Manual English
Manual English
Manual English
PORTABLE GENERATOR
2yEAR
LIMITED WARRANTY
4000 Peak Watts / 3500 Running Watts Wireless Remote Electric Start
46512
MADE IN CHINA
MODEL NUMBER
SAvE THESE INSTRuCTIONS Important Safety Instructions are included in this manual.
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10006 Santa Fe Springs Road Santa Fe Springs CA 90670 USA / 1 (877) 338-0999 www.championpowerequipment.com
1-877-338-0999
46512
PORTABLE GENERATOR
Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . Portable Power Generator. . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . This Booklet. . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Conventions. . . . . . . . . . . . . . . . . . . . . . . Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls and Features . . . . . . . . . . . . . . . . . . . . . . Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . Wireless Remote Control . . . . . . . . . . . . . . . . . . Remote Control Power Consumption . . . . . . . . Power Panel Load Management . . . . . . . . . . . Parts Included . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Kit . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Arrester Kit. . . . . . . . . . . . . . . . . . . . . Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Generator from the Shipping Carton. . Install the Wheel Kit. . . . . . . . . . . . . . . . . . . . . Install the Support Leg . . . . . . . . . . . . . . . . . . . Install the Handles . . . . . . . . . . . . . . . . . . . . . . Connect the Battery . . . . . . . . . . . . . . . . . . . . . Install the Spark Arrester. . . . . . . . . . . . . . . . . . Add Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . Add Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Location. . . . . . . . . . . . . . . . . . . . . . Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surge Protection. . . . . . . . . . . . . . . . . . . . . . . . Wireless Remote Start. . . . . . . . . . . . . . . . . . . . Starting the Engine without Remote. . . . . . . . . . . Connecting Electrical Loads. . . . . . . . . . . . . . . . Stopping the Engine . . . . . . . . . . . . . . . . . . . . . Do Not Overload Generator. . . . . . . . . . . . . . . . . Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Management. . . . . . . . . . . . . . . . . . . . Wattage Reference Chart. . . . . . . . . . . . . . . . . . . 1 . 1 . 1 . 1 . 1 . 2 . 3 . 5 . 5 . 6 . 7 . 7 . 7 . 8 . 8 . 8 . 8 . 9 . 9 . 9 . 9 . 9 10 10 10 11 11 12 12 12 12 12 12 13 13 14 14 14 14 Maintenance and Storage. . . . . . . . . . . . . . . . Engine Maintenance . . . . . . . . . . . . . . . . . Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plugs. . . . . . . . . . . . . . . . . . . . . Air Filter . . . . . . . . . . . . . . . . . . . . . . . Spark Arrester . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . Adjustments. . . . . . . . . . . . . . . . . . . . . Maintenance Schedule . . . . . . . . . . . . . Generator Maintenance . . . . . . . . . . . . . . . Storage. . . . . . . . . . . . . . . . . . . . . . . . . . Generator Storage. . . . . . . . . . . . . . . . . Disconnect the Battery . . . . . . . . . . . . . Charge the Battery. . . . . . . . . . . . . . . . Specifications. . . . . . . . . . . . . . . . . . . . . . . . Engine Specifications . . . . . . . . . . . . . . . . Generator Specifications . . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . Valve Clearance . . . . . . . . . . . . . . . . . . . . FCC Statement for Remote Control Device. . Parts Diagram . . . . . . . . . . . . . . . . . . . . . Parts List. . . . . . . . . . . . . . . . . . . . . . . . . Engine Parts Diagram . . . . . . . . . . . . . . . . Engine Parts List . . . . . . . . . . . . . . . . . . . Wiring Diagram. . . . . . . . . . . . . . . . . . . . . Troubleshooting. . . . . . . . . . . . . . . . . . . . . . Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Qualifications . . . . . . . . . . . . . . . Repair/Replacement Warranty. . . . . . . . . . . Do Not Return The Unit To The Place Of Purchase . . . . . . . . . . . . . . . Warranty Exclusions . . . . . . . . . . . . . . . . . Normal Wear . . . . . . . . . . . . . . . . . . . . Installation, Use and Maintenance . . . . . Other Exclusions. . . . . . . . . . . . . . . . . . Limits of Implied Warranty and Consequential Damage . . . . . . . . . . Contact Information. . . . . . . . . . . . . . . . . Address. . . . . . . . . . . . . . . . . . . . . . . . Customer Service. . . . . . . . . . . . . . . . . Technical Service. . . . . . . . . . . . . . . . . Emission Control System Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 15 15 15 15 16 16 16 16 17 17 17 17 17 18 18 18 18 18 18 18 18 19 20 21 22 23 24 25 25 25 25 25 25 25 25 25 25 25 25 25 26
4000 Peak Watts / 3500 Running Watts Wireless Remote Electric Start
Introduction
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.
