Champion Power Equipment 46539 Systemhandbuch

OWNER’S MANUAL & OPERATING INSTRUCTIONS

10006 Santa Fe Springs Road

Santa Fe Springs CA 90670

USA / 1 (877) 338-0999

www.championpowerequipment.com

4000 Peak Watts / 3500 Running Watts

PORTABLE GENERATOR

SAVE THESE INSTRUCTIONS

Important Safety Instructions

are included in this manual.

MADE IN CHINA

REV 46539-20101109

Wireless Remote Electric Start

46539

MODEL NUMBER

2YEAR

LIMITED WARRANTY

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

• Tech Bulletins

• Product Registration

– or –

Call our Customer Care Team Toll-Free at:

1-877-338-0999

24/7 Tech Support: (562) 204-1188

46539

Wireless Remote Electric Start

PORTABLE GENERATOR

4000 Peak Watts / 3500 Running Watts

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

Vacuum Fuel Valve ...................... 7

Starting with a “Dry Fuel Line”............ 7

Starting with a “Primed Fuel Line” ......... 7

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

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

Spark Arrester Kit ..................... 8

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

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

Remove the Generator from the Shipping Carton .. 9

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

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

Install the Handles ...................... 9

Connect the Battery .................... 10

Install the Spark Arrester ................. 10

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

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

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

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

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

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

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

Wireless Remote Start ................... 12

Starting the Engine without Remote.......... 12

Connecting Electrical Loads ............... 13

Stopping the Engine .................... 13

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

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

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

Wattage Reference Chart ................. 14

Maintenance and Storage ................... 15

Engine Maintenance .................... 15

Oil .............................. 15

Spark Plugs ........................ 15

Air Filter .......................... 15

Spark Arrester ...................... 16

Cleaning .......................... 16

Adjustments........................ 16

Maintenance Schedule ................ 16

Generator Maintenance .................. 17

Storage ............................. 17

Generator Storage .................... 17

Disconnect the Battery ................ 17

Charge the Battery ................... 17

Speciﬁcations ........................... 18

Engine Speciﬁcations ................... 18

Generator Speciﬁcations ................. 18

Fuel ............................... 18

Oil ................................ 18

Spark Plugs .......................... 18

Valve Clearance ....................... 18

FCC Statement for Remote Control Device ..... 18

Parts Diagram ........................ 19

Parts List............................ 20

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

Engine Parts List

Wiring Diagram ........................ 23

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 24

Warranty .............................. 25

Warranty Qualiﬁcations .................. 25

Repair/Replacement Warranty .............. 25

Do Not Return The Unit To

The Place Of Purchase .................. 25

Warranty Exclusions .................... 25

Normal Wear ....................... 25

Installation, Use and Maintenance ........ 25

Other Exclusions..................... 25

Limits of Implied Warranty

and Consequential Damage ............. 25

Contact Information. . . . . . . . . . . . . . . . . . . . . 25

Address........................... 25

Customer Service .................... 25

Technical Service .................... 25

Emission Control System Warranty .......... 26

1REV 46539-20101109

ENGLISH 46539

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 web site at:

www.championpowerequipment.com

This Booklet

Every effort has been made to ensure the accuracy and

completeness of the information in this manual. We reserve

the right to change, alter and/or improve the product and

this document at any time without prior notice.

Champion Power Equipment Support

Model Number

Serial Number

Date of Purchase

Purchase Location

1 (877) 338-0999

46539

For Oil Type see ‘Add Engine Oil‘ section. For Fuel Type see ‘Add Fuel‘ section.

INTRODUCTION

REV 46539-20101109 2

46539 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.

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.

CAUTION

DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death

or serious injury.

DANGER

WARNING indicates a potentially hazardous

situation which, if not avoided, could result in

death or serious injury.

