CHAMPION 41534 User Manual

OWNER’S MANUAL & OPERATING INSTRUCTIONS

9500 Starting Watts / 7500 Rated Watts

PORTABLE GENERATOR

MODEL NUMBER

41534

10006 Santa Fe Springs Road

SAVE THESE INSTRUCTIONS

Important Safety Instructions
are included in this manual.

MADE IN CHINA

REV 41534-20140124

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

41534

9500 Starting Watts / 7500 Rated Watts

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

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

Connect the Battery ..................... 8

Add Engine Oil ......................... 9

Add Fuel ............................ 10

Grounding ........................... 10

Operation .............................. 11

Generator Location ..................... 11

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

Surge Protection ....................... 11

Starting the Engine ..................... 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 .................. 15

Storage ............................. 16

Generator Storage .................... 16

Battery ........................... 16

Charge the Battery ................... 16

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

INTRODUCTION

ENGLISH 41534

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

41534

Serial Number

Date of Purchase

Purchase Location

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

1 REV 41534-20140124

41534 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

REV 41534-20140124 2

SAFETY RULES

ENGLISH 41534

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.

3 REV 41534-20140124

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
euipment 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.

41534 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 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.

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 41534

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

4

1

2

3

9

5

6

(1) Fuel Tank – 5.9 gallon (22.4 L) capacity fuel tank.

(2) Choke – Controls choke valve. Used when starting

a cold engine.

(3) Fuel Valve – Used to turn fuel supply on and off to

engine.

(4) Air Cleaner – Protects the engine by filtering dust

and debris from the intake air.

8

7

(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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41534 ENGLISH

Power Panel

CONTROLS AND FEATURES

1 2 4

3

(1) Ignition Switch – Used to start or stop the

generator.

(2) 120/240 Volt AC, 30 Amp Twist-Lock Receptacle

(NEMA L14-30R) – May be used to supply

electrical power for the operation of 120
and/or 240 Volt AC, 30 Amp, single phase 60 Hz
electrical loads.

(3) Circuit Breakers – Protects the generator against

electrical overloads. Push to reset breaker.

(4) Intelligauge – Three mode digital meter for

displaying running hours, voltage and hertz.

65 8

(5) 120/240 Volt AC, 50 Amp Receptacle

(NEMA 14-50R) – May be used to supply
electrical power for the opertaion of 120
and/or 240 Volt AC, 50 Amp, single phase 60 Hz
electrical loads.

(6) 120 Volt AC, 30 Amp Recreational Vehicle (RV)

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.

(7) 120 Volt AC, 20 Amp Duplex (2)

(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.

(8) Ground Terminal – Consult an electrician for local

grounding regulations.

7

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CONTROLS AND FEATURES

Parts Included

Your 41534 Gasoline Powered Generator ships with the
following parts:

Wheel Kit

– 10 in. Wheel ..........................2

– Flange Bolt (M10x120 for Wheel) ............2

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

– Flat Washer Ø10 ........................2

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

– Support Leg w/Vibration Mounts .............1

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

– Nut (M8) .............................2

Other

– Oil ........................ 1.2 qt. (1.1 L)

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

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

– Cap Screw (M5x10 for Battery Terminals) .......2

– Nut (M5 for Battery Terminals) ..............2

ENGLISH 41534

(Battery Bolts)

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41534 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

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 it’s side.

2. Slide the M10x120 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.

Connect the Battery

1. Remove the protective cover from the red (+) lead on
the bat tery.

2. Attach the red (+) lead to the red (+) terminal on the
battery with the cap screw (M5x10) and secure with
the lock washer (M5).

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

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ASSEMBLY

ENGLISH 41534

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 automotive
oil.

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

Add Engine Oil Cont’d.

CAUTION

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.

NOTE

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.

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

3. Add up to 1.2 qt. (1.1 L) of oil (included) and replace
oil fill cap/dipstick. DO NOT OVERFILL.

4. Check engine oil level daily and add as needed.

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41534 ENGLISH

ASSEMBLY

Add Fuel

1. Use clean, fresh, regular unleaded fuel with a
minimum octane rating of 85 and an ethanol content
of less than 10% by volume.

2. DO NOT mix oil with fuel.

3. Clean the area around the fuel cap.

4. Remove the fuel cap.

5. Slowly add fuel to the tank. DO NOT OVERFILL.
Fuel can expand after filling. A minimum of ¼
in. (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.

Add Fuel Cont’d.

NOTE

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
carbureto r.

– 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.

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 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.

