OPERATOR'S MANUAL MODEL #100462 6500W PORTABLE GENERATOR REGISTER YOUR PRODUCT ONLINE at championpowerequipment.com or visit championpowerequipment.com READ AND SAVE THIS MANUAL. 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.
100462 - 6500W PORTABLE GENERATOR TABLE OF CONTENTS Introduction ................................................ 3 TABLE OF CONTENTS Storage .................................................. ... 21 Short Term Storage (up to 1 year) ............................. 21 Long Term Storage (over 1 year) .............................. 22 Safety Definitions ....................................... 3 Removing from Storage ........................................ 22 Important Safety Instructions ................
INTRODUCTION 100462 - 6500W PORTABLE GENERATOR INTRODUCTION SAFETY DEFINITIONS Congratulations on your purchase of a Champion Power Equipment (CPE) product. CPE 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. The purpose of safety symbols is to attract your attention to possible dangers.
100462 - 6500W PORTABLE GENERATOR IMPORTANT SAFETY INSTRUCTIONS ! DANGER Generator exhaust contains carbon monoxide, a colorless, odorless, poison gas. Breathing carbon monoxide will cause nausea, dizziness, fainting or death. If you start to feel dizzy or weak, get to fresh air immediately. OPERATE GENERATOR OUTDOORS ONLY IN A WELL VENTILATED AREA.
100462 - 6500W PORTABLE GENERATOR ! WARNING IMPORTANT SAFETY INSTRUCTIONS ! CAUTION Running engines produce heat. Severe burns can occur on contact. Combustible material can catch fire on contact. Improper treatment or use of the generator can damage it, shorten its life and void your warranty. DO NOT touch hot surfaces. Use the generator only for intended uses. Avoid contact with hot exhaust gases. Operate only on level surfaces. Allow equipment to cool before touching.
100462 - 6500W PORTABLE GENERATOR Fuel Safety IMPORTANT SAFETY INSTRUCTIONS When operating the generator: ! DANGER GASOLINE 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.
100462 - 6500W PORTABLE GENERATOR IMPORTANT SAFETY INSTRUCTIONS Safety Symbols Some 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 from this machine.
IMPORTANT SAFETY INSTRUCTIONS 100462 - 6500W PORTABLE GENERATOR Operation Symbols Some 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 SYMBOL Engine START MEANING Fuel Valve OFF. Engine ON Choke Engine STOP Run Locking Receptacle Circuit Breaker Reset: Push 10 W-30 Circuit Breaker Reset: Flip Neutral Bonded to Frame.
100462 - 6500W PORTABLE GENERATOR SYMBOL IMPORTANT SAFETY INSTRUCTIONS MEANING Choke. Move choke lever to “RUN” position. Recoil Starter. Pull recoil starter to start the engine. Plug In. Plug in desired devices. Unplug. Unplug devices when turning generator off.
IMPORTANT SAFETY INSTRUCTIONS 100462 - 6500W PORTABLE GENERATOR Safety Labels These 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 B Top Back LABEL A Safety Icons/ CO Danger 1028-L-SF-B ! DANGER ! PELIGRO ! DANGER Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide.
100462 - 6500W PORTABLE GENERATOR CONTROLS AND FEATURES CONTROLS AND FEATURES Read 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 9 1 2 3 8 4 5 7 6 10 1. Gasoline Tank – 6 gal. (22.9 L) 7. Oil Fill Cap/Dipstick – Used to check and fill oil level. 2. Choke – Used to start the engine. 8. Control Panel – See “Control Panel” section. 3.
CONTROLS AND FEATURES 100462 - 6500W PORTABLE GENERATOR Control Panel 3 2 4 1 A B 1. Circuit Breakers (Push Reset) – Protects the generator against electrical overloads. 2. Circuit Breakers (Flip Reset) – Protects the generator against electrical overloads. RECEPTACLES A 3. Intelligauge – Three mode digital meter for displaying run time, voltage and hertz. 4. Engine Switch – Used to put in START mode or STOP the generator.