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Accessories
Champion Power Equipment manufactures and sells accessories designed to help you get the most from your purchase. To find out more about our covers, power cables and storm kits, please visit our web site at: www.championpowerequipment.com
This Booklet
Every effort has been made to ensure the accuracy and completeness of the information in this manual. We reserve the right to change, alter and/or improve the product and this document at any time without prior notice.
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.
1 (877) 338-0999
Model Number
46512
Serial Number
Date of Purchase
Purchase Location
For Oil Type see Add Engine Oil section. For Fuel Type see Add Fuel section.
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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.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
CAUTION
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
NOTE
If you have questions regarding your generator, we can help. Please call our help line at 1 (877) 338-0999
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
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Safety Rules
WARNING
Read this manual thoroughly before operating your generator. Failure to follow instructions could result in serious injury or death.
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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.
WARNING
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm.
DANGER
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.
WARNING
Sparks can result in fire or electrical shock.
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.
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.
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Safety Rules
WARNING
Rapid retraction of the starter cord will pull hand and arm towards the engine faster than you can let go. Unintentional startup can result in entanglement, traumatic amputation or laceration. Broken bones, fractures, bruises or sprains could result. When starting engine, pull the starter cord slowly until resistance is felt and then pull rapidly to avoid kickback. DO NOT start or stop the engine with electrical devices plugged in.
DANGER
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.
CAUTION
Exceeding the generators 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
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
WARNING
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.
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Read this owners manual before operating your generator. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference.
Generator
1
2 3 4 8
(1)
(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.
(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.
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Power Panel
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) 120V / 30A Twist-Lock This receptacle powers 120 Volt AC, 60 Hz, single phase loads requiring up to 29.2 Amps or 3500 Watts of power.
(7) 120V / 30A Recreational Vehicle (RV) Receptacle
This receptacle powers 120 Volt AC, 60 Hz, single phase loads requiring up to 29.2 Amps or 3500 Watts of power. (8) 120V / 20A Duplex Protected by a 20 Amp push-to-reset circuit breaker . Use each recepticle to operate 120 Volt AC, single phase, 60 Hz loads requiring up to 20 Amp 0r 2400 Watts of power.
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Parts Included
Your 46512 Gasoline Powered Generator ships with the following parts:
Wheel Kit
8 Wheel. . . . . . . . . . . . . . . . . . . . . . . . . Vibration Mounts. . . . . . . . . . . . . . . . . . . . Support Leg. . . . . . . . . . . . . . . . . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . Flange Bolt (M10x105 for Wheel) . . . . . . . . Flange Bolt (M8x45 for Handle) . . . . . . . . . Flange Bolt (M8x25 for Vibration Mounts) . . Flange Bolt (M8x16 for Support Leg). . . . . . Nut (M10). . . . . . . . . . . . . . . . . . . . . . . . Flat Washer 10. . . . . . . . . . . . . . . . . . . . . Nut (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 1 2 1 2 2 2 2 2 2 6
Other
Oil Funnel . . . . . . . . . . . . . . . . . . . . . . . Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug Socket. . . . . . . . . . . . . . . . . . Remote. . . . . . . . . . . . . . . . . . . . . . . . . Cap Screw (M6x10 for Battery Terminals). . Nut (M6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0.6 L . . . 1 . . . 1 . . . 2 . . . 2
(Battery Bolts)
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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.