WARNING

Pouring fuel too fast through the fuel screen may
result in blow back of fuel at the operator while filling.

Grounding

Your generator must be properly connected to an
appropriate ground to help prevent electric shock.

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.

REV 41534-20140124 10

OPERATION

ENGLISH 41534

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.

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.

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. They’re designed to protect against virtually
all short-duration voltage fluctuations.

WARNING

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

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.

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41534 ENGLISH

OPERATION

Starting the Engine

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

2. Disconnect all electrical loads from the generator.
Never start or stop the generator with electrical
devices plugged in or turned on.

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

4. Move the choke lever to the “CHOKE” position.

5. Flip the ignition switch to the “ON” position.

6. ELECTRIC START: Press and hold the ignition switch
to the “START” position. Release as the engine
begins to roll over. If the engine fails to start within
five seconds, release the switch and wait at least ten
seconds before attempting to start the engine again.

7. RECOIL START: Pull the starter cord slowly until
resistance is felt and then pull rapidly

8. Do not over-choke. As as soon as engine starts, move
the choke lever to the “RUN” position.

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
sparkplug fouling/engine flooding due to the lack of
incoming air. This will cause the engine not to start.

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.

NOTE

When the battery switch is in the “ON” position,
the switch will light up if the battery is sending
out a charge. If the switch does not light up while
in the “ON” position, check that the battery
connection is still good.

NOTE

The supplied 12V 15AH battery does re-charge
while the engine is running, but it is also
recommended that the battery be fully charged at
least once per month.

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 120/240 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.

NOTE

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.

Stopping the Engine

1. Turn off and unplug all electrical loads. Never start
or stop the generator with electrical devices plugged
in or turned on.

2. Let the generator run at no-load for several minutes
to stabilize internal temperatures of the engine and
generator.

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

4. Let the engine run until fuel starvation has stopped
the engine. This usually takes a few minutes.

5. Press the engine switch to the “OFF” position.

6. Press the battery switch to the “OFF” position.

Important: Always ensure that the Fuel Valve and the
Engine Switch are in the “OFF” position when the engine
is not in use.

NOTE

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.

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OPERATION

ENGLISH 41534

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.

NOTE

Never exceed the specified capacity when adding
loads to the generator.

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 air­fuel 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.

Carburetor
Code

P28-2-R

P28-2-Z

P28-2-H

Main Jet Part Number Altitude

Standard 47. 13 10 17. 2 1.R

Altitude 47.131017.21.01. R

Standard 47. 13 10 17. 2 1.Z

Altitude 47.131017.21.01. Z

Standard 47. 13 10 17. 2 1.H

Altitude 47.131017.21.01.H

5500 Feet
(1676 Meters)

13 REV 41534-20140124

WARNING

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.

41534 ENGLISH

MAINTENANCE AND STORAGE

The owner/operator is responsible for all periodic
maintenance.

WARNING

Never operate a damaged or defective generator.

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.

Oil Cont’d.

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.

Spark Plugs

1. Remove the spark plug cable from the spark plug.

2. Use the spark plug tool that shipped with your
generator to remove the plug.

3. Inspect the electrode on the plug. It must be clean and
not worn to produce the spark required for ignition.

4. Make certain the spark plug gap is 0.7 - 0.8 mm or
(0.028 - 0.031 in.).

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.

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 oil fill cap/dipstick.

2. Use pliers to slide the spring clamp down the oil
drain hose and pull the hose off the plug bracket.

3. Point the hose into a drain pan and allow the oil to
drain completely. Note: The hose end must be lower
than the engine base to allow the oil to drain.

4. Replace oil drain hose onto plug bracket and slide
spring clamp back into position.

5. Add 1.2 qt. (1.1 L) of oil and replace oil fill
cap /dipstick. DO NOT OVERFILL.

6. Dispose of used oil at an approved waste
management facility.

0.7-0.8 mm

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.

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.

REV 41534-20140124 14

MAINTENANCE AND STORAGE

ENGLISH 41534

Spark Arrester

1. Allow the engine to cool completely before servicing
the spark arrester.

2. Remove the three 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 three screws.

CAUTION

Failure to clean the spark arrester will result in degraded
engine performance.

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.

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.

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

*To be performed by knowledgeable, experienced owners or
Champion Power Equipment certified dealers.

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.

15 REV 41534-20140124

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.

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.

41534 ENGLISH

MAINTENANCE AND STORAGE

Storage

The generator should be started at least once every 14
days and allowed to run for at least 20 minutes. For
longer term storage, please follow these guidelines.

