Professional Documents
Culture Documents
6500 Generator
6500 Generator
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
Connect the Battery ..................................8
Install the Spark Arrester .........................8
Add Engine Oil .........................................8
Add Fuel.................................................... 9
Grounding................................................. 9
Operation ....................................... 10
Generator Location................................. 10
Grounding............................................... 10
Surge Protection ..................................... 10
Starting the Engine................................. 10
Connecting Electrical Loads................... 10
Stopping the Engine ................................11
Do Not Overload Generator ....................11
Capacity................................................11
Power Management .............................11
Wattage Reference Chart.........................11
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
Troubleshooting .............................20
Warranty ........................................ 21
Warranty Qualifications ......................... 21
Repair/Replacement Warranty .............. 21
Do not return the unit to the place of
purchase .................................................. 21
Warranty Exclusions............................... 21
Normal Wear....................................... 21
Installation, Use and Maintenance..... 21
Other Exclusions ................................. 21
Limits of Implied Warranty and
Consequential Damage ........................... 21
Contact Information ...............................22
Address................................................22
Customer Service ................................22
Technical Service.................................22
Notes ..............................................23
Introduction
Introduction
Accessories
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
(877) 338-0999
Model Number
CSA41155E
Serial Number
Date of Purchase
Purchase Location
Manual Conventions
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.
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
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
Safety Rules
Safety Rules
DANGER
Generator produces powerful voltage.
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.
WARNING
Sparks can result in fire or electrical shock.
DANGER
Generator exhaust contains carbon monoxide, a
colorless, odorless, poison gas. Breathing carbon
monoxide will cause nausea, dizziness, fainting or
death.
Operate generator outdoors only in a well
ventilated area
DO NOT operate the generator inside any
building, 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
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
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.
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 generators 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
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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 (877) 338-0999. Please have your
serial number and model number available.
7.
CAUTION
The wheel kit is not intended for over-the-road
use.
8.
Assembly
1.
CAUTION
The engine is equipped with a low-oil-shutoff and
the will stop when the oil level in the crankcase
falls below the threshold level.
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 fuel tank.
DO NOT light cigarettes or smoke when filling the
fuel tank.
NOTE
Check oil often during the break-in period. Refer
to the Maintenance section for recommended
service intervals.
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.
2.
3.
4.
5.
Grounding
Your generator must be properly connected
to an appropriate ground to help prevent
electric shock.
WARNING
Failure to properly ground the generator can
result in electric shock.
Operation
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 of 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.
3.
4.
5.
Grounding
The generator system ground connects the
frame to the ground terminals on the power
panel. The system ground is connected to
the AC neutral wire.
6.
7.
Surge Protection
CAUTION
Voltage fluctuation may impair the proper
functioning of sensitive electronic equipment.
10
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.
Operation
Stopping the Engine
1.
NOTE
Never exceed the generator capacity when
adding loads.
NOTE
Starting watts can exceed three times the
running watts. The values in the following table
are approximate. Refer to your tool or appliance
for actual wattage consumption.
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
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 = Watts
To prolong the life of your generator and
attached devices, follow these steps to add
electrical load:
1. Start the generator with no electrical
load attached.
2. Allow the engine to run for several
minutes to stabilize.
3. Plug in 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. Plug in and turn on the next item.
6. Allow the engine to stabilize.
7. Repeat steps 5-6 for each additional
item.
