Champion Power Equipment 46554 Operator's Manual for All Serial Numbers in

OWNER’S MANUAL & OPERATING INSTRUCTIONS

4000 Starting Watts / 3000 Max Rated Watts

PORTABLE GENERATOR

MODEL NUMBER

YEAR

LIMITED WARRANTY

SAVE THESE INSTRUCTIONS

Important Safety Instructions
are included in this manual.

2

MADE IN CHINA

REV 46554-20110223

46554

10006 Santa Fe Springs Road

Santa Fe Springs CA 90670

USA / 1-877-338-0999

www.championpowerequipment.com

Have questions or need assistance?

Do not return this product to the store!

WE ARE HERE TO HELP!

Visit our website:

www.championpowerequipment.com

for more info:

• Product Info & Updates

• Frequently Asked Questions

– or –

Call our Customer Care Team Toll-Free at:

• Tech Bulletins

• Product Registration

1-877-338-0999

TABLE OF CONTENTS

46554

4000 Starting Watts / 3000 Max Rated Watts

PORTABLE GENERATOR

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 ........................ 6

Assembly .............................. 7

Remove The Generator From

The Shipping Carton .................... 7

Install The Wheel Kit .................... 7

Install The Support Leg .................. 7

Add Engine Oil ........................ 7

Add Fuel ............................ 8

Grounding ........................... 8

Operation .............................. 9

Generator Location ..................... 9

Surge Protection ....................... 9

Starting The Engine .................... 9

Connecting Electrical Loads ............... 9

Stopping The Engine .................... 9

Do Not Overload Generator ............... 10

Capacity ......................... 10

Power Management ................. 10

Wattage Reference Chart ................ 10

Maintenance And Storage .................. 11

Engine Maintenance ................... 11

Oil ............................. 11

Spark Plugs ....................... 11

Air Filter ......................... 11

Cleaning ......................... 12

Adjustments ...................... 12

Maintenance Schedule ............... 12

Generator Maintenance ................. 12

Storage ............................ 12

Engine Storage ..................... 12

Generator Storage ................... 12

Specifications .......................... 13

Engine Specifications .................. 13

Generator Specifications ................ 13

Fuel .............................. 13

Oil ............................... 13

Spark Plugs ......................... 13

Valve Clearance ...................... 13

Wiring Diagram ....................... 14

Parts Diagram ....................... 15

Parts List ........................... 16

Engine Parts Diagram .................. 17

Engine Parts List ..................... 18

Troubleshooting ......................... 19

Warranty ............................. 20

Warranty Qualifications ................. 20

Repair/Replacement Warranty ............. 20

Do Not Return The Unit To The

Place Of Purchase. . . . . . . . . . . . . . . . . . . . . 20

Warranty Exclusions ................... 20

Normal Wear ...................... 20

Installation, Use And Maintenance ....... 20

Other Exclusions ................... 20

Limits Of Implied Warranty And

Consequential Damage ................. 20

Contact Information ................... 20

Address ......................... 20

Customer Service ................... 20

Technical Service ................... 20

INTRODUCTION

ENGLISH 46554

Introduction

Congratulations on your purchase of a Champion

Power Equipment generator. CPE designs and builds

generators to strict specifications. With proper use and

maintenance, this generator will bring years of satisfying

service.

Portable Power Generator

This unit is a gasoline engine driven, alternating current

(AC) generator. It is designed to supply electrical power

for lighting, appliances, tools and similar equipment.

Record the model and serial numbers as well as date and place of purchase for future reference. Have this

information available when ordering parts and when making technical or warranty inquiries.

Accessories

Champion Power Equipment manufactures and sells

accessories designed to help you get the most from

your purchase. To find out more about our covers, power

cables and storm kits, please visit our website 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

46554

Serial Number

Date of Purchase

Purchase Location

For Oil Type see “Add Engine Oil” section. For Fuel Type see “Add Fuel” section.

1 REV 46554-20110223

46554 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 46554-20110223 2

SAFETY RULES

ENGLISH 46554

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
colourless, odourless, 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.

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.

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.

