Champion 46598, Owner'S Manual & Operating Instructions

Page 1: ... Fe Springs CA 90670 USA 1 877 338 0999 www championpowerequipment com 4000 Starting Watts 3500 Rated Watts PORTABLE GENERATOR SAVE THESE INSTRUCTIONS Important Safety Instructions are included in this manual MADE IN CHINA REV 46598 20130614 Recoil Start 46598 MODEL NUMBER ...

Page 2: ...y Asked Questions Tech Bulletins Product Registration or Call our Customer Care Team Toll Free at 1 877 338 0999 AN IMPORTANT MESSAGE ABOUT TEMPERATURE Your Champion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to 40 C 104 F When your product is needed your product may be operated at temperatures ranging from 15 C 5 F to 50 C 122 F for short per...

Page 3: ...enance and Storage 13 Engine Maintenance 13 Oil 13 Spark Plugs 13 Air Filter 13 Spark Arrester 14 Cleaning 14 Adjustments 14 Maintenance Schedule 14 Generator Maintenance 15 Storage 15 Generator Storage 15 Specifications 16 Engine Specifications 16 Generator Specifications 16 Fuel 16 Oil 16 Spark Plugs 16 Maintenance Valve Clearance 16 An Important Message About Temperature 16 Parts Diagram 17 Par...

Page 4: ...s 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 and power cables please visit our web site at www championpowerequipment com This Booklet Every effort has been made to ensure the accuracy and compl...

Page 5: ...y 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 si...

Page 6: ...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 DANGER 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 appr...

Page 7: ...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 pump gas directly into the generator at the gas station Use an approved container to transfer the fuel to the generator DO NOT overfill the fuel tank Always keep fuel away from sparks open flames pilot lights h...

Page 8: ...ence Generator Controls and Features 1 Fuel Tank 3 8 gal 14 4 L capacity fuel tank 2 Choke Used to start the engine 3 Fuel Valve Used to turn fuel supply on and off to engine 4 Air Filter Protects the engine by filtering dust and debris from the intake air 5 Recoil Starter Used to manually start the engine 6 Oil Filler Cap Check and fill engine oil level 7 Power Panel See Power Panel section 1 2 3...

Page 9: ...l power for the operation of 120 240 Volt AC 30 Amp single phase 60 Hz electrical loads 5 Voltage switch Choose between 120V or 240V 6 120 Volt AC 30 Amp Receptacle NEMA TT 30R May be used to supply electrical power for the operation of 120 Volt AC 30 Amp single phase 60 Hz electrical loads 7 120 Volt AC 20 Amp Receptacle NEMA 5 20R May be used to supply electrical power for the operation of 120 V...

Page 10: ...7 REV 46598 20130614 ENGLISH 46598 Controls and Features Parts Included Your 46598 Gasoline Powered Generator ships with the following parts Other Oil Funnel 1 Spark Plug Socket 1 ...

Page 11: ... 30 automotive oil NOTE Add Engine Oil 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 CAUTION 1 Place the generator on a flat level surface 2 Remove oil fill cap dipstick to add oil 3 Add up to 0 63 qt 0 6 L of oil and repla...

Page 12: ...RNING Use regular unleaded gasoline with a minimum octane rating of 85 Do not mix oil and gasoline Fill tank to approximately in 0 64 cm below the top of the tank to allow for fuel expansion DO NOT pump gas directly into the generator at the gas station Use an approved container to transfer the fuel to the generator DO NOT fill fuel tank indoors DO NOT fill fuel tank when the engine is running or ...

Page 13: ...when positioning generator Failure to follow proper safety precautions may void manufacturer s warranty Do not operate or store the generator in rain snow or wet weather Using a generator or electrical appliance in wet conditions such as rain or snow or near a pool or sprinkler system or when your hands are wet could result in electrocution WARNING WARNING During operation the muffler and exhaust ...

Page 14: ...ugged 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 Turn the Fuel Valve to the OFF position 4 Let the engine run until fuel starvation has stopped the engine This usually takes a few minutes 5 Press the ignition switch to the OFF position Important Always ensure that the Fuel Valve and the Engine Switch are i...

Page 15: ...roximately 3 for every 1000 feet of elevation above sea level This is a natural trend and cannot be changed by adjusting the engine At high altitudes increased exhaust emissions can also result due to the increased enrichment of the air fuel ratio Other high altitude issues can include hard starting increased fuel consumption and spark plug fouling To alleviate high altitude issues other than the ...

