PORTABLE GENERATOR - Tractor Supply Company
Contents
1. h OO Rev 41115 20100317 E 22 Troubleshooting 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 or 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 Out of fuel Fill fuel tank Place generator on a flat level surface Generator cannot supply enough Review load and adjust See Power power or overheating Management well ventilated area No AC output Circuit breaker is open Reset circuit breaker Capacitor defective Replace capacitor Service Center Faulty brush assembly Replace brush assembly Service Center Faulty AVR Replace AVR Service Center connections Management wires Replace defective device Rev 41115 20100317 E 23 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 p2. 14 Engine Maintenance 14 Os 14 Spark PINS 14 MT 15 Spark Arrester 15 OLEG ENE 15 15 Maintenance Schedule 15 Generator Maintenance 15 STOP GOE qo ei esee UR E SRL a ee 17 Engine Storage 17 Generator Storage 17 Specifications 18 Engine Specifications 18 Generator Specifications 18 18 Ms 18 SDark PS 18 Valve Clearance 18 Parts Did uuu ayasa u 19 Parts DL dr redi tu eb 20 Wire DIIS Fd EX Iud 22 Troubleshooting A 23 Warranty der 24 Warranty Qualifications 24 Repair Replacement Warranty 24 Do not return the unit to the place of 24 Warranty Exclusions 24 Normal Vessel 24 Installation Use and Maintenance 24 Other Exclusions 24 Limits of Implied Warranty and Consequential Damage 24 Contact Information 24 Address ae 24 Customer 1 24 Technical Service 24 frg
3. DO NOT overload the generator Start the generator and allow the engine to stabilize before connecting electrical loads Connect electrical equipment in the off position and then turn them on for operation Turn electrical equipment off and disconnect before stopping the generator DO NOT tamper with the governed speed DO NOT modify the generator in any way CAUTION Improper treatment or use of the generator can damage it shorten its life and void your warranty Use the generator only for intended uses Operate only on level surfaces DO NOT expose generator to excessive moisture dust or dirt DO NOT allow any material to block the cooling Slots If connected devices overheat turn them off and disconnect them from the generator DO NOT use the generator if Electrical output is lost Equipment sparks smokes or emits flames Equipment vibrates excessively Rev 41115 20100317 E Controls and Features Controls and Features Read this owner s manual before operating your generator Familiarize yourself with the location and function of the controls and features Save this manual for future reference Generator 1 Fuel Tank 6 5 gallon capacity fuel 6 Serial Number Please have this tank number available when calling for assistance 2 Fuel Valve Turn this valve to the On position to supply fuel to the engine 7 Low Oil Sensor Senses the level of oil in th
4. 28 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 This Owner s Manual contains important safety instructions and information SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE 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 Introduction Accessories Champion Power Equipment manufactures and sells accessories designed to help you get the most from your purchase To find out more about our covers power cables and storm kits please visit our web site at www championpowerequipment com This Booklet Every effort has been made to ensure the accuracy and completeness of the information in this manual We reserve the right to change alter and or improve the product and this document at any time without prior notice Record the model and serial numbers as well as date and place of purchase for future reference Have this information available when ordering parts and when making technical or warranty inquiries Champion Power Equipment Support 1 877 338 0999 Model Number 41115 Serial Number Date of Purchase Purchase Location Rev 41115 20100317 E Manual Conven
5. remember to plug your appliances directly into the generator Do not plug the generator into any electric outlet in your home Doing so could create a connection to the utility company power lines You are responsible for ensuring that your generator s electricity does not feed back into the electric utility power lines If the generator will be connected to a building electrical system consult your local utility company or a qualified electrician Connections must isolate generator power from utility power and must comply with all applicable laws and codes Stopping the Engine 1 Turn off and unplug all electrical loads Never start or stop the generator with electrical devices plugged in or turned on 2 Let the generator run at no load for several minutes to stabilize internal temperatures of the engine and generator 3 Flip the ignition switch to the Off position 4 Turn the fuel valve to the 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 12 number to the number calculated in step 2 Surge wattage is the extra burst of power nee