Generator Storage

1. Add a properly formulated fuel stabilizer to the tank.

2. Be sure all appliances are disconnected from the
generator.

3. Run the generator for a few minutes so the treated
fuel cycles through the fuel system and carburetor.

4. Turn the fuel valve to the “Off” position.

5. Let the generator run until fuel starvation has
stopped the engine. This usually takes a few minutes.

6. The generator needs to cool acompletely before
cleaning and storage.

7. Clean the generator according to the maintenance
section.

8. Change the oil.

9. Remove the spark plug and pour about 1⁄2 ounce
(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.

Battery

This product is equipped with an automatic battery
charging circuit. The battery will receive charging
voltage when the engine is running. The battery will
maintain a proper charge if the unit is used on a regular
basis (about once every two weeks). If it is used less
frequently, the battery should be connected to a trickle
charger or battery maintainer to keep the battery
properly charged. If the battery is not able to start the
engine, it can be started by manually pulling the engine
recoil cord. If the battery voltage is extremely low,
the charging circuit may not be able to re-charge the
battery. In this case, the battery must be connected
to a standard automotive style battery charger for re­charging before it can be used.

Charge the Battery

For pressure washers equipped with batteries for electric
starting, proper battery maintenance and storage
should be followed. An automatic battery charger with
automatic trickle charging capability should be used to
charge the battery. Maximum charging rate should not
exceed 1.5 amps. Follow the instructions included with
the battery charger. The battery should be fully charged
at least once per month.

NOTE

A Float Charger will maintain the battery condition
over long storage periods.

Disconnect the Battery

1. Remove the protective cover from the black/negative
battery lead.

2. Disconnect the black/negative lead from the black/
negative terminal on the battery and store the cap
screw (M5x10) and lock washer (M5).

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

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

DANGER

Generator exhaust contains odorless and colorless
carbon monoxide gas.

To avoid accidental or unintended ignition of your
electric 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.

REV 41534-20140124 16

SPECIFICATIONS

ENGLISH 41534

Engine Specifications

– Model .....................YF190FD-2-111

– Displacement .......................439cc

– Typ e ........................4-Stroke OHV

– Start Type ....................Electric Start

Generator Specifications

– Model ........................... 4153 4

– Rated Wattage ..................7500 Watts

– Starting Wattage .................9500 Watts

– AC Load ...................... 120/240 V

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

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

– Fuel Capacity ............. 5.9 gallons (22.4 L)

– Gross Weight .............. 224.9 lb. (102 kg)

– Net Weight .................211.6 lb. (96 kg)

– Height ................... 26.0 in. (66.1 cm)

– Width ................... 27.3 in. (69.3 cm)

– Length. . . . . . . . . . . . . . . . . . . 27.8 in. (70.5 cm)

Fuel

Fuel capacity is 5.9 gallons (22.4 L). Use regular
unleaded gasoline with a minimum octane rating of 85
and an ethanol content of less than 10% by volume.

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.).

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.

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.

Oil

Use 10W-30 automotive oil.
Oil capacity is up to 1.2 qt. (1.1 L).
DO NOT OVERFILL.
Please reference the following chart for recommended
oil types for use in the generator.