Page 16: ...hread 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 For service or parts assistance contact our help line at 1 877 338 0999 NOTE Maintenance replacement or repair of emission control devices and systems may be performed by any non road engine repair establishment or individual NOTE WARNING WARNING Improper maintenance will vo...

Page 17: ...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 Failure to clean the spark arrester will result in degraded engine performance CAUTION Federal and local laws ...

Page 18: ...iances are disconnected from the generator 3 Run the generator for a few minutes so the treated fuel cycles through the fuel system and carburetor 4 Turn the fuel valve to the Off position 5 Let the generator run until fuel starvation has stopped the engine This usually takes a few minutes 6 The generator needs to cool completely before cleaning and storage 7 Clean the generator according to the m...

Page 19: ... 2 inches 59 cm Specifications Maintenance Valve Clearance Intake 0 13 0 17 mm 0 005 0 007 in Exhaust 0 18 0 22 mm 0 007 0 009 in Note Tech bulletin regarding the valve adjustment procedure is on www championpowerequipment com Spark Plugs OEM spark plug NHSP F6RTC Replacement spark plug NGK BPR6ES or equivalent Make certain the spark plug gap is 0 7 0 8 mm or 0 028 0 031 in An Important Message Ab...

Page 20: ...4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 16 24 25 26 27 28 29 30 31 32 27 33 34 35 36 37 38 39 40 41 42 43 44 45 47 49 50 51 52 53 55 27 64 65 66 67 68 69 74 75 62 76 77 78 79 80 81 82 83 84 86 87 88 89 71 72 46 54 85 70 13 17 57 58 60 61 62 22 56 59 63 48 73 ...

Page 21: ...6 007 Clamp 2 41 122 070400 05 Fuel Cock 1 42 122 071000 05 48 Fuel Tank 1 43 122 070015 01 Mount Vibration Fuel Tank 4 44 2 03 004 Washer Ø6 4 45 1 5789 0620 2 Flange Bolt M6 20 4 Part Number Description Qty 46 23 070301 00 Fuel Filter 1 47 24 070100 00 Fuel Tank Cap 1 48 24 070030 00 Hole Breather Tube 1 49 24 070014 03 Pipe Reversal Valve 1 50 2 06 006 Clamp 1 51 24 070800 00 Reversal Valve 1 5...

Page 22: ... 13 25 26 27 29 30 32 35 37 38 12 40 41 42 43 44 46 47 21 22 23 24 31 34 36 39 53 52 102 51 50 49 55 56 57 58 54 60 62 61 63 65 66 67 68 69 70 71 72 74 25 75 1 93 94 95 92 91 90 97 78 79 80 82 83 84 85 86 87 88 76 59 12 77 96 33 81 73 15 20 48 14 101 51 100 98 45 64 16 99 89 19 11 18 17 19 28 103 ...

Page 23: ...21 Seal Air Cleaner 1 49 23 110006 00 Rod Governor 1 50 21 110003 00 Arm Governor 1 51 1 6177 06 Flange Nut M6 3 52 21 110001 00 Shaft Governor Arm 1 Part Number Description Qty 53 22 123000 01 Ignition Coil Silicon Rubber EPA 1 54 1 5789 0625 Flange Bolt M6 25 2 55 23 110005 01 Spring Throttle Return 1 56 23 110007 00 Spring Governor 1 57 2 08 040 Bolt Governor Arm M6 21 1 58 21 110008 00 Pin Sha...

Page 24: ...21 REV 46598 20130614 ENGLISH 46598 Wiring Diagram Specifications ...

Page 25: ...se to the proper level Place generator on a flat level surface Generator cannot supply enough power or overheating Generator is overloaded Review load and adjust See Power Management Insufficient ventilation Check for air restriction Move to a well ventilated area No AC output Cable not properly connected Check all connections Connected device is defective Replace defective device Circuit breaker ...

Page 26: ...r 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 Installation Use and Maintenance Cont d Normal maintenance such as spark plugs air filters adjustments fuel system cleaning and obstruction due to buildup is not covered by this warr...

Page 27: ...tem 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 recommend...

Page 28: ...cement 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 repla...

Page 29: ...arburetor Purge Port Connector 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 Alternate ser...