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CAUTION
The wheel kit is not intended for over-the-road use. 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 its 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.
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Assembly
Add Engine Oil
CAUTION
DO NOT attempt to crank or start the engine before it has been properly filled with the recommended type and amount of oil. Damage to the generator as a result of failure to follow these instructions will void your warranty.
NOTE
The recommended oil type is 10W-30 4-cycle automotive oil. Please see Specifications section for more information on oil types. 1. Place the generator on a flat, level surface.
Secure the cover plate with the two screws and lock washers provided with the spark arrester kit.
NOTE
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.
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. See Specifications pages for oil recommendations based on operating conditions.
CAUTION
Failure to install the spark arrester may result in an increased risk of fire. 4. Check engine oil level daily and add as needed.
CAUTION
The engine is equipped with a low-oil-shutoff and will stop when the oil level in the crankcase falls below the threshold level.
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Assembly
Add Engine Oil Contd.
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Grounding
Your generator must be properly connected to an appropriate ground to help prevent electric shock.
NOTE
Check oil often during the break-in period. Refer to the Maintenance section for recommended service intervals.
WARNING
Failure to properly ground the generator can result in 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.
NOTE
The generator rotor has a sealed, pre-lubricated ball bearing that requires no additional lubrication for the life of the bearing.
Add Fuel
1. Use clean, fresh, regular unleaded fuel with a minimum octane rating of 85 and an ethanol content of less than 10% by volume. 2. DO NOT mix oil with fuel. 3. Clean the area around the fuel cap. 4. Remove the fuel cap. 5. Slowly add fuel to the tank. DO NOT overfill. Allow approximately inch of space for fuel expansion.
6. Screw on the fuel cap and wipe away any spilled fuel.
CAUTION
Use regular unleaded gasoline with a minimum octane rating of 85. Do not mix oil and gasoline. Fill tank to approximately inch below the top of the tank to allow for fuel expansion. 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.
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Operation
Wireless Remote 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. Press the Ignition Switch to ON. 3. Press the Battery Switch to ON. 4. Turn the Fuel Valve to the ON position. 5. To start the engine, 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 6 times. 6. 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. 7. If the generator fails to start, check the battery condition and cable connections.
Generator Location
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. This generator must have at least five feet of clearance from combustible material. Leave at least three feet of clearance on all sides of the generator to allow for adequate cooling, maintenance and servicing. 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.
Grounding
The generator system ground connects the frame to the ground terminals on the power panel.
Surge Protection
CAUTION
Voltage fluctuation may impair the proper functioning of sensitive electronic equipment. 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. Theyre designed to protect against virtually all short-duration voltage fluctuations. 2. Obtain an Uninterruptible Power Supply (UPS) device. Most UPS devices come with a rechargeable battery between the electronic equipment and power supply source. The device buffers the voltage and protects against virtually all short-duration voltage fluctuations.
NOTE
If the engine starts but does not run make certain that the generator is on a flat, level surface. The engine is equipped with a low oil sensor that will prevent the engine from running when the oil level falls below a critical threshold.
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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 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.
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NOTE
Connecting a generator to your electric utility companys 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 generators 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
When the stop button on the remote is pressed, power to the receptacles is turned off and the engine will stop after 5 seconds. Important: If the generator will be moved or stored turn the Fuel Valve to the OFF position, press the Ignition Switch and the Battery Switch on the power panel to the OFF position.
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Operation
Wattage Reference Chart
Use the chart to determine approximate wattage requirements for your equipment.