17 REV 41534-20140124

41534 ENGLISH

Wiring Diagram

SPECIFICATIONS

REV 41534-20140124 18

SPECIFICATIONS

Parts Diagram

2

23242

2

1

2

0

2
9

1

7 18

1

6
5 1

3 14 1

1

1

0

9

1

1

8

3 4
2
1

5

6

7

ENGLISH 41534

6

445

4

43

8

3

33

5

12

31 32

8

2

27

26

62
63

4

6
65

6

6

7

6

34

5

3

36

30

29

7

2

8

6

9

2

69

0

7

715

2

7

73

27

74

5

7

6

7

42

41

23

40

9

3

8

3

37

52

3

5

4

5

55

6

5

7

5

8

58

9

5

60

61

5

90

7

17

1

6

1

1

15

1

14

2

3

1

1

1

1

1

1

9

92

93

8 4
37 3

474
8

9

4

8

4

50

51

7
10

6
10

8
10

9

0

1

110

111

2

7

4

5
10

02 103 10

71 101 1

8

99

9

0

97

10

6

9
5

9

4

9

19 REV 41534-20140124

80

9

7

77

78

81

3

8

4

6

8

85

82

86

87

88

8

89

41534 ENGLISH

Parts List

# Part Number Description Qty

2.06.006 Clamp (Ø7×Ø1) 3

1

152.070013.01 Pipe, Air Cleaner 1

2

2.05.001 Clamp (Ø8×6.5) 2

3

152.070014.03 Pipe, Reversal Valve 830 mm 1

4

1.16 674. 0812 Flange Bolt M8×12 2

5

152.070702.03 Support Arm, Top 1

6

152.070018.02 Board, Heat Insulation 1

7

1.5789.06 08 Flange Bolt M6×8 6

8

152.070700.01 Carbon Canister (650cc) 1

9

152.070702.01 Support Arm, Bottom 1

10

2.06.010 Clamp (Ø10.5 ×Ø1) 1

11

152.070027.01 Vent Hose 1

12

152.070011.07 Pipe, Fuel (7.7 in.) 1

13

2.06.007 Clamp (Ø8×b6) 2

14

122.070400.05 Fuel Cock 1

15

152.071000.09.48 Fuel Tank, Yellow 1

16

1.819.0510 Screw M5 ×10 2

17

152.072000.02 Fuel Meter Assembly 1

18

24.070800.00 Reversal Valve 1

19

24.070100.00 Fuel Tank Cap 1

20

23.070301.00 Fuel Filter 1

21

1.5789.0620.2 Flange Bolt M6×20 4

22

1.93.06 Spring Washer Ø6 8

23

2.03.004 Washer (Ø24×Ø6.5 ×1.5) 4

24

122. 070015.01 Mount Vibration, Fuel Tank 4

25

45.090006.20 Holder, Air Cleaner 1

26

1.6177.1.06 Flange Lock Nut M6 3

27

1.848.08 Washer Ø8 2

28

1.93.08 Spring Washer Ø8 4

29

1.617 5.08 Nut M8 2

30

46.100001.07 Muffler Gasket 1

31

46.10100 0.01.2 Muffler Assembly 1

32

1.9074.4.0510

33

46.101300.00 Spark Arrester Assembly 1

34

1.16 674. 082 0 Flange Bolt M8 ×20 2

35

1.617 5.05 Nut M5 2

36

1.97.1.05 Washer Ø5 4

37

1.93.05 Spring Washer Ø5 5

38

2.08.071 Bolt M5× 229 2

39

1.97.1.06 Washer Ø6 4

40

152.190300.00 Carbon Brush Assembly 1

41

122.190004.01 Pinch, Carbon Brush 1

42

1.5783.0520 Bolt M5×20 1

43

1.16 674. 0512. 2 Flange Bolt M5×12 2

44

152.190003.00.48 Generator End Cover, Yellow 1

45

1.5783.0516 Bolt M5 ×16 2

46

122.190400.00 Terminal Block 1

47

1.16674.0516 Flange Bolt M5×16 3

48

153 .190 20 0. 03 AVR (6KW CPE) 1

49

152.190002.00 End Housing 1

50

2.08.069 Flange Bolt M6×194 4

51

153.191002.00 Stator Cover 1

52

2.08.070 Flange Bolt M10×280 1

53

153.191200.07

54

1.724 4.10 Locking Washer Ø10 1

55

1.96.10 Washer Ø10 3

56

153.191100.0 2

57

152.192300.00 Air Guide 1

58

152.190005.00 Ru bb er, Fore -Co ve r, A 1

59

Screw And Washer Assembly
M5 ×10

Stator Assembly, Cu, 155 mm,
No DC

Rotor Assembly, Cu, 155 mm,
No DC

# Part Number Description Qty

152.190005.01 Ru bb er, Fore -Co ve r, B 1

60

47. 6 0 4 Engine 1

61

152.200702.02 Cover, Handle 1

62

152.200701.0 2 Handle, U Shape 1

63

152.200703.02 Short Pin, Handle 2

64

1.89 4.1.08 Circlip Ø 8 2

65

152.200703.04 Long Pin,Handle 2

66

1.8 94 .1.10 Circlip Ø10 2

67

1.5789.08 35 Flange Bolt M8×35 2

68

1.96.08 Big Washer Ø8 2

69

152.201200.00 Motor Mount 2

70

1.86 2.06 Lock Washer Ø6 2

71

1.5789.0612 Flange Bolt M6×12 5

72

5.19 00 .026 Grounding Line 150 mm 1

73

152.201200.04 Motor Mount, II 1

74

1.6177.1.08 Flange Lock Nut M8 8

75

152.201200.03 Motor Mount, I 1

76

1.618 2.10 Lock Nut M10 2

77

1.6177.1.10 Flange Lock Nut M10 2

78

6.5 . 19 2 . 41 7. 2 Frame 1

79

152.201701.0 4. 2 10 in. Wheel 2

80

253.200016.00 Bushing (Ø16× Ø10.5×69.5) 2

