BD100619 5500W Electric Start Generator
OPERATOR’S MANUALMODEL #BD100619 5500W ELECTRIC START GENERATOR
or visit black-diamond.comSAVE THESE INSTRUCTIONS. This manual contains important safety precautions which should be read and understood before operating the product. Failure to do so could result in serious injury. This manual should remain with the product. Specifications, descriptions and illustrations in this manual are as accurate as known at the time of publication, but are subject to change without notice.
REV 20210623
Mid-States Distributing, LLC., 2800 Meacham Blvd., Fort Worth, TX 76137 USA
CARBON MONOXIDE SAFETY: THE BIG PICTUREAs the only safe way to use a portable generator, taking your generator outside is absolutely mandatory to keep your family safe from carbon monoxide. But there’s even more you can do. By educating yourself about all carbon monoxide risks, you’ll be better prepared to protect your family from this colorless, oderless threat.
ALWAYS READ MANUAL THE OPERATOR’SMANUAL FIRST
KNOW THE SYMPTOMS
· Headache
· Dizziness
· Nausea
· Fatigue
· Shortness of breath
STAY ALERT WITH CARBON MONOXIDE DETECTORS
KEEP IT OUTSIDE AND AWAY FROM DOORS, WINDOWS, AND GARAGES
IF YOU FEEL SYMPTOMS, LEAVE RIGHT AWAY
POINT FUMES AWAY FROM NEARBY PEOPLE
www.TakeYourGeneratorOutside.com
TABLE OF CONTENTSIntroduction…………………………………………… 4 Safety Definitions …………………………………… 4 Important Safety Instructions ………………….. 5Fuel Safety ……………………………………………….. 7 Safety and Dataplate Labels……………………………….. 8 Safety Symbols……………………………………………. 9 Operation Symbols ……………………………………….. 10 Quick Start Label Symbols………………………………… 11Controls and Features …………………………… 12Generator ………………………………………………… 12 Control Panel …………………………………………….. 13 Intelligauge ………………………………………………. 14 Parts Included ……………………………………………. 15 Tools Needed …………………………………………….. 15Assembly …………………………………………….. 16Unpacking ……………………………………………….. 16 Install the Wheel Kit………………………………………. 16 Connect the Battery………………………………………. 16 Add Engine Oil……………………………………………. 16 Add Fuel …………………………………………………. 17 Grounding ……………………………………………….. 18 Generator Location……………………………………….. 19Operation …………………………………………….. 19Surge Protection …………………………………………. 20 Starting the Engine……………………………………….. 20 Battery…………………………………………………… 21 Connecting Electrical Loads ………………………………. 22 Do Not Overload Generator ……………………………….. 22 GFCI……………………………………………………… 22 Stopping the Engine………………………………………. 23 Moving the Generator …………………………………….. 23 Operation at High Altitude ………………………………… 24 Cleaning the Generator …………………………………… 24
Maintenance ………………………………………… 24Changing the Engine Oil …………………………. ………. 25 Cleaning and Adjusting the Spark Plug…………………….. 25 Cleaning the Air Filter …………………………………….. 25 Cleaning the Spark Arrestor ………………………………. 25 Adjusting the Governor…………………………… ………. 26 Generator Battery ………………………………………… 26 Maintenance Schedule…………………………… ………. 26Storage ……………………………………………….. 27Short Term Storage (up to 30 days) ………………. ………. 27 Mid Term Storage (30 days 1 year) ……………………… 27 Long Term Storage (over 1 year) ………………………….. 28 Removing from Storage…………………………………… 28Specifications………………………………………. 29Generator Specifications…………………………. ………. 29 Engine Specifications …………………………………….. 29 Oil Specifications…………………………………………. 29 Fuel Specifications ………………………………. ………. 29 Battery Specifications…………………………………….. 29 Temperature Specifications……………………………….. 29 ICES002 Warning………………………………. ………. 29Troubleshooting……………………………………. 30 Warranty……………………………………………… 32Warranty Qualifications …………………………………… 32 Repair/Replacement Warranty…………………………….. 32 Do Not Return The Unit To The Place Of Purchase …………. 32 Warranty Exclusions …………………………….. ………. 32 Other Exclusions …………………………………………. 32 Limits of Implied Warranty and Consequential Damage…….. 32 Contact Information ………………………………………. 32
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INTRODUCTIONCongratulations on your purchase of a Black Diamond product. Black Diamond designs, builds, and supports all of our products to strict specifications and guidelines. With proper product knowledge, safe use, and regular maintenance, this product should bring years of satisfying service.Every effort has been made to ensure the accuracy and completeness of the information in this manual at the time of publication, and we reserve the right to change, alter and/or improve the product and this document at any time without prior notice.Black Diamond highly values how our products are designed, manufactured, operated, and serviced as well as providing safety to the operator and those around the generator. Therefore, it is IMPORTANT to review this product manual and other product materials thoroughly and be fully aware and knowledgeable of the assembly, operation, dangers and maintenance of the product before use. Fully familiarize yourself, and make sure others who plan on operating the product fully familiarize themselves too, with the proper safety and operation procedures before each use. Please always exercise common sense and always err on the side of caution when operating the product to ensure no accident, property damage, or injury occurs. We want you to continue to use and be satisfied with your Black Diamond product for years to come.When contacting Black Diamond/Champion Power Equipment about parts and/or service, you will need to supply the complete model and serial numbers of your product. Transcribe the information found on your product’s dataplate label to the table belowBLACK DIAMOND TECHNICAL SUPPORT TEAM1-888-373-8272MODEL NUMBERBD100619SERIAL NUMBER
SAFETY DEFINITIONSThe purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and their explanations, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures.DANGERDANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.WARNINGWARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.CAUTIONCAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.NOTICENOTICE indicates information considered important, but not hazard-related (e.g., messages relating to property damage).
DATE OF PURCHASE
PURCHASE LOCATION
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IMPORTANT SAFETY INSTRUCTIONSWARNINGCancer and Reproductive Harm www.P65Warnings.ca.govDANGERGenerator exhaust contains carbon monoxide, a colorless, odorless, poisonous 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 AND POINT EXHAUST AWAY. 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.DANGERUsing a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use inside a home or garage, EVEN IF doors and windows are open. ONLY use OUTSIDE and far away from windows, doors, and vents.Install battery-operated carbon monoxide alarms or plug-in carbon monoxide alarms with battery back-up according to the manufacturer’s instructions.WARNINGAlthough the generator contains a spark arrester, maintain a minimum distance of 5 ft. (1.5 m) from dry vegetation to prevent fires.
DANGEROperate equipment with guards in place. 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. DO NOT wear loose-fitting clothing, dangling drawstrings or items that could become caught.DANGERGenerator 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. Connection to your home’s electrical system requires a listed 30A transfer switch installed by a licensed electrician and approved by the local authority having jurisdiction. The connection must isolate the generator from the utility power and must comply with all applicable laws and electrical codes.WARNINGDo not use generator for medical and life support uses.In case of emergency, call 911 immediately. NEVER use this product to power life support devices or life support appliances. NEVER use this product to power medical devices or medical appliances. Inform your electricity provider immediately if you or anyone in your household depends on electrical equipment to live. Inform your electrical provider immediately if a loss of power would cause you or anyone in your household to experience a medical emergency.
