Champion Category 5 46538 Manual

46538
Rev46538-20100614
www.championpowerequipment.com
10006SantaFeSpringsRoad
SantaFeSprings,CA90670USA
MadeinChina
3500PeakWatts/3000RunningWatts
WirelessRemoteElectricStart
PORTABLEGENERATOR
SAVETHESEINSTRUCTIONS
ImportantSafety
Instructionsareincludedin
thismanual
Owner’sManualandOperatingInstructions

Table of Contents
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 .......................................... 7
Assembly ..........................................8
Remove the Generator from the Shipping
Carton .......................................................8
Install the Wheel Kit.................................8
Install the Support Leg.............................8
Install the Handles ...................................8
Connect the Battery ..............................9
Install the Spark Arrester.........................9
Add Engine Oil .........................................9
Add Fuel..................................................10
Grounding...............................................10
Operation ........................................11
Generator Location..................................11
Surge Protection......................................11
Wireless Remote Start.............................11
Starting the Engine without Remote.......11
Connecting Electrical Loads................... 12
Stopping the Engine............................... 12
Do Not Overload Generator ................... 12
Capacity............................................... 12
Power Management............................ 13
Wattage Reference Chart........................ 13
Maintenance................................... 14
Engine Maintenance............................... 14
Oil........................................................ 14
Spark Plugs ......................................... 14
Air Filter.............................................. 14
Spark Arrester..................................... 15
Cleaning .............................................. 15
Adjustments........................................ 15
Maintenance Schedule........................ 15
Generator Maintenance.......................... 15
Storage ...........................................16
Engine Storage........................................16
Generator Storage...................................16
Specifications ................................. 17
Engine Specifications.............................. 17
Generator Specifications......................... 17
Fuel.......................................................... 17
Oil............................................................ 17
Spark Plugs ............................................. 17
Valve Clearance....................................... 17
FCC Statement for Remote Control
Device .................................................. 17
Parts Diagram.........................................18
Parts List.................................................19
Wiring Diagram ......................................22
Troubleshooting .............................23
Warranty ........................................24
Warranty Qualifications .........................24
Repair/Replacement Warranty..............24
Do not return the unit to the place of
purchase..................................................24
Warranty Exclusions...............................24
Normal Wear.......................................24
Installation, Use and Maintenance.....24
Other Exclusions.................................24
Limits of Implied Warranty and
Consequential Damage...........................24
Contact Information ...............................24
Address................................................24
Customer Service ................................24
Technical Service.................................24

Introduction
Rev 46538-20100614 E 1
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 an electric-start gasoline engine
driven, alternating current (AC) generator. It
is designed to supply electrical power for
lighting, appliances, tools and similar
equipment.
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
46538
Serial Number
Date of Purchase
Purchase Location

Manual Conventions
2 Rev 46538-20100614 E
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.

Safety Rules
Rev 46538-20100614 E 3
Safety Rules
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
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.
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.

Safety Rules
4 Rev 46538-20100614 E
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.
DANGER
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.
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.
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

Controls and Features
Rev 46538-20100614 E 5
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 – 3.8 gallon capacity fuel
tank.
(2) Fuel Valve – Turn this valve to the
“On” position to supply fuel to the engine.
(3) Auto -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) Battery – Used to start the engine.
(7) Power Panel – See “Power Panel”

Controls and Features
6 Rev 46538-20100614 E
Power Panel
(1) Ignition Switch
(2) Intelligauge – Three mode digital
meter for running hours, voltage and hertz.
(3) Circuit Breakers – Protects the
generator against electrical overload.
(4) 120 V 20 A Duplex – each duplex is
protected by a 20 A push-to-reset circuit
breaker to operate 120 Volt AC, single phase,
60 Hz loads requiring up to 20 A 0r 2400
Watts of power.
(5) 120 V 30 A Recreational Vehicle
(RV) Receptacle –This receptacle powers
120 Volt AC, 60 Hz, single phase loads
requiring up to25 A or 3000 watts of power.
(6) 120 V 30 A Twist-Lock – Protected
by a 25 A push-to-reset circuit breaker. This
receptacle powers 120 Volt AC, 60 Hz, single
phase loads requiring up to 25 A or 3000
Watts of power.
(7) Ground Terminal – Consult an
electrician for local grounding regulations.