Champion Power Equipment 40008, Owner'S Manual And Operating Instructions

Page 1: ...40008 Rev 40008 20070531 4000 Peak Watts 3500 Running Watts PORTABLE GENERATOR Owner s Manual and Operating Instructions ...

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Page 3: ...11 Wattage Reference Chart 12 Maintenance 13 Engine Maintenance 13 Oil 13 Spark Plugs 13 Air Filter 13 Spark Arrester 14 Cleaning 14 Adjustments 14 Maintenance Schedule 14 Generator Maintenance 14 Storage 15 Engine Storage 15 Generator Storage 15 Specifications 16 Engine Specifications 16 Generator Specifications 16 Fuel 16 Oil 16 Spark Plugs 16 Valve Clearance 16 Parts Diagram 17 Parts List 18 Wi...

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Page 5: ...ls 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 wi...

Page 6: ...mminently 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 pote...

Page 7: ... 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 a...

Page 8: ...e 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 i...

Page 9: ... valve to the On position to supply fuel to the engine 3 Choke Used to start 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 Serial Number Please have this number available when calling for assistance 7 Low Oil Sensor Senses the level of oil in the crankcase and shuts the engine down if the level falls too lo...

Page 10: ...ush to reset circuit breaker This receptacle powers 120 Volt AC 60 Hz single phase loads requiring up to 30 Amps or 3000 watts of power 5 120 V 30 A Recreational Vehicle RV Receptacle protected by a 25 A push to reset circuit breaker This receptacle powers 120 Volt AC 60 Hz single phase loads requiring up to 30 Amps or 3000 watts of power 6 120 V 20 A Duplex protected by a 20 A push to reset circu...

Page 11: ...owered Generator ships with the following parts Wheel Kit Axle 1 piece Solid Wheel 2 pieces Vibration Mounts 2 pieces Handle 1 piece Support Leg 1 piece Bolt Kit Wheel Retaining Pins 2 pieces Flat Washers 2 pieces Cap Screws and Nuts 10 sets Oil Funnel 1 piece Wrench 1 piece Spark Plug Socket 1 piece ...

Page 12: ...n back around the axle 7 Repeat steps 3 6 to attach the second wheel Install the Support Leg 1 Attach the rubber vibration mount to the support leg with a cap screw M8x20 and lock nut M8 2 Attach the support leg to the generator frame with cap screws M8x30 and lock nuts M8 3 Tip the generator slowly so that it rests on the wheels and support leg Install the Handle 1 Place the handle over the mount...

Page 13: ...fill Allow approximately 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 Do not mix oil and gasoline Fill tank to approximately 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...

Page 14: ...tlet 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 Starting the Engine 1 Make certain the ge...

Page 15: ...rting 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 ...

Page 16: ...000 Water Heater 4000 Security System 180 AM FM Radio 300 Garage Door Opener 1 2 HP 500 600 Battery Charger 12V DC 110 Heating Cooling Air Conditioner 12000 BTU 1700 2500 Fan 300 600 Furnace Fan 1 3 HP 1200 2000 Home Appliances Microwave 1000W 1000 Electric Range One Element 1500 Electric Skillet 1250 Coffee Maker 1500 Clothes Washer 1200 Entertainment CD DVD Player 100 VCR 100 Stereo Receiver 450...

Page 17: ...4 Remove oil fill cap dipstick to add oil 5 Add 0 63 qt 0 6 L of oil and replace oil fill cap dipstick 6 Dispose of used oil at an approved waste management facility 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 require...

Page 18: ...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 ...

Page 19: ... the fuel line and carburetor to prevent gum from forming 4 Add a fuel stabilizer into the fuel tank 5 Change the oil 6 Remove the spark plug and pour about ounce of oil into the cylinder Crank the engine slowly to distribute the oil and lubricate the cylinder 7 Reattach the spark plug Generator Storage 1 Allow the generator to cool completely before storage 2 Turn off the fuel supply at the fuel ...

Page 20: ... 4 US gallons 15 L Use regular unleaded gasoline with a minimum octane rating of 85 Oil Oil capacity is 0 63 qt 0 6 L Spark Plugs Your generator comes equipped with a long reach plug 18mm Intermittent use less than 1 hour month or colder temperatures below 60 F NGK B6ES or equivalent Moderate use less than 3 hours month or seasonal temperatures 50 80 F NGK B7ES or equivalent Extreme use continuous...

Page 21: ...Specifications Rev 40008 20070531 17 Parts Diagram ...

Page 22: ...Washer Φ6 4 24 GB93 1987 Spring Washer φ6 4 25 ST02FD 1152032 Rear Frame 1 26 GB5789 86 Flange Bolt M6 155 4 27 ST02FD 1152001 Stator Cover 1 28 ST02FD 1152020 Stator Assembly 1 29 GB5780 86 Flange Bolt M8 233 1 30 GB90 85 Washer 1 31 GB279 88 6202 Bearing 1 32 ST02FD 1152010 Rotor Comp 1 33 ST02FD 1152009 Cooling Fan 1 34 ST168FD 1030007 Crankcase Cover 1 35 GB5789 86 Flange Bolt M6 15 1 36 ST02F...

Page 23: ...t M5 10 2 74 GB93 1987 Spring Washer φ5 2 75 ST188FD 1100010 88 Spark Arrester Cover 1 76 ST188FD 1180121 Spark Arrester Assembly 1 77 ST02FD 1150100 Muffler Stay II 1 78 ST02FD 1151400 Handle 1 79 GB5789 86 Flange Bolt M8 45 2 80 GB5789 86 Bolt M8 35 2 81 GB93 1987 Spring Washer φ8 2 82 GB96 85 Big Washer φ8 2 83 ST182FD 1742003 UC Straight Bottom Rubber 2 84 GB5789 86 Flange Bolt M8 16 10 85 ST1...

Page 24: ...Specifications 20 Rev 40008 20070531 Wiring Diagram ...

Page 25: ...aded Review load and adjust See Power Management Generator cannot supply enough power or overheating Insufficient ventilation Check for air restriction Move to a well ventilated area Cable not properly connected Check all connections Connected device is defective Replace defective device Circuit breaker is open Reset circuit breaker Capacitor defective Replace capacitor Service Center Faulty brush...

Page 26: ...ithout 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 Maintena...

Page 27: ... 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...

Page 28: ...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...

Page 29: ...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 Peri...

Page 30: ...l Line Fittings Clamps Pressure Relief Valves Control Valves Control Solenoids Electronic Controls Vacuum Control Diaphragms Control Cables Control Linkages Purge Valves Vapor Hoses Liquid Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector TO OBTAIN WARRANTY SERVICE You must take your CPE engine or the product on which it is installed along with your warrant...

Page 31: ...Notes Rev 40008 20070531 27 Notes ...