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IMPORTANT SAFETY INSTRUCTIONSWARNINGSpark from removed spark plug wire 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 or any other metal object. DO NOT check for spark with the plug removed. Use only approved spark plug testers.WARNINGRunning 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 3 ft. (91.4 cm) of clearance on all sides to ensure adequate cooling. Maintain at least 5 ft. (1.5 m) of clearance from combustible materials.WARNINGRapid retraction of the recoil cord will pull hand and arm towards the engine faster than you can let go. Broken bones, fractures, bruises or sprains could result. Unintentional startup can result in entanglement, traumatic amputation or laceration.When starting engine, pull the recoil 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 and turned on.CAUTIONExceeding the generator’s running capacity can damage the generator and/or electrical devices connected to it.DO NOT overload the generator. DO NOT tamper with the governed speed. DO NOT modify the generator in any way.
CAUTIONStart 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.CAUTIONImproper treatment or use of the generator can damage it, shorten its life or void the 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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IMPORTANT SAFETY INSTRUCTIONSFuel SafetyDANGERGASOLINE AND GASOLINE VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE.Fire or explosion can cause severe burns or death.Gasoline and gasoline vapors: Gasoline is highly flammable and explosive. Gasoline can cause a fire or explosion if ignited. Gasoline is a liquid fuel but it’s vapors can ignite. Gasoline is a skin irritant and needs to be cleaned upimmediately if spilled on skin or clothes. Gasoline has a distinctive odor, this will help detect potentialleaks quickly. Gasoline expands or contracts with ambient temperatures.Never fill the gasoline tank to full capacity, as gasoline needs room to expand when temperatures rise. In the case of any petroleum gasoline fire, flames should never be extinguished unless the fuel supply valve can be turned OFF. By not doing so, if a fire is extinguished and the supply of fuel is not turned OFF, an explosion hazard could be created. When adding or removing gasoline: DO NOT light or smoke cigarettes. Turn the generator off and let cool for at least two minutes before removing the gasoline cap. Always loosen the cap slowly to relieve pressure in the tank. Only fill or drain gasoline outdoors in a well-ventilated area. DO NOT pump gasoline directly into the generator at the gas station. Always use an approved container to transfer the fuel to the generator. DO NOT overfill the gasoline tank. Always keep gasoline away from sparks, open flames, pilot lights, heat and other sources of ignition. When starting the generator: DO NOT attempt to start a damaged generator. Always check that the gasoline cap, air filter, spark plug, fuel lines and exhaust system are properly in place. Always allow spilled gasoline to evaporate fully before attempting to start the engine. Always be certain that the generator is resting firmly on level ground. When operating the generator: DO NOT move or tip the generator during operation.
When transporting or servicing the generator: Always check that the fuel valve is in the OFF position and the gasoline tank is empty. For LPG compatible models, check that the LPG cylinder is disconnected and stored securely away from the generator. Disconnect the spark plug wire. When storing the generator: Store away from sparks, open flames, pilot lights, heat and other sources of ignition. Do not store generator, gasoline or LPG cylinders near furnaces, water heaters, or any other appliances that produce heat or have automatic ignitions.DANGERNEVER place a gasoline container, gasoline tank, LPG cylinder or any combustible material in the path of the exhaust stream during operation of the engine.WARNINGNever use a gasoline container, gasoline tank, or any other fuel item that is broken, cut, torn or damaged.
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IMPORTANT SAFETY INSTRUCTIONSSafety and Dataplate LabelsThese labels warn you of potential hazards that can cause serious injury. Read them carefully. If a label comes off or becomes hard to read, contact Technical Support Team for possible replacement.
A
C
D
B
Top
Side
LABEL
DANGER
PELIGRO
1385-L-SF-CDANGER
Using a generator indoors CAN KILL YOU El uso de un generador en Utiliser une génératrice à
A
IN MINUTES. Generator exhaust contains interiores PUEDE MATARLO l’intérieur PEUT VOUS TUER EN
carbon monoxide. This is a poison you cannot see or smell.
EN MINUTOS. El escape del QUELQUES MINUTES.
generador contiene monóxido L’échappement de la génératrice
de carbono. Éste es un
contient du monoxyde de carbone.
veneno que no se puede ver Il s’agit d’un poison que vous ne
ni oler. NUNCA lo use dentro pouvez ni voir ni sentir.
NEVER use inside a home or garage, EVEN IF doors and windows are open.
ONLY use OUTSIDE and far away from windows, doors, and vents.
del hogar ni el garaje, INCLUSO SI las puertas y ventanas están abiertas. Úselo SÓLO a la INTEMPERIE lejos de ventanas, puertas, y orificios de ventilación.
Ne l’utilisez JAMAIS dans la maison ou le garage MÊME SI les portes et les fenêtres sont ouvertes. Utilisez-la UNIQUEMENT À L’EXTÉRIEUR, loin des fenêtres, portes et trappes de ventilation.
B
UNLEADED FUEL ONLY. Minimum octane rating of 87. Maximum 10% ethanol.GASOLINA REGULAR SOLAMENTE. 87 octanos como mínimo. Máximo de etanol de 10%.ESSENCE SANS PLOMB SEULEMENT. Indice d’octane minimal de 87. Maximum 10 % d’éthanol.1110-L-OP-B
WARNING
AVERTISSEMENT
DO NOT TOUCH! Operation of this equipment may create sparks that
NE PAS TOUCHER! Les Cet équipement peut créer des étincelles et provoquer un incendie
C
Exhaust gases, can start fires around dry vegetation. A spark muffler and engine arrestor may be required. The operator should
gaz d’échappement, le dans la végétation sèche. Un pare-étincelles peut être requis. silencieux et les pièces du L’opérateur doit communiquer avec le service d’incendie
components are contact local fire agencies for laws and regulations
moteur sont extrêmement local pour connaître les lois et les règlements en matière
extremely HOT and relating to fire prevention requirements. If
CHAUDS et peuvent
de prévention des incendies. Si elle est installée,
cause burns.
installed, clean every 100 hours or every season.
causer des brûlures.
nettoyez toutes les 100 heures ou chaque saison.
MID-STATES DISTRIBUTING, LLC. 2800 Meacham Blvd Fort Worth, TX 76137 USA / É.-U. 1-888-373-8272
FREQUENCY (Hz) FRÉQUENCE (Hz)RPM TR / MIN
60 3600
MAX AMBIENT TEMP. 104°F TEMP. AMBIANTE MAX. 40°CH INSULATION CLASSCLASSE D’ISOLATION
2165-L-PR-A
D
MADE IN CHINA / FABRIQUÉ EN CHINE
MODEL MODÈLE
BD100619
PHASE PHASEPOWER FACTOR FACTEUR DE PUISSANCE
1 1.0
GASOLINE WATTS WATTS D’ESSENCE
5500
4010077Certified to CSA
SERIAL NO. N° DE SÉRIE
XXXXXXXXXXXX
AC VOLTS VOLTS C.A.
120/240
Standard C22.2 No. 100
Certifié selon la norme CSA C22.2 N° 100
XXXX MANUFACTURE DATEDATE DE FABRICATION
AC AMPS AMPÈRES C.A.
45.8/22.9
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BackDESCRIPTION Safety Symbols/CO DangerFuel Hot Surface Dataplate
IMPORTANT SAFETY INSTRUCTIONSSafety SymbolsSome of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to more safely operate the product.
SYMBOL
MEANING
Read Operator’s Manual. To reduce the risk of injury, user must read and understand operator’s manual before using this product.
Clearance. Keep all objects at least 5 feet (1.5m) from generator. Heat from the muffler and exhaust gas can ignite combustible objects.
