Champion Power Equipment 41535 Operator's Manual for All Serial Numbers in

OWNER’S MANUAL & OPERATING INSTRUCTIONS

9375 Starting Watts / 7500 Running Watts
Wireless Remote Electric Start

PORTABLE GENERATOR

MODEL NUMBER

41535

10006 Santa Fe Springs Road

SAVE THESE INSTRUCTIONS

Important Safety Instructions
are included in this manual.

MADE IN CHINA

REV 41535-20120723

www.championpowerequipment.com

Santa Fe Springs CA 90670

USA / 1-877-338-0999

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

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

41535

9375 Starting Watts / 7500 Running Watts

Wireless Remote Electric Start

PORTABLE GENERATOR

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Remove the Generator from the Shipping Carton .. 9

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

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

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

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

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

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

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

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

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

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

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

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

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

Stopping the Engine .................... 14

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

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

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

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

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

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

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

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

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

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

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

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

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

Generator Maintenance .................. 18

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Do Not Return The Unit To

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

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

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

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

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

Limits of Implied Warranty

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

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

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

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

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

INTRODUCTION

ENGLISH 41535

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, 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

41535

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 41535-20120723

41535 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 41535-20120723 2

SAFETY RULES

ENGLISH 41535

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 three feet of clearance on all sides
to ensure adequate cooling.
Maintain at least five feet 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 41535-20120723

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.

41535 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.

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 41535-20120723 4

ENGLISH 41535

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

adjustment required.

(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.

5 REV 41535-20120723

41535 ENGLISH

CONTROLS AND FEATURES

Power Panel

(1) Intelligauge – Three mode digital meter for

displaying running hours, voltage and hertz.

(2) Battery Switch – Enables/disables starting

electrically – via remotely or by Ignition Switch.

(3) Circuit Breakers – Protects the generator against

electrical overloads. Push to reset breaker.

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

generator.

2

1

4

(5) 120 Volt AC, 30 Amp Twist-Lock Receptacle

(NEMA L5-30R) –

power for the operation of 120 Volt AC, 30 Amp,

single phase 60 Hz electrical loads.

(6) 120/240 Volt AC, 30 Amp Twist-Lock Receptacle

(NEMA L14-30R) –

electrical power for the operation of 120

and/or 240 Volt AC, 30 Amp, single phase 60 Hz

electrical loads.

3

7

65

May be used to supply electrical

May be used to supply

8

(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.

REV 41535-20120723 6

CONTROLS AND FEATURES

ENGLISH 41535

Wireless Remote Control

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

1. Receiver Control Module (RCM)

2. Wireless Remote

3. Battery Switch

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

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

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

“STOP” button on the Remote one time.

Power Panel Load Management Cont’d.

The on/off voltage delay at startup and shut down only
happen when the Remote Control is used. There is no
voltage delay when the pushbutton electric start or recoil
start method is used.

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

Remote Control Power Consumption

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

there is no current draw on the battery.

Power Panel Load Management

When the generator initially starts by the Remote, no
voltage is supplied to the Power Panel for approximately
15 seconds. This allows the engine to reach full speed
before electrical loads are applied to the generator.
When the generator is stopped by the Remote, the
voltage to the Power Panel is immediately turned off.
Then the engine stops 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.

7 REV 41535-20120723

41535 ENGLISH

Parts Included

Your 41535 Gasoline Powered Generator ships with the

following parts:

Wheel Kit

– 10” Whe el ............................ 2

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

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

– Flat Washer 10 .........................2

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

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

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

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

Other

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

– Oil ....................... 1.16 qt. (1.1 L)

– Remote .............................. 1

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

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

– Nut (M5) ............................. 2

– 25ft. Power Distribution Cord ............... 1

CONTROLS AND FEATURES

(Battery Bolts)

REV 41535-20120723 8

ASSEMBLY

ENGLISH 41535

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.

