10006 Santa Fe Springs Road
Santa Fe Springs, CA 90670 USA
Made in China
CSA40020
Rev CSA40020-20070809
Owner’s Manual and Operating Instructions
4000 Peak Watts/3000 Running Watts
PORTABLE GENERATOR
Table of Contents
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
Assembly ..........................................8
Remove the Generator from the Shipping
Carton .......................................................8
Install the Wheel Kit (not included).........8
Install the Support Leg (not included).....8
Install the Handle (not included).............8
Install the Spark Arrester (not included).8
Add Engine Oil .........................................8
Add Fuel....................................................9
Grounding.................................................9
Operation .......................................10
Generator Location.................................10
Grounding............................................... 10
Surge Protection..................................... 10
Starting the Engine................................. 10
Connecting Electrical Loads................... 10
Stopping the Engine...............................10
Do Not Overload Generator ....................11
Capacity................................................11
Power Management.............................11
Wattage Reference Chart.........................11
Maintenance................................... 12
Engine Maintenance............................... 12
Oil........................................................ 12
Spark Plugs ......................................... 12
Air Filter.............................................. 12
Spark Arrester (if installed)................ 13
Cleaning .............................................. 13
Adjustments........................................ 13
Maintenance Schedule........................ 13
Generator Maintenance.......................... 13
Storage ........................................... 14
Engine Storage........................................14
Generator Storage...................................14
Specifications ................................. 15
Engine Specifications..............................15
Generator Specifications.........................15
Fuel..........................................................15
Oil............................................................15
Spark Plugs ............................................. 15
Valve Clearance....................................... 15
Parts Diagram......................................... 16
Parts List.................................................17
Wiring Diagram ......................................19
Troubleshooting .............................20
Warranty ........................................ 21
Warranty Qualifications .........................21
Repair/Replacement Warranty.............. 21
Do not return the unit to the place of
purchase..................................................21
Warranty Exclusions...............................21
Normal Wear.......................................21
Installation, Use and Maintenance.....21
Other Exclusions.................................21
Limits of Implied Warranty and
Consequential Damage...........................21
Contact Information...............................21
Address................................................21
Customer Service ................................ 21
Technical Service.................................21
Notes ..............................................22
Introduction
Introduction
Congratulations on your purchase of a
Champion Power Equipment generator. CPE
designs and builds generators to strict
specifications. With proper use and
maintenance, this generator will bring years
of satisfying service.
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.
Champion Power Equipment Support
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.
1-877-338-0999
Model Number
CSA40020
Serial Number
Date of Purchase
Purchase Location
Rev CSA40020-20070809 1
Manual Conventions
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.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided,
minor or moderate injury.
may
result in
CAUTION
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided,
or serious injury.
will
result in death
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided,
death or serious injury.
could
result in
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 1-877338-0999.
2 Rev CSA40020-20070809
Safety Rules
DANGER
Safety Rules
Generator produces powerful voltage.
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.
Operate generator outdoors only in a well
ventilated area
DO NOT operate the generator inside any
building, 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
Rotating parts can entangle hands, feet, hair,
clothing and/or accessories.
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 three feet of clearance on all
sides to ensure adequate cooling.
Maintain at least five feet of clearance from
combustible materials.
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.
Rev CSA40020-20070809 3
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
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
4 Rev CSA40020-20070809
Controls and Features
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
Fuel Tank (1) – 4.0 gallon capacity fuel
tank.
Fuel Valve (2) – Turn this valve to the
“On” position to supply fuel to the engine.
Choke (3) – Used to start the engine
Air Cleaner (4) – Protects the engine by
filtering dust and debris from the intake air.
Recoil Starter (5) – Used to start the
engine
Rev CSA40020-20070809 5
Serial Number (6) – Please have this
number available when calling for
assistance.
Low Oil Sensor (7) – Senses the level of
oil in the crankcase and shuts the engine
down if the level falls too low.
Oil Filler Cap (8) – Check and fill engine
oil level.
Power Panel (9) – See “Power Panel”
Controls and Features
Power Panel
Circuit Breakers (1, 2) – Protects the
generator against electrical overload.
Engine Switch (3) – Flip the switch to the
“On” position and pull the recoil starter to
start the generator. Turn to the “Off”
position to turn off the generator.
Voltmeter (4) – Displays the output
voltage of the generator..