3 REV 46554-20110223

46554 ENGLISH

SAFETY RULES

DANGER

Fuel and fuel vapours 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.

WARNING

Operation of this equipment may create sparks that
can start fires around dry vegetation.

A spark arrestor may be required. The operator
should contact local fire agencies for laws or
regulations relating to fire prevention requirements.

Use the generator only for intended uses.
Operate only on level surfaces.
DO NOT expose generator to excessive moisture,
dust, or dirt.
DO NOT allow any material to block the cooling slots.
If connected devices overheat, turn them off and
disconnect them from the generator.
DO NOT use the generator if:

– Electrical output is lost
– Equipment sparks, smokes or emits flames
– Equipment vibrates excessively

REV 46554-20110223 4

ENGLISH 46554

CONTROLS AND FEATURES

Read this owner’s manual before operating your generator. Familiarize yourself with the location and function of the

controls and features. Save this manual for future reference.

Generator

1

2

3

4

5

(1) Fuel Tank – 4.0 gallon (15 L) capacity fuel tank.

(2) Choke Lever – Used to start the engine.

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

supply fuel to the engine.

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

and debris from the intake air.

8

7

6

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

(6) Low Oil Sensor – Senses the level of oil in the

crankcase and shuts the engine down if the level

falls too low.

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

(8) Power Panel – See “Power Panel”.

5 REV 46554-20110223

46554 ENGLISH

Power Panel

CONTROLS AND FEATURES

1 2 3 4 6

(1) Engine Switch – 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.

(2) Circuit Breakers – Protects the generator against

electrical overload.

(3) Voltmeter – Displays the output voltage of the

generator.

(4) 120/240 V Twist-Lock – protected by 20 A circuit

breakers. This receptacle powers 120 Volt AC, 60 Hz,

5A 5B

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.

(5) 120V / 20A Duplex (2) – Each duplex is protected

by a 20 Amp flip-to-reset circuit breaker to operate

120 Volt AC, single phase, 60 Hz loads requiring

up to 20 Amps 0r 2400 Watts of power.

(6) Ground – Consult an electrician for local grounding

regulations.

Parts Included

Your 46554 Gasoline Powered Generator ships with the

following parts:

Spark Arrester Kit

– Spark Arrestor ......................... 1

– Cover Plate ........................... 1

– Screw with Lock Washer .................... 2

Other

– 18’ Power Cord ......................... 1

– Wind-Up Flashlight ...................... 1

– Oil .............................. 0.6 L

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

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

– Wrench .............................. 1

REV 46554-20110223 6

ASSEMBLY

ENGLISH 46554

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.

Install the Wheel Kit Cont’d.

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 (M8x25) and lock nut (M8).

2. Attach the support leg to the generator frame with

cap screws (M8x16) and lock nuts (M8).

3. Tip the generator slowly so that it rests on the

wheels and support leg.

You will need the following tools to install the wheels:

• 12 mm wrench OR adjustable wrench (not included)

• Socket wrench with a 12 mm socket (not included)

• Pliers (not included)

1. Locate and remove the 4 rubber vibration mounts on

the bottom of the generator frame.

2. Bolt the axle to the frame with four cap screws

(M8x16) and lock nuts (M8).

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.

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 REV 46554-20110223

NOTE

The recommended type of oil for use in the
generator is 10W-30. Please see “Specifications”
section for more information on oil types.

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

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

46554 ENGLISH

ASSEMBLY

Add Oil Cont’d.

3. Add 0.63 qt (0.6 L) of oil and replace oil fill cap/

dipstick. See “Specifications” page in the manual for

oil recommendations based on operating conditions.

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

Add Fuel Cont’d.

4. Remove the fuel cap.

5. Slowly add fuel to the tank. DO NOT overfill. Allow

approximately ½ inch of space for fuel expansion.

6. Screw on the fuel cap and wipe away any spilled fuel.

CAUTION

Use regular unleaded gasoline with a minimum
octane rating of 85.

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.

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.

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.

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 46554-20110223 8

OPERATION

ENGLISH 46554

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 short-duration 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 short-duration voltage fluctuations.