11
Operation
Item
Running
Watts
Essentials
Light Bulb 100W
Refrigerator/Freezer
Freezer
Sump Pump
Well Pump 1 HP
Water Heater
Security System
AM/FM Radio
Garage Door Opener 1/2 HP
Battery Charger 12V DC
Heating/Cooling
Air Conditioner 12000 BTU
Fan
Furnace Fan 1/3 HP
Home Appliances
Microwave 1000W
Electric Range - One Element
Electric Skillet
Coffee Maker
Clothes Washer
Entertainment
CD/DVD Player
VCR
Stereo Receiver
Television 27"
PC with 15" Monitor
Job Site
Belt Sander 3"
Bench Grinder 6"
Circular Saw
Compressor 1 1/2 HP
Edge Trimmer
Hand Drill 1/2"
Lawn Mower
Paint Sprayer
Table Saw
12
100
1200
500
600
2000
4000
180
300
500
110
1700
300
1200
Starting
Watts
2400
500
1800
4000
600
2500
600
2000
1000
1500
1250
1500
1200
100
100
450
500
800
1000
700
1500
2500
500
1000
1200
600
2000
1500
1500
1500
2500
500
1000
1800
1200
2000
Maintenance
Maintenance
WARNING
Never operate a damaged or defective generator.
Spark Plugs
1.
WARNING
Tampering with the factory set governor will void
your warranty.
2.
3.
4.
WARNING
5.
6.
7.
8.
Complete all scheduled maintenance in a
timely manner. Correct any issue before
operating the generator.
NOTE
For service or parts assistance, contact our help
line at (877) 338-0999.
Engine Maintenance
To prevent accidental starting, remove and
ground spark plug wire before performing
any service.
Air Filter
1.
2.
3.
4.
5.
6.
7.
Oil
Change oil when the engine is warm. Refer
to the oil specification to select the proper
grade of oil for your operating environment.
1. Remove the oil drain plug with a 15 mm
socket and extension.
2. Allow the oil to drain completely.
3. Replace the drain plug.
4. Remove oil fill cap/dipstick to add oil.
5. Add 1.16 qt (1.1 L) of oil and replace oil
fill cap/dipstick.
13
Maintenance
Spark Arrester
1.
2.
3.
4.
5.
6.
Cleaning
CAUTION
DO NOT spray engine with water.
Water can contaminate the fuel system.
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 (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 (877) 338-0999 to
locate the nearest Champion Power
Equipment certified service dealer for your
generator or engine maintenance needs.
14
Change oil
First 10 hours
Check/Adjust Valve Clearance *
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
Change oil
Clean/Adjust spark plug
Check/Adjust valve clearance *
Clean spark arrester
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
Generator Maintenance
Make certain 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
DO NOT use a garden hose to clean the
generator.
Water can enter the generator through the
cooling slots and damage the generator
windings.
Storage
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.
Generator Storage
Engine Storage
1.
1.
2.
3.
4.
5.
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Troubleshooting
Troubleshooting
Problem
Generator will not start
Cause
No fuel
Faulty spark plug
Unit loaded during start up
Low oil level
Choke in the wrong position.
Spark plug wire loose
Out of fuel
Low oil level
Generator is overloaded
Insufficient ventilation
No AC output
Generator gallops
Repeated circuit breaker tripping
Other
Engine governor defective
Overload
Faulty cords or device
20
Solution
Add fuel
Replace spark plug
Remove load from unit
Fill crankcase to the proper level
Place generator on a flat, level surface
Adjust choke.
Attach wire to spark plug
Fill fuel tank
Fill crankcase to the proper level.
Place generator on a flat, level surface
Review load and adjust. See Power
Management
Check for air restriction. Move to a
well ventilated area
Check all connections
Replace defective device
Reset circuit breaker
Replace capacitor (Service Center)
Replace brush assembly (Service
Center)
Replace AVR (Service Center)
Inspect and tighten wiring
connections
Contact the help line.
Contact the help line
Review load and adjust. See Power
Management
Check for damaged, bare or frayed
wires. Replace defective device
Warranty
Warranty Exclusions
Warranty
CHAMPION POWER EQUIPMENT
1 YEAR LIMITED WARRANTY
Effective September 1, 2006. Replaces all
undated warranties and all warranties dated
before September 1, 2006.
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 purchase.
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 (1) year
from the original date of purchase (90 days
for commercial & 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.
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.
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 to due acts of God and other force
majeure events beyond the manufacturers
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.
21
Warranty
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 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
[email protected]
22
Notes
Notes
23