9 REV 41535-20120723

41535 ENGLISH

ASSEMBLY

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-shutoff 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 1.16 qt (1.1 L) of oil (included) and replace oil

fill cap/dipstick. See “Specifications” pages for oil

recommendations based on operating conditions.

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

REV 41535-20120723 10

ASSEMBLY

ENGLISH 41535

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. of space

left in the tank is required for fuel expansion, more

than ¼ in. 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

carbur eto 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” 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

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.

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

11 REV 41535-20120723

41535 ENGLISH

OPERATION

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 five feet of clearance from all

combustible material. In addition to clearance from all

combustible material, generators must also have at least

three feet 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.

REV 41535-20120723 12

OPERATION

ENGLISH 41535

Wireless Remote and Electric Start

Wireless remote starting is only possible within 80 feet of

the generator.

Do not attempt to adjust the carburetor choke. The remote

system will automatically close and open the choke.

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

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

3. Press the Ignition Switch to “ON”.

4. Press the Battery Switch to “ON”.

5. ELECTRIC START: Press the ignition switch to the

“START” position.

6. WIRELESS REMOTE START: press and release the

“START” button on the handheld Remote Control

device. DO NOT hold the button down, only press

the button once. The engine will attempt to start 6

times.

7. A safety feature is provided which delays the

electrical power availability during starting mode.

The delay lasts for approximately 15 seconds. The

delay is provided to prevent damage to the generator

if electrical loads are inadvertently turned on during

engine startup.

8. If the generator fails to start, check the battery

condition and cable connections.

Recoil Start

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

2. Turn off all electrical loads connected to the generator.

Never start or stop the generator with electrical

devices plugged in and turned on.

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

4. Press the Ignition Switch to “ON”.

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

6. Pull the starter cord slowly until resistance is felt and

then pull rapidly.

7. 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 spark plug 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 continue to 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.

13 REV 41535-20120723

41535 ENGLISH

OPERATION

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.

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

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.

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.

REV 41535-20120723 14

OPERATION

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 air-

fuel 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.

ENGLISH 41535

Part Number Altitude

Standard main jet

Altitude main jet

ST 190FD -2-113100 0 -17

490.131017.01

6000 Feet
(180 0 Meters)

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.

15 REV 41535-20120723

41535 ENGLISH

0.7 - 0.8 mm

0.028 - 0.031 in.

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 fi ll 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 - 0.8mm 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
specifi cation to select the proper grade of oil for your
operating environment.

1. Remove oil fi ll 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 1.16 qt (1.1 L) of oil and replace oil fi ll
cap /dipstick.

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

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 fi rmly install the plug.

8. Attach the spark plug wire to the plug.

Air Filter

1. Remove the snap-on cover holding the air fi lter 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 fi lter in the assembly.

7. Reattach the air fi lter cover and snap in place.

REV 41535-20120723 16

MAINTENANCE AND STORAGE

ENGLISH 41535

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

muf fler.

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.

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.

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.

17 REV 41535-20120723

41535 ENGLISH

MAINTENANCE AND STORAGE

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.

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
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.

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.

Charge the Battery

For generators equipped with batteries for electric
starting, proper battery maintenance and storage
should be followed. An automatic battery charger with

Charge the Battery Cont’d.

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.

DANGER

Generator exhaust contains odorless and colorless
carbon monoxide gas.

To avoid accidental or unintended ignition of your
remote 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.

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
carbur eto 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.

REV 41535-20120723 18

SPECIFICATIONS

ENGLISH 41535

Engine Specifications

– Model ........................... 615 60

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

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

– Start Type .................. Wireless Remote

Generator Specifications

– Model ........................... 415 35

– Running Wattage ................. 7500 Watts

– Starting Wattage ................. 9375 Watts

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

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

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

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

– Gross Weight ............. 231.6 lbs (107.3 kg)

– Net Weight ............... 219.3 lbs (99.7 kg)

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

– Width ................ 27.0 inches (68.8 cm)

– Length. . . . . . . . . . . . . . . . . 27.5 inches (69.9 cm)

Fuel

Fuel capacity is 5.9 gal. (22.4 L). Use regular unleaded

gasoline with a minimum octane rating of 85 and an

ethanol content of less than 10% by volume.