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

7. As engine warms up, move the choke lever to “Run.”

NOTE

The generator rotor has a sealed, pre-lubricated ball
bearing that requires no additional lubrication for
the life of the bearing.

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.

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. Flip the engine switch to the “On” position.

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

9 REV 46554-20110223

46554 ENGLISH

OPERATION

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. Flip 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 specified capacity when adding
loads to the generator.

Wattage Reference Chart

Use the chart to determine approximate wattage

requirements for your equipment.

CAUTION

Exceeding specified load capacity can result in
damage to the generator.

To determine total wattage necessary to power a
device, ADD Running Watts to Starting Watts. (A+B)

Item

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

Batter y 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 / VCR 100

Stereo Receiver 450

Television 27” 500

PC with 15” Monitor 800

Belt Sander 3” 1000 1500

Bench Grinder 6” 700 1500

Circular Saw 1500 1500

Compre ssor 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 (A)

Essentials

Job Site

Starting
Watts (B)

REV 46554-20110223 10

0.7 - 0.8 mm

0.028 - 0.031 in.

MAINTENANCE AND STORAGE

ENGLISH 46554

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.

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

Spark Plugs

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

2. Use the spark plug tool that shipped with your

generator to remove the plug.

3. Inspect the electrode on the plug. It must be clean and

not worn to produce the spark required for ignition.

4. Make certain the spark plug gap is 0.7 - 0.8 mm or

(0.028 - 0.031 in.).

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.

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 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 fi ll cap/dipstick to add oil.

5. Add 0.63 qt (0.6 L) of oil and replace oil fi ll

cap/dipstick.

6. Dispose of used oil at an approved waste

management facility.

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.

11 REV 46554-20110223

46554 ENGLISH

MAINTENANCE AND STORAGE

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.

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.

Maintenance Schedule

Follow the service intervals indicated in the following

maintenance schedule.

Service your generator more frequently when operating

in adverse conditions.

Contact our help line at 1-877-3 3 8-0999 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 3 years

Replace fuel line

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

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. Allow the engine to cool completely before storage.

2. Clean the generator according to the instructions in

the Maintenance section.

3. Turn off the fuel supply at the Fuel Valve.

4. Drain all fuel completely from the fuel line and

carburetor to prevent gum from forming.

5. Add a fuel stabilizer into the fuel tank.

6. Change the oil.

7. 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.

8. Reattach the spark plug.

9. Store the unit in a clean, dry place out of direct

sunlight.

REV 46554-20110223 12

SPECIFICATIONS

ENGLISH 46554

Engine Specifications

– Engine .................... 196 cc OHV CPE

Generator Specifications

– Max Rated Wattage .............. . 3000 Watts

– Starting Wattage ................ . 4000 Watts

– AC Voltage ........................ . 120 V

– Neutral bonded to frame

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

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

– Fuel Capacity ................ 4 gallons (15 L)

– Weight ............... .G.W. 118.8 lbs. (54 kg)

................... .N.W. 103.4 lbs. (47 kg)

– Height ................ .17.4 inches (44.2 cm)

– Width ................ .17.5 inches (44.5 cm)

– Length. . . . . . . . . . . . . . . . . . 23.2 inches (59 cm)

Fuel

Fuel capacity is 4 gallons (15 L). Use regular unleaded

gasoline with a minimum octane rating of 85 and an

ethanol content of less than 10% by volume.

Spark Plugs

Recommended replacement spark plug:

– NGK BR6ES or equivalent

Make certain the spark plug gap is 0.7 - 0.8 mm or

(0.028 - 0.031 in.).

Valve Clearance

– Intake: 0.13 – 0.17 mm (0.005 – 0.007 in.)

– Exhaust: 0.18 – 0.22 mm (0.007 – 0.009 in.)

Oil

Use 4-Cycle automotive oil.

Oil capacity is 0.63 qt (0.6 L).

Please reference the following chart for recommended

oil types for use in the generator.

