Champion Power Equipment 46577 Owners Manual

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2015-08-26

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POWERED BY
OWNER’S MANUAL & OPERATING INSTRUCTIONS
Champion Power Equipment
12039 Smith Ave.
Santa Fe Springs CA 90670
USA / 1-877-338-0999
www.championpowerequipment.com
Cabela’s
Sidney, NE 69160
1-800-237-4444
www.cabelas.com
4000 Starting Watts / 3500 Rated Watts
PORTABLE GENERATOR
SAVE THESE INSTRUCTIONS
Important Safety Instructions
are included in this manual.
MADE IN CHINA
REV 46577-20140214
Recoil Start
46577
MODEL NUMBER
*We are always working to improve our products. Therefore, the enclosed product may differ slightly from the image on the cover.
WARNING:
The Engine Exhaust from this product contains chemicals known to the State of California
to cause cancer, birth defects or other reproductive harm.
Have questions or need assistance?
Do not return this product to the store!
WE ARE HERE TO HELP!
Visit our website:
www.championpowerequipment.com
for more info:
• Product Info & Updates
• Frequently Asked Questions
• Tech Bulletins
• Product Registration
– or –
Call our Customer Care Team Toll-Free at:
1-877-338-0999
AN IMPORTANT MESSAGE ABOUT TEMPERATURE:
Your 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.
46577
Recoil Start
4000 Starting Watts / 3500 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
Wheel Kit .......................... 7
Other ............................ 7
Assembly .............................. 8
Remove the Generator from the Shipping Carton . 8
Install the Wheel Kit .................... 8
Install the Support Leg .................. 8
Install the Handle ...................... 8
Add Engine Oil ........................ 9
Add Fuel ........................... 10
Grounding .......................... 10
Operation ............................. 11
Generator Location .................... 11
Grounding .......................... 11
Surge Protection ...................... 11
Recoil Start ......................... 12
Connecting Electrical Loads .............. 12
Stopping the Engine ................... 12
Do Not Overload Generator ............... 13
Capacity ......................... 13
Power Management .................. 13
Operation at High Altitude ............... 13
Maintenance and Storage .................. 14
Engine Maintenance ................... 14
Oil ............................. 14
Spark Plugs ....................... 14
Air Filter ......................... 14
Spark Arrester ..................... 15
Cleaning ......................... 15
Adjustments ....................... 15
Maintenance Schedule ................ 15
Generator Maintenance ................. 16
Storage ............................ 16
Generator Storage ................... 16
Specifications .......................... 17
Engine Specifications .................. 17
Generator Specifications ................ 17
Fuel .............................. 17
Oil ............................... 17
Spark Plugs ......................... 17
Maintenance Valve Clearance ............. 17
An Important Message About Temperature .... 17
Wiring Diagram ....................... 18
Parts Diagram ........................ 19
Parts List ........................... 20
Engine Parts Diagram .................. 21
Engine Parts List ..................... 22
Troubleshooting ......................... 23
Warranty ............................. 24
Warranty Qualifications ................. 24
Repair/Replacement Warranty ............. 24
Do Not Return The Unit To
The Place Of Purchase .................. 24
Warranty Exclusions. . . . . . . . . . . . . . . . . . . . 24
Normal Wear ...................... 24
Installation, Use and Maintenance ........ 24
Other Exclusions .................... 24
Limits of Implied Warranty
and Consequential Damage ............ 24
Contact Information .................... 24
Address .......................... 24
Customer Service ................... 24
Technical Service ................... 24
PORTABLE GENERATOR
1 REV 46577-20140214
ENGLISH 46577
Introduction
Congratulations on your purchase of a Cabela’s
Outdoorsmen 4000 series generator, powered by
Champion Power Equipment. 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 accessories
designed to help you get the most from your purchase.
To find out more about accessories, please visit either
web site:
www.championpowerequipment.com
www.cabelas.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
46577
For Oil Type see ‘Add Engine Oil‘ section. For Fuel Type see ‘Add Fuel‘ section.
