Cabela's 46578 User Manual

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OWNER’S MANUAL & OPERATING INSTRUCTIONS

4000 Starting Watts/3500 Running Watts Wireless Remote, Electric Start

PORTABLE GENERATOR

MODEL NUMBER

46578

12039 Smith Ave.

SAVE THESE INSTRUCTIONS

Important Safety Instructions are included in this manual.

MADE IN CHINA

REV 46578-20140521

www.championpowerequipment.com

Santa Fe Springs CA 90670

USA / 1-877-338-0999

AN IMPORTANT MESSAGE ABOUT TEMPERATURE:

Your Champion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to 40°C (104°F). When your product is needed your product may be operated at temperatures ranging from -15°C (5°F) to 50°C (122°F) for short periods. If the product is exposed to temperatures outside this range during storage, it should be brought back within this range before operation. In any event, the product must always be operated outdoors, in a well-ventilated area and away from doors, windows and other vents.

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

– or –

Call our Customer Care Team Toll-Free at:

1-877-338-0999

• Tech Bulletins

• Product Registration

WARNING:

The Engine Exhaust from this product contains chemicals known to the State of California

to cause cancer, birth defects or other reproductive harm.

*We are always working to improve our products. Therefore, the enclosed product may differ slightly from the image on the cover.

TABLE OF CONTENTS

46578

4000 Starting Watts/3500 Running Watts

Wireless Remote, Electric Start

PORTABLE GENERATOR

Introduction ............................. 1

Introduction ........................... 1

Portable Power Generator .................. 1

Accessories ........................... 1

This Booklet ........................... 1

Manual Conventions. . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Rules ............................. 3

Controls and Features ...................... 5

Generator ............................. 5

Power Panel ........................... 6

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

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

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

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

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

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

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

Remove the Generator from the Shipping Carton .. 9

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Stopping the Engine

Electric or Recoil ................... 14

Wireless Remote .................... 14

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Generator Battery .................... 18

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Do Not Return The Unit To

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

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

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

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

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

Limits of Implied Warranty

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

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

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

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

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

INTRODUCTION

ENGLISH 46578

Introduction

Congratulations on your purchase of a Champion Power Equipment generator. CPE designs and builds generators to strict speciﬁcations. With proper use and maintenance, this generator will bring years of satisfying service.

Portable Power Generator

This unit is a gasoline engine driven, alternating current (AC) generator. It is designed to supply electrical power for lighting, appliances, tools and similar equipment.

Record the model and serial numbers as well as date and place of purchase for future reference. Have this information available when ordering parts and when making technical or warranty inquiries.

Accessories

Champion Power Equipment manufactures and sells accessories designed to help you get the most from your purchase. To ﬁnd out more about our covers and power cables, please visit our web site at:

www.championpowerequipment.com

This Booklet

Every effort has been made to ensure the accuracy and completeness of the information in this manual. We reserve the right to change, alter and/or improve the product and this document at any time without prior notice.

Champion Power Equipment Support

1-877-338-0999

Model Number

46578

Serial Number

Date of Purchase

Purchase Location

For O il Typ e see ‘Add Engine Oil‘ section. For Fue l Typ e see ‘Add Fuel‘ section.

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46578 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.

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

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.

NOTE

If you have questions regarding your generator, we can help. Please call our help line at 1-877-338-0999

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SAFETY RULES

ENGLISH 46578

WARNING

Read this manual thoroughly before operating your generator. Failure to follow instructions could result in serious injury or death.

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.

DANGER

Rotating parts can entangle hands, feet, hair, clothing and/or accessories. Traumatic amputation or severe laceration can result.

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

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

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.

WARNING

This product contains a button battery. If swallowed, it could cause severe injury or death in just 2 hours. Seek medical attention immediately.

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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.

46578 ENGLISH

SAFETY RULES

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.

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.

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.

CAUTION

Exceeding the generator’s running capacity can damage the generator and/or electrical devices connected to it.