Ground. Consult with local electrician to determine grounding requirements before operation.Electric Shock. Failure to use in dry conditions and to observe safe practices can result in electric shock. Improper connections to a building can allow current to backfeed into utility lines, creating an electrocution hazard. A transfer switch must be used when connecting to a building.Fire/Explosion. Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death. Keep generator at least 5 feet (1.5m) from all objects to prevent combustion.
Hot Surface. To reduce the risk of injury or damage, avoid contact with any hot surface.
Open Flame Alert. Fuel and its vapors are extremely flammable and explosive. Keep fuel away from smoking, open flames, sparks, pilot lights, heat, and other ignition sources.
Wet Conditions Alert. Do not expose to rain or use in damp locations.
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IMPORTANT SAFETY INSTRUCTIONSOperation SymbolsSome of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to more safely operate the product.
SYMBOL
Choke
MEANING
Circuit Breaker Reset: Push
Locking ReceptacleNeutral Bonded to Frame. Neutral circuit IS electrically connected to the frame/ground of the generator.Hertz
Volts
Run time
Ground Terminal
Recoil
Fuel/Gasoline Valve On/Off
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IMPORTANT SAFETY INSTRUCTIONSQuick Start Label SymbolsSome of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to more safely operate the product.
1
2
3
4
56
7
8
1
2
3
5W-30Starting the EngineDANGERMove generator outside and far away from windows, doors and intake ventilation covers.1. Check oil level. Recommended oil is 5W-30.2. Check gasoline level. When adding gasoline, use a minimum octane rating of 87 and an ethanol content of 10% or less by volume.3. Turn the fuel valve to “ON” position. 4. Press ignition switch to the “ON” position. 5. Pull choke knob to “CHOKE” position. 6. Pull the recoil cord. 7. Push the choke knob to “RUN” position. 8. Plug in desired device.
2906-L-OP-BStopping the Engine 1. Turn off and unplug all connected electrical loads. 2. Press ignition switch to the “STOP” position. 3. Turn the fuel valve to “OFF” position. For Electric Start, see “Starting the Engine” section in the Operation section.
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CONTROLS AND FEATURESRead this operator’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
13
12
2
3
11
10 9
4
5 6
7 8
1. Gasoline Tank 8.5 gal. (32 L) 2. Control Panel See Control Panel section. 3. Air Filter Protects the engine by filtering dust and debrisfrom the intake air. 4. Never Flat Wheels 9.5 in. (24.1 cm) 5. Recoil Starter Used to manually start the engine. 6. Fuel Valve Used to turn fuel supply on and off to engine. 7. Support Leg
8. Ground Terminal Consult an electrician for local grounding regulations.9. Oil Fill Cap/Dipstick Used to check and fill oil level. 10. Battery Provides 12V DC power the starting system. 11. Folding Handle Used to move unit by lifting and rolling onwheels. Do not use to lift or carry the unit. 12. Gasoline Gauge 13. Fuel Cap Remove to add fuel.
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CONTROLS AND FEATURES Control Panel
5
2
3
4
1 B
A
1. Choke Used to start a cold engine.2. Ignition Switch Used to START or STOP the generator.3. Intelligauge Three mode digital meter for displaying total run time, voltage and hertz.4. Circuit Breakers (Flip Reset) Protects the generator against electrical overloads from receptacle A5. Circuit Breakers (Push Reset) Protects the generator against electrical overloads from receptacles B.
AYBC
RECEPTACLES120/240V AC, 30A Locking (NEMA L14-30R) May be used to supply electrical power for operation of 120/240 Volt AC, 30 Amp, single phase, 60 Hz electrical loads.(4×) 120V AC, 20A GFCI (NEMA 5-20R) May be used to supply electrical power for operation of 120 Volt AC, 20 Amp, single phase, 60 Hz electrical loads.
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CONTROLS AND FEATURESIntelligaugeThree mode digital meter for displaying frequency, voltage, and total run time. The LCD displays each mode for several seconds and then automatically cycles through.
MODE
DESCRIPTION Output frequency in hertz.
Frequency (Hz) Example: 60.0 hertz
Output voltage of the generator.
Voltage (V)
Example: 120 volts
Total run time of the generator since first operation
Total Run Time (Hrs.) Example: 16 hours
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CONTROLS AND FEATURES
Parts IncludedAccessories Engine Oil………………………………. 37.2 fl. oz. (1100 ml) Oil Funnel ………………………………………………….. 1Assembly Parts Wheels 9.5 in. (24.1 cm) Never Flat Wheel (A) ……………………. 2 Roll Pin (B) ……………………………………………… 2 Large R-clip (C) …………………………………………. 2 Support Leg Support Leg with Vibration Mounts (D) …………………… 2 Flange Bolt (M8×16) (E) …………………………………. 4
Tools Needed
Wrench/Socket set (metric)
A
Pliers
D
B
C
E
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ASSEMBLYYour 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 Technical Support Team at 1-888-373-8272. Please have your serial number and model number available.Unpacking1. Set the shipping carton on a solid, flat surface. 2. Remove everything from the carton except the generator. 3. Carefully cut each corner of the box from top to bottom. Foldeach side flat on the ground to provide a surface area to work with the generator.Install the Wheel KitCAUTIONThe wheel kit is not intended for over-the-road use.Install the Wheels 1. Before adding fuel and oil, tip the generator onto it’s recoilend. 2. Slide the roll pin (B) through the wheel (A) from the outside. 3. Slide the roll pin through the mounting bracket on the frame. 4. Secure with the r-clip (C). 5. Repeat to attach the second wheel.
Install the Support Leg 1. Attach the support leg (D) to the generator frame with flangebolts (E). 2. Slowly tip the generator back down so that it rests on thewheels and support Leg.D EConnect the Battery1. Cut cable tie on each side of battery connector. 2. Push two halves of battery connector together tightly.
C BA
Add Engine OilWARNINGDO 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 failing to follow these instructions will void your warranty.NOTICEThe generator rotor has a sealed, pre-lubricated ball bearing that requires no additional lubrication for the life of the bearing.
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ASSEMBLYNOTICEThe recommended oil type for typical use is 5W-30 automotive oil. However, using the listed conventional oils shown in the “Recommended Engine Oil Type” chart may be used for typical use including the first 5 hours of the break-in run time period of the engine. If running generator in extreme temperatures, refer to the “Recommended Engine Oil Type” chart.
Recommended Engine Oil Type 10W-30
5W-30
10W-40
5W-30 Full Synthetic
°F -20
0
20 40 60 80 100 120
°C -28.9 -17.8 -6.7 4.4 15.6 26.7 37.8 48.9
Ambient temperature
1. Place the generator on a flat, level surface. 2. Remove oil fill cap/dipstick to add oil. 3. Using a funnel, add up to 37.2 fl. oz. (1100 ml) of oil (included)and replace oil fill cap/dipstick. DO NOT OVERFILL.
NOTICECheck oil level often during the break-in period. Refer to the Maintenance section for recommended service intervals.CAUTIONThis engine is equipped with a low oil shut-off and will stop when the oil level in the crankcase falls below the threshold level.NOTICEThe first 5 hours of run time are the break-in period for the unit. During the break in period stay at or below 50% of the running watt rating and vary the load occasionally to allow stator windings to heat and cool. Adjusting the load will also cause engine speed to vary slightly and help seat piston rings. After the 5 hour break-in period, change the oil.NOTICESynthetic oil may be used after the 5 hour initial break-in period. Using synthetic oil does not decrease the recommended oil change interval. Full synthetic 5W-30 oil will aid in starting in cold ambient < 41º F (5º C) temperatures.
