Champion 46539 User Manual

OWNER’S MANUAL & OPERATING INSTRUCTIONS

4000 Peak Watts / 3500 Running Watts
Wireless Remote Electric Start

PORTABLE GENERATOR

MODEL NUMBER

YEAR

LIMITED WARRANTY

SAVE THESE INSTRUCTIONS

Important Safety Instructions
are included in this manual.

2

MADE IN CHINA

REV 46539-20101109

46539

10006 Santa Fe Springs Road

Santa Fe Springs CA 90670

USA / 1 [phone]

www.championpowerequipment.com

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:

• Tech Bulletins

• Product Registration

1-877-338-0999

24/7 Tech Support: [phone]

TABLE OF CONTENTS

46539

4000 Peak 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

Vacuum Fuel Valve ...................... 7

Starting with a “Dry Fuel Line” ............ 7

Starting with a “Primed Fuel Line” ......... 7

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

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

Spark Arrester 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 .................... 10

Install the Spark Arrester ................. 10

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

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

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

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

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

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

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

Wireless Remote Start ................... 12

Starting the Engine without Remote .......... 12

Connecting Electrical Loads ............... 13

Stopping the Engine .................... 13

Do Not Overload Generator ................ 14

Capacity .......................... 14

Power Management ................... 14

Wattage Reference Chart ................. 14

Maintenance and Storage ................... 15

Engine Maintenance .................... 15

Oil .............................. 15

Spark Plugs ........................ 15

Air Filter .......................... 15

Spark Arrester ...................... 16

Cleaning .......................... 16

Adjustments ........................ 16

Maintenance Schedule ................ 16

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

Storage ............................. 17

Generator Storage .................... 17

Disconnect the Battery ................ 17

Charge the Battery ................... 17

Specifications ........................... 18

Engine Specifications ................... 18

Generator Specifications ................. 18

Fuel ............................... 18

Oil ................................ 18

Spark Plugs .......................... 18

Valve Clearance ....................... 18

FCC Statement for Remote Control Device ..... 18

Parts Diagram ........................ 19

Parts List ............................ 20

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

Engine Parts List

Wiring Diagram ........................ 23

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 24

Warranty .............................. 25

Warranty Qualifications .................. 25

Repair/Replacement Warranty .............. 25

Do Not Return The Unit To

The Place Of Purchase .................. 25

Warranty Exclusions .................... 25

Normal Wear ....................... 25

Installation, Use and Maintenance ........ 25

Other Exclusions ..................... 25

Limits of Implied Warranty

and Consequential Damage ............. 25

Contact Information. . . . . . . . . . . . . . . . . . . . . 25

Address ........................... 25

Customer Service .................... 25

Technical Service .................... 25

Emission Control System Warranty .......... 26

INTRODUCTION

ENGLISH 46539

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, power

cables and storm kits, please visit our web site at:

www.championpowerequipment.com

This Booklet

Every effort has been made to ensure the accuracy and

completeness of the information in this manual. We reserve

the right to change, alter and/or improve the product and

this document at any time without prior notice.

Champion Power Equipment Support

1 [phone]

Model Number

46539

Serial Number

Date of Purchase

Purchase Location

For Oil Type see ‘Add Engine Oil‘ section. For Fuel Type see ‘Add Fuel‘ section.

1 REV 46539-20101109

46539 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 [phone]

REV 46539-20101109 2

SAFETY RULES

ENGLISH 46539

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

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.

DANGER

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

Keep hands and feet away from rotating parts.
Tie up long hair and remove jewelry.
Operate equipment with guards in place.
DO NOT wear loose-fitting clothing, dangling
drawstrings or items that could become caught.

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DO NOT touch hot surfaces.
Avoid contact with hot exhaust gases.
Allow equipment to cool before touching.
Maintain at least three feet of clearance on all sides
to ensure adequate cooling.
Maintain at least five feet of clearance from
combustible materials.

46539 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 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.

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.

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.

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

REV 46539-20101109 4

ENGLISH 46539

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

2

3

4

5

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

(2) Auto-Choke – Used to start the engine. No manual

adjustment required.

(3) Vac Fuel Valve – Turn this valve to the “On”

position to supply fuel to the engine.

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

and debris from the intake air.

8

6

(5) Recoil Starter – Used to start the engine.

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

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

DC to the electric starter and receiver control

module.

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

7

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46539 ENGLISH

Power Panel

CONTROLS AND FEATURES

1

2

4

5 6 7 8

3

(1) Intelligauge – Three mode digital meter for running

hours, voltage and hertz.

(2) Ignition Switch

(3) Circuit Breaker(s) – Protects the generator against

electrical overload.

(4) Battery Switch – Enables/disables starting

electrically – via remotely or by Ignition Switch.

(5) Ground Terminal – Consult an electrician for local

grounding regulations.

(6) 120V / 30A Twist-Lock – Protected by a 25 Amp

push-to-reset circuit breaker. This receptacle

powers 120 Volt AC, 60 Hz, single phase loads

requiring up to 29.2 Amps or 3500 Watts of power.

(7) 120V / 30A Recreational Vehicle (RV) Receptacle –

This receptacle powers 120 Volt AC, 60 Hz, single

phase loads requiring up to 29.2 Amps or 3500

Watts of power.

(8) 120V / 20A Duplex – Protected by a 20 Amp

push-to-reset circuit breaker . Use each recepticle

to operate 120 Volt AC, single phase, 60 Hz loads

requiring up to 20 Amp 0r 2400 Watts of power.

REV 46539-20101109 6

CONTROLS AND FEATURES

ENGLISH 46539

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 [phone].
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.

Vacuum Fuel Valve

This generator is equipped with a Vacuum Fuel Valve.
The Vac Fuel Valve functions similar to a standard on/
off fuel valve with the addition of a vacuum sensor that
can open and close the fuel valve based on whether the
engine is running or not.

The Vac Fuel valve has (3) selectable positions:

OFF

RUN PRIME

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

1. OFF (pointing up)
a. Valve is switched CLOSED so no fuel passes

through the valve.

2. RUN (pointing left)
a. Turns on the Vac feature of the valve. The valve

only opens to allow fuel to flow when the engine is

running which provides vac pressure to the valve.
b. Valve stays OPEN while engine is running.
c. Valve automatically CLOSES when the engine stops.

3. PRIME (pointing down)
a. Valve is switched OPEN to allow fuel to flow

freely to the carburator.

Starting with a “Dry Fuel Line”

When there is no residual fuel in the carburetor, the
Vacuum Fuel Valve must be in the “PRIME” position in
order to start the generator. This case occurs when the
unit is:

– Brand new out of the box, OR
– The fuel line and carburetor have been drained for

long term storage.

When the engine starts and reaches full speed, the Vac
Fuel Valve can be turned to the “RUN” position.

Starting with a “Primed Fuel Line”

When residual fuel is present in the fuel line and
carburetor, the Vacuum Fuel Valve may be turned to the
“PRIME” or “RUN” position to start the generator.

7 REV 46539-20101109