INTRODUCTION
REV 46577-20140214 2
46577 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 46577-20140214
ENGLISH 46577
SAFETY RULES
Generator exhaust contains carbon monoxide, a
colorless, odorless, poison gas. Breathing carbon
monoxide will cause nausea, dizziness, fainting or
death. If you start to feel dizzy or weak, get to fresh
air immediately.
Operate generator outdoors only in a well ventilated
area.
DO NOT operate the generator inside any building,
including garages, basements, crawlspaces and
sheds, enclosure or compartment, including the
generator compartment of a recreational vehicle.
DO NOT allow exhaust fumes to enter a confined
area through windows, doors, vents or other
openings.
DANGER CARBON MONOXIDE: using a generator
indoors CAN KILL YOU IN MINUTES.
DANGER
Rotating parts can entangle hands, feet, hair,
clothing and/or accessories.
Traumatic amputation or severe laceration can result.
Keep hands and feet away from rotating parts.
Tie up long hair and remove jewelry.
Operate equipment with guards in place.
DO NOT wear loose-fitting clothing, dangling
drawstrings or items that could become caught.
DANGER
Generator produces powerful voltage.
DO NOT touch bare wires or receptacles.
DO NOT use electrical cords that are worn, damaged
or frayed.
DO NOT operate generator in wet weather.
DO NOT allow children or unqualified persons to
operate or service the generator
Use a ground fault circuit interrupter (GFCI) in damp
areas and areas containing conductive material such
as metal decking.
Use approved transfer equipment to isolate generator
from your electric utility and notify your utility
company before connecting your generator to your
power system.
DANGER
Sparks can result in fire or electrical shock.
When servicing the generator:
Disconnect the spark plug wire and place it where it
cannot contact the plug.
DO NOT check for spark with the plug removed.
Use only approved spark plug testers.
WARNING
Running engines produce heat. Severe burns can
occur on contact.
Combustible material can catch fire on contact.
DO NOT touch hot surfaces.
Avoid contact with hot exhaust gases.
Allow equipment to cool before touching.
Maintain at least 3 ft. (91.4 cm) of clearance on all
sides to ensure adequate cooling.
Maintain at least 5 ft. (1.5 m) of clearance from
combustible materials.
WARNING
Medical and Life Support Uses.
In case of emergency, call 911 immediately.
NEVER use this product to power life support
devices or life support appliances.
NEVER use this product to power medical devices
or medical appliances.
Inform your electricity provider immediately if you
or anyone in your household depends on electrical
equipment to live.
Inform your electrical provider immediately if a
loss of power would cause you or anyone in your
household to experience a medical emergency.
WARNING
The engine exhaust from this product contains
chemicals known to the state of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
Read this manual thoroughly before operating your
generator. Failure to follow instructions could result
in serious injury or death.
WARNING
REV 46577-20140214 4
46577 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 and disconnect 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 46577-20140214
ENGLISH 46577
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 – 3.8 gal. (14.4 L) capacity fuel tank.
(2) Choke – Used to start the engine.
(3) Fuel Valve – Used to turn fuel supply on and off to
engine.
(4) Air Filter – Protects the engine by filtering dust
and debris from the intake air.
(5) Recoil Starter – Used to manually start the engine.
(6) Never Flat Tires
(7) Oil Filler Cap – Check and fill engine oil level.
(8) Power Panel – See “Power Panel” section.
(9) Power Cord Clips – Used to hold power cord when
not in use.
(10) Handle
1
2
3
4
56
7
8
9
10
REV 46577-20140214 6
46577 ENGLISH
CONTROLS AND FEATURES
Power Panel
(1) Engine Switch – Used to start or stop the
generator.
(2) Circuit Breakers – Protects the generator against
electrical overloads.
(3) Voltmeter – Used to display generator output
voltage.
(4) 120/240 Volt AC, 30 Amp Twist-Lock Receptacle
(NEMA L14-30R) – May be used to supply
electrical power for the operation of 120/240 Volt
AC, single phase 60 Hz electrical loads.