6. space for fuel expansion Ese Assembly 6 Screw on the fuel cap and wipe away any spilled fuel CAUTION Use regular unleaded gasoline with a minimum octane rating of 85 DO NOT mix oil and gasoline Fill tank to approximately 1 4 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 10 Grounding Your generator must be properly connected to an appropriate ground to help prevent electric shock A 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 41115 20100317 E Operation Generator Location Please consult your local authority In some areas generators must be registered with the local utility Generators used at construction sites may be subject to additional rules and regulations This generator must have at least five feet of clearance from combustible material Leave at least three feet o
7. 30 days If you have any questions regarding your warranty rights and responsibilities you should contact Champion Power Equipment Inc Customer Service 10006 Santa Fe Springs Road Santa Fe Springs CA 90670 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 Rev 41115 20100317 E 25 Warranty 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 California small off road engines for other states 1997 and later model year engines 1 APPLICABILITY This warranty shall apply to 1997 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is delivered to its original end use purchaser and shall continue for 24 consecutive months thereafter 2 GENERAL EMISSIONS WARRANTY COVERAGE CPE warrants to the original end use purchaser of the new engine or equipment and to each subsequent purchaser that each of its small off road engines is a Designed built and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Ac as amended 42 U S C 7401 et seq b Free from defects in materials and workmanship that cause the failure of a warranted part to be identical
8. Notes 28 Rev 41115 20100317 E
9. gt 500 800 Job Site 1000 700 1500 2500 500 1000 1200 600 2000 Rev 41115 20100317 E 13 Maintenance Maintenance The owner operator is responsible for all periodic maintenance A NOTICE Maintenance replacement or repair of the emission control devices and systems may be performed by any non road engine repair establishment or individual Never operate a damaged or defective generator Tampering with the factory set governor will void your warranty Improper maintenance will void your warranty Complete all scheduled maintenance in a timely manner Correct any issue before operating the generator V NOTE For service or parts assistance contact our help line at 1 877 338 0999 Engine Maintenance To prevent accidental starting remove and ground spark plug wire before performing any service Oil Change oil when the engine is warm Refer to the oil specification to select the proper grade of oil for your operating environment 14 Remove the oil drain plug with a 15 mm socket and extension Allow the oil to drain completely Replace the drain plug Remove oil fill cap dipstick to add oil Add 1 16 qt 1 1 L of oil and replace oil fill cap dipstick Dispose of used oil at an approved waste management facility a MAXIMUM FLL K MIM MUM FLL gt Spark Plugs 1 Remove the spark plug cable from the spark plug 2 Use the sp
10. not apply to parts and or labor if this generator is deemed to have been misused neglected involved in an accident abused loaded beyond the generator s limits modified installed improperly or connected incorrectly to any electrical component Normal maintenance such 24 as spark plugs air filters adjustments fuel system cleaning and obstruction due to buildup is not covered by this warranty Other Exclusions This warranty excludes Cosmetic defects such as paint decals etc Wear items such as filter elements o rings etc Accessory parts such as starting batteries and storage covers Failures due to acts of God and other force majeure events beyond the manufacturer s control Problems cause by parts that are not original Champion Power Equipment parts This warranty does not apply to generators used for prime power in place of a utility 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
