Important Safety Instructions
are included in this manual.
2
MADE IN CHINA
REV 46558-20110310
46558
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
46558
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
ENGLISH46558
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
46558
Serial Number
Date of Purchase
Purchase Location
For Oil Type see “Add Engine Oil” section. For Fuel Type see “Add Fuel” section.
1REV 46558-20110310
46558 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 46558-20110310 2
SAFETY RULES
ENGLISH46558
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.
3REV 46558-20110310
46558 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 46558-20110310 4
ENGLISH 46558
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.
(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”.
5REV 46558-20110310
46558 ENGLISH
Power Panel
CONTROLS AND FEATURES
1234
(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.
5A5B
(4) 120V / 30A Twist-Lock – protected by a 25 Amp
circuit breaker. This receptacle powers 120 Volt AC,
60 Hz, single phase loads requiring up to 25 Amps or
3000 watts of power.
(5) 120V / 20A Duplex (2) – 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.
6
Parts Included
Your 46558 Gasoline Powered Generator ships with the
following parts:
Spark Arrester Kit
– Spark Arrestor .........................1
– Cover Plate ...........................1
– Screw with Lock Washer ....................2
Other
– RV Adapter Plug........................1
– 120V Twist-lock Adapter Cord...............1
– Cover (not pictured)......................1
– Oil Funnel ............................1
– Spark Plug Socket.......................1
REV 46558-20110310 6
ASSEMBLY
ENGLISH46558
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.
7REV 46558-20110310
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.
46558 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 ¼ 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 46558-20110310 8
OPERATION
ENGLISH46558
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 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
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.
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 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.
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.
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.
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.
9REV 46558-20110310
46558 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, ADDRunning Watts to Starting Watts. (A+B)
Item
Light Bulb 100W100
Refrigerator/Freezer12002400
Freezer500500
Sump Pump6001800
Well Pump 1 HP20004000
Water Heater4000
Security System180
AM/ FM Radio300
Garage Door Opener 1/2 HP500600
Batter y Charger 12V DC110
Heating /Cooling
Air Conditioner 12000 BTU17002500
Fan300600
Furnace Fan 1/3 HP12002000
Home Appliances
Microwave 1000W1000
Electric Range - One Element1500
Electric Skillet1250
Coffee Maker1500
Clothes Washer1200
Entertainment
CD/ DVD Player / VCR100
Stereo Receiver450
Television 27”500
PC with 15” Monitor800
Belt Sander 3”10001500
Bench Grinder 6”7001500
Circular Saw15001500
Compre ssor 1 1/2 HP25002500
Edge Trimmer500500
Hand Drill 1/2”10001000
Lawn Mower12001800
Paint Sprayer6001200
Table Saw20002000
Running
Watts (A)
Essentials
Job Site
Starting
Watts (B)
REV 46558-20110310 10
0.7 - 0.8 mm
0.028 - 0.031 in.
MAINTENANCE AND STORAGE
ENGLISH46558
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 12 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.
11REV 46558-20110310
46558 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 46558-20110310 12
SPECIFICATIONS
ENGLISH46558
Engine Specifications
– Engine....................196 cc OHV CPE
Generator Specifications
– Max Rated Wattage...............3000 Watts
– Starting Wattage.................4000 Watts
– AC Voltage.........................120 V
– Neutral floating
– Phase ............................Single
– Frequency .........................60 Hz
– Fuel Capacity................4 gallons (15 L)
– Weight.................G.W. 108 lbs. (49 kg)
......................N.W. 99 lbs. (45 kg)
– Height.................17.5 inches (44.4 cm)
– Width .................17.7 inches (44.9 cm)
– Length................23.3 inches (59.3 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.
