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.

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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

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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.

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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 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

(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.

(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

(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.

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