13 REV 46554-20110223

46554 ENGLISH

Wiring Diagram

SPECIFICATIONS

REV 46554-20110223 14

SPECIFICATIONS

Parts Diagram

ENGLISH 46554

15 REV 46554-20110223

46554 ENGLISH

# Part Number Description Qty

GB819 M5x10 Screw M5x10

1

ST02FD-04140000 Fuel Meter A ssembly

2

ST02FD-04120000-A Fuel Tank Cap

3

ST02FD-04130000 Fuel Filter

4

GB5789 M6x20 Flange Bolt M6x20

5

ST02FD-04100014 Washer 6.5 mm

6

ST02FD-04100010 Tank Rubber

7

ST02FD-04110000(Y) Fuel Tank

8

ST02FD-0416000 0 Fuel Cock

9

ST168FD-1160002 Fuel Line

10

ST188FD -1070006A Clip

11

GB5789 M6x12 Flange Bolt M6x12

12

GB5789 M8x 20 Flange Bolt M8x20

13

ST02FD-1150100 Muf fler Stay (II)

14

ST02FD-1150200 Muf fler Stay (I)

15

ST02FD-02100010 Terminal

16

GB16674 M5x12 Flange Bolt M5x12

17

ST02FD-02100004( Y) Generator End Cover

18

GB16674 M5x16 Flange Bolt M5x16

19

ST02FD-02100007(CSA) AVR (CSA)