13REV 46558-20110310
46558 ENGLISH
Wiring Diagram
SPECIFICATIONS
REV 46558-20110310 14
SPECIFICATIONS
Parts Diagram
ENGLISH46558
15REV 46558-20110310
46558 ENGLISH
#Part NumberDescriptionQty
GB819 M5X10Screw M5x10
1
ST02FD-04140000Fuel Meter Assembly
2
ST02FD-04120000-AFuel Tank Cap
3
ST02FD-04130000Fuel Filter
4
GB5789 M6X20Flange Bolt M6x20
5
ST02FD-04100014Washer 6.5
6
ST02FD-04100010Tank Rubber
7
ST02FD-04110000( C )Fuel Tank
8
ST02FD-0416000 0Fuel Cock
9
ST168FD-1160002Fuel Line
10
ST188FD -1070006AClip
11
GB5789 M6X12Flange Bolt M6x12
12
GB5789 M8X 20Flange Bolt M8x20
13
ST02FD-1150100Muffler Stay (II)
14
ST02FD-1150200Muffler Stay (I)
15
ST02FD-02100010Terminal
16
GB16674 M5X12Flange Bolt M5x12
17
ST02FD-02100004( C )Generator End Cover
18
GB16674 M5X16Flange Bolt M5x16
19
ST02FD-02100007(CSA)AVR
20
GB16674 M5X16Bolt M5x16
21
GB93 5Lock Washer 5
22
GB97.1 5Washer 5
23
ST02FD-02100009Brush Assembly
24
ST02FD-02100001-2.5Flange Boltm6x158
25
GB93 6Lock Washer 6
26
GB97.1 6Washer 6
27
ST02FD-02100003End Cover
28
ST02FD-02100002-2.5Stator Cover
29
ST02FD-02120000-2.5(CSA)Stator Assembly
30
ST02FD-02100005-2.5Flange Bolt M8x233
31
GB7244 8Lock Washer 8
32
GB96 8Washer 8
33
ST02FD-02110000-2.5(CSA)Rotor Comp
34
ST02FD-02100012Build Up (A)
35
ST02FD-02100011Build Up (B)
36
ST168FD-2-01000000- G (C)Engine
37
ST02FD-03170001 F Right Control Panel Guard
38
ST02FD-02100013-14(CSA)Earth Line
39
GB6177 M6Nut M6
40
ST02FD-1151300C-1Bottom Rubber II
41
GB6177 M8Nut M8
42
ST02-1151400Rubber Pad
43
11
12
#Part NumberDescriptionQty
ST02FD-1151300D-1Bottom 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
1
1
1
2
4
44
ST02FD-0185(F)Frame
45
ST02FD-03030400( F )Muf fler Cover
46
ST168FD-1090006Air Cleaner Stay
47
GB5789 M6X8Flange Bolt M6x8
48
ST168F-1100200-GMuffler Gasket
49
GB848 8Washer 8
50
GB93 8Lock Washer 8
51
GB6175 M8Nut M8
52
ST168FD-1100000-GMuffler
53
ST188FD -1180121Spark Arrester Assembly
54
ST188FD -1100010-8 8Spark Arrester Cover
55
GB93 5Lock Washer 5
56
GB818 M5X15Screw M5x15
57
ST02FD-02100008Plate Pinch
58
ST02FD-05212005Build Up
59
ST02FD-05202006Conduit
60
ST02FD-05212001Build Up
61
ST02FD-05202002 C SA C ontrol Box
62
GB823 M5X14Screw M5x14
63
0V02-0 0000000 CSA Transition
64
GB5783 M6X22Bolt M6x22
65
GB6175 M6Nut M6
66
GB823 M4X14Screw M4x14
67
GB859 4Lock Washer 4
68
GB848 4Flat Washer 4
69
GB6177 M4Nut M4
70
ST02FD-05502023 CSA Receptacle 5-20R
71
ST02FD-05502020 CSA Receptacle L5-30R
72
ST02FD-05602010-DVoltmeter
73
GB848 3Flat Washer 3
74
GB859 3Lock Washer 3
75
GB6175 M3Nut M3
76
ST02FD-05302003-20 CSA Ac.20A Circuit Breakers
77
ST02FD-05302003-25 CSA Ac.25A Circuit Breakers
78
GB848 3Flat Washer 3
79
GB859 3Lock Washer 3
80
GB823 M3X6Screw M3x6
81
ST02FD-05702003Ignition Switch
82
2A70 F Control Panel
83
ST02FD-05010703Flange Bolt M5x13
84
ST188FD -1020001Grommet
85
ST02FD-03170002 F Left Control Panel Guard
86
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
1
1
4
4
4
1
1
4
1
1
REV 46558-20110310 16
SPECIFICATIONS
Engine Parts Diagram
ENGLISH46558
17REV 46558-20110310
46558 ENGLISH
Engine Parts List
#Part NumberDescriptionQty
GB5789- -86 -FB6-8Flange Bolt 6X85
1
ST160F--1061200Recoil Starter Knob
2
ST160F--1061100- QRecoil Starter Comp
3
ST160F--1061005Recoil Starter Spring
4
ST160F--1061009Recoil Starter Rope
5
ST160F--1061001-ARecoil Starter Reel
6
ST188F--1060 006Return Spring
7
ST188F--1060 005Starter Ratchet (Metal)
8
GB5789--86 -FB6-12Flange Bolt M6X12
9
ST188F--1060 003Ratchet Guide
10
ST188F--1060 004Ratchet Guide Spring