CAUTION
Exceeding specified load capacity can result in damage to the generator. To determine total wattage necessary to power a device, ADD Running Watts to Starting Watts. (A+B). Starting watts can exceed three times the running watts. The values in the following table are approximate. Refer to your tool or appliance for actual wattage consumption. Item
Light Bulb 100W Refrigerator/Freezer Freezer Sump Pump Well Pump 1 HP Water Heater Security System AM/FM Radio Garage Door Opener 1/2 HP Battery Charger 12V DC Air Conditioner 12000 BTU Fan Furnace Fan 1/3 HP Microwave 1000W Electric Range - One Element Electric Skillet Coffee Maker Clothes Washer CD/DVD Player / VCR Stereo Receiver Television 27 PC with 15 Monitor Belt Sander 3 Bench Grinder 6 Circular Saw Compressor 1 1/2 HP Edge Trimmer Hand Drill 1/2 Lawn Mower Paint Sprayer Table Saw
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.
600
NOTE
Never exceed the specified capacity when adding loads to the generator.
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Oil Contd.
WARNING
Never operate a damaged or defective generator .
NOTE
Once oil has been added, a visual check should show oil about 1-2 threads from running out of the fill hole . If using the dipstick to check oil level, DO NOT screw in the dipstick while checking .
WARNING
Tampering with the factory set governor will void your warranty .
WARNING
Improper maintenance will void your warranty .
NOTE
Maintenance, replacement, or repair of emission control devices and systems may be performed by any non-road engine repair establishment or individual . Complete all scheduled maintenance in a timely manner . Correct any issue before operating the generator .
Spark Plugs
1 . Remove the spark plug cable from the spark plug . 2 . Use the spark plug tool that shipped with your generator to remove the plug . 3 . Inspect the electrode on the plug . It must be clean and not worn to produce the spark required for ignition . 4 . Make certain the spark plug gap is 0 .7 - 0 .8mm or (0 .028 - 0 .031 in .) .
NOTE
For service or parts assistance, contact our help line at 1 (877) 338-0999
Engine Maintenance
To prevent accidental starting, remove and ground spark plug wire before performing any service . 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 .
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 0 .63 qt (0 .6 L) of oil and replace oil fill cap/dipstick . 6 . Dispose of used oil at an approved waste management facility .
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 .
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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.
CAUTION
Failure to clean the spark arrester will result in degraded engine performance.
Cleaning
CAUTION
DO NOT spray engine with water. Water can contaminate the fuel system. 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.
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.
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DANGER
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.
CAUTION
DO NOT use a garden hose to clean the generator. Water can enter the generator through the cooling slots and damage the generator windings. 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.
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. Allow the engine to cool completely before storage. 2. Clean the generator according to the instructions in the Maintenance section. 3. Turn the Fuel Valve to the OFF position. 4. Be sure all appliances are disconnected from the generator. Start the engine and let it run until the fuel in the line and the carburator is consumed and the engine dies. 5. Press the Battery Switch to OFF. 6. Add a fuel stabilizer into the fuel tank. 7. Change the oil. 8. Remove the spark plug and pour about ounce of oil into the cylinder. Crank the engine slowly to distribute the oil and lubricate the cylinder. 9. Reattach the spark plug. 10. Store the unit in a clean, dry place out of direct sunlight.
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Specifications
Spark Plugs
Recommended replacement spark plug: NGK BR6ES or equivalent Make certain the spark plug gap is 0.7 0.8 mm or (0.028 0.031 in.).
Engine Specifications
Engine. . . . . . . . . . 196 cc OHV CPE (Electirc Start)
Generator Specifications
Running Wattage. . Starting Wattage. . AC Load . . . . . . . Phase. . . . . . . . . Frequency . . . . . . Fuel Capacity. . . . Weight. . . . . . . . . . . . . . . . . . . . . . Height. . . . . . . . . Width . . . . . . . . . Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3500 Watts . . . . . . . . 4000 Watts . . . . . . . . . . . . . 120V . . . . . . . . . . . . Single . . . . . . . . . . . . 60 Hz . . . . . . 4 gallons (15 L) G.W. 135.3 lbs (61.5 kg) . . N.W. 125.4 lbs (57 kg) . . 22.9 inches (58.2 cm) . . 24.1 inches (61.1 cm) . . . 40 inches (101.7 cm)
Valve Clearance
Intake: 0.13 0.17 mm (0.005 0.007 in.) Exhaust: 0.18 0.22 mm (0.007 0.009 in.)