100462 - 6500W PORTABLE GENERATOR CONTROLS AND FEATURES Parts Included Accessories Oil Funnel .............................................................................. 1 Assembly Parts Wheels 8 in. (20.3 cm) Never Flat Wheel (A) .................................. 2 Roll Pin (B)........................................................................ 2 Large R-clip (C) ................................................................ 2 Engine Vibration Mounts Support Leg with Vibration Mounts (D)......
ASSEMBLY 100462 - 6500W PORTABLE GENERATOR 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. E If you have any questions regarding the assembly of your generator, call our Technical Support Team at 1-877-338-0999. Please have your serial number and model number available. Unpacking D F Install the Handle 1. Set the shipping carton on a solid, flat surface. 2.
ASSEMBLY 100462 - 6500W PORTABLE GENERATOR 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 1.2 qt. (1.1 L) of oil (not included) and replace oil fill cap/dipstick. DO NOT OVERFILL. " NOTICE Weather will affect engine oil and engine performance. Change the type of engine oil used based on weather conditions to suit the engine needs. " NOTICE Synthetic oil may be used after the 5 hour initial breakin period.
OPERATION 100462 - 6500W PORTABLE GENERATOR ! CAUTION Use regular unleaded gasoline with a minimum octane rating of 85 and an ethanol content of 10% or less by volume. DO NOT mix oil and gasoline. 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 container to transfer the gasoline to the generator. DO NOT fill tank indoors. DO NOT fill tank when the engine is running or hot.
OPERATION 100462 - 6500W PORTABLE GENERATOR ! WARNING Do not operate or store the generator in rain, snow, or wet weather. Using a generator or electrical appliance in wet conditions, such as rain or snow, or near a pool or sprinkler system, or when your hands are wet, could result in electrocution. Starting the Engine 1. Make certain the generator is on a flat, level surface. 2. Disconnect all connected electrical loads from the generator.
OPERATION 100462 - 6500W PORTABLE GENERATOR Connecting Electrical Loads Power Management Let the engine stabilize and warm up for a few minutes after starting. Use the following formula to convert voltage and amperage to watts: 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.
MAINTENANCE 100462 - 6500W PORTABLE GENERATOR Operation at High Altitude ! WARNING The density of air at high altitude 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. This is a natural trend and cannot be changed by adjusting the engine.
MAINTENANCE 100462 - 6500W PORTABLE GENERATOR 2. Allow the oil to drain completely into an appropriate container. 5. Squeeze in a clean, absorbent cloth to remove all excess oil. 3. Replace the oil drain plug. 6. Place the filter in the assembly. 4. Remove the oil fill cap/dipstick to add oil. 7. Reattach the air filter cover and snap in place. 5. Add oil according to “Add Engine Oil” on Assembly section. DO NOT OVERFILL. Oil not included for routine maintenance. 6.
STORAGE 100462 - 6500W PORTABLE GENERATOR Maintenance Schedule Follow the service intervals indicated in the following maintenance schedule. STORAGE ! DANGER Service your generator more frequently when operating in adverse conditions. Gasoline and gasoline vapors are highly flammable and extremely explosive. Contact our Technical Support Team at 1-877-338-0999 to locate the nearest CPE certified service dealer for your generator or engine maintenance needs.
STORAGE 100462 - 6500W PORTABLE GENERATOR 6c. 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. 7. Option 2: Run Dry 7a. Turn engine switch to the “ON” position and start the generator. 7b. 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.
SPECIFICATIONS 100462 - 6500W PORTABLE GENERATOR SPECIFICATIONS Fuel Specifications Generator Specifications Use regular unleaded gasoline with a minimum octane rating of 85 and an ethanol content of 10% or less by volume. DO NOT USE E15 or E85. DO NOT OVERFILL. Generator Model ........................................ 100462 Start Type ................................................ Manual Watts (Starting/Running) ........................... 8125/6500 AC Volts ........................................