20

GB16674 M5x16 Bolt M5x16

21

GB93 5 Lock Washer 5 mm

22

GB97.1 5 Washer 5 mm

23

ST02FD-02100009 Brush Assembly

24

ST02FD-02100001-2.5 Flange Bolt M6x158

25

GB93 6 Lock Washer 6 mm

26

GB97.1 6 Washer 6 mm

27

ST02FD-02100003 End Cover

28

ST02FD-02100002-2.5 Stator Cover

29

ST02FD-02120000-2.5(CSA) Stator Assembly

30

ST02FD-02100005-2.5 Flange Bolt M8x233

31

GB7244 8 Lock Washer 8 mm

32

GB96 8 Washer 8 mm

33

ST02FD-02110000-2.5(CSA) Rotor Comp

34

ST02FD-02100012 Build Up A

35

ST02FD-02100011 Build Up B

36

ST168FD-2-01000000- G Engine

37

ST168FD-1151301B-CSA(F) Control Panel Defend

38

ST02FD-02100013-14(CSA) Earth Line

39

GB6177 M6 Nut M6

40

ST02FD-1151300C-1 Bottom Rubber II

41

GB6177 M8 Nut M8

42

ST02-1151400 Rubber Pad

43

Board

11

12

# Part Number Description Qty

ST02FD-1151300D-1 Bottom Rubber I

2

1

1

1

4

4

4

1

1

1

2

3

1

1

1

3

1

2

1

3

4

2

1

4

6

6

1

1

1

1

1

1

1

1

1

1

2

1

1

2

4

44

ST02FD-0185-2.5 (F) Frame

45

ST02FD-03030400(F) Muffler Cover

46

ST168FD-1090006 Air Cleaner Stay

47

GB5789 M6x8 Flange Bolt M6x8

48

ST168F-1100200-G Muffler Gasket

49

GB848 8 Washer 8 mm

50

GB93 8 Lock Washer 8 mm

51

GB6175 M8 Nut M8

52

ST168FD-1100000-G Muf fler

53

ST188FD -1180121 Spark Arrester

54

ST188FD -1100010-8 8 Spark Arrester Cover

55

GB93 5 Lock Washer 5 mm

56

GB818 M5x15 Screw M5x15

57

ST02FD-02100008 Plate Pinch

58

ST02FD-05212002 Build Up

59

ST02FD-05212006 Conduit

60

ST02FD-05212001 Build Up

61

ST02FD-05202002(CSA) Control Box

62

GB823 M5x14 ScrewM5x14

63

0V02-0 0000000(CSA) Transition

64

GB5783 M6x22 Bolt M6x22

65

GB6175 M6 Nut M6

66

GB823 M4x14 Screw M4x14

67

GB859 4 Lock Washer 4 mm

68

GB848 4 Flat Washer 4 mm

69

GB6177 M4 Nut M4

70

ST02FD-05502023(CSA) Receptacle 5 -20R

71

ST02FD-05502021(CSA) Receptacle L14-20R

72

ST02FD-05602010-A Tension List

73

GB848 3 Flat Washer 3 mm

74

GB859 3 Lock Washer 3 mm

75

GB6175 M3 Nut M3

76

GB848 3 Flat Washer 3 mm

77

GB859 3 Lock Washer 3 mm

78

GB823 M3x6 Screw M3x6

79

ST02FD-05302005 -20 (CSA) 125/250V 20A

80

ST02FD-05702004 Ignition Switch

81

2A89 (F) Control Panel

82

ST02FD-05010703 Flange Bolt M5x13

83

ST188FD -1020001 Grommet

84

ST02FD-03170001(F) Grommet

85

Assembly

Double pole

2

1

1

1

1

1

2

2

2

1

1

1

2

2

1

1

1

1

1

2

1

1

2

8

6

8

7

2

1

1

4

4

4

4

4

4

1

1

1

4

1

1

REV 46554-20110223 16

SPECIFICATIONS

Engine Parts Diagram

ENGLISH 46554

17 REV 46554-20110223

46554 ENGLISH

Engine Parts List

# Part Number Description Qty

GB5789- -86 -FB6-8 Flange Bolt 6X8 5

1

ST160F--1061200 Recoil Starter Knob

2

ST160F--1061100- Q Recoil Starter Comp

3

ST160F--1061005 Recoil Starter Spring

4

ST160F--1061009 Recoil Starter Rope

5

ST160F--1061001-A Recoil Starter Reel

6

ST188F--1060 006 Return Spring

7

ST188F--1060 005 Starter Ratchet (Metal)

8

GB5789--86 -FB6-12 Flange Bolt M6X12

9

ST188F--1060 003 Ratchet Guide

10

ST188F--1060 004 Ratchet Guide Spring

11

ST188F--1060 002 Setting Screw

12

ST168F--1080100-G Fan Cover Comp

13

ST160F--1050010 Nut M14

14

ST160F--1060001 Start Hub

15

ST168F--1080001 Cooling Fan

16

ST168F--1120100 Fly Wheel

17

ST168F--1080200 Side Place (Ii)

18

ST168F--1030100 Oil Seal

19

GB5789- -86 -FB6-15 Flange Bolt M6X15

20

ST160F--1030003 Drain Plug Bolt

21

ST160F--103000 4 Drain Bolt Washer

22

ST168F-2-1030012-G Crankcase (For USA)

23

GB/ T—276--94 Radial Ball Bearing 6205

24

ST160F-1127000 -A Oil Level Switch As sembly

25

ST160F--1110108 Governor Washer (Ii)

26

ST160F--1110101 Governor Weight Holder

27

ST160F--1110102 Governor Weight Pin

28

ST160F--1110104 Governor Shaft

29

ST160F--1110103 Governor Holder Clip

30

ST160F--1110107 Governor Weight

31

ST160F--1110108 Governor Washer (Ii)

32

ST160F--1110105-A Governor Cover

33

ST168FD-2-10500 01-A Crankshaf t Comp

34

ST168F-1030008-G Case Over Packing (No

35

ST160F--1030001-B Oil Filler Cap Assembly

36

ST160F--1030002 Oil Filler Cap Packing

37

GB5789- -86 -FB8-32 Flange Bolt 8X32

38

ST168F--1110005 Throttle Return Spring

39

ST168F--1110007 Governor Spring

40

ST160F--1110003 Governor Arm

41

GB6177-- 86 Nut M6

42

ST160F--1110008 Lock Pin

43

ST160F--1110001 Governor Arm Shaft

44

ST168F--1110006 Governor Rod

45

ST160F--1110004 Governor Arm Bolt

46

GB5789- -86 -FB6-25 Flange Bolt 6X25

47

ST160F--1123000-G Ignition

48

152FMD--1001007 Dowel Pin 10X16

49

GB5789- -86 -FB8-55 Flange Bolt 8X55

50

Asbestos)