Oil

Use 10-30W automotive oil.

Oil capacity is up to 1.16 qt. (1.1 L).

DO NOT OVERFILL.

Please reference the following chart for recommended

oil types for use in the generator.

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.

FCC Statement for Remote Control Device

1. This device complies with Part 15 of the FCC Rules.

Operation is subject to the following two conditions:

(1) This device may not cause harmful interference.

(2) This device must accept any interference

received, including interference that may cause

undesired operation.

2. Changes or modifications not expressly approved by

the party responsible for compliance could void the

user’s authority to operate the equipment.

NOTE: This equipment has been tested and found to

comply with the limits for a Class B digital device,

pursuant to Part 15 of the FCC Rules. These limits

are designed to provide reasonable protection against

harmful interference in a residential installation.

This equipment generates uses and can radiate radio

frequency energy and, if not installed and used in

accordance with the instructions, may cause harmful

interference to radio communications. However, there

is no guarantee that interference will not occur in a

particular installation. If this equipment does cause

harmful interference to radio or television reception,

which can be determined by turning the equipment

off and on, the user is encouraged to try to correct the

interference by one or more of the following measures:

– Reorient or relocate the receiving antenna.

– Increase the separation between the equipment and

receiver.

– Connect the equipment into an outlet on a

circuit different from that to which the receiver is

connected.

Consult the dealer or an experienced radio/TV technician

for help.

19 REV 41535-20120723

41535 ENGLISH

Wiring Diagram

SPECIFICATIONS

REV 41535-20120723 20

SPECIFICATIONS

Parts Diagram

ENGLISH 41535

21 REV 41535-20120723

41535 ENGLISH

Parts List

# Part Number Description Qty

ST160F-1070007 Fuel Line Clip 7mm

1

ST05FD-04712003-CARB Air Cleaner Hose

2

ST168FD-1070408-CARB Clip

3

509.070014.00 Rollover Valve Hose

4

GB 578 9 -FB 8-1 2 Flange Bolt M8×12

5

ST05FD-04712100-CARB Charcoal Canister

6

ST05FD-04712005-CARB suppor t arm

7

ST05FD-04712002-CARB 90o Elb ow

8

ST188FD-1070006A Clip ø8

9

50 9.070 011.01 Fuel tube (8.9in )