(5) Voltage Switch – Choose between 120 Volts or
240 Volts opportation
(6) 120 Volt AC, 30 Amp Receptacle
(NEMA TT-30R) – May be used to supply electrical
power for the operation of 120 Volt AC, single
phase 60 Hz electrical loads.
(7) 120 Volt AC, 20 Amp Receptacle (NEMA 5-20R)
– May be used to supply electrical power for the
operation of 120 Volt AC, single phase 60 Hz
electrical loads.
(8) Ground Terminal – Consult an electrician for local
grounding regulations.
61 4 53 7 82
7 REV 46577-20140214
ENGLISH 46577
CONTROLS AND FEATURES
Parts Included
Your 46577 gasoline powered generator ships with the
following parts:
Wheel Kit
– 8 in. Wheel ...........................2
– Flange Bolt (M10x105 for Wheel) ............2
– Bushing ..............................2
– Flat Washer Ø10 ........................2
– Lock Nut (M10) ........................2
– Support Leg (w/vibration mounts) ............1
– Flange Bolt (M8x16 for Support Leg) ..........2
– Handle ..............................1
– Flange Bolt (M8x45 for Handle) .............2
– Flange Nut (M8) ........................4
Other
– 19 in. Generator Cable ....................1
– Oil Funnel ............................1
– Spark Plug Socket ....................... 1
REV 46577-20140214 8
46577 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.
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 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
Install the Handle
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.
9 REV 46577-20140214
ENGLISH 46577
1. Place the generator on a flat, level surface.
2. Remove oil fill cap/dipstick to add oil.
3. Add up to 0.6 qt. (0.6 L) of oil and replace oil fill
cap/dipstick. DO NOT OVERFILL.
4. Check engine oil level daily and add as needed.
The recommended oil type is 10W-30 automotive
oil.
NOTE
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.
REV 46577-20140214 10
46577 ENGLISH
Add Fuel Cont’d.
ASSEMBLY
Grounding
Your generator must be properly connected to an
appropriate ground to help prevent electric shock.
A ground terminal connected to the frame of the generator
has been provided on the power panel. For remote
grounding, connect of a length of heavy gauge
(12 AWG minimum) copper wire between the generator
ground terminal and a copper rod driven into the ground.
We strongly recommend that you consult with a qualified
electrician to ensure compliance with local electrical codes.
Failure to properly ground the generator can result
in electric shock.
WARNING
Our engines work well with 10% or less ethanol
blend fuels. When using blended fuels there are
some issues worth noting:
– Ethanol-gasoline blends can absorb more water
than gasoline alone.
– These blends can eventually separate, leaving
water or a watery goo in the tank, fuel valve and
carburetor.
– With gravity-fed fuel supplies, this compromised
fuel can be drawn into the carburetor and cause
damage to the engine and/or potential hazards.
– There are only a few suppliers of fuel stabilizer
that are formulated to work with ethanol blend
fuels.
– Any damages or hazards caused by using
improper fuel, improperly stored fuel, and/
or improperly formulated stabilizers, are not
covered by manufacture’s warranty.
It is advisable to always shut off the fuel supply,
run the engine to fuel starvation and drain the tank
when the equipment is not in use for more than 30
days.
NOTE
Add Fuel
1. Use clean, fresh, regular unleaded fuel with a minimum
octane rating of 85 and an ethanol content up to 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. (6.4 mm)
of space left in the tank is required for fuel expansion,
more than ¼ in. (6.4 mm) 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. (6.4 mm) below the
top of the tank to allow for fuel expansion.
DO NOT pump gas directly into the generator at the
gas station. Use an approved container to transfer
the fuel to the generator.
DO NOT fill fuel tank indoors.
DO NOT fill fuel tank when the engine is running or hot.
DO NOT overfill the fuel tank.
DO NOT light cigarettes or smoke when filling the
fuel tank.
CAUTION
Pouring fuel too fast through the fuel screen may
result in blow back of fuel at the operator while filling.