11
ST188F--1060 002Setting Screw
12
ST168F--1080100-GFan Cover Comp
13
ST160F--1050010Nut M14
14
ST160F--1060001Start Hub
15
ST168F--1080001Cooling Fan
16
ST168F--1120100Fly Wheel
17
ST168F--1080200Side Place (Ii)
18
ST168F--1030100Oil Seal
19
GB5789- -86 -FB6-15Flange Bolt M6X15
20
ST160F--1030003Drain Plug Bolt
21
ST160F--103000 4Drain Bolt Washer
22
ST168F-2-1030012-GCrankcase (For USA)
23
GB/ T—276--94Radial Ball Bearing 6205
24
ST160F-1127000 -AOil Level Switch Assembly
25
ST160F--1110108Governor Washer (Ii)
26
ST160F--1110101Governor Weight Holder
27
ST160F--1110102Governor Weight Pin
28
ST160F--1110104Governor Shaft
29
ST160F--1110103Governor Holder Clip
30
ST160F--1110107Governor Weight
31
ST160F--1110108Governor Washer (Ii)
32
ST160F--1110105-AGovernor Cover
33
ST168FD-2-10500 01-ACrankshaf t Comp
34
ST168F-1030008-GCase Over Packing (No
35
ST160F--1030001-BOil Filler Cap A ssembly
36
ST160F--1030002Oil Filler Cap Packing
37
GB5789- -86 -FB8-32Flange Bolt 8X32
38
ST168F--1110005Throttle Return Spring
39
ST168F--1110007Governor Spring
40
ST160F--1110003Governor Arm
41
GB6177-- 86Nut M6
42
ST160F--1110008Lock Pin
43
ST160F--1110001Governor Arm Shaft
44
ST168F--1110006Governor Rod
45
ST160F--1110004Governor Arm Bolt
46
GB5789- -86 -FB6-25Flange Bolt 6X25
47
ST160F--1123000-GIgnition
48
152FMD--1001007Dowel Pin 10X16
49
GB5789- -86 -FB8-55Flange 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 NumberDescriptionQty
ST168FD--1090200 -GAir Cleaner Cover Comp
51
ST168FD--1090004Element
52
ST168FD--1090003Separator
53
ST168FD--1090002Air Cleaner Seal
54
ST168FD--1090004Air Cleaner Case C omp
55
ST160F--1130003- CPECarburetor Packing (No
56
ST168F--1130001Carburetor Insulator
57
ST168F--1130002-CPEInsulator Packing (No
58
ST160F--1010001Stud Bolt 6X110
59
ST168F-2-1010100-GCylinder Head Comp
60
ST168F-2-1030009-GCylinder Head Gasket
61
ST168F--1040002Intake Valve
62
ST168F--1040006Exhaust Valve
63
ST168F-2-1040013Valve Lifter
64
ST168F-2-1041000C amshaf t Assemblybly
65
ST168F--1030015-GDowel Pin 9X14
66
ST168FD--1111100Control Assembly
67
GB1099--79Key
68
ST168FD--1030007-GCrankcase Cover
69
ST168F--1050100Connecting Rod Comp
70
ST168F--1050003Piston Pin
71
ST168F--105000 4Piston Pin Clip
72
ST168F-2-1050005Piston
73
ST168F--1050007First Ring Set
74
ST168F--105000 6Second Ring Set
ST168F--1050200Ring Comp
ST168F--1080002-GShroud Comp (I)
75
GB900 -- 88Stud Bolt
76
ST168F--1040005Push Rod
77
ST168-1040014-AOil Seal
78
ST168F--1040027Pivot Bolt
79
ST168F--1040026Valve Rocker Arm
80
GB6177-- 86-N6Nut M6
81
ST168F--1040023Exhaust Rocker
82
ST160F--1020001Breather Tube
83
ST168F--1020100-CHead Over Comp
84
ST160F--1020002-AHead Over Packing
85
ST168F--1040024Rectify Bolt
86
ST168F--1040025Locknut
87
ST168F--1040022Entrance Rocker
88
ST168F--1040021Rocker Axes
89
ST160F--1040008Valve Rotator
90
ST160F--1040001Intake Valve Spring Retainer
91
ST160F--1040007Exhaust Valve Spring Retainer
92
ST160F--1040003Valve Spring
93
ST160F--1124000Spark Plug
94
ST168FD-2-1131000Carburetor
95
ST168FD--1130005-
96
CPE
ST02FD-1151201AChoke 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 46558-20110310 18
TROUBLESHOOTING
ProblemCauseSolution
Generator will not startNo fuelAdd fuel
Faulty spark plugReplace spark plug
Unit loaded during start upRemove load from unit
Generator will not start;Low oil levelFill crankcase to the proper level
Generator starts but runs roughlyPlace generator on a flat, level surface
Choke in the wrong positionAdjust choke.