10

ST02FD-04160000 Fuel Coc k

11

509.071000.14 F ue l Ta nk

12

GB16 67-S 5-10 Screw M5 ×10

13

ST05FD-04711200-CARB Fuel Meter Assembly

14

ST168FD-1070400-CARB Rollover Valve

15

168.07010 0.01 Fuel Tank Cap

16

ST168F-1070006A Fuel Filter

17

GB5789-FB6-20 Flange Bolt M6×20

18

GB93-LW-6 Lock Washer ø6

19

ST02FD-04100014 Washer ø6.5

20

ST02F D- 0 4100 010 Tan k R ub be r

21

ST188FD-1090006 Air Cleaner Stay

22

GB 41- N- 6 Nut M6

23

GB90-W-8 Washer ø8

24

GB93-LW-8 Lock Washer ø8

25

GB 41- N- 8 Nut M8

26

ST188FD-1100001-G Muffler Gasket

27

188.101000.06 Muffler

28

GB16 67-S 5-12 Scre w M5×12

29

188.1015 00 .31 Spark Arrester Assy

30

GB5789-FB8-20 Flange Bolt M8× 20

31

GB 578 9 -FB6-1 2 Flange Bolt M6×12

32

ST168FD-1100003-CARB SAI Valve Washer

33

ST168FD-1100300-CARB SAI Valve

34

GB 41- N- 5 Nut M5

35

GB90-W-5 Washer ø5

36

GB93-LW-5 Lock Washer ø5

37

ST07FD-02010003 Flange Bolt M5×229

38

GB90-W-6 Washer ø6

39

GB93-LW-6 Lock Washer ø6

40

ST05FD-1152035 Brush Assembly

41

ST02FD-02100008 Brush Support Plate

42

GB5781-B5-20 Bolt M5× 20

43

GB5789-FB5-12 Flange Bolt M5×12

44

ST05FD-1152001(S) Generator End Cover

45

GB5781-B5-16 Bolt M 5×16

46

ST02F D- 02100 010 Ter mi nal

47

GB5789-FB5-16 Flange Bolt M5×16

48

50 9.19 02 00.01 AV R

49

ST05FD-1152002 End Cover

50

ST07FD-02010002 Flange Bolt M6×194

51

ST07FD -020110 01 Stator cover

52

ST07FD -02010 001 Flange Bolt M10 ×1.25×280

53

ST 07FD - 0201110 0 Stator assembly

54

GB93-LW-10 Lock Washer ø10

55

GB 90 - W-10 Washer ø10

56

ST07FD-02011200 Rotor comp

57

GB5789-FB6-8 Flange Bolt M6×8

58

ST 05 FD-1151600 Cover

59

ST05FD-1152008 Plug-A

60

ST05FD-1152009 Plug-B

61

190FDE- 2-GC1 Engine

62

# Part Number Description Qty

2

1

2

1
4
1
1
1
2
1
1
1
2
1
1
1
1
4
4
4
4
1
3
2
4
2
1
1
3
1
1
2
1
1
2
5
5
2
6
6
1
1
1
2
1
2
1
2
1
1
4
1
1
1
1
1
1
2
1
1
1
1