Fuel
Fuel capacity is 4 gallons (15 L). Use regular unleaded gasoline with a minimum octane rating of 85 and an ethanol content of less than 10% by volume.
Oil
Use 4-Cycle automotive oil. Oil capacity is 0.63 qt (0.6 L). Please reference the following chart for recommended oil types for use in the generator.
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Specifications
Parts Diagram
ENGLISH 46512
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#
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
Parts List
Description
Engine Build Up (B) Build Up (A) Rotor Comp Flange BoltM8x233 Washer 8mm Lock Washer 8mm Stator Assembly Stator Cover End Cover Flange Bolt M6x158 Washer 6mm Lock Washer 6mm Brush Assembly Plate Pinch Lock Washer 5 Bolt M5x16 Washer 5mm Bolt M5x16 AVR Flange Bolt M5x16 Generator End Cover Flange Bolt M5x12 Terminal Muffler Stay (I) Flange Bolt M8x20 Muffler Stay (II) Flange Bolt M6x12 Screw M5x15 Spark Arrester Cover Spark Arrester Assembly Muffler Muffler Cover NutM8 Lock Washer 8mm Washer 8mm Muffler Gasket Air Cleaner stay Flange Bolt M6x8 Clip Fuel Line Fuel Cock Screw M5x10 Fuel Meter Assembly Fuel Tank Cap Fuel Filter Flange Bolt M6x20 Washer 6.5mm Tank Rubber Fuel Tank Handle sheath Handle
Part Number
168FDE-2-G1 ST02FD-02100011 ST02FD-02100012 ST02FD-02110000-2.5 ST02FD-02100005-2.5 GB96 8 GB7244 8 ST02FD-02120000-2.5 ST02FD-02100002-2.5 ST02FD-02100003 ST02FD-02100001-2.5 GB97.1 6 GB93 6 ST02FD-02100009 ST02FD-02100008 GB93 5 GB5783 M5x16 GB97.1 5 GB5783 M5x16 AVR02-00000000 GB16674 M5X16 ST02FD-02100004(A) GB16674 M5X12 ST02FD-02100010 ST02FD-1150200 GB5789 M8X20 ST02FD-1150100 GB5789 M6X12 GB818 M5X15 ST188FD-1100010-88 ST188FD-1180121 ST168FD-1100000-G ST02FD-03030400(F) GB6175 M8 GB93 8 GB848 8 ST168F-1100200-G ST168FD-1090006 GB5789 M6x8 ST188FD-1070006A 168.070011.03 ST02FD-04160000 GB819 M5X10 ST02FD-04140000 ST02FD-04120000-A ST02FD-04130000 GB5789 M6x20 ST02FD-04100014 ST02FD-04100010 ST02FD-04110000(A) ST188FD-1741002-C ST182FD-1151110-B
Qty
1 1 1
#
53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99
Part Number
GB6177 M8 GB5789 M8x45 ST02FD-0184-2.5(F) ST02FD-1151300C-1 ST02FD-1151300D-1 GB6182 M10 ST177FD-1152300(H) ST02FD-03621001 GB96 10 GB5782 M10x105 504.200904.00 FM1290 ST188FD-1750002-C3 ST05FD-03011112 ST168FD-1751002-A ST188FD-1750002-C7 GB5789 M8x16 ST05FD-03020301-60 ST188FD-1743002-C GB5789 M8x25 ST02FD-02100013-2.5 GB6177 M6 GB862 6 ST188FD-1020001 GB823 M5x38 504.210002.10 ST02FD-05612005 ST02FD-05612004 WR05-00000000 GB823 M5x14 EC02 ST02FD-05302010 2P6(F) DP03-00000000 GB823 M4x14 GB848 4 GB859 4 29.001.00 21.001000.02 GB5781 M6x22 GB6175 M6 ST02FD-05502020 GB6177 M4 ST02FD-05502029 ST02FD-05502023 ST02FD-05302001-L25 ST02FD-05302001-L20
Description
Nut M8 Flange Bolt M8x45 Frame Bottom Rubber II Bottom Rubber I Nut M10 8in Wheel Bush 10.5x58.5 Flat Washer 10 Bolt M10x105 Rubber Belt 9AH Battery Battery Red Wire (+) Jacket Jacket Battery Black Wire (-) Flange Bolt M8x16 Support Leg Vibration Mount Flange Bolt M8x25 Earth Line Nut M6 Washer 6mm Grommet Screw M5x38 Control Box Indicator Light Button Remote Control Screw M5x14 Charger FUSE (10A) Control panel Trigitai meter III Screw M4x14 Washer 4mm Lock Washer 4mm Switch Switch Bolt M6x22 Nut M6 Receptacle L5-30R Nut M4 RV Receptacle 5-20R Receptacle AC.25A CIRCUIT BREAKERS Transition Control Box Build Up Conduit Build Up
