Emergency Start Procedures
My brand new engine won't start - what should I do?I broke my starter rope (recoil) - what should I do?
I broke my choke lever - what should I do?
What type and how much oil do I put into the engine?
Contacting Champion Power Equipment
How can I contact your 24 hour technical assistance?What information should I have available before I call for assistance?
General Questions
How does the three-position toggle switch control the voltage on my C46540 RV Generator?My equipment causes my generator to surge or gallop in rolling cycles, why is this?
I have an RV with a 3 blade plug-in but I can't connect it to the twist-lock receptacle on the generator.
What is the difference between running load and peak/surge load?
My generator runs great for about 20-40 minutes and then the engine just quits.
I am confused about the recommendation of a grounding rod attachment.
I hear a loud vibration sound from my gas tank.
What do I do if all the parts weren't in my box after unpacking it?
Should I use a surge protector?
What is "floating neutral" and how does it affect my generator?
What is the best way to store my generator between periods of use?
How can I rewind the rope in my recoil starter?
How can I re-program my remote control?
My brand new engine won't start - what should I do?
Verify that the correct amount of oil is in the engine. Champion Power Equipment engines come equipped with a low oil sensor that prevents the engine from running when too little oil is in the crankcase. The sensor may stick on engines that have not been run for long periods of time.
Locate the yellow wire on the crankcase. Follow this wire until you locate the green quick connect. Grasp the two ends firmly and separate the two wires at the connector.
Start the engine and allow it to run for 15 minutes before reconnecting the sensor.
I broke my starter rope (recoil) - what should I do?
Champion Power Equipment engines are equipped with an emergency recoil option. If you remove the three bolts holding the recoil assembly, you'll see a silver cup that receives the pawls from the recoil. You can use the original rope or any suitable length of rope you may have on hand. Tie a stop knot (e.g. a figure eight or overhand) in the end of the rope. Place the knot in the notch on the outside rim of the silver cup and wind the rope clockwise around the cup. WARNING: DO NOT tie the rope to the cup - it needs to fall off the cup at the end of the pull to prevent entanglement or injury.
Contact our customer service team to order a replacement recoil assembly.
I broke my choke lever - what should I do?
Use a piece of tape (masking, scotch or electrical) to cover the air intake holes on the air cleaner cover, leaving enough extra tape to grasp for removal. Start the engine and immediately remove the tape as the engine begins to run.
Contact our customer service team to order a replacement choke lever.
What type and how much oil do I put into the engine? (All generators)
| Engine HP | Oil (qt) | Oil (l) |
| 2.4 | 0.42 | 0.4 |
| 4.0 | 0.63 | 0.6 |
| 6.5 | 0.63 | 0.6 |
| 9.0 | 1.16 | 1.1 |
| 11.0 | 1.16 | 1.1 |
| 13.0 | 1.16 | 1.1 |
Add small amounts until the oil appears at the bottom of the filler plug threaded hole in the crankcase. Too little oil will activate the low oil sensor and not allow the engine to start. Too much oil will cause the engine breather system to purge excess oil into the air cleaner box near the carburetor and eventually obstruct air flow to the engine. This will flood the engine with too much fuel and foul the spark plug. Your engine will not start when this happens.
We recommend 10W-30 for general, all-temperature use. Please refer to the following chart for your climate conditions that may require different weight oil.
How can I contact your 24 hour technical assistance?
During regular business hours (Pacific Time Zone), call our toll-free line at (877) 338-0999. Outside of regular business hours, we are pleased to offer two options:- Contact our technical staff via email at tech@championpowerequipment.com; we will respond promptly. Please be sure to include your model number and a brief description of how we can help.
- For power emergencies, please contact our on-call technical staff at (562) 204-1188, weekends and holidays included. If we aren't able to answer your call immediately, please leave a voicemail. Be sure to include your contact information, model number and a brief description of how we can help. A response will usually be made within minutes.
What information should I have available before I call for assistance?
Please have the following information ready when you call:- Model Number
- Serial Number
- Proof of Purchase (for warranty claims)
- Date and Place of Purchase
How does the three-position toggle switch control the voltage on my C46540 RV Generator?
- Left
- Activates the 240v twist lock, the 120v and RV receptacles are disabled.
- Center
- Disables all receptacles.
- Right
- Activates the 120v and TT30 (RV) receptacles. The 240v receptacle is disabled.