81

1.5782.10120 Bol t M10 ×12 0 2

82

1.9 074. 3. 0510

83

1.6177.1.05 Flange Lock Nut M5 2

84

9.1000.150 Battery 12V15AH 1

85

152.200904.00 Pinch, Rubber 1

86

5.19 00 .014 Black Wire, 320 mm, Battery 1

87

5.19 00 .021 Red Wire, 480 mm, Battery 1

88

152.200013.01 Jacket, Wire 3

89

1.57 89. 0816 Flange Bolt M8×16 2

90

152.200002.01.2 Support Leg 1

3

1

1

91

152.201400.0 0 Rubber, Support 2

92

1.5789.0825 Flange Bolt M8 ×25 2

93

152.159.019.2 Control Panel 1

94

5.1000.001.3 Ignition Switch 1

95

5.1120 .0 39 Re ceptacle 14-50R 1

96

5.1120 .0 34 Receptacle TT-30R 1

97

5.1120 .010 Re ceptacle 5-20R (Duplex) 2

98

1.9074.4.0414.1

99

1.6177.1.04.1 Flange Lock Nut M4, Black 12

100

1.5783.0622.3 Bolt M6 ×22, Green 1

101

1.617 5.06 .3 Nut M6, Green 2

102

1.97.1.06.3 Washer Ø6, Green 2

103

1.93.06.3 Spring Washer Ø6, Green 2

104

122.210003.01 Plug, Control Box 1

105

5.13 30.002 Sheath, Wire 1

106

152.210003.02 Plug, End Cover 1

107

5.14 30.002 Intelligauge 1

108

5.1210 .920

109

5.1210 .93 0

110

5.1120 .0 09 Receptacle L14-30R 1

111

5.1810 .0 01 Over Voltage Protector 1

112

1.8 23.0514 Screw M5×14, Black 2

113

122.210003.00 Grommet 1

114

5.1800.000 Rectifi er 1

115

1.9074.1.0538 .2

116

152.210002.09 Control Box 1

117

Screw And Washer Assembly
M5 ×10

Screw And Washer Assembly
M4 ×14, Black

AC 20A Breaker, Push Button,
CSA

AC 30A Breaker, Push Button,
CSA

Screw And Washer Assembly
M5×38

2

12

2

2

3

REV 41534-20140124 20

SPECIFICATIONS

45

64

40

102

103

104

105

91

106

107

110
109

108

85

10

1

2

3

4

5

6

7

8

9

11

12

13

14

15

16

17

18

19

20

16

24

25

26

27

28

29

30

31

33

34

35

12

36

30

37

38

23

39

41

42

43

44

46

47

48

49

50

51

52

53

12

54

55

57

58

59

60

61

62

65

66

68

69

70

71

72

73

74

75

76

77

78

79

80

81

82

86

87

88

67

83

84

56

94

95

96

111

89

97

98

99

100

101

2

21

22

23

93

89

112

63

32

92

113

114

90

91

115

116

117

Engine Parts Diagram

ENGLISH 41534

21 REV 41534-20140124

41534 ENGLISH

# Part Number Description Qty

21.061300.00 Recoil Handle 1

1

1.5789.06 08 Flange Bolt M6×8 4

2

46.061100.00.2 Recoil Star ter Cover, Black 1

3

45.060005.00 Recoil Starter Spring 1

4

45.061102.00 Recoil Starter Reel 1

5

2.10. 00 3 Rope ( Ø5 ×1550) 1

6

45.060003.00 Spring, Ratchet 2

7

45.060002.00 Starter Ratchet (Iron) 2

8

45.060009.00 Spring, Ratchet Guide 1

9

45.060007.00 Ratchet Guide 1

10

45.060008.00 Screw, Ratchet Guide 1

11

1.5789.0612 Flange Bolt M6×12 12

12

2.05.005 Clamp ( Ø6) 2

13

47.08010 0.01.48 Fan Cover, Yellow 1

14

2.02.007 Nut (M16 ×1.5) 1

15

1.5789.0629 Flange Bolt M6×29 4

16

45.060001.00 Pulley, Starter 1

17

46.123000.03 Ignition Coil 1

18

47.080001.00 Cooling Fan 1

19

46 .120100.04 Flywheel (Electric Start EPA) 1

20

45.030006.00 Plate, C oil 1

21

45.121000.00 Coil, Charging 1

22

2.11.0 07 Oil Seal (Ø35×Ø52×8) 2

23

2.05.050 Wire Clip, 100 mm 1

24

45.030032.00 Sheath, Wire 1

25

2.03.023 Washer (Ø12.5×Ø20×2) 2

26

47.03010 0.01 Crankcase 1

27

45.127000.01 Oil Level Sensor 1

28

1.5789.0 615 Flange Bolt M6×15 2

29

1.276.620 2 Bearing 6202 2

30

47.050006.00 Weight Balancer 1

31

47.05010 0.01 Crankshaft 1

32

46.030008.00 Gasket, Crankcase Cover 1

33

2.04.001 Dowel Pin (Ø9×14) 2

34

46.080600.00 Air Guide, Right Side 1

35

1.276.6207 Bearing 6207 1

36

46.031000.01.48 Oil Dipstick Assembly, Yellow 1

37

45.030007.00 Cover, Crankcase 1

38

1.5789.0840.0.8 Flange Bolt M8 ×40 7

39

2.03.021.1 Washer (Ø6.4×Ø13×1), Black 1

40

45.110013.00 Shaft, Governor Gear 1

41

45.11010 0.00 Governor Gear 1

42

21.110 011.0 0 Clip, Governor G ear 1

43

45.110012.00 Bushing, Governor Gear 1

44

47.050200.0 0 Connecting Rod 1