Qty
14 2 1 2 2 2 2 2 2 2 1 1 1 1 2 1 2 1 2 2 1 1 1 1 5 1 1 1 1 4 1 1 1 1 8 8 8 1 1 1 2 1 6 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 4 6 10 1 1 5 1 7 2 1 2 1 2 1 1 3 1 12 2 1 1 1 1 2 2 2 1 1 1 2 1 1 2 1 1 1 4 4 4 1 1 1
100 OV01-00000000-1 101 504.210002.00 102 ST02FD-05212001 103 ST02FD-05212007 104 ST02FD-05212002
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Specifications
Engine Parts Diagram
ENGLISH 46512
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#
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
Part Number
GB5789--86-FB6-8 ST160F--1061200 ST160F--1061100-Q ST160F--1061005 ST160F--1061009 ST160F--1061001-A ST188F--1060006 ST188F--1060005 GB5789--86-FB6-12 ST188F--1060003 ST188F--1060004 ST188F-1060002 168.080100.06(A) ST160F--1050010 ST160F--1060001 ST168F--1080001 ST168F--1120100-A ST168F--1080200-A ST168F--1030100 GB5789--86-FB6-15 ST160F--1030003 ST160F--1030004 ST168F-2-1030012-G-E GB/T276--94 ST160F--1127000-A ST160F--1110108 ST160F--1110101 ST160F--1110102 ST160F--1110104 ST160F--1110103 ST160F--1110107 ST188FD-1130004 ST160F--1110105 ST168FD-2-1050001-A ST168F--1030008-G ST160F--1030001-B ST160F--1030002 GB5789--86-FB8-32 ST168F--1110005 ST168F--1110007 ST160F--1110003 GB6177--86 ST160F--1110008 ST160F--1110001 ST168F--1110006 ST160F--1110004 GB5789--86-FB6-25 ST160F--1123000-G 152FMD--1001007 GB5789--86-FB8-55 ST168FD--1090200-G ST168FD--1090004 ST168FD--1090003 ST168FD--1090002 ST168FD--1090004 ST160F--1130003-CPE
Description
Flange Bolt 6X8 Recoil Starter Knob Recoil Starter Comp Recoil Starter Spring Recoil Starter Rope Recoil Starter Reel Return Spring Starter Ratchet (Metal) Flange Bolt M6X12 Ratchet Guide Ratchet Guide Spring Setting Screw Fan Cover Comp Nut M14 Start Hub Cooling Fan Fly Wheel Side Place (II) Oil Seal Flange Bolt M6X15 Drain Plug Bolt Drain Bolt Washer Crankcase (For USA) Radial Ball Bearing 6205 Oil Level Switch Assembly Governor Washer (II) Governor Weight Holder Governor Weight Pin Governor Shaft Governor Holder Clip Governor Weight Clip,String Governor Cover Crankshaft Comp Case Over Packing (No Asbestos) Oil Filler Cap Assembly Oil Filler Cap Packing Flange Bolt 8X32 Throttle Return Spring Governor Spring Governor Arm Nut M6 Lock Pin Governor Arm Shaft Governor Rod Governor Arm Bolt Flange Bolt 6X25 Ignition Dowel Pin 10X16 Flange Bolt 8X55 Air Cleaner Cover Comp Element Separator Air Cleaner Seal Air Cleaner Case Comp Carburetor Packing (No Asbestos)
Qty
6 1
#
57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74
Part Number
ST168F--1130001 ST168F--1130002-CPE ST168FD--1010001 ST168F-2-1010100-G ST168F-2-1030009-G ST168F--1040002 ST168F--1040006 ST168F-2-1040013 ST168F-2-1041000 ST168F--1030015-G ST168FD--1111100 GB1099--79 ST168FD--1030007-G ST168F--1050100 ST168F--1050003 ST168F--1050004 ST168F-2-1050005 ST168F--1050007 ST168F--1050006 ST168F--1050200
Description