ST 18 2F D -174 22 0 3-U C Handle Cover

63

509.200701.07 Handle

64

ST05FD-03161202 Handle underlay

65

GB896-B-6 Baffle ø6

66

27.0 01 Pin

67

GB896-B-8 Baffle ø8

68

GB5789-FB8 -35 Flange Bolt M8 ×35

69

GB96 8×24×3 Big washer ø8

70

ST 18 2F D -174 20 0 3 -U C Straight Bottom rubber

71

GB 578 9 -FB6-1 2 Flange Bolt M6×12

72

ST02FD-1152010-5 Grounding Wire

73

ST 05 FD -115140 0 -1 Bottom Rubber 2

74

GB 41- N- 8 Nut M8

75

ST 05 FD -1151 30 0 -1 Bottom Rubber 1

76

GB 41- LN -10 Lock Nut M10

77

GB 41- N-10 Nut M10

78

ST05FD-192(F) Frame

79

ST 18 8 FD -1744 0 0 2-T 10in Wheel

80

ST36QXG-03000002 Bushing ø10.5×69.5

81

GB 96 - F W-10 Flat Washer ø10

82

GB 578 1-B10-120 B olt M10 ×120

83

GB 41- N- 5 Nut M5

84

FM1218 0 Battery12V15AH

85

509.200904.00 Rubber Battery Tie Down

86

ST168FD-1750002-C7 Battery Wire, Negative

87

ST168FD-1750002-C6 Battery Wire, Positive

88

ST 05 FD- 0 3011112 Battery Gromet

89

GB 578 9 -FB 8-16 Flange Bolt M8×16

90

ST05FD-03020301-84 Support leg

91

ST 18 8 FD -1743 0 02 - C Vibration mount

92

GB5789-FB8 -25 Flange Bolt M8 ×25

93

5P15E(F ) Control Panel 41535

94

29.001.00 Switch

95

ST02FD-05502020 Receptacle L5-30R

96

ST02FD-05502022 Receptacle L14-30 R

97

ST02FD-05502023 Receptacle 5-20R

98

GB16 67-S 4-14 Sc rew M4×14

99

GB93-LW-4 Lock Washer ø4

100

GB90-W-4 Washer ø4

101

GB 41- N- 4 Nut M4

102

GB5781- B6 -2 2 Bolt M6×22

103

GB 41- N- 6 Nut M6

104

GB90-W-6 Washer ø6

105

ST05FD-05215001 Grommet

106

ST05FD-05215009 Conduit

107

ST05FD-05215003 Grommet

108

ST02FD-05302001-L20 20 Amp Circuit Breaker

109

ST02FD-05302001-L30 30 Amp Circuit Breaker

110

DP03-00000000-2 Intellig auge

111

21.001000.02 Switch

112

ST188FD-1020001 Grommet

113

0V01-00000000 Transition

114

GB16 67-S 5-14 Sc rew M5 ×14

115

BG01-00000000 Rectifier

116

GB1667-S5-38 Screw M5×38

117

ST05FD-05205011 Muffler Inner Protector

118

ST02FD-05302010 FUSE(10A)