45

47.050 00 5.01 Piston 1

46

2.09.004 Circlip (Ø21× Ø1) 2

47

45.050003.00 Piston Pin 1

48

46.050303.02 Ring, Oil 1

49

46.050302.02 Ring, Second Piston 1

50

46.050301.02 Ring, First Piston 1

51

2.04.004 Dowel Pin (Ø12×20) 2

52

46.030009.02 Gasket, Cylinder Head 1

53

46.080 400.00 Air Guide, Lower 1

54

47.010100.01 Cylinder He ad 1

55

2.01.006 Stud Bolt M8×35 2

56

2.15.002 (F6RTC) Spark Plug (F6RTC) 1

57

2.08.014 Flange Bolt M10× 80 4

58

46.020002.00 Gasket, Cylinder Head Cover 1

59

# Part Number Description Qty

47.021000.00 Cylinder Head Cover (CPE) 1

60

45.020001.02 Breather Tube 1

61

47.02010 0.0 0 Bolt, Cylinder Head Cover 1

62

2.08.039 D rain Bolt (M12×1.5×15) 1

63

47.04100 0.01 Camshaft (EPA) 1

64

47.040004.00 Lifter, Valve 2

65

47.040002.00 Valve, Intake 1

66

47.040006.00 Valve, Exhaust 1

67

46.040005.00 Push Rod 2

68

45.040015.00 Retainer, Valve Spring (Down) 2

69

45.040017.00 Oil Seal, Valve 2

70

45.040003.00 Spring, Valve 2

71

23.040010.00 Bolt, Rocker Arm 2

72

45.040001.00 Retainer, Intake Valve Spring (Up) 1

73

45.040007.00 Retainer, Exhaust Valve Spring (Up) 1

74

45.040008.00 Rotator, Exhaust Valve 1

75

46.040004.00 Guide Plate, Push Rod 1

76

46.040016.00 Shaft, Rocker Arm 1

77

46.040201.00 Retainer, Rocker Arm 1

78

46.040009.00 Rocker Arm, Intake Valve 1

79

46.040018.00 Rocker Arm, Exhaust Valve 1

80

1.97.1.06 Washer Ø6 2

81

22.040012.00 Screw, Valve Adjustment 2

82

1.6177.1.06 Flange Lock Nut M6 2

83

21.040021.00 Nut, Lock (M6×0.5) 2

84

2.01.008 Stud Bolt M6×M8 ×105 2

85

46.130002.20 Gasket, Insulator 1

86

45.130001.00 Insulator, Carburetor 1

87

46.130003.20 Gasket, Carburetor 1

88

47.131000.21 Carburetor 1

89

46.130004.20 Gasket, Air Cleaner 1

90

1. 6 17 7. 0 6 Flange Nut M6 3

91

46.091100.03 Base, Air Cleaner 1

92

45. 0910 02.20 Seal, Air Cleaner 1

93

45. 0910 01.20 Separator, Air Cleaner 1

94

45.091003.20 Element, Air Cleaner 1

95

46.091200.04 Cover, Air Cleaner 1

96

1.5789.08 35 Flange Bolt M8 ×35 2

97

45.125100.00 Starter Motor Assembly 1

98

45.125200.03 Relay, Starter (Three Gear) 1

99

1.93.05 Spring Washer Ø5 2

100

1.16674.0516 Flange Bolt M5×16 2

101

45.110001.00 Shaft, Governor Arm 1

102

2.03.019 Washer (Ø8.2×Ø17×0.8) 1

103

2.11.0 06 Oil Seal (Ø7×Ø14×5) 1

104

45.110008.00 Pin, Shaft 1

105

45.110003.00 Arm, Governor 1

106

2.08.040 Bolt, Governor Arm (M6 ×21) 1

107

45.110006.00 Governor Rod 1

108

45.110005.00 Spring, Throttle Return 1

109

45.110007.00 Spring, Governor 1

110

46.080300.20 Air Guide, Upper 1

111

47. 13 10 17. 2 1 Standard Main Jet 1

112

47.131017.21.01 Altitude Main Jet /

46.091000.03 Air Cleaner A ssembly 1

113

46.061000.00 Recoil Assembly 1

114

45.030200.00 Suppor t 1

115

2.06.013 Clamp (Ø13.5×b10) 1

116

45.032000.00 Oil Drain Hose Assembly 1

117

REV 41534-20140124 22

TROUBLESHOOTING

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

Generator shuts down during operation Out of fuel Fill fuel tank

Generator cannot supply enough power or
overheating

No AC output Cable not properly connected Check all connections

Generator gallops Engine governor defective Contact the help line

Repeated circuit breaker tripping Overload Review load and adjust. See “Power

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

Low oil level Fill crankcase to the proper level. Place

generator on a flat, level surface

Generator is overloaded Review load and adjust. See “Power

Management”

Insufficient ventilation Check for air restriction. Move to a well

ventilated area

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

Management”

Faulty cords or device Check for damaged, bare or frayed wires.

Replace defective device

ENGLISH 41534

For further technical support:

Technical Service

Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
[e-mail]

23 REV 41534-20140124

41534 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.

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

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.

Address

Champion Power Equipment, Inc.
Customer Service
10006 Santa Fe Springs Rd.
Santa Fe Springs, CA 90670
www.championpowerequipment.com

Customer Service

Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
[e-mail]
Fax no.: 1-562-236-9429

Technical Service

Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
[e-mail]
24/7 Tech Support: 1-562-204-1188

REV 41534-20140124 24

Champion Power Equipment, Inc. (CPE),

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

Emission Control System Warranty

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

YOUR WARRANTY RIGHTS AND OBLIGATIONS:

The US EPA, California Air Resources Board, and CPE are pleased to explain the Federal and California Emission
Control Systems Warranty on your 2014 small off-road engine and engine powered equipment. In California, new,
small off-road engines and new equipment that use small off-engines must be designed, built and equipped to meet
the State’s stringent anti smog standards. In the other states, new engines and equipment must be designed, built
and equipped, at the time of sale, to meet U.S. EPA regulations for small non-road engines. CPE warrants the
emission control system on your small off-road engine and equipment for the period of time listed below, provided
there has been no abuse, neglect, unapproved modification, or improper maintenance of your equipment.

Your emission control system may include parts such as the carburetor, fuel-injection system, the ignition system,
catalytic converter and fuel lines. Also included may be hoses, belts, connectors and other emission related
assemblies. Where a warrantable condition exits, CPE will repair your small off-road engine at no cost to you
including diagnosis, parts and labor. For engines less than or equal to 80cc, only the fuel tank and fuel line is
subject to the evaporative emission control warranty requirements of this section.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

This emission control system is warranted for two years, subject to provisions set forth below. If, during the
warranty period, emission related part on your engine is defective in materials or workmanship, the part will be
repaired or replaced by CPE.

OWNER WARRANTY RESPONSIBILITIES:

As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in
your Owner’s Manual. CPE recommends that you retain all your receipts covering maintenance on your small off­road engine, but CPE cannot deny warranty solely for the lack of receipts or for your failure to ensure the
performance of all scheduled maintenance.

As the small off-road engine owner, you should however be aware that CPE may deny you warranty coverage if
your small, off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved
modifications.

You are responsible for presenting your small off-road engine to an Authorized CPE service outlet or alternate
service outlet as described in (3)(f.) below, CPE dealer or CPE, Santa Fe Springs, Ca. as soon as a problem exists.
The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact:

Champion Power Equipment, Inc.

Customer Service

10006 Santa Fe Springs Road

Santa Fe Springs, CA 90670

1-877-338-0999

[e-mail]

EMISSION CONTROL SYSTEM WARRANTY

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

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

other states, 1997 and later model year engines). The ECS Warranty Period shall begin on the date the new engine
or equipment is delivered to its original, end-use purchaser, and shall continue for 24 consecutive months
thereafter.