11. 115 Gasoline Powered Generator ships with the following parts Wheel Kit Handle Assembly 1 set 8 Solid Wheel 2 piece Axle Assembly 2 sets Support Leg 1 piece Vibration Mounts 2 piece Support Leg Hardware 1 set Ra Oil Funnel 1 piece Spark Plug Socket 1 piece Spark Arrester Kit AN Spark Arrester 1 piece Cover Plate 1 piece Screws Lock Washers 2 pieces RAA INS Oil P 4 1 piece Rev 41115 20100317 E Assembly Assembly Your generator requires some assembly This unit ships from our factory without oil It must be properly serviced with fuel and oil before operation If you have any questions regarding the assembly of your generator call our help line at 1 877 338 0999 Please have your serial number and model number available Remove the Generator from the Shipping Carton 1 Set the shipping carton on a solid flat surface 2 Remove everything from the carton except the generator 3 Carefully cut each corner of the box from top to bottom Fold each side flat on the ground to provide a surface area to install the wheel kit and support leg Install the Wheel Kit CAUTION The wheel kit is not intended for over the road use You will need the following tools to install the wheels 17 mm wrench OR adjustable wrench not included Socket wrench with a 16 mm socket Pliers not included 1 Before adding oil to the engine tip the generato
12. 41119 Rev 41115 20101217 POWER EQUIPMENT 10006 Santa Fe Springs Road Santa Fe Springs CA 90670 USA Made in China SAVE THESE INSTRUCTIONS Important Safety 6000 Starting Watts 5000 Running Watts PORTABLE GENERATOR Table of Contents TRUE OGUCH ON os oie versa susu usss 1 Portable Power Generator 1 JACCOSSOFIOS Lua 1 TS aa 1 Manual Conventions 2 Safety Rules uu eee eee eee ooo 3 Controls and Features 5 Gerrard 5 Power Panel 6 Parts Ineluded o za bo e ns 7 AsSemDl aS 8 Remove the Generator from the Shipping Can OR EE 8 Install the Wheel Kit 8 Install the Support Leg 8 Attach the Handle 8 Install the Spark Arrester 9 Add Engine 9 Add Fuel 9 oec RUM Gode 10 Operation uuu 2 11 Generator Location 11 Surge Protection 11 Starting the Engine 11 Connecting Electrical Loads 11 Stopping the Engine 12 Do Not Overload 12 Cape 12 Power Management 12 Wattage Reference Chart 13 Maintenance
13. 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 26 Rev 41115 20100317 E Warranty ECS Warranty claim CPE shall not be liable hereunder for failures of any warr
14. agram Rev 41115 20100317 E 19 Specifications Parts List No Part Number Description Q 1 STOSFD O5705001 Ignition Switch 1 7 10 H 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Spring washer 10 30 Washer 10 31 32 33 34 35 36 37 38 39 0 I 2 43 4 45 46 47 48 49 lt 20 Rev 41115 20100317 Specifications Part Number Description Qty No 52 STO2FD 04100014 Washer 6 1 4 53 STO2FD 04100010 Tank rubber 54 ST188FD 1100001 G Mufflergasket 12 55 STI88FD 1100100 G Exhaustpipe 1 56 GB16674 M8x25 Flange Bolt M8x25 1 2 57 ST188FD 1090006 Air cleaner stay 1 58 GB617M6 JNtM6 1 2 59 GB8488 amp Washer 8 9 2 60 GB938 JjSpinwaher 8 1 2 61 GB6175 M8 JNM 1 2 62 STI88FD 1101300 A Muffler 1 63 STI88FD 1100103 Muffler outer protector 1 64 STI88FD 1100104 Muffler life protector 1 65 ST188FD 1180121 Sparkarresterassemby 1 66 STI88FD 1100010 88 Sparkarrestercover 1 67 GB818M5xi4 Flange Bolt M5x14 1 2 68 GB935 amp jSpingwahe 5 1 4 69 STI88FD 1100107 G Muffler inner protector 1 70 GB5789 8 20 FlangeBotM8xX20 3 71 STI88FD 1101200 Muffler stay 1 1 72 GB5789M8x35 FlangeBoltM8x35 1 73 168916 Washer 6 1 4 74 GB036 S
15. anted parts of a CPE engine caused by the use of such an unapproved add on or modified part EMISSION RELATED PARTS INCLUDE THE FOLLOWING using those portions of the list applicable to the engine Systems covered by this Parts eee warranty Fuel Metering System gt regulator Carburetor and internal parts Air Induction Intake manifold Bead System et plug and parts Magneto ignition system Exhaust ae Exhaust manifold NA 5 converter Manausa Parts sss Fittings Seals Gaskets and Clamps associated with these 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 10006 Santa Fe Springs Road Santa Fe Springs CA 90670 1 877 338 0999 Attn Customer Service Rev 41115 20100317 E 27 Notes
16. ark 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 CLEAN 4 Make certain the spark plug gap is 0 7 0 8mm 0 028 0 031 in 5 Refer to the spark plug recommendation chart when replacing the plug 6 Carefully thread the plug into the engine 7 Use the spark plug tool to firmly install the plug 8 Attach the spark plug wire to the plug Rev 41115 20100317 E Air Filter 1 Remove the snap on cover holding the air filter to the assembly 2 Remove the foam element 3 Wash in liquid detergent and water Squeeze thoroughly dry in a clean cloth 4 Saturate in clean engine oil 5 Squeeze in a clean absorbent cloth to remove all excess oil 6 Place the filter in the assembly 7 Reattach the air filter cover and snap in place Spark Arrester 1 Allow the engine to cool completely before servicing the spark arrester 2 Remove the two screws holding the cover plate which retains the end of the spark arrester to the muffler 3 Remove the spark arrester screen 4 Carefully remove the carbon deposits from the spark arrester screen with a wire brush 5 Replace the spark arrester if it is damaged 6 Position the spark arrester in the muffler and attach with the two screws CAUTION Failure to clean the spark arrester will result in degra