With the toggle switch in the right position, the generator field coils are in parallel type configuration, providing 29Amp 120V output.
My equipment causes my generator to surge or gallop in rolling cycles, why is this?
Air compressors, tile saws, table saws, and industrial vacuums draw as much as 3 times the running load. For example, the average 1 HP electric motor requires about 1500 watt running load. However, under startup, the load exceeds 4500 watts, which is at the high limit for this generator. Whenever any additional load is added, such as the compressor starting with 80 lbs. to 100 lbs. existing air in the holding tank, the electric motor will labor until fully up to its running RPM. The same holds true with a circular saw that is cutting through a large piece of wood. As the voltage drops, the amperage increases until the possibility of exceeding the circuit breaker load.
Note - champion Power Equipment offers a 5500 watt generator that is now available and will easily run this equipment in most cases. It is always important to check the amperage or wattage needs before loading the generator. This will prevent equipment or generator damage. A call to our technical line at anytime including weekends will answer your questions regarding your existing equipment needs.
I have an RV with a 3 blade plug-in but I can't connect it to the twist-lock receptacle on the generator. (3500w. generators)
Since our generators may have either one or two twist-lock connectors, you may find the need to purchase separately the correct plug for your generator. If you have a generator with two twist-lock connectors built in, then you would use a plug with NEMA (National Electrical Manufacturers Assn.) no. L5-30P (3 blade). The receptacle on the generator has the mating female blade holes for entry. Your wiring would be only 3 wires that would include a ground, a neutral and a black lead from an interface cord that would plug into the RV receptacle plug.
If your generator has only the 120v/240v outlet, then you must use a NEMA plug no. L14-30P for your application. This plug can be wired for 120v or 240v applications. When using your RV as an application, you would obtain an RV connector plug for the RV end. This would be wired as using only 3 of the 4 blades on the L14-30P plug. The L-shaped blade is the ground. Directly opposite from the ground blade is the neutral blade and each of the other two blades are the hot blades. The hot blades are each 120v. Using only one of the hot blades will give you the 3 wire configuration you will need for the RV application. Using 4 blades would allow the 240v to be configured. DO NOT attach both 120v hot blades together at any time. Doing this will void your warranty and damage both generator and your appliance from excessive voltage. If in doubt at any time, please call our 24hr. technical line at (562) 204-1188. You will receive a quick response to your questions.
Note - When using the 4 blade plug-in for your 3 blade RV connection, it is possible to pick the hot blade that may only be breakered with a 15A circuit breaker. If this is the case, you can identify it by visually seeing the R/H breaker popping out of the dash panel. It will cool and can be pushed in to reset. If this happens, you need to change the hot wire to the other unused terminal of the L14-30P plug. You will now be connected with a 20 amp breaker which is the L/H on of the pair next to the ignition switch.
What is the difference between running load and peak/surge load? (All generators)
When using an appliance that has a motor, you will need to compare the running current (amps) with the starting load. For instance a 1 hp capacitor start electric motor typically runs at about 1500 watts, but has a starting load of about 4500 watts. This application would be considered at the upper edge of the model C46535 performance and may not be suitable for your needs. Our larger model 5500w generator would be much more desirable for your use. A peak or surge rating would only be good for a few seconds until the motor spins up to its operation RPM. In the event that the startup load is too high, it will cause the generator to labor and possibly stall from too much electrical loading. Air compressors and commercial grade circular saws are common problems with this possible for the compressor or saw to work properly. 240v motors will usually require less amperage for their operation which is a better condition for your generator. When in doubt, be sure to call our tech line.My generator runs great
for about 20-40 minutes and then the engine just quits.(All generators)
As the outside temperatures rise, it is possible for the fuel tank to pressurize or actually become vacuum sealed due to the gas cap failing to check the pressure or vacuum. As the tank gets warmer the gas expands and requires the expansion of air space to breathe and balance from inside the tank to the outside atmospheric pressure. In the event that the gas cap fails to allow air to balance, it is possible for a vacuum to be created as the fuel is gravity drained to the carburetor. If a vacuum happens, it will cause the fuel to stop its flow until the vacuum is allowed to balance with the outside air. If this happens, when you open the gas cap, you will hear a rush of air into the tank. The fuel cap is defective and must be replaced. If you think you have these symptoms, it is best to call our tech line for evaluation and/or replacement.