WARNING

If you have questions regarding your generator, we can

help. Please call our help line at 1 (877) 338-0999

NOTE

3REV 46539-20101109

ENGLISH 46539

SAFETY RULES

The engine exhaust from this product contains

chemicals known to the state of California to cause

cancer, birth defects, or other reproductive harm.

Read this manual thoroughly before operating your

generator. Failure to follow instructions could result

in serious injury or death.

Generator exhaust contains carbon monoxide, a

colorless, odorless, poison gas. Breathing carbon

monoxide will cause nausea, dizziness, fainting or

death. If you start to feel dizzy or weak, get to fresh

air immediately.

Operate generator outdoors only in a well ventilated

area.

DO NOT operate the generator inside any building,

including garages, basements, crawlspaces and

sheds, enclosure or compartment, including the

generator compartment of a recreational vehicle.

DO NOT allow exhaust fumes to enter a conﬁned

area through windows, doors, vents or other

openings.

DANGER CARBON MONOXIDE: using a generator

indoors CAN KILL YOU IN MINUTES.

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.

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.

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.

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.

DANGER

WARNING

REV 46539-20101109 4

46539 ENGLISH

SAFETY RULES

Fuel and fuel vapors are highly ﬂammable and

extremely explosive.

Fire or explosion can cause severe burns or death.

Unintentional startup can result in entanglement,

traumatic amputation or laceration.

When adding or removing fuel:

Turn the generator off and let it cool for at least two

minutes before removing the fuel cap. Loosen the

cap slowly to relieve pressure in the tank.

Only ﬁll or drain fuel outdoors in a well-ventilated area.

DO NOT overﬁll the fuel tank.

Always keep fuel away from sparks, open ﬂames,

pilot lights, heat and other sources of ignition.

DO NOT light or smoke cigarettes.

When starting the generator:

DO NOT attempt to start a damaged generator.

Make certain that the gas cap, air ﬁlter, spark plug,

fuel lines and exhaust system are properly in place.

Allow spilled fuel to evaporate fully before

attempting to start the engine.

Make certain that the generator is resting ﬁrmly on

level ground.

When operating the generator:

DO NOT move or tip the generator during operation.

DO NOT tip the generator or allow fuel or oil to spill.

When transporting or servicing the generator:

Make certain that the fuel shutoff valve is in the off

position and the fuel tank is empty.

Disconnect the spark plug wire.

When storing the generator:

Store away from sparks, open ﬂames, pilot lights,

heat and other sources of ignition.

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.

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.

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

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.

CAUTION

WARNING

DANGER

CAUTION

5REV 46539-20101109

ENGLISH 46539

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.

(1) Fuel Tank – 3.8 gallon (14.4 L) capacity fuel tank.

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

adjustment required.

(3) Vac 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.

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

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

(7) Battery – Used to start the engine. Provides 12V

DC to the electric starter and receiver control

module.

(8) Power Panel – See “Power Panel” section.

Generator

CONTROLS AND FEATURES

REV 46539-20101109 6

46539 ENGLISH

Power Panel

5 6 7 8

(1) Intelligauge – Three mode digital meter for running

hours, voltage and hertz.

(2) Ignition Switch

(3) Circuit Breaker(s) – Protects the generator against

electrical overload.

(4) Battery Switch – Enables/disables starting

electrically – via remotely or by Ignition Switch.

(5) Ground Terminal – Consult an electrician for local

grounding regulations.

(6) 120V / 30A Twist-Lock – Protected by a 25 Amp

push-to-reset circuit breaker. This receptacle

powers 120 Volt AC, 60 Hz, single phase loads

requiring up to 29.2 Amps or 3500 Watts of power.

(7) 120V / 30A Recreational Vehicle (RV) Receptacle –

This receptacle powers 120 Volt AC, 60 Hz, single

phase loads requiring up to 29.2 Amps or 3500

Watts of power.

(8) 120V / 20A Duplex – Protected by a 20 Amp

push-to-reset circuit breaker . Use each recepticle

to operate 120 Volt AC, single phase, 60 Hz loads

requiring up to 20 Amp 0r 2400 Watts of power.