DO NOT overload the generator. Start the generator and allow the engine to stabilize before connecting electrical loads. Connect electrical equipment in the off position, and then turn them on for operation. Turn electrical equipment off before stopping the generator. DO NOT tamper with the governed speed. DO NOT modify the generator in any way.

CAUTION

Improper treatment or use of the generator can damage it, shorten its life and void your warranty.

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.

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.

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

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ENGLISH 46578

CONTROLS AND FEATURES

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

5 6

(1) Fuel Tank – 3.8 gal. (14.4 L) capacity fuel tank.

(2) Auto-Choke – Automatically chokes the engine

in wireless or electric start modes. No manual adjustment required.

(3) Fuel Valve – Turn this valve to the “ON” position to

supply fuel to the 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) Quick Drain Tube – Used to easily and quickly

drain oil from the engine.

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

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

DC to the electric starter and receiver control module.

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

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46578 ENGLISH

Power Panel

CONTROLS AND FEATURES

5 6 7 8

(1) Intelligauge – Three mode digital meter for running

hours, voltage and hertz.

(2) Ignition Switch

(3) Circuit Breakers – Protects the generator against

electrical overload.

(4) Battery Switch – Enables/disables starting

electrically – via remotely or by ignition switch.

(5) Ground Terminal – Consult an electrician for local

grounding regulations.

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

(NEMA L5-30R) –

power for the operation of 120 Volt AC, 30 Amp, single phase 60 Hz electrical loads.

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

May be used to supply electrical power for the

–

operation of 120 Volt AC, 30 Amp, single phase 60 Hz electrical loads.

(8) 120 Volt AC, 20 Amp Duplex (NEMA 5-20R) –

May be used to supply electrical power for the operation of 120 Volt AC, 20 Amp, single phase 60 Hz electrical loads.

May be used to supply electrical

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CONTROLS AND FEATURES

ENGLISH 46578

Wireless Remote Control

This generator is equipped with a wireless remote control system for starting and stopping. The system consists of (4) main components:

1. Receiver Control Module (RCM)

2. Wireless Remote

3. Battery Switch

4. Ignition Switch The Remote Control functions are enabled when:

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

2. The Battery Switch is in the “ON” position. The Remote Control functions are disabled if either of the above conditions is not met. To start the generator by Remote Control, press the “START” button on the Remote one time. The engine will attempt to start (6) times. The RCM controls the Auto Choke during each attempt to start. If the generator does not start, call Champion Customer Care team for assistance at 1-877-338-0999. To stop the generator by Remote Control, press the

“STOP” button on the Remote one time.

Power Panel Load Management Cont’d.

voltage delay when the pushbutton electric start or recoil start method is used.

When the pushbutton electric start or recoil start method is used, the operator must be sure all electrical loads (appliances) are turned OFF during startup and shutdown. Damage to the generator or the attached appliances can be caused by starting or stopping the generator while appliances are plugged in and turned ON.

Remote Control Power Consumption

While the Ignition Switch is in the “ON: position, the RCM is active and waiting for a remote signal. This function requires electrical current from the battery. If the Ignition Switch is left in the “ON” position for extended periods (several weeks), the battery can be completely drained. Moving the Ignition Switch to the “OFF” position disables the Remote functions, but the RCM still consumes approximately 2 mA from the battery. To prevent battery drain, press the Battery Switch to the “OFF” position. This disconnects power to the RCM so

there is no current draw on the battery.

Power Panel Load Management

When the generator initially starts by the Remote, no voltage is supplied to the Power Panel for approximately 15 seconds. This allows the engine to reach full speed before electrical loads are applied to the generator. When the generator is stopped by the Remote, the voltage to the Power Panel is immediately turned off. Then the engine stops approximately 5 seconds after the “STOP” button on the Remote is pressed. Turning the Power Panel voltage off before the engine shutdown protects connected appliances from being damaged by non-60 Hz voltage while the generator coasts to a stop.

The on/off voltage delay at startup and shut down only happen when the Remote Control is used. There is no

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