4. Check engine oil level at every use and add as needed.MAX OIL DIP STICKNOTICEOnce oil has been added, a visual check should show oil about 1-2 threads from running out of the fill hole. When using the dipstick to check oil level, DO NOT screw in the dipstick while checking.
Add FuelDANGERGasoline vapors are highly flammable and extremely explosive.DO NOT light or smoke cigarettes. Fire or explosion can cause severe burns or death. Only fill or drain fuel outdoors in a well-ventilated area. DO NOT pump gasoline directly into the generator. Use an approved container to transfer the fuel to the generator. Never use a gasoline container, gasoline tank, or any other fuel item that is broken, cut, torn or damaged. DO NOT overfill the gasoline tank. Always keep fuel away from sparks, open flames, pilot lights, heat and other sources of ignition.Use clean, fresh, regular unleaded gasoline with a minimum octane rating of 87 and an ethanol content of 10% or less by volume. y b c DO NOT mix oil with gasoline. 1. Remove the gasoline cap.
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ASSEMBLY2. Slowly add gasoline to the tank. Tank is full when gasoline reaches red circle on screen. DO NOT OVERFILL. Gasoline can expand after filling. A minimum of ¼ in. (6.4 mm) of space left in the tank is required for gasoline expansion, although more than ¼ in. (6.4 mm) is recommended. Gasoline can be forced out of the tank as a result of expansion if overfilled, and can affect the stable running condition of the generator.
3. The approximate fuel level is shown on the fuel gauge on top of the fuel tank.
EMPTY
FULL
WARNINGPouring gasoline too fast through the fuel screen may result in gasoline splashing over the generator and operator while filling.NOTICEThe generator engine works well with 10% or less ethanol blended gasoline. When using ethanol-gasoline blends there are some issues worth noting: Ethanol-gasoline blends can absorb more water than gasoline alone. These ethanol blends can eventually separate, leaving water or a watery goo in the tank, fuel valve and carburetor. The compromised gasoline can be drawn into the carburetor and cause damage to the engine and/or create potential hazards. If a fuel stabilizer is used, confirm that it is formulated to work with ethanol-gasoline blends. Any damages or hazards caused by using ethanol blended gasoline higher than 10% by volume, improperly stored gasoline, and/or improperly formulated stabilizers, are not covered by manufacturer’s warranty.It is advisable to always shut off the gasoline supply and run the engine to starvation after each use. See Storage instructions for extended non-use.
4. Screw on the gasoline cap and wipe away any spilled fuel.CAUTIONUse unleaded gasoline with a minimum octane rating of 87 and an ethanol content of 10% or less by volume.DO NOT light cigarettes or smoke when filling the tank. DO NOT mix oil and gasoline. DO NOT overfill the tank. Fill tank to approximately ¼ in. (6.4 mm) below the top of the tank to allow for gasoline expansion. DO NOT pump gasoline directly into the generator at the pump. Use an approved fuel container to transfer the gasoline to the generator. DO NOT fill tank indoors. DO NOT fill tank when the engine is running or hot.
GroundingYour generator must be properly connected to an appropriate ground to help prevent electric shock.WARNINGFailure to properly ground the generator can result in electric shock.A ground terminal connected to the frame of the generator has been provided (see Controls and Features for terminal location). For remote grounding, connect a length of heavy gauge (12 AWG minimum) copper wire between the generator ground terminal and a copper rod driven into the ground. We strongly recommend that you consult with a qualified electrician to ensure compliance with local electrical codes. Neutral Floating* Neutral circuit IS NOT electrically connected to the frame/ground of the generator.
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OPERATION The generator (stator winding) is isolated from the frame and from the AC receptacle ground pin. Electrical devices that require a grounded receptacle pin connection will not function if the receptacle ground pin is not functional.Neutral Bonded to Frame* Neutral circuit IS electrically connected to the frame/ground of the generator. The generator system ground connects lower frame crossmember below the alternator. The system ground is connected to the AC neutral wire.* See your Specifications section for specified type of grounding.
Generator LocationWARNINGNEVER operate the generator inside any building, garage, basement, crawlspace, shed, enclosure or compartment, including a generator compartment of a recreational vehicle.NEVER operate or start the generator in the back of an SUV, camper, trailer, truck bed (regular sides, flat or other configuration), under staircases, stairwells, next to walls or buildings or in any other location that will not allow for adequate cooling of the generator or for the proper exit of the exhaust flow from the muffler system.DO NOT operate or store the generator in wet weather conditions such as rain or snow. Using a generator in wet conditions could result in serious injury or death due to electrocution.In some state’s generators may be required to be registered with the local utility company when used at construction sites and may be subject to additional rules and regulations, consult your local municipal authority.Generators should always be operated on a flat, level surface at all times (even when not in operation).Generators must have a minimum of 5 feet (1.5 m) of clearance from all combustible material.Generators must also have a minimum of 3 feet (91.4 cm) of air flow clearance on all sides to allow for adequate performance cooling, maintenance and servicing.Always place the generator in a well-ventilated area. NEVER place the generator near air intake vents or where exhaust fumes could be drawn into occupied or confined spaces.Always carefully consider wind and air currents when positioning generator.Always allow generators to properly cool before transport or for storage purposes.Failure to follow proper safety precautions may result in personal injury, damage to the generator and void the manufacturer’s warranty.
WARNINGDuring operation the muffler and exhaust fumes will become hot. If adequate cooling and breathing space are not supplied, or if the generator is blocked or enclosed, temperatures can become extremely heated and may lead to fire.
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OPERATIONWARNINGDo not expose to rain or use in damp locations. Keep all objects a minimum of 5 feet (1.5m) away from the generator at all times. Heat from the muffler surface and exhaust gas stream can ignite combustible materials.
Electric Start 4. Pull choke knob out to the full “CHOKE” position.4a. For restarting a warm engine, pull the choke knob out to 75% of the full “CHOKE” position.
WARNINGIf you must operate in rain or damp locations, DO NOT operate without proper protection of the electrical components.
Use of a safety canopy that is fire retardant and will provide proper air ventilation for the engine exhaust gas stream may be used.Surge ProtectionElectronic 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.Starting the Engine1. Make certain the generator is on a flat, level surface.2. Disconnect all electrical loads from the generator. Never start or stop the generator with electrical devices plugged in or turned on.3. Turn the gasoline fuel valve to the “ON” position.
5. Press and hold the ignition switch to the “START” position. Release as the engine begins to start. If the engine fails to start within five seconds, release the switch and wait at least ten seconds before attempting to start the engine again.CAUTIONIf the ignition switch is held down in the “START” position longer than 5 seconds it could damage the starter. 6. Do not over-choke. As engine warms up, push the choke knobin to the “RUN” position.
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OPERATIONManual Start 4. Push the ignition switch to the “ON” position.5. Pull choke knob out to the full “CHOKE” position. 5a. For restarting a warm engine, pull the choke knob out to 75% of the full “CHOKE” position.6. Pull the recoil cord slowly until resistance is felt and then pull rapidly.