17. ded engine performance 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 Rev 41115 20100317 E Maintenance Adjustments The air fuel mixture is not adjustable Tampering with the governor can damage your generator and your electrical devices and will void your warranty CPE recommends that you contact our service line at 1 877 338 0999 for all other service and or adjustment needs Maintenance Schedule Follow the service intervals indicated in the schedule below Service your generator more frequently when operating in adverse conditions Contact our help line at 1 877 338 0999 to locate the nearest Champion Power Equipment certified service dealer for your generator or engine maintenance needs Every 8 hours or daily Check oil level Clean around air intake and muffler First 5 Hours Change oil 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 Clean fuel tank and filter Every 3 years Replace fuel line To be performed by knowledgeable experienced owners or Champion Power Equipment certified service dealers 15 Maintenance Generator Maintenance Make cer
18. ded 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 Startthe generator with no electrical load attached 2 Allow the engine to run for several minutes to stabilize 3 Plugin 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 Plugin and turn on the next item 6 Allow the engine to stabilize 7 Repeat steps 5 6 for each additional item V NOTE Never exceed the generator capacity when adding loads Rev 41115 20100317 E Operation Wattage Reference Chart Use the chart to determine approximate Running Starting Item Watts Watts Essentials wattage requirements for your equipment 100 l NOTE 1200 500 Starting watts can exceed three times the 600 running watts The values in the following table 2000 are approximate Refer to your tool or appliance 4000 wA for actual wattage consumption 180 1 300 500 600 0 Heating Cooling 1700 300 600 1200 Home Appliances 1000 1500 1250 1500 gt 1200 Entertainment 100 100 450
19. e crankcase and shuts the engine 3 Choke Lever Used to start the down if the level falls too low engine 8 Oil Filler Cap Check and fill engine 4 Air Cleaner Protects the engine by oil level filtering dust and debris from the intake air 9 Power Panel See Power Panel 5 Recoil Starter Used to start the engine Rev 41115 20100317 E 5 Controls and Features Power Panel o o Y 1 Ignition Switch Flip switch to the 4 120 240 V 30 A Twist Lock On position to start the generator Flip to Protected by a 25 A flip to reset circuit the position to turn off the generator breaker on each 120 Volt leg of the receptacle This receptacle powers 240 Volt 2 Circuit Breakers Protects the AC single phase loads requiring up to 5000 generator against electrical overload watts If an L14 30P plug is wired for only one 120 Volt leg 3 wire connection then 3 Voltmeter Displays the output this receptacle powers 120 Volt AC 60 Hz voltage of the generator single phase loads requiring up to 20 8 A or 2500 Watts of power 5 120 V 20 A Duplex Each duplex is protected by a 20 A flip to reset circuit breaker to operate 120 Volt AC single phase 60 Hz loads requiring up to 20 A or 2400 Watts of power 6 Ground Bolt Consult an electrician for local grounding regulations 6 Rev 41115 20100317 E Controls and Features Parts Included Your Model 41
20. f 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 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 Rev 41115 20100317 E Operation Starting the Engine 1 Makecertain the generator is on a flat level surface 2 Disconnect all electrical loads fr
21. 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
22. ition 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 as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed
23. of the original unit This warranty gives you certain legal rights which may change from state to state Your state may also have other rights you may be entitled to that are not listed within this warranty Contact Information Address Champion Power Equipment Inc Customer Service 10006 Santa Fe Springs Rd Santa Fe Springs CA 90670 Customer Service Mon Fri 8 30 AM 5 00 PM PST PDT Toll Free 1 877 338 0999 Fax no 1 562 236 9429 Technical Service Mon Fri 8 30 AM 5 00 PM PST PDT Toll Free 1 877 338 0999 tech championpowerequipment com Rev 41115 20100317 E Warranty Champion Power Equipment Inc CPE and the United States Environment Protection Agency U S EPA Emission Control System Warranty Your Champion Power Equipment CPE engine complies with U S EPA emission regulations YOUR WARRANTY RIGHTS AND OBLIGATIONS The US EPA AND CPE are pleased to explain the Federal Emission Control Systems Warranty on your 2010 small off road engine New engines must be designed built and equipped at the time of sale to meet U S EPA 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 ign