WARNING
11 REV 46577-20140214
ENGLISH 46577
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 5 ft. (1.5 m) of clearance from all
combustible material. In addition to clearance from
all combustible material, generators must also have
at least 3 ft. (91.4 cm) of clearance on all sides to
allow for adequate cooling, maintenance and servicing.
Generators should never be started or operated in the
back of a SUV, camper, trailer, in the bed of a truck
(regular, flat or otherwise), under staircases/stairwells,
next to walls or buildings, or in any other location that
will not allow for adequate cooling of the generator
and/or the muffler. DO NOT contain generators during
operation. Allow generators to properly cool before
transport or storage.
Place the generator in a well-ventilated area. DO NOT
place the generator near vents or intakes where exhaust
fumes could be drawn into occupied or confined
spaces. Carefully consider wind and air currents when
positioning generator.
Failure to follow proper safety precautions may void
manufacturer’s warranty.
Do not operate or store the generator in rain, snow,
or wet weather.
Using a generator or electrical appliance in wet
conditions, such as rain or snow, or near a pool or
sprinkler system, or when your hands are wet, could
result in electrocution.
WARNING
WARNING
During operation the muffler and exhaust fumes
produced will become hot. If adequate cooling and
breathing space are not supplied, or if the generator
is blocked or contained, temperatures can become
extremely heated and may lead to fire.
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.
REV 46577-20140214 12
46577 ENGLISH
OPERATION
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 or 240 Volt AC
single phase, 60 Hz electrical loads.
– DO NOT connect 3-phase loads to the generator.
– DO NOT connect 50 Hz loads to the generator.
– DO NOT overload the generator.
Connecting a generator to your electric utility
company’s power lines or to another power source
may be against the law. In addition this action,
if done incorrectly, could damage your generator
and appliances and could cause serious injury or
even death to you or a utility worker who may be
working on nearby power lines. If you plan to run a
portable electric generator during an outage, please
notify your electric utility company immediately
and remember to plug your appliances directly
into the generator. Do not plug the generator into
any electric outlet in your home. Doing so could
create a connection to the utility company power
lines. You are responsible for ensuring that your
generator’s electricity does not feed back into the
electric utility power lines.
If the generator will be connected to a building
electrical system, consult your local utility company
or a qualified electrician. Connections must isolate
generator power from utility power and must comply
with all applicable laws and codes.
NOTE
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
Connecting Electrical Loads Cont’d.
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 Engine 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
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
13 REV 46577-20140214
ENGLISH 46577
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 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 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
Carburetor
Code Main Jet Part Number Altitude
P19-2-R
Standard 2 6 .131 017. 2 0 . R
3500 Feet
(1067 Meters)
Altitude 26.131017.20.01.R
P19-2-Z
Standard 2 6 .131 017. 2 0 . Z
Altitude 26.131017.20.01.Z
P19-2-H
Standard 2 6 .131 017. 2 0 . H
Altitude 26.131017.20.01.H
REV 46577-20140214 14
46577 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.
Air Filter
1. Remove the snap-on cover holding the air filter to
the assembly.
2. Remove the foam element.
3. Wash in liquid detergent and water. Squeeze
thoroughly dry in a clean cloth.
4. Saturate in clean engine oil.
5. Squeeze in a clean, absorbent cloth to remove all
excess oil.
6. Place the filter in the assembly.
7. Reattach the air filter cover and snap in place.
Spark Plugs
1. Remove the spark plug cable from the spark plug.
2. Use a 13/16 in. or 21 mm socket 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 firmly install the plug.
8. Attach the spark plug wire to the plug.
For service or parts assistance, contact our help
line at 1-877-338-0999
NOTE
Maintenance, replacement, or repair of emission
control devices and systems may be performed
by any non-road engine repair establishment or
individual.
NOTE
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 fill 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
specification 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 fill cap/dipstick to add oil.
5. Add up to 0.6 qt. (0.6 L) of oil and replace oil fill
cap/dipstick. DO NOT OVERFILL.
6. Dispose of used oil at an approved waste
management facility.