2. GENERAL EMISSIONS WARRANTY COVERAGE

CPE warrants to the original, end-use purchaser of the new engine or equipment and to each subsequent
purchaser that each of its small off-road engines is:
a. Designed, built and equipped so as to conform to U.S. EPA emissions standards for spark-ignited
engines at or below 19 kilowatts and all applicable regulations adopted by the California Air Resources Board
and
b. Free from defects in materials and workmanship that cause the failure of a warranted part to be identical
in all material respects to the part as described in the engine manufacturer’s application for certification for a period
of two years.

3. THE WARRANTY ON EMISSION-RELATED PARTS WILL BE INTERPRETED AS FOLLOWS:

a. Any warranted part that is not scheduled for replacement as required maintenance in the Owners
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it
shall be repaired or replaced by CPE according to Subsection “d” below. Any such part repaired or replaced under
the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period.
b. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the
Owners Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the
effect of “repair or replace as necessary”, shall not reduce the ECS Warranty Period. Any such part repaired or
replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
c. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in
the Owner’s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that
part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by CPE
according to Subsection “d” below. Any such emissions-related part repaired or replaced under the ECS Warranty,
shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for
such emissions-related part.
d. Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be
performed at no charge to the owner at a CPE Authorized Service Outlet.
e. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered
by the ECS Warranty is in fact defective, provided that such diagnostic work is performed at a CPE Authorized
Service Outlet.
f. CPE shall pay for covered emissions warranty repairs at non-authorized service outlets under the
following circumstances:
i. The service is required in a population center with a population over 100,000 according to U.S.
Census 2000 without a CPE Authorized Service Outlet AND
ii. The service is required more than 100 miles from a CPE Authorized Service Outlet. The 100 mile
limitation does not apply in the following states: Alaska, Arizona, Colorado, Hawaii, Idaho, Montana, Nebraska,
Nevada, New Mexico, Oregon, Texas, Utah and Wyoming.
g. CPE shall be liable for damages to other original engine components or approved modifications
proximately caused by a failure under warranty of an emission-related part covered by the ECS Warranty.
h. Throughout the ECS Warranty Period, CPE shall maintain a supply of warranted emission-related parts
sufficient to meet the expected demand for such emission-related parts.
i. Any CPE Authorized and approved emission-related replacement part may be used in the performance of
any ECS Warranty maintenance or repair and will be provided without charge to the owner. Such use shall not
reduce CPE’s warranty obligation.
j. Unapproved add-on or modified parts may not be used to modify or repair a CPE engine. Such use voids
this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. CPE shall not be liable
hereunder for failures of any warranted parts of a CPE engine caused by the use of such an unapproved add-on or
modified part.

EMISSION-RELATED PARTS INCLUDE THE FOLLOWING: (using those portions of the list applicable to the
engine)

Systems covered by this
warranty

Parts Description

Fuel Metering System

Fuel regulator, Carburetor and internal parts

Air Induction System

Air cleaner, Intake manifold

Ignition System

Spark plug and parts, Magneto ignition system

Exhaust System

Exhaust manifold, catalytic converter

Miscellaneous Parts

Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed
systems.
Evaporative Emissions

Fuel Tank, Fuel Cap, Fuel Line, Fuel Line Fittings, Clamps, Pressure
Relief Valves, Control Valves, Control Solenoids, Electronic Controls,
Vacuum Control Diaphragms, Control Cables, Control Linkages, Purge
Valves, Vapor Hoses, Liquid/Vapor Separator, Carbon Canister, Canister
Mounting Brackets, Carburetor Purge Port Connector

TO OBTAIN WARRANTY SERVICE:

You must take your CPE engine or the product on which it is installed, along with your warranty registration card or
other proof of original purchase date, at your expense, to any Champion Power Equipment dealer who is
authorized by Champion Power Equipment, Inc. to sell and service that CPE product during his normal business
hours. Alternate service locations defined in Section (3)(f.) above must be approved by CPE prior to service. Claims
for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because
the engine was not properly maintained and used.

If you have any questions regarding your warranty rights and responsibilities, or to obtain warranty
service, please write or call Customer Service at Champion Power Equipment, Inc.

Champion Power Equipment, Inc.

10006 Santa Fe Springs Road

Santa Fe Springs, CA 90670

1-877-338-0999

Attn.: Customer Service

[e-mail]