NOTICEKeep choke in “CHOKE” position for only 1 pull of the recoil cord. After first pull, press the choke knob in to the “RUN” position for up to the next 3 pulls of the recoil cord. Too much choke leads to spark plug fouling/engine flooding due to the lack of incoming air. This will cause the engine not to start.NOTICEFor gasoline restarts with hot engine in hot ambient > 86°F (30°C): Keep the choke in 75% of the “CHOKE” position for only 1 pull of the recoil cord. After first pull, push choke to the “RUN” position for up to 3 more pulls of the recoil cord. Too much choke leads to spark plug fouling/engine flooding due to the lack of incoming air. This will cause the engine not to start.NOTICEFor gasoline starting in cold ambient < 59°F (15°C): The choke must be in 100% of the “CHOKE” position for manual start procedures. Do not over-choke. As soon as engine starts, push the choke knob in the “RUN” position.NOTICEIf the engine starts but does not continue to 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.
7. Do not over-choke. As engine warms up, push the choke knob in to the “RUN” position.
BatteryNOTICEThe supplied 12V battery does re-charge while the engine is running. It is also recommended that the battery be fully charged at least once per month or maintained with a trickle charger or battery maintainer (not included).
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OPERATIONConnecting Electrical LoadsLet the engine stabilize and warm up for a few minutes after starting.Plug in and turn on the desired 120 or 240 (if applicable) Volt AC single phase, 60 Hz electrical loads. DO NOT connect 3-phase loads to the generator. DO NOT overload the generator. Use only a high quality, insulated, compatible (3-wire or4-wire) grounded cord set rated equal to or greater (volts and amps) than the receptacle plugging into.WARNINGAlways remember to plug your appliances directly into the generator and do not plug the generator power cord into any electrical outlet or connect to the circuit breaker panel in your home. Connecting a generator to your home’s electric utility company’s power lines, or to another power source, called `backfeeding’ is a dangerous practice that is illegal in many states and municipalities.This action if done incorrectly could damage your generator, appliances and could cause serious injury or death to you or a utility worker when attempting to restore power during an outage occurrence in the neighborhood who may then unexpectedly encounter high voltage on the utility line and suffer a fatal shock.Whether injuries occur or not, if installed incorrectly and not to applicable laws and codes, you may be subject to fines or the utility company may disconnect your home power should this practice be found in your home.If the generator will be connected to a building electrical system, those connections must isolate the generator power from the utility power. You are responsible for ensuring your generator’s electricity does not backfeed into the electric utility power lines. These connections must comply with all applicable laws and codes Consult your local utility company or a qualified electrician to properly install this connection.Do Not Overload GeneratorCapacityFollow 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. Starting wattage is the surge 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 ManagementUse the following formula to convert voltage and amperage to watts:Volts × Amps = WattsTo 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 get up to temperature.3. Make sure all circuit breakers are set to the run position.4. Plug in and turn on the first item. It is best to attach the item with the largest load first.5. Allow the engine to stabilize.6. Plug in and turn on the next item.7. Allow the engine to stabilize.8. Repeat steps 5-6 for each additional item.NOTICENever exceed the specified capacity when adding loads to the generator.GFCIYour generator is equipped with ground fault circuit interrupter (GFCI) receptacles. In the event of a ground fault, a GFCI trips automatically to stop the flow of electricity and prevent serious injury. The green indicator light (A) on the receptacle will also turn off. Press the “RESET” (B) button located on the front of the receptacle to restore flow of electricity. The indicator light will also turn back on. GFCI does not protect against circuit overloads.To ensure proper operation of the GFCI duplex, perform this test monthly:1. With the generator running, plug a lamp into the GFCI receptacle. Turn the lamp on.2. Press the “TEST” (C) button located on the front of the receptacle to trip the device. This should immediately stop the flow of electricity and shut off the lamp. If the electricity is not stopped, do not use this receptacle until it has been serviced or replaced.
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OPERATION3. Press the “RESET” button located on the front of the receptacle to restore the flow of electricity. If the indicator light does not come back on or if the GFCI cannot be reset then it must be replaced.
4. Turn the fuel valve to the “OFF” position.
AB CNOTICEIn any electrical application, some current will flow through the protective ground conductor to the ground, this is called leakage current. It takes 4 mA (0.004 A) and higher of leakage current from the hot wire to the ground to cause a GFCI to trip. On circuits protected by GFCI’s, leakage current can cause unnecessary and intermittent tripping. Some stationary motors, such as a bathroom vent fan, fluorescent lighting fixtures or some refrigerators, may produce enough leakage to cause nuisance tripping. To avoid nuisance tripping, a GFCI should not supply: Fluorescent or other types of electric-discharge lightingfixtures. Permanently installed electric motors, like air conditioners,furnaces or refrigerators.Stopping the Engine1. Turn off and unplug all connected electrical loads. Never start or stop the generator with electrical devices plugged 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. Press the ignition switch to the “OFF” position.
Important: Always ensure that the fuel valve and the ignition switch are in the “OFF” position when the generator is not in use.NOTICEIf the engine will not be used for a period of two (2) weeks or longer, please see the Storage section for proper engine and fuel storage.Moving the GeneratorCAUTION NEVER lift or carry the generator using the folding handle. NEVER tilt sideways while moving the generator. ALWAYS place the generator on its wheels in the uprightposition. ALWAYS turn the generator off and ensure the fuel valve isclosed. ALWAYS make sure engine and muffler are cooled downbefore the generator can be handled safely (typically 15-30 minutes).WARNINGThe folding handle is not long enough to hold and walk with a full stride when moving the generator. Always side step as you walk to avoid injury to your heels and/or feet. Failure to follow these instructions could result in personal injury or damage to the generator.1. Begin by raising the folding handle, found on opposite side of wheels.2. Using the handle, tilt the end of the generator slightly off the ground until balanced on the wheels.
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MAINTENANCE3. While maintaining balance, roll the generator to the desired location.
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.WARNINGNever operate a damaged or defective generator.
WARNINGImproper maintenance will void your warranty.
Operation at High AltitudeThe density of air at high altitudes is lower than at sea level. Engine power is reduced as the air mass and air-fuel ratio decrease. Engine power and generator output will be reduced approximately 3½% for every 1000 ft. of elevation above sea level. 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 natural power loss, Champion Power Equipment can provide a high altitude carburetor main jet. The alternative main jet and installation instructions can be obtained by contacting our Technical Support Team.The part number and recommended minimum altitude for the application of the high altitude carburetor main jet is listed in the following table.In order to select the correct high altitude main jet it is necessary to identify the carburetor model. For this purpose, a code is stamped on the side of the carburetor. Select the correct high altitude jet part number corresponding to the carburetor code found on your particular carburetor.
Carb. Code P27-11-H
High Alt. Jet Part Number 46.131017.20.01.H
Min. Altitude5000 ft. (1524 m)
WARNINGOperation using the alternative main jet at elevations lower than the recommended minimum altitude can damage the engine. For operation at lower elevations, the originally supplied standard main jet must be used. Operating the engine with the wrong engine configuration at a given altitude may increase its emissions and decrease fuel efficiency and performance.
NOTICEFor Emission control devices and systems, read and understand your responsibilities for service as stated in the Emission Control Warranty Statement of this manual.The owner/operator is responsible for all periodic maintenance. Complete all scheduled maintenance in a timely manner. Correct any issue before operating the generator. For service or parts assistance, contact our Technical Support Team at 1-888-373-8272.Cleaning the GeneratorCAUTIONDO NOT spray generator directly with water.Water can enter the generator through the cooling slots and damage the generator windings. It can also contaminate the fuel system.1. Use a damp cloth to clean exterior surfaces of the generator. 2. Use a soft bristle brush to remove dirt and oil. 3. Use an air compressor (25 PSI) to clear dirt and debris fromthe generator. 4. Inspect all air vents and cooling slots to ensure that they areclean and unobstructed. To prevent accidental starting, remove and ground the spark plug wire before performing any service.