15 REV 46577-20140214
ENGLISH 46577
MAINTENANCE AND STORAGE
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
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.
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 46577-20140214 16
46577 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.
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
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
(14.8 mL) of oil into the cylinder. Crank the engine
slowly to distribute the oil and lubricate the cylinder.
10. Reattach the spark plug.
11. Store the unit in a clean, dry place out of direct
sunlight.
Our engines work well with 10% or less ethanol
blend fuels. When using blended fuels there are
some issues worth noting:
– Ethanol-gasoline blends can absorb more water
than gasoline alone.
– These blends can eventually separate, leaving
water or a watery goo in the tank, fuel valve and
carburetor.
– With gravity-fed fuel supplies, this compromised
fuel can be drawn into the carburetor and cause
damage to the engine and/or potential hazards.
– There are only a few suppliers of fuel stabilizer
that are formulated to work with ethanol blend
fuels.
– Any damages or hazards caused by using
improper fuel, improperly stored fuel, and/
or improperly formulated stabilizers, are not
covered by manufacture’s warranty.
It is advisable to always shut off the fuel supply,
run the engine to fuel starvation and drain the tank
when the equipment is not in use for more than 30
days.
NOTE
Generator Storage Cont’d.
17 REV 46577-20140214
ENGLISH 46577
Engine Specifications
– Model .....................YF168FD-2-010
– Displacement .......................196cc
– Type ........................4-Stroke OHV
– Start Type .........................Recoil
Oil
Use 10W-30 automotive oil.
Oil capacity is up to 0.6 qt. (0.6 L).
DO NOT OVERFILL.
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 up to 10% by volume.
Generator Specifications
– Model ........................... 46577
– Running Wattage .................3500 Watts
– Starting Wattage .................4000 Watts
– AC Load ...................... 120/240 V
– Phase ............................Single
– Frequency .........................60 Hz
– Fuel Capacity ................3.8 gal. (14.4 L)
– Gross Weight ................ 119 lb. (54 kg)
– Net Weight ................109.1 lb. (49.5 kg)
– Height .................... 20.9 in. (53 cm)
– Width .................... 23.2 in. (59 cm)
– Length. . . . . . . . . . . . . . . . . . . 26.3 in. (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.).
An Important Message About Temperature
Your 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.
REV 46577-20140214 18
46577 ENGLISH
SPECIFICATIONS
Wiring Diagram
19 REV 46577-20140214
ENGLISH 46577
SPECIFICATIONS
Parts Diagram
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18 19 20 21
22
23
16
24
25
26
27
28
29
30
31
32
27
33
34
35
36
37
38
39
40
41
43
44
45
47
48
5051
52
53
59
27
67 68
69
70
75
76
77787980
85
86 73 87 88 89 90
91
92
93
94
95
97
101
102
8283
46
58
96
81
13
49
17
54
55
56
57
56
60
61
62
63
64
65
66
56
71
72
73
22
74
84
98
99
22
100
42
REV 46577-20140214 20
46577 ENGLISH Parts List
#Part Number Description Qty
126.401.94 Engine, Green 1
2122.190005.00 Rubber, Fore-Cover, B 1
