CHAMPION 201094 Portable Generator Instruction Manual
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PARTS INFORMATION
201094 - 5500W PORTAble GeNeRATOR 7 eNGINe PARTS PART lIST # Part Number Description Qty. 61 46.041000.00 Camshaft 1 62 45.040013.00 Lifter, Valve 2 63 45.110005.00 Spring, Throttle Return 1 64 45.110007.00 Spring, Gove…
Parts Information for All in English
5500-Watt Generator - Champion Power Equipment
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Champion Power Equipment, Inc., Santa Fe Springs, CA USA MODEL #201094 PARTS INFORMATION 5500W PORTABLE GENERATOR SERIAL NUMBER RANGE: ALL To order replacement parts please visit: shop.championpowerequipment.com or call 1-877-338-0999. REV 20210816 TABLE OF CONTENTS Generator Parts Diagram. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 3 Generator Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine Parts Part List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder Head Part Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cylinder Head Part List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Alternator Part Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Alternator Part List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fuel Tank Part Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Fuel Tank Part List . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 13 Control Panel Part Diagram. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 14 Control Panel Part List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Frame Part Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Frame Part List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Wiring Diagram .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2 201094 - 5500W PORTABLE GENERATOR GENERATOR PARTS DIAGRAM 1 2 3 22,See Figure H 21 27 26 25 8 24 23 4 28 29 4 20 ,See Figure B 19 18 17 16 30 31,See Figure G Figure A 3 5 ,See Figure F 6 7 8 9 10 11 12 13 14 15 ,See Figure E 201094 - 5500W PORTABLE GENERATOR GENERATOR PARTS LIST # Part Number Description Qty. # Part Number Description Qty. 1 2.06.006 Clamp, �7 x �1 1 30 1.5789.0615.1 Flange Bolt M6 x 15, Black 4 2 24.070030.00 Orifice, Breather Tube 1 31 201094.21 Control Panel Assembly, See Figure G 1 3 152.070014.08 Tube, Reversal Valve 1 4 2.06.007 Clamp �8 x b6 3 5 152.070000.64.48 Fuel Tank Assembly, See Figure F 1 6 2.08.143.1 Flange Bolt/Washer Assembly M6 x 20, Black 4 7 45.090006.20 Bracket, Air Cleaner Support 1 8 1.6177.1.06 Lock Nut M6, Flange 2 9 1.6177.1.08 Lock Nut M8, Flange 2 10 46.100001.07 Gasket, Exhaust 1 11 46.101000.12.2 Muffler Assembly 1 12 1.9074.4.0510 Screw/Washer Assembly M5 x 10 3 13 46.101300.00 Spark Arrester 1 14 1.16674.0820.1 Flange Bolt M8 x 20, Black 2 15 151.190000.15 Alternator Assembly, See Figure E 1 16 1.5789.0608 Flange Bolt M6 x 8 1 17 152.192300.01 Vent, Alternator Fan 1 18 152.190005.00 Rubber, Fore-Cover, A 1 19 152.190005.01 Rubber, Fore-Cover, B 1 20 46.401 Engine Assembly, See Figure B 1 21 1.6177.1.10 Lock Nut M10, Flange 4 22 65309.201094 Frame Assembly, See Figure H 1 23 1.862.06 Lock Washer �6, Toothed 1 24 5.1900.029 Grounding Line 150 mm 1 25 1.97.1.06.2 Washer �6 2 26 1.93.06 Lock Washer �6 1 27 1.62.06 Butterfly Type Nut M6 1 28 2.05.009 Clamp �12.5 x 7 2 29 152.070011.29 Fuel Tube, Fuel Valve to Carburator, 430+20mm 1 4 201094 - 5500W PORTABLE GENERATOR ENGINE PARTS DIAGRAM 54 64 65 94 69 93 72 92 91 90 100 82 81 60 99 80 89 71 79 78 59 58 98 77 76 57 97 75 96 95 89 88 87 86 85 84 74 73 56 55 53See Figure C 52 12 67 66 63 62 50 49 48 47 46 45 44 43 22 23 61 24 25 26 27 28 29 83 2 1 3 4 5 70 6 789 10 11 30 31 32 33 12 34 28 35 36 12 13 14 15 16 17 18 19 Figure B 20 21 42 41 40 39 38 21 37 5 201094 - 5500W PORTABLE GENERATOR ENGINE PARTS PART LIST # Part Number 1 21.061006.02 2 1.16674.0608 3 46.061100.03.2 4 45.060005.00 5 45.061102.00 6 2.10.003.1 7 45.060003.00 8 45.060002.00 9 45.060009.00 10 45.060007.00 11 45.060008.00 12 1.5789.0612 13 2.05.005 14 47.080100.01.48 15 2.02.007 16 1.5789.0629 17 45.060001.00 18 46.123000.01 19 45.080001.00 20 46.120100.06 21 2.11.007 22 2.05.050 23 152.070031.01 24 2.03.023 25 46.030100.04.1 26 45.127000.02 27 1.5789.0615 28 1.276.6202 29 47.050006.00 30 45.050100.14 Description Handle, Recoil, Soft Flange Bolt M6 x 8 Cover, Recoil Starter, Black Spring, Recoil Starter Reel, Recoil Starter Rope �4 x 1550, Black Spring, Ratchet Starter Ratchet, Steel Spring, Ratchet Guide Ratchet Guide Screw, Ratchet Guide Flange Bolt M6 x 12 Clamp �6 Fan Cover, Yellow Nut M16 x 1.5 Flange Bolt M6 x 29 Pulley, Starter Ignition Coil Cooling Fan Flywheel Oil Seal �35 x �52 x 8 Wire Clip, 100 mm Sheath, Wire Washer �12.5 x �20 x 2, Drain Bolt Crankcase Oil Level Sensor Flange Bolt M6 x 15 Bearing 6202 Weight Balancer Crankshaft Qty. # Part Number Description Qty. 1 31 46.030008.00 Gasket, Crankcase Cover 1 3 32 2.04.001 Dowel Pin �9 x 14 2 1 33 46.080600.00 Air Guide, Right Side 1 1 34 1.276.6207 Bearing 6207 1 1 35 46.031000.01.48 Oil Dipstick Assembly, Yellow 1 1 36 45.030007.00 Cover, Crankcase 1 2 37 1.5789.0840 Flange Bolt M8 x 40 7 2 38 2.03.021.1 Washer �6.4 x �13 x 1, Black 1 1 39 45.110013.00 Shaft, Governor Gear 1 1 40 45.110100.00 Gear, Governor 1 1 41 21.110011.00 Clip, Governor Gear 1 12 42 45.110012.00 Bushing, Governor Gear 1 2 43 47.050200.00 Connecting Rod 1 1 44 46.050005.00 Piston 1 1 45 2.09.004 Circlip �21 x �1 2 2 46 45.050003.00 Pin, Piston 1 1 47 46.050303.00 Ring, Oil 1 1 48 46.050302.00 Ring, Second Piston 1 1 49 46.050301.00 Ring, First Piston 1 1 50 2.04.004 Dowel Pin �12 x 20 2 2 51 46.080400.00 Air Guide, Lower 1 1 52 46.010000.00 Cylinder Head Assembly,See Figure C 1 1 53 45.110006.00 Rod, Governor 1 1 54 2.15.002(F6RTC) Spark Plug F6RTC 1 1 55 2.08.014 Flange Bolt M10 x 80 4 1 56 46.020002.00 Gasket, Cylinder Head Cover 1 2 57 46.021000.00 Cover, Cylinder Head 1 2 58 45.020001.02 Breather Tube 1 1 59 45.020100.00 Bolt, Cylinder Head Cover 1 1 60 2.08.039 Drain Bolt M12 x 1.5 x 15 1 6 201094 - 5500W PORTABLE GENERATOR # Part Number 61 46.041000.00 62 45.040013.00 63 45.110005.00 64 45.110007.00 65 46.040005.00 66 46.080300.20 67 45.040017.00 68 46.091000.11 69 46.061000.03.2 70 46.040200.00 71 1.6177.1.05 72 45.040008.00 73 46.040004.00 74 46.040016.00 75 46.040201.00 76 46.040009.00 77 46.040018.00 78 1.97.1.06 79 22.040012.00 80 1.6177.1.06 81 21.040021.00 82 21.061301.01.48 83 46.130002.20 84 45.130001.00 85 46.130003.20 86 46.131000.20 87 46.130004.20 88 1.6177.06 89 46.091100.09 90 45.091002.20 91 45.091001.20 