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MAINTENANCEChanging the Engine OilChange oil when the engine is warm. Refer to the oil specification to select the proper grade for your operating environment. 1. Remove the oil drain bolt with a 12 mm socket(not included) and extension.
3. Inspect the electrode on the plug. It must be clean and not worn to produce the spark required for ignition.4. Make certain the spark plug gap is 0.028-0.031 in. (0.7-0.8 mm).SPARK PLUG GAP
DRAIN BOLT 2. Allow the oil to drain completely into an appropriate container.
5. Refer to the spark plug types in Specifications when replacing the plug.6. Firmly re-install the plug.7. Attach the spark plug cable to the spark plug.Cleaning the Air Filter1. Remove the snap-on cover holding the air filter to the assembly.
3. Replace the oil drain bolt. 4. Add oil according to Add Engine Oil in Assembly section.DO NOT OVERFILL. Oil not included for routine maintenance. 5. Dispose of used oil at an approved waste managementfacility.NOTICEOnce oil has been added, a visual check should show oil about 1-2 threads from running out of the fill hole. If using the dipstick to check oil level, DO NOT screw in the dipstick while checking.Cleaning and Adjusting the Spark Plug1. Remove the spark plug cable from the spark plug. 2. Use a spark plug socket tool (not included), or a13/16 in. (21 mm) socket (not included) to remove the plug.
2. Remove the foam element. 3. Wash in liquid detergent and water. Squeeze thoroughly dry ina clean cloth. 4. Saturate in clean engine oil. 5. Squeeze in a clean, absorbent cloth to remove all excess oil. 6. Place the filter in the assembly. 7. Reattach the air filter cover and snap in place.Cleaning the Spark Arrestor1. Allow the engine to cool completely before servicing the spark arrestor.2. Remove the three screws holding the cover plate which retains the spark arrestor to the muffler.3. Remove the spark arrestor screen.
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MAINTENANCE4. Carefully remove the carbon deposits from the spark arrestor screen with a wire brush.
Maximum charging rate should not exceed 1.5 amps. Follow the instructions included with the battery charger. The battery should be fully charged at least once per month. If the battery is not able to start the engine, it can be started by manually pulling the engine recoil cord. If the battery voltage is extremely low, the charging circuit may not be able to re-charge the battery. In this case, the battery must be connected to a standard automotive style battery charger for re-charging before it can be used.Disconnect the Battery1. Pull two halves of battery connector apart.
5. Replace the spark arrestor if it is damaged. 6. Position the spark arrestor on the muffler and attach with thescrews removed in step 2.CAUTIONFailure to clean the spark arrestor will result in poor engine performance.
NOTICEFederal and local laws and administrative requirements indicate when and where spark arrestors are required. When ordered, spark arrestors are required for operation of this generator in National Forest lands. In California, this generator must not be used on any forest-covered land, brush-covered land, or grass-covered land unless the engine is equipped with a spark arrestor.Adjusting the GovernorWARNINGTampering with the factory set governor will void your warranty.The air-fuel mixture is not adjustable. Tampering with the governor can damage your generator and your electrical devices and will void your warranty. Contact our Technical Support Team at 1-888-373-8272 for all other service and/or adjustment needs.Generator BatteryYour generator is equipped with an automatic battery charging circuit that charges the battery while the engine is running. The battery will maintain a proper charge if the unit is used on a regular basis (about once every two weeks). If it is used less frequently, the battery should be connected to a trickle charger or battery maintainer (not included) to keep the battery properly charged.
Charge the Battery For a generator equipped with batteries for electric starting, proper battery maintenance and storage should be followed. A trickle charger or battery maintainer should be used to charge the battery while the generator is in storage. Maximum charging rate should not exceed 1.5 amps. Follow the instructions included with the trickle charger or battery maintainer. The battery should be fully charged at least once per month.Maintenance ScheduleFollow the service intervals indicated in the following maintenance schedule. Service your generator more frequently when operating in adverse conditions. Contact our Technical Support Team at 1-888-373-8272 to locate the nearest certified service dealer for your generator or engine maintenance needs.EVERY 8 HOURS OR PRIOR TO EACH USE Check oil level Clean around air intake and mufflerFIRST 5 HOURS (BREAK IN) Change oil
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STORAGEEVERY 50 HOURS OR ANNUALLY Clean air filter Change oil if operating under heavy load or in hotenvironmentsEVERY 100 HOURS OR ANNUALLY Change oil Clean/adjust spark plug Clean spark arrestor Clean fuel valve filter*EVERY 250 HOURS Clean combustion chamber* Check/adjust valve clearance*EVERY 3 YEARS Replace fuel line** To be performed by knowledgeable, experienced owners or certified service centers.WARNINGTo avoid accidental or unintended ignition of your generator during periods of storage, the following precautions should be followed: When storing the generator make sure the ignition switchand fuel valve are set to the “OFF” position.Short Term Storage (up to 30 days)Ethanol blended gasoline may gum up and clog the carburetor if the generator is not run or carburetor drained within 4 weeks. 1. Be sure all appliances are disconnected from the generator. 2. Start the generator as instructed in Starting the Enginesection. 3. Turn the fuel valve to the “OFF” position. 4. Let the engine run until fuel starvation has stopped theengine. This usually takes a few minutes. 5. Move the ignition switch to the “OFF” position.
Mid Term Storage (30 days 1 year)Ethanol blended gasoline in the tank has a maximum shelf life of up to 1 year with the addition of a properly formulated fuel stabilizer and stored in a cool, dry place. 1. Be sure all appliances are disconnected from the generator. 2. Add a properly formulated fuel stabilizer to the gasoline tank. 3. Turn the fuel valve to the “ON” position. 4. Start and run the generator for 10 minutes so the treatedgasoline cycles through the fuel system. 5. Option 1: Drain Gasoline from Carburetor5a. Turn ignition switch to the “OFF” position and allow generator to cool completely before continuing.5b. Turn the fuel valve to the “OFF”. 5c. Use the drain bolt on the carburetor to empty anyexcess gasoline from the carburetor into an appropriate container. Use a funnel (and appropriate hose if necessary) under the carburetor drain bolt to avoid spillage.5d. When gasoline stops flowing from the carburetor, replace and tighten the carburetor drain bolt and be sure to properly dispose of the drained gasoline according to local regulations or guidelines.6. Option 2: Run Dry 6a. With the generator running, turn the fuel valve to the “OFF” position and allow the generator to run until the engine stops from complete fuel starvation. This may take a few minutes. 6b. Turn ignition switch to the “OFF” position and allow generator to cool completely before continuing.7. Remove the spark plug cap and spark plug and pour about a tablespoon of oil into the cylinder.8. Pull the recoil cord slowly to crank the engine to distribute the oil and lubricate the cylinder.9. Install the spark plug and spark plug cap. 10. Clean the generator according to Cleaning the Generator. 11. Store the generator in a cool, dry place out of direct sunlight.