3122.190005.01 Rubber, Fore-Cover, A 1
4123.191100.19 Rotor Assembly, Al,
120 mm, No DC 1
52.08.022 Flange Bolt M8×242 1
61.96.08 Washer Ø8 1
71.7244.08 Spring Washer Ø8 1
8123.191200.23 Stator Assembly, Al,
120 mm, No DC 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 Spring Washer Ø6 8
14 122.190300.00 Carbon Brush Assembly 1
15 122.190004.01 Pinch, Carbon Brush 1
16 1.93.05 Spring Washer Ø5 3
17 1.5783.0516 Bolt M5×16 3
18 1.97.1.05 Washer Ø5 2
19 122.190200.03 AVR (2KW CPE) 1
20 1.16674.0516 Flange Bolt M5×16 2
21 122.190003.00.94 Generator End Cover, Green 1
22 1.16674.0512.2 Flange Bolt M5×12 7
23 122.190400.00 Terminal Block 1
24 122.190018.00 Bracket I, Muffler 1
25 1.16674.0820 Flange Bolt M8×20 3
26 122.190018.01 Bracket II, Muffler 1
27 1.5789.0612 Flange Bolt M6×12 7
28 1.9074.4.0514 Screw And Washer Assembly
M5×14 2
29 46.101503.08 Plate, Spark Arrester 1
30 46.101300.08 Spark Arrester Assembly 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 Spring Washer Ø8 2
35 1.848.08 Washer Ø8 2
36 26.100001.00 Muffler Gasket 1
37 23.090006.21 Holder, Air Cleaner 1
38 1.5789.0608 Flange Bolt M6×8 1
39 23.070011.04 Pipe, Fuel (6.1 in.) 1
40 2.06.007 Clamp (Ø8×b6) 2
41 122.070400.05 Fuel Cock 1
42 122.071000.05.94 Fuel Tank, Green 1
43 122.070015.01 Mount Vibration, Fuel Tank 4
44 2.03.004 Washer (Ø24×Ø6.5×1.5) 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 24.070014.05 Pipe, Reversal Valve,
630 mm 1
49 24.070030.00 Hole, Breather Tube 1
50 2.06.006 Clamp (Ø7×Ø1) 1
51 24.070800.00 Reversal Valve 1
#Part Number Description Qty
52 1.819.0510 Screw M5×10 2
53 122.072000.00 Fuel Meter Assembly 1
54 152.200702.00 Cover, Handle 1
55 122.200700.03.2 Handle 1
56 1.6177.1.08 Flange Lock Nut M8 14
57 1.5789.0845 Flange Bolt M8×45 2
58 6.2.263.318.2 Frame 1
59 2.05.001 Clamp (Ø8×6.5) 2
60 122.201200.05 Motor Mount, II 2
61 122.201200.04 Motor Mount, I 2
62 1.6182.10 Lock Nut M10 2
63 122.201701.05.2 8 in. Wheel 2
64 122.200016.01 Bushing (Ø16×Ø10.5×58.5) 2
65 1.96.10 Washer Ø10 2
66 1.5782.10105 Bolt M10 ×105 2
67 1.5789.0816 Flange Bolt M8×16 2
68 152.200002.00.2 Support Leg 1
69 152.201400.00 Rubber, Support 2
70 1.5789.0825 Flange Bolt M8×25 2
71 1.6177.1.06 Flange Lock Nut M6 1
72 5.1900.026 Grounding Line 150 mm 1
73 1.862.06 Lock Washer Ø6 2
74 2.08.068.2 Flange Bolt M5×13 4
75 122.01.110.2 Control Panel 1
76 5.1000.004.3 Ignition Switch 1
77 5.1400.003 Voltage Meter 1
78 1.848.03.2 Washer Ø3 4
79 1.859.03.2 Spring Washer Ø3 4
80 1.6175.03.2 Nut M3 4
81 5.1120.0 09 Receptacle L14-30R 1
82 1.9074.4.0414.1 Screw And Washer Assembly
M4×14, Black 6
83 1.6177.1.04.1 Flange Lock Nut M4, Black 6
84 5.1020.002 120/240V Change-over
Switch 1
85 5.1120.034 Receptacle TT-30R 1
86 5.1120.030 Receptacle 5-20R 1
87 1.5783.0622.3 Bolt M6×22, Green 1
88 1.6175.06.3 Nut M6, Green 2
89 1.97.1.06.3 Washer Ø6, Green 2
90 1.93.06.3 Spring Washer Ø6, Green 2
91 122.210003.01 Plug, Control Box 1
92 5.1330.001 Sheath, Wire 1
93 122.210003.03 Plug, End Cover 1
94 5.1810.001 Over Voltage Protector 1
95 1.823.0514 Screw M5×14 1
96 5.1210.920 AC 20A Breaker, Push
Button, CSA 1
97 5.1200.215 AC 15A Breaker, Push
Button, CSA 2
98 1.6177.1.05 Flange Lock Nut M5 4
99 254.200015.00.2 Clamp, Wand 2
100 122.210002.02 Control Box 1