120/240 V Twist-Lock (5) – protected by
a 20 A circuit breaker. This receptacle
powers 120 Volt AC, 60 Hz, single phase
loads requiring up to 20 Amps or 2400
watts of power or 240 Volt AC, 60 Hz, single
phase loads requiring up to .12.5 Amps or
3000 watts
120 V 20 A Duplex (6) – protected by a
20 A circuit breaker. Use this duplex to
operate 120 Volt AC, single phase, 60 Hz
loads requiring up to 20 A 0r 2400 Watts of
power.
12 V 8.3 A DC Terminal (7) – This
terminal allows you to recharge a 12 V
automotive or utility style storage battery.
6 Rev CSA40020-20070809
Controls and Features
Parts Included
Your CSA40020 Gasoline Powered Generator ships with the following parts:
Wind-Up LED Flashlight
Oil
18’ Power Cord
6’ Charging Cord
Oil Funnel 1 piece
Wrench 1 piece
Spark Plug Socket 1 piece
Rev CSA40020-20070809 7
Assembly
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 (not
included)
CAUTION
The wheel kit is not intended for over-the-road
use.
You will need the following tools to install
the wheels:
12 mm wrench
Socket wrench with a 12 mm socket
Pliers
1. Before adding oil to the engine, tip the
generator slowly so that the engine side
is up.
2. Attach the axle to the bottom of the
frame with four mounting bolts and
nuts.
3. Slide a wheel onto the axle.
4. Place a washer on the end.
5. Install the cotter pin through the hole on
the end of the axle.
6. Carefully bend the legs of the cotter pin
back around the axle.
7. Repeat steps 3-6 to attach the second
wheel.
Install the Support Leg (not
included)
1. Attach the rubber vibration mount to
the support leg with a cap screw
(M8x20) and lock nut (M8).
2. Attach the support leg to the generator
frame with cap screws (M8x30) and lock
nuts (M8).
3. Tip the generator slowly so that it rests
on the wheels and support leg.
Install the Handle (not
included)
1. Place the handle over the mounting
channel on the frame.
2. Secure the handle to the frame using the
two handle bolts.
3. Place a lock nut (M8) on the end of each
bolt and fasten securely. DO NOT over
tighten the lock nuts.
Install the Spark Arrester (not
included)
Insert the spark arrester screen into the
muffler outlet. Secure the spark arrester by
placing the cover plate over the end of the
screen, with the lettering facing outward.
Secure the cover plate with the two screws
and lock washers provided with the spark
arrester kit.
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.
1. Place the generator on a flat, level
surface.
2. Remove oil fill cap/dipstick to add oil.
8 Rev CSA40020-20070809
Assembly
3. Add 0.63 qt (0.6 L) of oil and replace oil
fill cap/dipstick.
4. Check engine oil level daily and add as
needed.
CAUTION
The engine is equipped with a low-oil-shutoff and
the 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.
CAUTION
Use regular unleaded gasoline with a minimum
octane rating of 85.
Do not mix oil and gasoline.
Fill tank to approximately ¼” below the top of
the tank to allow for fuel expansion.
DO NOT fill fuel tank indoors.
DO NOT fill fuel tank when the engine is running
or hot.
DO NOT overfill the fuel tank.
DO NOT light cigarettes or smoke when filling the
fuel tank.
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.
Add Fuel
1. Use clean, fresh, regular unleaded fuel
with a minimum octane rating of 85.
2. DO NOT mix oil with fuel.
3. Clean the area around the fuel cap.
4. Remove the fuel cap
5. Slowly add fuel to the tank. DO NOT
overfill. Allow approximately ¼ inch of
space for fuel expansion.
6. Screw on the fuel cap and wipe away any
spilled fuel.
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 CSA40020-20070809 9
Operation
Operation
Generator Location
Please consult your local authority. In some
areas, generators must be registered with
the local utility.
Generators used at construction sites may be
subject to additional rules and regulations.
This generator must have at least five feet of
clearance from combustible material. Leave
at least three feet of clearance on all sides of
the generator to allow for adequate cooling,
maintenance and servicing.
Place the generator in a well-ventilated area.
DO NOT place the generator near vents or
intakes where exhaust fumes could be drawn
into occupied or confined spaces. Carefully
consider wind and air currents when
positioning generator.