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STORAGELong Term Storage (over 1 year)For storage over 1 year, the gasoline tank and carburetor must be completely drained of gasoline. 1. The generator is to be OFF and all appliances disconnected. 2. Turn the fuel valve to the “ON” position. 3. Use the drain bolt on the carburetor to empty any excessgasoline from the gasoline tank and carburetor into an appropriate container. Use a funnel (and appropriate hose if necessary) under the carburetor drain bolt to avoid spillage. 4. When gasoline stops flowing from the carburetor, replace and tighten the carburetor drain bolt and be sure to properly dispose of the drained gasoline according to local regulations or guidelines. 5. Turn the fuel valve to the “OFF” position. 6. Follow steps 7-11 according to Mid Term Storage.Removing from StorageNOTICEIf the generator has been improperly stored for a period longer than 30 days with ethanol blended gasoline in the gasoline tank and/or carburetor, all fuel must be drained and the carburetor must be thoroughly cleaned of ethanol build up. This process involves technically advanced tasks. For assistance please call our Technical Support Team at 1-888-373-8272. If the gasoline tank and carburetor were properly emptied of all ethanol blended gasoline prior to the generator being stored, follow the below steps when removing from storage.1. Be sure the ignition switch is in the “OFF” position. 2. Add gasoline to the generator according to Add Fuel. 3. Turn the fuel valve to the “ON” position. 4. After 5 minutes check the carburetor and air filter areas forany leaking gasoline. If any leaks are found, the carburetor will need to be disassembled and cleaned or replaced. If no gasoline leaks are found, turn the fuel valve to the “OFF” position. 5. Check engine oil level and add clean, fresh oil if needed. See Oil Specifications for proper oil type. 6. Check and clear air filter of any obstructions such as bugs or cobwebs. If necessary, clean air filter according to Cleaning the Air Filter. 7. Start the generator according to Starting the Engine.28
SPECIFICATIONS
Generator SpecificationsGenerator Model …………………………………. BD100619 Start Type ………………………………….. Electric, Manual Watts (Starting/Running) ………………………… 6800/5500 Volts AC…………………………………………….. 120/240 AC Amps @ 120V ………………………………………. 45.8 AC Amps @ 240V ………………………………………. 22.9 Frequency …………………………………………….. 60 Hz Phase ………………………………………………… Single Grounding Type…………………….. Neutral Bonded to Frame Weight ……………………………………. 175.9 lb. (79.8 kg) Length ……………………………………..29.3 in. (74.5 cm) Width …………………………………….. 27.8 in. (70.6 cm) Height…………………………………….. 26.3 in. (66.9 cm)
Engine SpecificationsModel …………………………………………. YF188FD-110 Displacement ………………………………………… 389 cc Type…………………………………………… 4-Stroke OHV Spark Plug OEM Type…………………………………………….. F6RTC Replacement Type…………………. NGK BPR6ES or equivalent Gap …………………………….0.028-0.031 in. (0.7-0.8 mm) Valve Intake Clearance …………….. 0.005-0.007 in. (0.13-0.17 mm) Exhaust Clearance …………… 0.007-0.009 in. (0.18-0.22 mm)
Oil SpecificationsDO NOT OVERFILL. Type…………………………………….. *See following chart Capacity ……………………………….. 37.2 fl. oz. (1100 ml)
Recommended Engine Oil Type 10W-30
5W-30
10W-40
5W-30 Full Synthetic
°F -20
0
20 40 60 80 100 120
°C -28.9 -17.8 -6.7 4.4 15.6 26.7 37.8 48.9
Ambient temperature
Fuel SpecificationsUse unleaded gasoline with a minimum octane rating of 87 and an ethanol content of 10% or less by volume. DO NOT USE E15 or E85. DO NOT OVERFILL.Gasoline Capacity ……………………………… 8.5 gal. (32 L)Battery SpecificationsType………………….. Rechargeable, Non-Spillable Lead Acid Volts DC ………………………………………… ………. 12 Capacity ………………………………………… ……. 15 AhTemperature SpecificationsStarting Temperature Range (°F/°C) ……….. 5 to 104/-15 to 40NOTICEAn important message about temperature: Your product is designed and rated for continuous operation at ambient temperatures up to 104°F (40°C). When needed, it may be operated at temperatures ranging from 5°F (-15°C) to 122°F (50°C) for short periods of time. If exposed to temperatures outside this range during storage, it should be brought back within this range before operation. In any event, the product must always be operated outdoors, in a well-ventilated area and away from doors, windows and vents.ICES002 WarningThis device complies with Industry Canada license – exempt RSS standard(s).Operation is subject to the following two conditions: 1. This device may not cause interference, and 2. This device must accept any interference, includinginterference that may cause undesired operation of the device.
NOTICETemperature will affect engine oil and engine performance. Change the type of engine oil used based on temperature shown in the “Recommended Engine Oil Type” table.
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TROUBLESHOOTING
Problem
Cause No fuel. Faulty spark plug.
Low oil level.
Engine will not start.
Spark plug wire loose. Fuel valve is closed. Ignition switch OFF. Old fuel or water in fuel. Flooded with fuel.
Choke in the wrong position.
Engine starts but runs roughly. Engine will not start electrically.
Dirty air filter. Dirty fuel valve. Clogged spark arrestor. Generator battery is dead. Battery switch is in the OFF position. Out of fuel.
Engine shuts down during operation. Low oil level.
Clogged spark arrestor.
Generator cannot supply enough power or overheating.
Generator is overloaded. Dirty air filter. Choke in wrong position.
Engine is running but no AC output.
Poor cord connection. Circuit breaker is open. Faulty brush assembly. Faulty AVR (auto voltage regulator). Loose wiring.
GFCI tripped.
Engine hunts or falters.
Other. Engine governor defective. Dirty fuel valve. Carburetor is dirty and running lean.Choke in wrong position.
Solution Add fuel. Clean and adjust spark plug or replace. Fill crankcase to the proper level. Place generator on a flat, level surface. Attach wire to spark plug. Open fuel valve. Press ignition switch ON. Drain fuel and replace with fresh fuel. Let unit stand for 10 mins. Move choke until it stops under RUN position or push in completely. Clean or replace air filter. Clean the fuel valve. Clean spark arrestor. Recharge generator battery. Turn battery switch to ON position. Fill fuel tank. Fill crankcase to the proper level. Place generator on a flat, level surface. Clean spark arrestor. Review load and adjust. See “Connecting Electrical Loads.” Clean or replace air filter. Move choke until it stops under RUN position or push in completely. Check all connections. Reset circuit breaker. Check all circuit breakers. Replace brush assembly (Service Center). Replace AVR (Service Center). Inspect and tighten wiring connections. Reset GFCI receptacle breakers by first pushing the TEST button then the RESET button until green LED illuminates. Contact the help line. Contact the help line. Contact the help line. Clean the fuel valve. Contact the help line. Move choke until it stops under RUN position or push in completely.
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TROUBLESHOOTING
Problem
Cause
Overload.
Repeated circuit breaker tripping.
Faulty power cords or device.
Circuit breaker still too hot.For other issues and technical support: Technical Support Team Toll Free 1-888-373-8272
Solution Review load and adjust. See “Connecting Electrical Loads.” Check for damaged, bare or frayed wires. Replace defective device. Let unit sit for 5 mins.