1

1

1

1

1

2

2

9

1

1

1

1

1

1

1

1

1

2

4

2

2

1

2

1

1

1

2

1

1

2

1

1

1

1

1

2

6

1

1

1

3

1

1

1

1

2

1

2

4

# Part Number Description Qty

ST168FD--1090200 -G Air Cleaner Cover Comp

51

ST168FD--1090004 Element

52

ST168FD--1090003 Separator

53

ST168FD--1090002 Air Cleaner Seal

54

ST168FD--1090004 Air Cleaner Case Comp

55

ST160F--1130003- CPE Carburetor Packing (No

56

ST168F--1130001 Carburetor Insulator

57

ST168F--1130002-CPE Insulator Packing (No

58

ST160F--1010001 Stud Bolt 6X110

59

ST168F-2-1010100-G Cylinder Head Comp

60

ST168F-2-1030009-G Cylinder Head Gasket

61

ST168F--1040002 Intake Valve

62

ST168F--1040006 Exhaust Valve

63

ST168F-2-1040013 Valve Lifter

64

ST168F-2-1041000 Camshaft Assemblybly

65

ST168F--1030015-G Dowel Pin 9X14

66

ST168FD--1111100 Control Assembly

67

GB1099--79 Key

68

ST168FD--1030007-G Crankcase Cover

69

ST168F--1050100 Connecting Rod Comp

70

ST168F--1050003 Piston Pin

71

ST168F--105000 4 Piston Pin Clip

72

ST168F-2-1050005 Piston

73

ST168F--1050007 First Ring Set

74

ST168F--105000 6 Second Ring Set

ST168F--1050200 Ring Comp

ST168F--1080002-G Shroud Comp (I)

75

GB900 -- 88 Stud Bolt

76

ST168F--1040005 Push Rod

77

ST168-1040014-A Oil Seal

78

ST168F--1040027 Pivot Bolt

79

ST168F--1040026 Valve Rocker Arm

80

GB6177-- 86-N6 Nut M6

81

ST168F--1040023 Exhaust Rocker

82

ST160F--1020001 Breather Tube

83

ST168F--1020100-C Head Over C omp

84

ST160F--1020002-A Head Over Packing

85

ST168F--1040024 Rectify Bolt

86

ST168F--1040025 Locknut

87

ST168F--1040022 Entrance Rocker

88

ST168F--1040021 Rocker Axes

89

ST160F--1040008 Valve Rotator

90

ST160F--1040001 Intake Valve Spring Retainer

91

ST160F--1040007 Exhaust Valve Spring Retainer

92

ST160F--1040003 Valve Spring

93

ST160F--1124000 Spark Plug

94

ST168FD-2-1131000 C arburetor

95

ST168FD--1130005-

96

CPE

ST02FD-1151201A Choke Lever Comp

97

Asbestos)

Asbestos)

Packing

1

1

1

1

1

1

1

1

2

1

1

1

1

2

1

2

1

1

1

1

1

2

1

1

1

1

1

2

2

2

2

1

2

1

1

1

1

2

2

1

1

1

1

1

2

1

1

1

1

REV 46554-20110223 18

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

Generator starts but runs roughly Place generator on a flat, level surface

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 (Ser vice 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 46554

For further technical support:

Technical Service

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

19 REV 46554-20110223

46554 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 labour) and two years (parts) from the
original date of purchase (90 days (parts and labour)
and 180 days (parts) for commercial & industrial
use). Transportation charges on product submitted
for repair or replacement under this warranty are the
sole responsibility of the purchaser. This warranty only
applies to the original purchaser and is not transferable.

Do Not Return The Unit To The Place Of Purchase

Contact CPE’s Technical Service and CPE will
troubleshoot any issue via phone or e-mail. If the
problem is not corrected by this method, CPE will, at its
option, authorize evaluation, repair or replacement of the
defective part or component at a CPE Service Center.
CPE will provide you with a case number for warranty
service. Please keep it for future reference. Repairs
or replacements without prior authorization, or at an
unauthorized repair facility, will not be covered by this
warranty.

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 labour 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 as spark plugs, air filters,

Warranty Exclusions Cont’d.

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 to due 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

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
Fax no.: 1-562-236-9429

Technical Service

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

REV 46554-20110223 20