Grounding
The generator system ground connects the
frame to the ground terminals on the power
panel. The system ground is connected to
the AC neutral wire.
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 shortduration voltage fluctuations.
2. Obtain an Uninterruptible Power
Supply (UPS) device.
Most UPS devices come with a
rechargeable battery between the
electronic equipment and power supply
source. The device buffers the voltage
and protects against virtually all shortduration voltage fluctuations.
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. Pull the starter cord slowly until
resistance is felt and then pull rapidly
6. As engine warms up, move the choke
lever to “Run”.
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.
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 or
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.
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
10 Rev CSA40020-20070809
Operation
temperatures of the engine and
generator.
3. Turn the ignition switch to the “Off”
position.
4. Turn the fuel valve to the “Off” position.
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 generator capacity when
adding loads.
Wattage Reference Chart
Use the chart to determine approximate
wattage requirements for your equipment.
NOTE
Starting watts can exceed three times the
running watts. The values in the following table
are approximate. Refer to your tool or appliance
for actual wattage consumption.
Item
Essentials
Light Bulb 100W 100
Refrigerator/Freezer 1200 2400
Freezer 500 500
Sump Pump 600 1800
Well Pump 1 HP 2000 4000
Water Heater 4000
Security System 180
AM/FM Radio 300
Garage Door Opener 1/2 HP 500 600
Battery Charger 12V DC 110
Heating/Cooling
Air Conditioner 12000 BTU 1700 2500
Fan 300 600
Furnace Fan 1/3 HP 1200 2000
Home Appliances
Microwave 1000W 1000
Electric Range - One Element 1500
Electric Skillet 1250
Coffee Maker 1500
Clothes Washer 1200
Entertainment
CD/DVD Player 100
VCR 100
Stereo Receiver 450
Television 27" 500
PC with 15" Monitor 800
Job Site
Belt Sander 3" 1000 1500
Bench Grinder 6" 700 1500
Circular Saw 1500 1500
Compressor 1 1/2 HP 2500 2500
Edge Trimmer 500 500
Hand Drill 1/2" 1000 1000
Lawn Mower 1200 1800
Paint Sprayer 600 1200
Table Saw 2000 2000
Running
Watts
Starting
Watts
Rev CSA40020-20070809 11
Maintenance
Maintenance
The owner/operator is responsible for all
periodic maintenance.
WARNING
6. Dispose of used oil at an approved waste
management facility.
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.
Complete all scheduled maintenance in a
timely manner. Correct any issue before
operating the generator.
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.
Spark Plugs
1. Remove the spark plug cable from the
spark plug.
2. Use the spark plug tool that shipped
with your generator to remove the plug.
3. Inspect the electrode on the plug. It
must be clean and not worn to produce
the spark required for ignition.
4. Make certain the spark plug gap is 0.7 -
0.8mm (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.
Oil
Change oil when the engine is warm. Refer
to the oil specification to select the proper
grade of oil for your operating environment.
1. Remove the oil drain plug with a 15 mm
socket and extension.
2. Allow the oil to drain completely.
3. Replace the drain plug.
4. Remove oil fill cap/dipstick to add oil.
5. Add 0.63 qt (0.6 L) of oil and replace oil
fill cap/dipstick.
12 Rev CSA40020-20070809
Maintenance
Spark Arrester (if installed)
1. Allow the engine to cool completely
before servicing the spark arrester.
2. Remove the two screws holding the
cover plate which retains the end of the
spark arrester to the muffler.
3. Remove the spark arrester screen.
4. Carefully remove the carbon deposits
from the spark arrester screen with a
wire brush.
5. Replace the spark arrester if it is
damaged.
6. Position the spark arrester in the
muffler and attach with the two screws.
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.
Maintenance Schedule
Follow the service intervals indicated in the
schedule below.
Service your generator more frequently
when operating in adverse conditions.
Contact our help line 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
First 10 hours
Check/Adjust Valve Clearance *
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 3 years
Replace fuel line
* To be performed by knowledgeable,
experienced owners or Champion Power
Equipment certified service dealers
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.
Rev CSA40020-20070809 13
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.
Engine Storage
1. Allow the engine to cool completely
before storage.
2. Clean the engine according to the
instructions in the Maintenance section.
3. Drain all fuel completely from the fuel
line and carburetor to prevent gum from
forming.