92 45.091003.20 Description Camshaft Lifter, Valve Spring, Throttle Return Spring, Governor Push Rod Air Guide, Upper Oil Seal, Valve Air Cleaner Assembly Recoil Assembly Rocker Arm Assembly Flange Nut M5 Rotator, Exhaust Valve Guide Plate, Push Rod Shaft, Rocker Arm Retainer, Rocker Arm Rocker Arm, Intake Valve Rocker Arm, Exhaust Valve Washer �6 Screw, Valve Adjustment Flange Nut M6 Nut M6 x 0.5, Lock Support, Handle, Recoil Gasket, Insulator Insulator, Carburetor Gasket, Carburetor Carburetor Assembly Gasket, Air Cleaner Flange Nut M6 Base, Air Cleaner Seal, Air Cleaner Separator, Air Cleaner Element, Air Cleaner Qty. 1 2 1 1 2 1 2 1 1 1 6 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 3 1 1 1 1 7 # Part Number 93 46.091200.11 94 45.110001.00 95 2.03.019 96 2.11.006 97 45.110008.00 98 45.110003.00 99 2.08.040 ENGINE PARTS PART LIST Description Qty. Cover, Air Cleaner 1 Shaft, Governor Arm 1 Washer �8.2 x �17 x 0.8 1 Oil Seal �7 x �14 x 5 1 Pin, Shaft 1 Arm, Governor 1 Bolt M6 x 21, Governor Arm 1 201094 - 5500W PORTABLE GENERATOR CYLINDER HEAD PART DIAGRAM 12 10 9 11 8 7 4 6 1 5 3 2 Figure C 8 201094 - 5500W PORTABLE GENERATOR CYLINDER HEAD PART LIST # Part Number Description Qty. 1 45.040002.00 Valve, Intake 1 2 45.040006.00 Valve, Exhaust 1 3 46.030009.01 Gasket, Cylinder Head 1 4 2.01.008 Stud Bolt M6 x M8 x 105 2 5 46.010100.00 Cylinder Head 1 6 2.01.010 Stud Bolt M8 x 35 2 7 45.040015.00 Retainer, Valve Spring 2 8 45.040017.00 Oil Seal, Valve 2 9 45.040003.00 Spring, Valve 2 10 45.040001.00 Retainer, Intake Valve Spring 1 11 45.040007.00 Retainer, Exhaust Valve Spring 1 12 23.040010.00 Bolt, Rocker Arm 2 9 201094 - 5500W PORTABLE GENERATOR ALTERNATOR PART DIAGRAM 22 21 20 19 18 1 234 5 67 8 9 17 16 15 14 13 12 Figure E 11 15 10 10 201094 - 5500W PORTABLE GENERATOR ALTERNATOR PART LIST # Part Number 1 1.6175.05 2 1.97.1.05 3 1.93.05 4 2.08.097 5 152.190300.00 6 122.190004.01 7 1.9074.15.0520 8 122.190018.03 9 2.08.068.1 10 152.190003.02.48 11 1.9074.17.0516 12 122.190400.02 13 1.16674.0516 14 153.190200.03 15 1.16674.0512 16 152.190002.00 17 2.08.096 18 151.191002.15 19 2.08.095 20 151.191200.15 21 151.191100.15 22 151.191000.15 Description Qty. Nut M5 2 Washer �5 2 Lock Washer �5 2 Bolt M5 x 184 2 Carbon Brush Assembly 1 Pinch, Carbon Brush 1 Bolt/Washer Assembly M5 x 20 1 Bracket, End Housing Cover 1 Flange Bolt M5 x 13, Black 1 Cover, End Housing, Yellow 1 Screw/Washer Assembly M5 x 16 2 Terminal Block 1 Flange Bolt M5 x 16 2 AVR 1 Flange Bolt M5 x 12 3 End Housing 1 Flange Bolt/Washer Assembly M6 x 149 4 Stator Cover 1 Flange Bolt/Washer Assembly M10 x 235 1 Stator Assembly, Al, �190 x 110 mm 1 Rotor Assembly, Al, �190x 110 mm 1 Alternator, Al, �190 x 110 mm 1 11 201094 - 5500W PORTABLE GENERATOR FUEL TANK PART DIAGRAM 1 2 7 8 9 3 4 5 6 Figure F 12 201094 - 5500W PORTABLE GENERATOR FUEL TANK PART LIST # Part Number 1 122.070100.09 2 122.070300.03 3 152.072000.06 4 24.070800.00 5 152.071000.64.48 6 122.070015.01 7 21.070600.03 8 2.06.016 9 152.070011.30 Description Qty. Fuel Tank Cap 1 Fuel Filter 1 Fuel Gauge 1 Valve, Reversal 1 Fuel Tank, 29.1L, Yellow 1 Mount Vibration, Fuel Tank 4 Fitting, Fuel Tank 1 Clamp �8.7 x b8 1 Fuel Tube 245+32 mm, Fuel Tank to Fuel Valve 1 13 201094 - 5500W PORTABLE GENERATOR