24. om the generator Never start or stop the generator with electrical devices plugged in or turned on 3 Turn the fuel valve to the On position 4 Move the choke lever to the Choke position 5 Flip the ignition switch to the On position 6 Pull the starter cord slowly until resistance is felt and then pull rapidly 7 As engine warms up move the choke lever to Run V NOTE If the engine starts but does not run make certain that the generator is on a flat level surface The engine is equipped with a low oil sensor that will prevent the engine from running when the oil level falls below a critical threshold Connecting Electrical Loads 1 Let the engine stabilize and warm up for a few minutes after starting 2 Plug in and turn on the desired 120 240 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 11 Operation V 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
25. ool completely before storage 2 Turn off the fuel supply at the fuel valve 3 Clean the generator according to the instructions in the Maintenance section 4 Store the unit in a clean dry area 5 Store ina clean dry place out of direct sunlight 17 Specifications Specifications Engine Specifications Engine 338 cc OHV CPE Generator Specifications Running Wattage 5000 Watts Starting Wattage 6000 Watts AC Load 120 240 V Phase Single Frequency 60 Hz Fuel Capacity 6 5 gallons 25 L Weight 171 7 lbs 77 9 kg Height 24 4 inches 62 cm Width 24 inches 61 cm Length 29 5 inches 75 cm Fuel Fuel capacity is 6 5 US gallons 25 L Use regular unleaded gasoline with a minimum octane rating of 85 Oil Oil capacity is 1 16 qt 1 1 L L LI Jj J 1 Ll J 20 0 20 40 60 80 100 120 Degrees Fahrenheit Em 18 Spark Plugs Your generator comes equipped with a 34 long reach plug 19mm Intermittent use less than 1 hour month or colder temperatures below 60 F NGK BR6ES or equivalent Moderate use less than 3 hours month or seasonal temperatures 50 80 F NGK BR7ES or equivalent Extreme use continuous or hot climates 80 100 F NGK BR8ES or equivalent Make certain the spark plug gap is 0 7 0 8mm 0 028 0 031 in Valve Clearance Intake 0 13 0 17mm 0 005 0 007 in Exhaust 0 18 0 22mm 0 007 0 009 in Rev 41115 20100317 E Specifications Parts Di
26. pringwashr 6 8 75 BG01 00000000 Rectifier 1 1 76 GB818 M5x14 ScewM5id 77 GB818 M4x14 ScewM4id 1 7 78 GB617 MW 1 7 79 GB818M5x38 ScrewM5x38 1 3 80 689715 Weser 5 1 5 81 GB5789M8x16 Flange Bolt M8x16 1 2 82 STOSFD 03020301 60 Supprtleg 1 1 83 STI88FD 1743002 C Vibration mount 1 2 84 GB5789 M8x25 FlangeBotM8x25 1 2 85 685789 M8x45 FlangeBoltM8x45 1 2 86 GB6177M8 JNM 1 2 87 ST182FD 1151110 B Handle o 1 88 STI88FD 1741002C Handle sheath 1 1 89 STI77FD 1152300 8nWnel 1 2 90 STO2FD 03621001 Bush 105x585 1 2 91 GB9610 sf Flatwasher 101 2 92 685782 10 105 Bolt M10x105 93 ST188FD 1100106 G Cover 1 94 STOSFD 1152007 4 FlangeboltM5x201 1 2 95 GB6175M5 JNM 1 2 96 Ovo1 00000000 Transition 1 AIZ COCO P N P F N N NI N P N PF N I N N IP INI IPP N OI O N Rev 41115 20100317 E 21 Specifications Wiring Diagram EARTH TERMINAL GENERATOR BLOCK OFF ENGINE BLOCK p WG CONTROL BOX BLOCK B G id B BLACK Br BROWN B G Y YELLOW B WEBLACK WHITE L BLUE W GWHIIE GR G GREEN G Y GREEN YELLOW IR RED WHITE BLUE FUEL CUT OW WHITE In INDIGO PARKING PLUG IGNITION COIL SOLENOIL OIL LEVEL SW B G BLACK GREEN
27. r slowly so that the engine side is up 2 Slide the M10x105 wheel bolt through the washer sleeve and wheel 3 Slide the bolt through the mount point on the frame 4 Fasten securely with the 1omm nut 5 Repeat steps 2 4 to attach the second wheel 8 Install the Support Leg 1 Attach the rubber vibration mount to the support leg with a cap screw M8x25 and lock nut M8 Attach the support leg to the generator frame with cap screws M8x16 and lock nuts M8 Tip the generator slowly so that it rests on the wheels and support leg Attach the Handle 1 2 Place the handle over the mounting channel on the frame Secure the handle to the frame using the two handle bolts Place a lock nut M8 on the end of each bolt and fasten securely DO NOT over tighten the lock nuts Rev 41115 20100317 E Install the Spark Arrester Insert the spark arrester screen into the muffler outlet Secure the spark arrester by placing the cover plate over the end of the screen with the lettering facing outward Secure the cover plate with the two screws and lock washers provided with the spark arrester kit V NOTE Federal and local laws and administrative requirements indicate when and where spark arresters are required When ordered spark arresters are required for operation of this generator in National Forest lands In California this generator must not be used on any forest covered land brush co