4. Add a fuel stabilizer into the fuel tank.
5. Change the oil.
6. Remove the spark plug and pour about
½ ounce of oil into the cylinder. Crank
the engine slowly to distribute the oil
and lubricate the cylinder.
7. Reattach the spark plug.
Generator Storage
1. Allow the generator to cool completely
before storage.
2. Turn off the fuel supply at the fuel valve.
3. Clean the generator according to the
instructions in the Maintenance section.
4. Store the unit in a clean, dry area.
5. Store in a clean, dry place out of direct
sunlight.
14 Rev CSA40020-20070809
Specifications
Specifications
Engine Specifications
Engine 196 cc OHV CPE
EPA certified
Generator Specifications
Running Wattage 3000 Watts
Starting Wattage 4000Watts
AC Load 120/240 V
DC Load 12 V
Phase Single
Frequency 60 Hz
Fuel Capacity 4.0 gallons (15 L)
Weight 105.7 lbs. (47.95 kg)
Height 17.2 inches (43.7 cm)
Width 17.5 inches (44.5 cm)
Length 23.2 inches (59.0 cm)
Fuel
Fuel capacity is 4.0 US gallons (15.L). Use
regular unleaded gasoline with a minimum
octane rating of 85.
Spark Plugs
Your generator comes equipped with a ¾”
long reach plug (18 mm)
Intermittent use (less than 1 hour/month) or
colder temperatures (below 60°F)
NGK B6ES or equivalent
Moderate use (less than 3 hours/month) or
seasonal temperatures (50-80°F)
NGK B7ES or equivalent
Extreme use (continuous) or hot climates
(80-100°F)
NGK B8ES or equivalent
Make certain the spark plug gap is 0.7 -
0.8mm (0.028 - 0.031 in.).
Valve Clearance
Intake 0.13-0.17mm (0.005 – 0.007 in.)
Exhaust 0.18-0.22mm (0.007 – 0.009 in.)
Oil
Oil capacity is 0.63 qt (0.6 L).
Rev CSA40020-20070809 15
Specifications
Parts Diagram
16 Rev CSA40020-20070809
Specifications
Parts List
No Part Number Description Qty
1 ST168FD-1160100 Fuel Meter Assembly 1
2 GB1667-S5-6 Screw M5×6 2
3 ST168FD-1160200 Fuel Tank Cap 1
4 ST168FD-1160200 Fuel Tank Cap Seal 1
5 ST168F-1160500 Fuel Filler 1
6 ST168FD-1160001A Fuel Tank 1
7 GB5781-B6-16 Bolt M6×16 4
8 ST168FD-1163000 Tank Rubber 4
9 ST168FD-1160400 Fuel Cock 1
10 ST188FD-1070006A Clip 2
11 ST168FD-1160002A Fuel Tank 1
12 GB41-N-6 Nut M6 1
13 GB5781-B6-15 Bolt M6×15 1
14 ST168FD-1100002B Muffler Stay 1
15 ST02FD-1152036 Brush Support Plate 1
16 ST02FD-1152002-2 Generator End Cover 1
17 GB5781-B5-10 Bolt M5×10 2
18 GB5781-B5-16 Bolt M5×16 2
19 ST168FD-1150230-CSA Terminal 1
20 GB5781-B5-15 Bolt M5×15 2
21 ST168FD-1152031-CSA AVR 1
22 ST168FD-1152004 Diode Assembly 1
23 ST02FD-1152035-CSA Brush Assembly 1
24 ST02FD-1152032 End Cover 1
25 GB5789-FB6-155 Flange Bolt M6×155 4
26 ST02FD-1152001 Stator Cover 1
27 ST02FD-1152020-CSA Stator Assembly 1
28 GB5789-FB8-227 Flange Bolt M8×227 1
29 GB90-W-8 Washer ø8 1
30 GB276-BB-6202-SS Radial Ball Bearing 6202 1
31 ST02FD-1152010-CSA Rotor Complete 1
32 ST02FD-1152009 Cooling Fan 1
33 ST168FD-1030007 Crankcase Cover 1
34 ST05FD-1170003-B Grommet 1
35 ST05FD-1151209 Conduit 1
36 ST02FD-1151201 Grommet 1
37 ST02FD-1151202A-CSA 10A DC Circuit Breaker 1
38 GB5781-B5-12 Bolt M5×12 4
39 ST168FD-1710004
39 ST168FD-1710004
40 ST02FD-1151200C-CSA Receptacle 2
41 ST02FD-1151200B-CSA Receptacle 1
42 ST02FD-1151204A-CSA Volt Meter 1
43 ST168FD-1716000-CSA-2 20A Double Throw Circuit Breaker 2
44 ST02FD-1151205A Engine Switch 1
45 ST02FD-1151211-CSA Control Panel 1
46 ST02FD-1151300-CSA Control Box 1
47 GB1667-S5-35 Screw M5×35 3
48 ST02FD-1151300B Motor Mount I 2
49 ST02FD-1151400-19 Rubber Pad 4
50 ST02FD-1151207-M Ground Wire 1
51 ST02FD-1151208-M Ground Terminal 1
52 GB41-N-8 Nut M8 16
53 ST02FD-1151300A Motor Mount II 2