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WARRANTYCHAMPION POWER EQUIPMENT 3 YEAR LIMITED WARRANTYWarranty QualificationsTo register your product for warranty please visit: https://www.championpowerequipment.com/register To complete registration you will need to include a copy of the purchase receipt as proof of original purchase. Proof of purchase is required for warranty service. Please register within ten (10) days from date of purchase.Repair/Replacement WarrantyChampion Power Equipment (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 three years (parts and labor) from the original date of purchase and 270 days (parts and labor) for commercial and 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.Do Not Return The Unit To The Place Of PurchaseContact CPE’s Technical Service and CPE will troubleshoot any issue via phone or e-mail. If the problem is not corrected by this method, CPE will, at its option, authorize evaluation, repair or replacement of the defective part or component at a CPE Service Center. CPE will provide you with a case number for warranty service. Please keep it for future reference. Repairs or replacements without prior authorization, or at an unauthorized repair facility, will not be covered by this warranty.Warranty ExclusionsThis warranty does not cover the following repairs and equipment: Normal Wear Products with mechanical and electrical components 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 Maintenance This warranty will not apply to parts and/or labor if the product is deemed to have been misused, neglected, involved in an accident, abused, loaded beyond the product’s limits, modified, installed improperly or connected incorrectly to any electrical component. Normal maintenance is not covered by this warranty and is not required to be performed at a facility or by a person authorized by CPE.
Other ExclusionsThis 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 due to acts of God and other force majeure events beyond the manufacturer’s control. Problems caused by parts that are not original Champion Power Equipment parts.When applicable, this warranty does not apply to products used for prime power in place of a utility.Limits of Implied Warranty and Consequential DamageChampion Power Equipment disclaims any obligation to cover any loss of time, use of this product, freight, or any incidental or consequential claim by anyone from using this product. THIS WARRANTY AND THE ATTACHED U.S. EPA and/or CARB EMISSION CONTROL SYSTEM WARRANTIES (WHEN APPLICABLE) ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. 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 or province to province. Your state or province may also have other rights you may be entitled to that are not listed within this warranty.Contact InformationAddress Mid-States Distributing, LLC. 2800 Meacham Blvd. Fort Worth, TX 76137 USA www.black-diamond.com Customer Service Toll Free: 1-888-373-8272
*Except as otherwise stipulated in any of the following enclosed Emission Control System Warranties (when applicable) for the Emission Control System: U.S. Environment Protection Agency (EPA) and/or California Air Resources Board (CARB). Whichever warranty applies for the longer period, either this 3 year limited warranty or the applicable Emission Control System Warranty, shall supersede the other.32
CHAMPION POWER EQUIPMENT, INC. (CPE) AND THE UNITED STATES ENVIRONMENT PROTECTION AGENCY (U.S. EPA)EMISSION CONTROL SYSTEM WARRANTYYour Champion Power Equipment (CPE) engine complies with U.S. EPA emission regulations.YOUR WARRANTY RIGHTS AND OBLIGATIONS:The US EPA AND CPE are pleased to explain the Federal Emission Control Systems Warranty on your 2021 small off-road engine (SORE) and engine powered equipment. New engines and equipment must be designed, built and equipped, at the time of sale, to meet U.S. EPA regulations for small off-road engines (SORE). CPE warrants the emission control system on your small off-road engine (SORE) and equipment for the period of time listed below, provided there has been no abuse, neglect, unapproved modification, or improper maintenance of your equipment.Your emission control system may include parts such as the carburetor, fuel-injection system, the ignition system, catalytic converter and fuel lines. Also included may be hoses, belts, connectors and other emission related assemblies. Where a warrantable condition exits, CPE will repair your small off-road engine (SORE) at no cost to you 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, an 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 (SORE) owner, you are responsible for the performance of the required maintenance listed in your Owner’s Manual. CPE recommends that you retain all your receipts covering maintenance on your small off-road engine (SORE), but CPE cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.As the small off-road engine (SORE) owner, you should however be aware that CPE may deny you warranty coverage if your small, off-road engine (SORE) or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.You are responsible for presenting your small off-road engine (SORE) to an Authorized CPE service outlet or alternate service outlet as described in (3)(f.) below, CPE dealer or CPE, Santa Fe Springs, Ca. as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.If you have any questions regarding your warranty rights and responsibilities, you should contact:Champion Power Equipment, Inc. Customer Service 12039 Smith Ave.Santa Fe Springs, CA 90670 1-877-338-0999
EMISSION CONTROL SYSTEM WARRANTYThe following are specific provisions relative to your Emission Control System (ECS) Warranty Coverage.1. APPLICABILITY: This warranty shall apply to 1997 and later model year small off-road engines (SORE). The ECS Warranty Period shall begin on the date the new engine or equipment is delivered to its original, end-use purchaser, and shall continue for 24 consecutive months thereafter.2. GENERAL EMISSIONS WARRANTY COVERAGE CPE warrants to the original, end-use purchaser of the new engine or equipment and to each subsequent purchaser that each of its small off-road engines (SORE) is:2a. Designed, built and equipped so as to conform to U.S. EPA emissions standards for spark-ignited engines at or below 19 kilowatts.2b. Free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to the part as described in the engine manufacturer’s application for certification for a period of two years.3. THE WARRANTY ON EMISSION-RELATED PARTS WILL BE INTERPRETED AS FOLLOWS:3a. Any warranted part that is not scheduled for replacement as required maintenance in the Owners Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by CPE according to Subsection “d” below. Any such part repaired or replaced under the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period.3b. Any warranted, 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 Period.3c. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the period of time prior to the first scheduled replacement 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 emissionsrelated 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.3d. Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a CPE Authorized Service Outlet.3e. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in fact defective, provided that such diagnostic work is performed at a CPE Authorized Service Outlet.3f. CPE shall pay for covered emissions warranty repairs at non-authorized service outlets under the following circumstances:i. The service is required in a population center with a population over 100,000 according to U.S. Census 2000 without a CPE Authorized Service Outlet ANDii.The service is required more than 100 miles from a CPE Authorized Service Outlet. The 100 mile limitation does not apply in the following states: Alaska, Arizona, Colorado, Hawaii, Idaho, Montana, Nebraska, Nevada, New Mexico, Oregon, Texas, Utah and Wyoming.3g. CPE shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of an emission-related part covered by the ECS Warranty.3h. Throughout the ECS Warranty Period, CPE shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand for such emission-related parts.3i. Any CPE Authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty maintenance or repair and will be provided without charge to the owner. Such use shall not reduce CPE’s warranty obligation.3j. Unapproved add-on or modified parts may not be used to modify or repair a CPE engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. CPE shall not be liable hereunder for failures of any warranted parts of a CPE engine caused by the use of such an unapproved add-on or modified part.
EMISSION-RELATED PARTS INCLUDE THE FOLLOWING: (using those portions of the list applicable to the engine)
Systems covered by this warrantyFuel Metering System Air Induction System Ignition System Exhaust System Miscellaneous Parts Evaporative Emissions
Parts DescriptionFuel regulator, Carburetor and internal parts Air cleaner, Intake manifold Spark plug and parts, Magneto ignition system Exhaust manifold, catalytic converter Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed systems. Fuel Tank, Fuel Cap, Fuel Line (for liquid fuel and fuel vapors), Fuel Line Fittings, Clamps, Pressure Relief Valves, Control Valves, Control Solenoids, Electronic Controls, Vacuum Control Diaphragms, Control Cables, Control Linkages, Purge Valves, Gaskets, 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 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 service locations defined in Section (3)(f.) above must be approved by CPE prior to service. Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used.If you have any questions regarding your warranty rights and responsibilities, or to obtain warranty service, please write or call Customer Service at Champion Power Equipment, Inc.Champion Power Equipment, Inc. 12039 Smith Ave.Santa Fe Springs, CA 90670 1-877-338-0999Attn.: Customer Service
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