Carburetor Insulator Insulator Packing (No Asbestos) Stud Bolt 6X90 Cylinder Head Comp Cylinder Head Gasket Intake Valve Exhaust Valve Valve Lifter Camshaft Assembly Dowel Pin 9X14 Control Assembly Key Crankcase Cover Connecting Rod Comp Piston Pin Piston Pin Clip Piston First Ring Set Second Ring Set Ring Comp Shroud Comp (I) Stud Bolt Push Rod Oil Seal Pivot Bolt Valve Rocker Arm Nut M6 Exhaust Rocker Breather Tube Head Over Comp Head Over Packing Rectify Bolt Locknut Entrance Rocker Rocker Axes Valve Rotator Intake Valve Spring Retainer Exhaust Valve Spring Retainer Valve Spring Spark Plug Carburetor Spring,Conn. Connector,Starter Packing Support,Stepper Motor Stepper Motor Comp. Screw M4X8 Cover,Stepper Motor Electrify Coil Grommet Wire Flat Flange Bolt 6X29 Dowel Pin 810 Start Motor Flange Bolt M516 Lock Washer 5mm Relay
Qty
1 1 2 1 1 1 1 2 1 2 1 1 1 1 1 2 1 1 1 1 1 2 2 2 2 1 2 1 1 1 1 2 2 1 1 1 1 1 2 1 1 1 1 2 1 1 2 1 1 1 1 1 2 1 2 2 1
1 1 1 1 2 2 8 1 1 1 1 1 1 1 1 1 2 4 2 2 1 2 1 1 1 2 1 1 2 2 1 1 1 1 2 6 1 1 1 3 1 1 1 1 5 1 2 4 1 1 1 1 1 1
75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99
ST168F--1080002-G GB900--88 ST168F--1040005 ST168--1040014-A ST168F--1040027 ST168F--1040026 GB6177--86-N6 ST168F--1040023 ST160F--1020001 ST168F--1020100-C ST160F--1020002-A ST168F--1040024 ST168F--1040025 ST168F--1040022 ST168F--1040021 ST160F--1040008 ST160F--1040001 ST160F--1040007 ST160F--1040003 ST160F--1124000 468.131000.02 0902.130010.00 168.130015.01 ST168FD--1130004 168.130005.01
100 188.132200.00 101 GB818 M48 102 0902.132001.00 103 ST188F-1123000 104 ST168F-1180104 105 ST168F-1180002 106 GB5789--86-FB6-29 107 ST168F-1180001 108 ST168F-1181100 109 GB29.2-88-FB5-16 110 GB93-87-SW5 111 168.125200.01
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Specifications
Wiring Diagram
ENGLISH 46512
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Troubleshooting
Cause
No fuel Faulty spark plug Unit loaded during start up
Problem
Generator will not start
Solution
Add fuel Replace spark plug Remove load from unit Fill crankcase to the proper level Place generator on a flat, level surface Adjust choke. Attach wire to spark plug Fill fuel tank Fill crankcase to the proper level. Place generator on a flat, level surface Review load and adjust. See Power Management Check for air restriction. Move to a well ventilated area Check all connections Replace defective device Reset circuit breaker Replace brush assembly (Service Center) Replace AVR (Service Center) Inspect and tighten wiring connections Contact the help line. Contact the help line Review load and adjust. See Power Management Check for damaged, bare or frayed wires. Replace defective device
Low oil level Choke in the wrong position. Spark plug wire loose
No AC output
Cable not properly connected Connected device is defective Circuit breaker is open Faulty brush assembly Faulty AVR (auto voltage regulator) Loose wiring Other
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Warranty
WARRANTY
CHAMPION POWER EQUIPMENT 2 YEAR LIMITED WARRANTY
ENGLISH 46512
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 CPEs 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.
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 manufacturers 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.
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.
Contact Information
Address
Champion Power Equipment, Inc. Customer Service 10006 Santa Fe Springs Rd. Santa Fe Springs, CA 90670 www.championpowerequipment.com
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.
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: (562) 204-1188
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Warranty
