of this section.

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 or alternate

service outlet as described in (3)(f.) below, CPE dealer or CPE, Santa Fe Springs, Ca. 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

10006 Santa Fe Springs Road

Santa Fe Springs, CA 90670

1-877-338-0999

tech@championpowerequipment.com

EMISSION CONTROL SYSTEM WARRANTY

The following are specific provisions relative to your Emission Control System (ECS) Warranty Coverage.

1. APPLICABILITY: This warranty shall apply to 1995 and later model year California small off-road engines (for

other states, 1997 and later model year engines). The ECS Warranty Period shall begin on the date the new engine

or equipment is delivered to its original, end-use purchaser, and shall continue for 24 consecutive months

thereafter.

2. 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 to U.S. EPA emissions standards for spark-ignited

engines at or below 19 kilowatts and all applicable regulations adopted by the California Air Resources Board

and

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 pay for covered emissions warranty repairs at non-authorized service outlets under the

following circumstances:

i. The service is required in a population center with a population over 100,000 according to U.S.

Census 2000 without a CPE Authorized Service Outlet AND

ii. The service is required more than 100 miles from a CPE Authorized Service Outlet. The 100 mile

limitation does not apply in the following states: Alaska, Arizona, Colorado, Hawaii, Idaho, Montana, Nebraska,

Nevada, New Mexico, Oregon, Texas, Utah and Wyoming.

g. 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.

h. 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.

i. 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.

j. 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)

Systems covered by this

warranty

Parts Description

Fuel Metering System

Fuel regulator, Carburetor and internal parts

Air Induction System

Air cleaner, Intake manifold

Ignition System

Spark plug and parts, Magneto ignition system

Exhaust System

Exhaust manifold, catalytic converter

Miscellaneous Parts

Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed

systems.

Evaporative Emissions

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. Alternate service locations defined in Section (3)(f.) above must be approved by CPE prior to service. 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.

10006 Santa Fe Springs Road

Santa Fe Springs, CA 90670

1-877-338-0999

Attn.: Customer Service

tech@championpowerequipment.com