CONTROLS AND FEATURES

7REV 46539-20101109

ENGLISH 46539

CONTROLS AND FEATURES

Wireless Remote Control

This generator is equipped with a wireless remote

control system for starting and stopping. The system

consists of (4) main components:

1. Receiver Control Module (RCM)

2. Wireless Remote

3. Battery Switch

4. Ignition Switch

The Remote Control functions are enabled when:

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

2. The Battery Switch is in the “ON” position.

The Remote Control functions are disabled if either of

the above conditions is not met.

To start the generator by Remote Control, press the

“START” button on the Remote one time. The engine

will attempt to start (6) times. The RCM controls

the Auto Choke during each attempt to start. If the

generator does not start, call Champion Customer Care

team for assistance at 1 (877) 338-0999.

To stop the generator by Remote Control, press the

“STOP” button on the Remote one time.

Remote Control Power Consumption

While the Ignition Switch is in the “ON: position, the

RCM is active and waiting for a remote signal. This

function requires electrical current from the battery.

If the Ignition Switch is left in the “ON” position for

extended periods (several weeks), the battery can be

completely drained.

Moving the Ignition Switch to the “OFF” position

disables the Remote functions, but the RCM still

consumes approximately 2 mA from the battery.

To prevent battery drain, press the Battery Switch to the

“OFF” position. This disconnects power to the RCM so

there is no current draw on the battery.

Power Panel Load Management

When the generator initially starts by the Remote, no

voltage is supplied to the Power Panel for approximately

15 seconds. This allows the engine to reach full speed

before electrical loads are applied to the generator.

When the generator is stopped by the Remote, the

voltage to the Power Panel is immediately turned off.

Then the engine stops approximately 5 seconds after

the “STOP” button on the Remote is pressed. Turning

the Power Panel voltage off before the engine shutdown

protects connected appliances from being damaged by

non-60 Hz voltage while the generator coasts to a stop.

The on/off voltage delay at startup and shut down only

happen when the Remote Control is used. There is no

voltage delay when the pushbutton electric start or recoil

start method is used.

When the pushbutton electric start or recoil start

method is used, the operator must be sure all electrical

loads (appliances) are turned OFF during startup and

shutdown. Damage to the generator or the attached

appliances can be caused by starting or stopping the

generator while appliances are plugged in and turned ON.

Vacuum Fuel Valve

This generator is equipped with a Vacuum Fuel Valve.

The Vac Fuel Valve functions similar to a standard on/

off fuel valve with the addition of a vacuum sensor that

can open and close the fuel valve based on whether the

engine is running or not.

The Vac Fuel valve has (3) selectable positions:

1. OFF (pointing up)

a. Valve is switched CLOSED so no fuel passes

through the valve.

2. RUN (pointing left)

a. Turns on the Vac feature of the valve. The valve

only opens to allow fuel to ﬂow when the engine is

running which provides vac pressure to the valve.

b. Valve stays OPEN while engine is running.

c. Valve automatically CLOSES when the engine stops.

3. PRIME (pointing down)

a. Valve is switched OPEN to allow fuel to ﬂow

freely to the carburator.

Starting with a “Dry Fuel Line”

When there is no residual fuel in the carburetor, the

Vacuum Fuel Valve must be in the “PRIME” position in

order to start the generator. This case occurs when the

unit is:

– Brand new out of the box, OR

– The fuel line and carburetor have been drained for

long term storage.

When the engine starts and reaches full speed, the Vac

Fuel Valve can be turned to the “RUN” position.

Starting with a “Primed Fuel Line”

When residual fuel is present in the fuel line and

carburetor, the Vacuum Fuel Valve may be turned to the

“PRIME” or “RUN” position to start the generator.

Power Panel Load Management Cont’d.

OFF RUN PRIME

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