119

WR05-00000000(02) Remote control

120

ST02FD-05612005 Indicator light

121

ST02FD-05612004 Button

122

ST05FD-05205012 Control Box

123

EC02 Charger

124

GB5789-FB5-10 Flange Bolt M5x10 2

125

1
1
2
2
2
2
2
2
2
6
1
1
8
1
2
2
1
2
2
2
2
2
1
1
1
1
3
2
1
2
2
1
1
1
1
2

10

8

10

8
1
2
1
1
1
1
2
2
1
1
1

1

2

1

3

1

1

1

1

1

1

1

REV 41535-20120723 22

SPECIFICATIONS

Engine Parts Diagram

ENGLISH 41535

23 REV 41535-20120723

41535 ENGLISH

# Part Number Description Q ty.

GB5789-FB6-8 Flange Bolt M6× 8 4

1

ST188 F-106 0100- G Recoil Star ter Case Comp 1

2

ST188F-1060009 Starter Return Spring 1

3

ST188F-1060008 Recoil Sta rter Pulley 1

4

ST160 F-1061 20 0 Recoil Starter Knob 1

5

ST188F-1060007 Recoil Starter Rope 1

6

ST188F-1060006 Return Spring 2

7

ST188F-1060004 Ratchet Guide Spring 1

8

ST188F-1060005 Starter Ratchet 2

9

ST188F-1060003 Ratchet Guide 1

10

ST188F-1060002 Ratchet Guide Bolt 1

11

ST160FD-1070408-CARB Wire clip 2

12

GB 578 9 -FB6-1 2 Flange Bolt M6 ×12 12

13

ST188 FD -10810 00- G (S ) Fan Cover (Silver) 1

14

ST188FD-1030003-A Oil Fille r Cap 1

15

ST18 8F D -103 0 014 Oil Fille r Cap Packing 1

16

GB5789-FB8-40 Flange Bolt M8×40 7

17

ST18 8F -103 020 0 Oil Seal 2

18

ST188F-1050004 Piston Pin Clip 2

19

ST188F-1050005 Piston Pin 1

20

ST190F-2-10 502 00 Connecting Rod Assembly 1

21

ST190F-2-1050001 Piston 1

22

ST19 0F-105 0100 Oil Ring Set 1

ST190F-1050003 Second Ring Set 1

23

ST190F-1050002 First Ring Set 1

ST188F-1080002-G Shroud 1

24

ST 190F -2-1040 011 Exhaust Valve 1

25

ST190F-2-1040003 Intake Valve 1

26

ST188F-1040004 Valve Stem Seal 2

27

ST188F-1040006 Valve Spring Washer 2

28

ST188F-1040007 Valve Spring 2

29

ST188F-1040008 Exhaust Valve Spring Retainer 1

30

ST188F-1040002 Intake Valve Spring Retainer 1

31

ST188F-1040009 Valve Rotator 1

32

ST188F-1020003-CPE Head Cover Gasket 1

33

ST19 0F-2-10 2010 0 Head Cover 1

34

ST190F-2-1020006 Valve Cover Bolt Comp. 1

35

ST188FD-1020002 Breather Tube 1

36

ST160 F-104 0025 Pivot Adjusting Nut 2

37

GB 41- N- 6 Nut M6 2

38

ST160 F-104 0024 Rocker Arm Bolt 2

39

GB90-W-6 Washer ø6 2

40

ST18 8F -1040 02 2 Intake Valve Rocker 1

41

ST18 8F -1040 02 3 Exhaust Valve Rocker 1

42

ST18 8F -1040 02 6 Valve Rocker Arm 1

43

ST18 8F -1040 02 1 Rocker A xis 1

44

ST18 8F -1040 02 8 Push Rod Guide Plate 1

45

ST168 F-104 0 027 Pivot Bolt 2

46

ST188F-1080001-G Shroud 1

47

ST19 0F-2-10110 00 - G Cylinder Head 1

48

ST188 F-1010001 Exhaust Stud 2

49

ST188F-1030009 Cylinder Head Bolt 4

50

ST188 F-1040 010- II Push Rod 2

51

ST190F-2-10 4 0012 Valve Lifter 2

52

139 FMD -10 03101 Drain Plug B olt 1

53

139 FMD -10 03102 Drain Plug Washer 2

54

ST188F-1030 013 Dowel Pin 2

55

ST190F-1030008-G Cylinder Head Gasket G-Style 1

56

ST188 FD -10100 02 Intake Stud 2

57

F6RTC Spark plug 1

58

ST188F-1122000-G Ignition Coil 1

59

GB5789-FB6-29 Flange Bolt M6×29 4

60

ST188FD -113000 3- CPE Carburetor Insulator Packing 1

61

# Part Number Description Q ty.

ST188F-11340 00 Carburetor Insulator 1

62

ST188F-11300 02- CPE Carburetor Packing 1

63

490.131000.01 Carburetor 1

64

188.130005.01 Stepper Motor Support 1

65

ST188FD -1130001- CPE Carburetor Packing 2

66

ST188 FD -109 0100 - CA RB Air Cleaner Case 1

67

GB 41- N- 6 Nut M6 3

68

ST188FD-1090003 Separator 1

69

ST188FD-1090004 Element 1

70

ST188FD-1090200-G Air Cleaner Cover 1

71

ST 18 8F -1110 002 Governor Rod 1

72

ST 18 8F -1110 001 Throttle Return Spring 1

73

ST188 FD -10810 00- G Control Assembly 1

74

ST 18 8F -1110 006 Governor Arm 1

75

ST 160F-111000 4 Governor Arm Bolt 1

76

ST 18 8F -1110 004 Governor Spring 1

77

ST 18 8F -1110 007 Pin Clip 2

78

ST 18 8F -1110 005 Washer8.2×17×0.8 1

79

ST 18 8F -1110 003 Cover Arm Shaft 1

80

ST188F-1050006 Flywheel Nut 1

81

ST188F-1060001 Starter Pulley 1

82

ST190F-2-1080002 Cooling Fan 1

83

ST188F-1121000-A Flywheel 1

84

ST18 8F -103 0 012 Grommet 1

85

ST190F-2-1030006-G Crankcase 1

86

ST188 F-103 0100 Oil S eal 1

87

ST188F-1030001 Wire Clip 1

88

ST168 F-103 0015-G Dowel Pin 9×14 2

89

GB276-BB-6207-UU

90

ST188 F-103 0010- G Case Cover Packing 1

91

ST188FD-1127000-A Oil level switch Assembly 1

92

GB 578 9 -FB6-15 Flange Bolt M6 ×15 2

93

GB276-BB-6202-UU

94

ST19 0F-2-10 4100 0 Camshaft C omp 1

95