CONTROL PANEL PART DIAGRAM 34 12 29 28 27 26 5 6 7 8 9 10 11 12 13 14 15 16 17 18 22 21 19 20 25 23 24 Figure G 14 201094 - 5500W PORTABLE GENERATOR CONTROL PANEL PART LIST # Part Number 1 5.1810.000 2 1.818.0514.2 3 5.1800.000 4 152.210002.63 5 1.6177.1.05 6 62.139002.00.48 7 1.9074.4.0414.1 8 122.139001.01 9 1.845.0.02216 10 5.1050.006 11 122.139004.01 12 1.845.4816 13 62.070400.00 14 1.818.0410 15 201094.21.10 16 152.210003.03 17 5.1320.024 18 152.210003.01 19 5.1210.920 20 5.1870.014 21 5.1240.923 22 1.9074.4.0306.1 23 5.1120.027 24 1.6177.1.04.1 25 5.1870.025 26 5.1120.026 27 5.1870.020 28 5.1470.005 29 152.25.5.2 Description Qty. OVP Module 1 Screw M5 x 14 2 Rectifier 1 Control Panel Housing 1 Lock Nut M5, Flange, Black 8 Cover, Fuel Dial, Yellow 1 Screw/Washer Assembly M4 x 14, Black 1 Fuel Dial 1 Screw, ST2.2 x 16 2 Microswitch, 2-Pole 1 Plate, Fuel Valve Mounting 1 Screw, ST4.8 x 16 4 Fuel Valve 1 Screw M4 x 10 2 Wire Assembly 1 Plug, Control Box 1 Sheath, Wire 1 Wire Jacket, Control Panel Housing 1 20Amp Circuit Breaker, Push Button, CSA 2 Cover, Push Button Circuit Breaker 2 23Amp Circuit Breaker, Double Pole, CSA 1 Screw/Washer Assembly M3 x 6, Black 4 Receptacle 5-20R, CSA 2 Lock Nut M4, Flange, Black 6 Cover, Receptacle 5-20R 2 Receptacle, L14-30R, CSA 1 Cover, Receptacle L14-30R 1 Intelligauge, INT1BOF 1 Control Panel 1 15 201094 - 5500W PORTABLE GENERATOR FRAME PART DIAGRAM 1 2 3 4 23 22 5 21 6 12 20 19 18 17 16 15 14 13 Figure H 16 11 10 7 98 201094 - 5500W PORTABLE GENERATOR FRAME PART LIST # Part Number 1 2.05.001 2 65309.0.8.2 3 152.200703.05 4 11.110008.00 5 152.100007.00 6 122.200702.14.48 7 122.200702.13.48 8 1.9074.4.0414.1 9 152.200701.22.2 10 152.200703.02 11 1.894.1.08 12 1.6177.1.08 13 1.6177.1.08.1 14 1.5789.0825.1 15 122.201400.04 16 152.200002.16.2 17 1.5789.0840.1 18 122.201701.11.48 19 122.201501.23.1 20 122.201702.11.48 21 2.16.001.1 22 152.201200.03 23 152.201200.04 Description Qty. Clamp, �8 x 6.5 2 Frame, 680 x 556 x 567 1 Long Pin, Handle 2 Pin �1.6 x 24, "R" Shape , Black 2 Heat Shield, Motor Mount 1 Cover, Handle, Lower, Yellow 1 Cover, Handle, Upper, Yellow 1 Screw/Washer Assembly M4 x 14, Black 2 Handle, U Shape, Black 1 Short Pin, Handle 2 Circlip �8 2 Lock Nut M8, Flange 4 Lock Nut M8, Flange , Black 6 Flange Bolt M8 x 25, Black 2 Rubber, Support, 55 x 36 x 22 2 Support Leg, 68 mm, Black 2 Flange Bolt M8 x 40, Black 4 8 in. Wheel, PU, Yellow 2 Pin Roll, Wheel, �16 x �10 x 97, Blcak 2 Wheel Cover, Tooth Profile 8-10 in, Yellow 2 Pin �2 x 33, "R" Shape , Black 2 Motor Mount 1 2 Motor Mount 2 2 17 201094 - 5500W PORTABLE GENERATOR WIRING DIAGRAM FUEL SELECT DIAL a2 a1 a3 b2 b1 b3 ON OFF B BLACK Br BROWN Y YELLOW B/W BLACK WHITE L BLUE W/G WHITE GREEN G GREEN G/Y GREEN YELLOW R RED W/L WHITE BLUE W WHITE B/G BLACK GREEN O ORANGE MW2 23A, 2P C.B. B B L L BW INTELLIGAUGE INT1BOF MW1 W 20A, C.B. B B L14-30R G/Y R B W 5-20R A 5-20R B B R W W W W FW EXW R Br Y LY YL YL R+ R G/Y AVR W 23A R R G/Y R W OVP 20A, C.B. G/Y R G/Y EARTH TERMINAL G/Y Y B G/Y G/Y B G/Y RECTIFIER B OFF B a1 a2 a3 G/Y b1 b2 W/G b3 L Br DCW B NO USE Br Br Br B GENERATOR BLOCK ENGINE BLOCK B B FUEL SELECT DIAL L W/G Y CONTROL BOX BLOCK W/G Y B/G B/G IGNITION COIL SPARK PLUG OIL LEVEL SW N.O. FUEL CUT SOLENOIL 18