I am confused about the recommendation of a grounding rod attachment.(All generators)
The recommendation for a grounding rod is best used for a permanent location, such as outside of your house for emergency use. A copper rod driven into the ground and a copper wire attached from the rod to the generator frame will give you solid protection against electrical shock. A GFI (Ground Fault Interrupter) is also another attachment that is effective against electrical shock. It is recommended to speak with a licensed electrician if you are considering this type of permanent installation. If you are running your generator in shallow water areas, it is a must to attach the generator to a grounding rod.
I hear a loud vibration sound from my gas tank. (3500w. & 5500w. generators)
This sound is an indicator of failing to remove the shipping brackets attached to the bottom of the engine and the frame. There are 2 L-shaped brackets that require removal. These brackets can be thrown away along with the bolts and nuts used to attach them. Removal of these brackets allows the rubber motor mounts to do their job. The rubber mounts allow movement of the engine and generator head.
What do I do if some parts are missing? (All Products)
Please call our toll free number at 877-338-0999 as soon as possible. We will need a copy of your sales receipt faxed to us with the warranty application. Using your generator manual as reference, find the parts list and write down the item number (#1-66), the quantity, and the description. We will send the missing parts out immediately.
Should I use a surge protector? (All generators)
Electronic devices, including computers and many programmable appliances use components that are designed to operate within a narrow voltage range and may be affected by momentary voltage fluctuations. While there is no way to prevent voltage fluctuations, you can take steps to protect sensitive electronic equipment.
- Install UL1449, CSA-listed, plug-in surge suppressors on the outlets feeding your sensitive equipment. Surge suppressors come in single- or multi-outlet styles. They're designed to protect against virtually all short-duration voltage fluctuations.
- 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.
What is "floating neutral" and how does it affect my generator? (All Generators)
All Champion Power Equipment generators, with the exception of our 40012 and all CSA-certified generators sold in Canada, have a "floating neutral", meaning that the neutral circuit is not connected to the frame or to earth ground. This also means that both legs on the receptacle are hot legs, which is normal for floating neutral generators. As a result, there is no specific hot leg and neutral leg wiring arrangement for the generator winding connection to the receptacle. The floating neutral configuration is common for applications such as connection to a recreational vehicle and connection to home power where the transfer switch does not switch out the neutral to ground connection.
The floating neutral eliminates the potential of being shocked by contacting a hot leg and the generator frame at the same time, which could occur if an electrical device such as a hand held tool suffered from an internal short circuit.
Meters or other devices intended to indicate polarity may not properly indicate polarity on a floating neutral circuit. Polarity indicators generally measure the voltage across the neutral and ground connectors. In electrical systems where the neutral is bonded to ground, the voltage will be zero and correct polarity will be indicated. In systems where the neutral is not bonded to ground, voltage is also not expected across this connection. However, in a portable generator some very small current voltage readings can be recorded by sensitive volt meters. This voltage may be induced in the frame by the magnetic field of the generator. The current associated with this induced voltage and the risk of electrical shock are negligible. However, very sensitive polarity meters may interpret this voltage as an indication of reversed connections.
If you have an indication of reversed polarity, please check with the manufacturer of your meter to determine if that reading capability applies to the floating neutral output from a portable generator.
What is the best way to store my generator between periods of use? (All Generators)
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.
- Allow the engine to cool completely before storage.
- Clean the generator.
- Use a damp cloth to clean exterior surfaces of the generator.
- Use a soft bristle brush to remove dirt and oil.
- Use an air compressor (25 PSI) to clear dirt and debris from the generator.
- Inspect all air vents and cooling slots to ensure that they are clean and unobstructed.
- Drain all fuel completely from the fuel line and carburetor to prevent gum from forming.
- Add a fuel stabilizer into the fuel tank.
- Change the oil.
- Remove the spark plug and pour about ½ ounce of oil into the cylinder. Crank the engine slowly to distribute the oil and lubricate the cylinder.
- Reattach the spark plug.
- Store in a clean, dry place out of direct sunlight.
How can I rewind the rope in my recoil starter? (All Generators)
How can I re-program my remote control? (46538)
- Turn the front panel engine switch ON (middle position)
- Push and hold the programming button next to the red light approximately three seconds until the light turns on
- Push and release the STOP button. The red light blinks once to erase the remote program
- Push and release the START button. The red light blinks once to program the remote
- Repeat step 4 with a second remote if desired
- Push and hold the programming button approximately three seconds until the red light turns off