ST190F-2-1050303 Balance gear 1

96

ST18 8F -105 030 4 Key 1

97

ST190F D-2-10 503 01 Crankshaft comp 1

98

ST 160F-111010 8 Governor Washer 1

99

ST 18 8F -1110101 Governor Weight Holder 1

100

ST 18 8F -111010 3 Governor Weight 3

101

ST 18 8F -111010 2 Governor Weight Pin 3

102

ST 18 8F -1110 009 Governor Shaft 1

103

ST 160F-111010 3 Governor Holder Clip 1

104

ST 18 8F -1110 008 Governor Slider 1

105

ST188F-1125000 Start Motor 1

106

GB5789-FB8 -35 Flange Bolt M8×35 2

107

ST188F-1126000 Relay 1

108

GB5789-FB5-20 Flange Bolt M5×20 2

109

GB93-LW-5 Lock Washer ø5 2

ST188F-1123000 Electric Charge Coil 1

110

ST188F-1030002 Wire Flat 1

111

ST190F D-2-1131000 -17 Standard Main JET 1

112

490 .131017.01 Altitude Main Jet -

ST188 FD -1031011- G Crankcase Cover 1

113

0902.132001.00 Stepper Motor Cover 1

114

GB16 67-S4 -8 Screw M4×8 2

115

188.132200 .00 Stepper Motor Comp. 1

116

0902.130010.00 Spring Conn. 1

117

168.130015.01 Connector,Starter 1

118

190.032000.00 Oil Drain Tube 1

119

190.030200.00 Support 1

120

06 .135 015.10 Clip 1

121

Radial Ball Bearing 6207 Unse aled

Radial Ball Bearing 6202 Uns ealed

REV 41535-20120723 24

2

2

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; Low oil level Fill crankcase to the proper level

Place generator on a flat, level surface

Generator starts but runs roughly Choke in the wrong position. Adjust choke.

Spark plug wire loose Attach wire to spark plug

Generator shuts down during operation Out of fuel Fill fuel tank

Low oil level Fill crankcase to the proper level. Place

generator on a flat, level surface

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

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 (Ser vice 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 41535

For further technical support:

Technical Service

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

25 REV 41535-20120723

41535 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
warr anty.

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 [phone]

Technical Service

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

REV 41535-20120723 26

Champion Power Equipment, Inc. (CPE),

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

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 California Air Resources Board, US EPA AND CPE are pleased to explain the Federal and California Emission
Control Systems Warranty on your 2012 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-r oad engine owner, you are r esponsible for the performance of the required maintenanc e listed in
your Owner’s Manual. C PE recommends that you reta in all your receipts cover ing 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 dea ler or CPE, Santa Fe Springs, Ca. as s oon as a pr oblem 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 Equipm ent, Inc.

Customer Service

10006 Santa Fe Springs Road

Santa Fe Springs, CA 90670

1-877-338-0999

EMISSION CONTROL SYSTEM WARRANTY
The following are specific provision s relative to your Emission Control System 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 with all applicable regulations adopted by the Air
Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code,
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, emiss ions -related part which is scheduled only for regular inspec tion as specif ied 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-r elated 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 obligati on.
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

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

Mounting Brackets, Carburetor Purge Port Connector

engine)

Relief Valves, Control Valves, Control Solenoids, Electronic Controls,
Vacuum Control Diaphragms, Control Cables, Control Linkages, Purge
Valves, Vapor Hoses, Liquid/ Vapor Sep arat or, Car bo n Canister, Canister

TO OBTAIN WARRANTY SERVICE:

You must take your C PE engi ne or the prod uct on whic h it is ins talled, along wit h your warr ant y registrat ion c ard or
other proof of original purchase date, at your expense, to any Champion Power Equipment dealer who is
authorized by Cham pion Power Equipment, I nc. 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 y o u r warranty rights and responsibilities, or to o b tain 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