Black Negative Terminal 1
Red Positive Terminal 1
Rev CSA40020-20070809 17
Specifications
No Part Number Description Qty
54 GB41-N-8 Nut M8 4
55 ST168FD-1151301B-CSA Control Panel Defend Board 1
56 ST168FD-1151300D-CSA Frame 1
57 GB5789-FB6-12 Flange Bolt M6×12 6
58 ST02FD-1151002 Muffler cover 1
59 ST02FD-1151201A Choke Lever Complete 1
60 ST168FD-1130005 Packing 1
61 ST168FD-1130003 Carburetor 1
62 ST168F-2-1000000G Engine 1
63 ST160F-1100001 Muffler Gasket 1
64 GB900-SB8-35 Stud Bolt 2
65 GB93-LW-8 Spring Washer ø8 3
66 GB41-N-8 Nut M8 2
67 ST02FD-1150100 Muffler Stay (II) 1
68 ST168FD-1100200 Muffler 1
69 ST168FD-1111100 Control Assembly 1
70 ST168FD-1090006 Air Cleaner Stay 1
71 ST168FD-1090100 Air Cleaner Case Complete 1
72 ST168FD-1090002 Air Cleaner Seal 1
73 ST168FD-1090003 Separator 1
74 ST168FD-1090004 Element 1
75 ST168FD-1090200 Air Cleaner Cover Complete 1
18 Rev CSA40020-20070809
Specifications
Wiring Diagram
Rev CSA40020-20070809 19
Wiring Diagram
Troubleshooting
Problem Cause Solution
Generator will not start
Generator will not start;
Generator starts but runs roughly
operation
Generator cannot supply enough
power or overheating
No AC output
Generator gallops Engine governor defective Contact the help line
Repeated circuit breaker tripping
No fuel Add fuel
Faulty spark plug Replace spark plug
Unit loaded during start up Remove load from unit
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
Out of fuel Fill fuel tank Generator shuts down during
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
Cable not properly connected Check all connections
Connected device is defective Replace defective device
Circuit breaker is open Reset circuit breaker
Capacitor defective Replace capacitor (Service Center)
Faulty brush assembly Replace brush assembly (Service
Center)
Faulty AVR Replace AVR (Service Center)
Loose wiring Inspect and tighten wiring
connections
Other Contact the help line.
Overload Review load and adjust. See “Power
Management”
Faulty cords or device Check for damaged, bare or frayed
wires. Replace defective device
20
Warranty
as spark plugs, air filters, adjustments, fuel
Warranty
CHAMPION POWER EQUIPMENT
1 YEAR LIMITED WARRANTY
Effective September 1, 2006. Replaces all undated
warranties and all warranties dated before September 1,
2006.
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.
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 to due acts of God and other force
majeure events beyond the manufacturer’s
control.
Problems cause by parts that are not original
Champion Power Equipment parts.
This warranty does not apply to generators used
for prime power in place of a utility.
Repair/Replacement Warranty
CPE warrants to the original purchaser that the
mechanical and electrical components will be free
of defects in material and workmanship for a
period of one (1) year from the original date of
purchase (90 days 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.
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.
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
Address
Champion Power Equipment, Inc.
Customer Service
10006 Santa Fe Springs Rd.
Santa Fe Springs, CA 90670
Customer Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
Fax no.: 1-562-236-9429
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. Normal maintenance such
Technical Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
tech@championpowerequipment.com
Rev CSA40020-20070809 21
Notes
Notes
22 Rev CSA40020-20070809
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