28. r to your power system 4 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 A 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 Safety Rules 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 Fuel and fuel vapors are highly flammable and extremely explosive Fire or explosion can cause severe burns or death Unintentional startup can result in entanglement traumatic amputation or laceration When adding or removing fuel Turn the generator off and let it cool for at least two minutes before removing the fuel cap Loosen the cap slowly to relieve pressure in the tank Only fill or drain fuel outdoors in a well ventilated area DO NOT overfill the fuel tank Always keep fuel away from spa
29. rks 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
30. tain 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 NOT use 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 16 Rev 41115 20100317 E Storage The generator should be started at least once every 14 days and allowed to run for at least 20 minutes For longer term storage please follow these guidelines Engine Storage 1 2 Allow engine cool completely before storage Clean the engine according to the instructions in the Maintenance section Drain all fuel completely from the fuel line and carburetor to prevent gum from forming Add a fuel stabilizer into the fuel tank Change the oil Remove the spark plug and pour about 1 2 ounce of oil into the cylinder Crank the engine slowly to distribute the oil and lubricate the cylinder Reattach the spark plug Rev 41115 20100317 E Storage Generator Storage 1 Allow the generator to c
31. tions 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 indicates an imminently hazardous situation which if not avoided will result in death or serious injury 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 V NOTE If you have questions regarding your generator we can help Please call our help line at 1 877 338 0999 Rev 41115 20100317 E Safety Rules Read this manual thoroughly before operating your generator Failure to follow instructions could result in serious injury or death The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm Generator exhaust contains carbon monoxide a colorless odorless poison gas Breathing carbon monoxide will cause nausea dizziness fainting or death If
32. urchase Repair Replacement Warranty CPE warrants to the original purchaser that the mechanical and electrical components will be free of defects in material and workmanship for a period of one year parts and labor and two years parts from the original date of purchase 90 days parts and labor and 180 days parts for commercial amp 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
33. vered land or grass covered land unless the engine is equipped with a spark arrester CAUTION Failure to install the spark arrester may result in an increased risk of fire Add Engine Oil A CAUTION DO NOT attempt to crank or start the engine before it has been properly filled with the recommended type and amount of oil Damage to the generator as a result of failure to follow these instructions will void your warranty 1 Placethe generator on a flat level surface Rev 41115 20100317 E Assembly 2 Remove oil fill cap dipstick to add oil 3 Add 1 16 qt 1 1 L of oil and replace oil fill cap dipstick See Specifications page in the manual for oil recommendations based on operating conditions 4 Checkengine oil level daily and add as needed 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 V NOTE Check oil often during the break in period Refer to the Maintenance section for recommended service intervals V 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 Useclean fresh regular unleaded fuel with a minimum octane rating of 85 DO NOT mix oil with fuel Clean the area around the fuel cap Remove the fuel cap Slowly add fuel to the tank DO NOT overfill Allow approximately 14 inch of
34. 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 Rotating parts can entangle hands feet hair clothing and or accessories Traumatic amputation or severe laceration can result Rev 41115 20100317 E Safety Rules 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 A 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 generato
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