Champion Power Equipment, Inc (CPE), and the United States Environment Protection Agency (U.S. EPA.) Emission Control System Warranty
Your Champion Power Equipment (CPE) engine complies with U.S. EPA emission regulations.
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Warranty
EMISSION CONTROL SYSTEM WARRANTY
The following are specific provisions relative to your Emission Control System Warranty Coverage. Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines):
ENGLISH 46512
1. APPLICABILITY: This warranty shall apply to 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 at the time of sale with applicable regulations under section 213 of the Clean Air Ac, as amended, 42 U.S.C. 7401 et seq. 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 manufacturers 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 Owners Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by CPE according to Subsection d below. Any such emissions-related part repaired or replaced under the ECS Warranty, shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part. d. Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a CPE Authorized Service Outlet. e. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in fact defective, provided that such diagnostic work is performed at a CPE Authorized Service Outlet. f. CPE shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of an emission-related part covered by the ECS Warranty. g. Throughout the ECS Warranty Period, CPE shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand for such emission-related parts. h. Any CPE Authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty maintenance or repair and will be provided without charge to the owner. Such use shall not reduce CPEs warranty obligation. i. Unapproved add-on or modified parts may not be used to modify or repair a CPE engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. CPE shall not be liable hereunder for failures of any warranted parts of a CPE engine caused by the use of such an unapproved add-on or modified part.
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Warranty
Parts Description Fuel regulator, Carburetor and internal parts Air cleaner, Intake manifold Spark plug and parts, Magneto ignition system Exhaust manifold, catalytic converter Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed systems
EMISSION-RELATED PARTS INCLUDE THE FOLLOWING (using those portions of the list applicable to the engine) :
Systems covered by this warranty Fuel Metering System Air Induction System Ignition System Exhaust System Miscellaneous Parts
TO OBTAIN WARRANTY SERVICE: You must take your CPE engine or the product on which it is installed, along with your warranty registration card or other proof of original purchase date, at your expense, to any Champion Power Equipment dealer who is authorized by Champion Power Equipment, Inc. to sell and service that CPE product during his normal business hours. Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used. If you have any questions regarding your warranty rights and responsibilities, or to obtain warranty service, please write or call the Customer service of Champion Power Equipment, Inc.: Champion Power Equipment, Inc. ATTN: Customer Service 10006 Santa Fe Springs Road Santa Fe Springs, CA 90670 Tel: 1-877-338-0999
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