Spark plug wire looseAttach wire to spark plug
Generator shuts down during operationOut of fuelFill fuel tank
Low oil levelFill crankcase to the proper level. Place
generator on a flat, level surface
Generator cannot supply enough power or
overheating
No AC outputCable not properly connectedCheck all connections
Generator gallopsEngine governor defectiveContact the help line
Repeated circuit breaker trippingOverloadReview load and adjust. See “Power
Generator is overloadedReview load and adjust. See “Power
Management”
Insufficient ventilationCheck for air restriction. Move to a well
ventilated area
Connected device is defectiveReplace defective device
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
CCPE 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
Your Champion Power Equipment (CPE) engine complies with Environment Canada (EC) emission regulations.
YOUR WARRANTY RIGHTS AND OBLIGATIONS:
CPE is pleased to explain the Emission Control Systems Warranty on your 2011 small off-road engine. New engines
must be designed, built and equipped, at the time of sale, to meet EC regulations for small non-road engines. CPE
must warrant the emission control system on your small off-road engine for the period of time listed below, provided
there has been no abuse, neglect, unapproved modification, or improper maintenance of your small off-road engine.
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.
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-road engine owner, you are responsible for the performance of the required maintenance listed in
your Owner’s Manual. CPE recommends that you retain all your receipts covering maintenance on your small off-road
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, CPE dealer or
CPE, Santa Fe Springs, CA., USA as soon as a problem 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 Equipment, Inc.
ATTN: Customer Service
10006 Santa Fe Springs Road
Santa Fe Springs, CA 90670
USA
Tel: 1-877-338-0999
The emission warranty is a defects warranty. Defects are judged on normal engine performance. The warranty is not
related to an in-use emission test.
21REV 46558-20110310
46558 ENGLISH
EMISSION CONTROL SYSTEM WARRANTY
The following are specific provisions relative to your Emission Control System Warranty Coverage.
Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines):
1. APPLICABILITY: 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 at the time of sale with applicable regulations under the
Canadian Environmental Protection Act, 1999 (CEPA 1999).
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, emissions-related part which is scheduled only for regular inspection as specified 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-related 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 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.
g. 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.
h. 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 obligation.
i. 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.
REV 46558-20110310 22
ENGLISH 46558
EMISSION-RELATED PARTS INCLUDE THE FOLLOWING
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 PartsTubing, Fittings, Seals, Gaskets, and Clamps associated with these
(using those portions of the list applicable to the engine):
listed systems
TO OBTAIN WARRANTY SERVICE:
You must take your CPE engine or the product on which it is installed, along with your warranty registration card or
other proof of original purchase date, at your expense, to any Champion Power Equipment dealer who is authorized
by Champion Power Equipment, Inc. to sell and service that CPE product during his normal business hours. 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 your warranty rights and responsibilities, or to obtain warranty service, please
write or call the Customer service of Champion Power Equipment, Inc.:
Champion Power Equipment, Inc.
ATTN: Customer Service
10006 Santa Fe Springs Road
Santa Fe Springs, CA 90670
USA
Tel: 1-877-338-0999
23REV 46558-20110310
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