101 1.9074.1.0538.2 Screw And Washer Assembly
M5×38 3
102 122.210003.00 Grommet 1
21 REV 46577-20140214
ENGLISH 46577
SPECIFICATIONS
Engine Parts Diagram
1
2345678910
12 13
25 26 27 29 30 32 35 37
38 12 40 41
42
43 44
46
47
21 22
23 24
31 34 36 39
53
52
45
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
12
77
96
33
81
73
15
20
48 14
101
51
100
64
16
99
89
19
11
18
17
19
28
98
REV 46577-20140214 22
46577 ENGLISH
#Part Number Description Qty
11.5789.0608 Flange Bolt M6×8 5
222.061100.00.2 Recoil Starter Cover, Black 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 24.080100.01.94 Fan Cover, Green 1
14 24.091100.21 Base, Air Cleaner 1
15 21.061300.00 Recoil Handle 1
16 24.130004.20 Gasket, Air Cleaner 1
17 22.061000.00 Recoil Assembly 1
18 24.091000.21 Air Cleaner Assembly 1
19 26.131000.20 Carburetor 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 24.120100.06 Flywheel 1
25 2.11.001 Oil Seal (Ø25×Ø41.3×6) 2
26 2.03.020.1 Washer (Ø6.2×Ø15×0.5),
Black 1
27 21.110100.00 Governor Gear 1
28 23.130100.20 Choke Lever 1
29 21.110013.00 Shaft, Governor Gear 1
30 21.110011.00 Clip, Governor Gear 1
31 22.130003.00 Gasket, Carburetor 1
32 21.110012.01 Bushing, Governor Gear (Iron) 1
33 24.130002.00 Gasket, Insulator 1
34 23.130001.00 Insulator, Carburetor 1
35 23.080600.00 Air Guide, Right Side 1
36 2.01.003 Stud Bolt M6×90 2
37 26.030100.00 Crankcase (200) 1
38 21.127000.02 Oil Level Sensor 1
39 26.010100.00 Cylinder Head (168-2) 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 1
44 22.031000.00.1 Oil Dipstick Assembly, Black 1
45 2.03.021.1 Washer (Ø6.4×Ø13×1), Black 1
46 23.030007.01 Cover, Crankcase (Engine For
Equipment) 1
47 1.5789.0832.0.8 Flange Bolt M8×32 6
48 23.091002.21 Seal, Air Cleaner 1
49 23.110006.00 Governor Rod 1
50 21.110003.00 Governor Arm 1
51 1. 617 7.0 6 Flange Nut M6 3
#Part Number Description Qty
52 21.110001.00 Shaft, Governor Arm 1
53 22.123000.01 Ignition Coil (Silicon Rubber
EPA) 1
54 1.5789.0625 Flange Bolt M6×25 2
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 23.111000.20 Control Assembly (Engine For
Equipment) 1
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 Woodruff Key (4×7.5×19) 1
64 2.08.037 Drain Bolt (M10×1.25×25) 2
65 26.050005.00 Piston 1
66 23.050003.00 Pin, Piston 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 26.080400.00 Air Guide, Lower (200G) 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 Lock Nut (M6×0.5) 2
87 1.97.1.06 Washer Ø6 2
88 1.6177.1.06 Flange Lock Nut M6 2
89 2 6 .1 31017. 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 1.5789.0620 Flange Bolt M6×20 1
99 24.091200.20 Cover, Air Cleaner 1
100 23.091003.21 Element, Air Cleaner 1
101 23.091001.21 Separator, Air Cleaner 1
23 REV 46577-20140214
ENGLISH 46577
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 46577-20140214 24
46577 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
12039 Smith Ave.
Santa Fe Springs, CA 90670
www.championpowerequipment.com
Customer Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
info@championpowerequipment.com
Fax no.: 1-562-236-9429
Technical Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
tech@championpowerequipment.com
24/7 Tech Support: 1-562-204-1188

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