62 61 60 58 63 18 66 18 67 68 69 64 65 18 70 71 72 81 56 80 79 84 73 74 75 83 82 85 60 51 9 50 17 49 48 59 76 57 77 47 55 78 46 86 54 87 45 88 44 53 43 1 42 52 89 2 4 18 17 16 41 3 90 40 39 91 38 92 32 26 19 5 6 93 37 15 36 20 7 35 13 14 33 94 34 23 21 33 24 25 22 12 8 9 10 11 31 27 28 29 30 100462 - 6500W PORTABLE GENERATOR SPECIFICATIONS Parts Diagram 24
SPECIFICATIONS 100462 - 6500W PORTABLE GENERATOR Parts List # Part Number Description Qty. # 1 34 153.190200.03 Part Number AVR Description Qty. 1 1 2.06.006 Clamp, Ø7 × Ø1 2 24.070030.00 Hole, Breather Tube 1 35 152.190002.00 End Housing 1 3 152.070014.06 Pipe, Reversal Valve, 730 mm 1 36 2.08.032 Flange Bolt/Washer Assembly M6 × 179 4 4 2.05.001 Clamp, Ø8 × 6.5 2 37 2.08.035 Bolt M5 × 214 2 5 122.070100.07 Fuel Tank Cap 1 38 1.6175.05 Nut M5 2 6 122.070300.
SPECIFICATIONS 100462 - 6500W PORTABLE GENERATOR # Part Number Description Qty. 67 152.200002.00.2 Support Leg 60 mm 1 68 152.201400.00 Rubber, Support 2 69 1.5789.0825 Flange Bolt M8 × 25 2 70 152.22.4.2 Control Panel, Black 1 71 5.1870.008 Receptacle Cover, Receptacle 5-20R, 2 72 5.1120.027 Receptacle 5-20R, CSA 2 73 5.1120.026 Receptacle L14-30R, CSA 1 74 5.1210.920 20Amp Circuit Breaker, Push Button, CSA 2 75 1.9074.4.0306.
105 87 2 1 3 95 96 97 98 89 99 100 107 4 22 5 23 101 6 89 7 8 9 24 25 26 102 103 10 11 27 28 104 88 29 87 12 86 13 85 14 30 84 94 15 62 61 83 93 64 16 17 31 63 110 65 68 91 67 18 32 66 92 19 33 69 70 90 106 73 20 12 34 71 72 75 21 28 35 74 76 108 77 79 43 36 78 44 80 45 81 47 48 21 37 46 82 49 109 50 12 52 42 41 51 55 40 39 64 83 53 54 38 65 67 56 69 53 68 57 70 59 54 71 58 72 60 100462 - 6500W
SPECIFICATIONS 100462 - 6500W PORTABLE GENERATOR Engine Parts List # Part Number Description Qty. # Part Number Description Qty. 2.03.021.1 Washer Ø6.4 × Ø13 × 1, Black 1 39 45.110013.00 Shaft, Governor Gear 1 40 45.110100.00 Gear, Governor 1 41 21.110011.00 Clip, Governor Gear 1 42 45.110012.00 Bushing, Governor Gear 1 43 47.050200.00 Connecting Rod 1 1 21.061300.01.48 Handle, Recoil, Soft, Yellow 2 1.5789.0608 Flange Bolt M6 × 8 3 3 46.061100.02.
SPECIFICATIONS 100462 - 6500W PORTABLE GENERATOR # Part Number Description Qty. 75 46.040016.00 Shaft, Rocker Arm 1 76 46.040201.00 Retainer, Rocker Arm 1 77 46.040009.00 Rocker Arm, Intake Valve 1 78 46.040018.00 Rocker Arm, Exhaust Valve 1 79 1.97.1.06 Washer Ø6 2 80 22.040012.00 Screw, Valve Adjustment 2 81 1.6177.1.06 Flange Nut M6 2 82 21.040021.00 Nut M6 × 0.5, Lock 2 83 2.01.008 Stud Bolt M6 × M8 × 105 2 84 46.130002.20 Gasket, Insulator 1 85 45.130001.
B Y L G R W BLACK YELLOW BLUE GREEN RED WHITE Br B/W W/G G/Y W/L In B/G DCW EXW BROWN BLACK WHITE WHITE GREEN GREEN YELLOW WHITE BLUE INDIGO BLACK GREEN GENERATOR BLOCK FW MW2 W + no use R Y W L L R MW1 L Y Y L L SPARKING PLUG ENGINE BLOCK L B B B R R H V Hz Intelligauge IGNITION COIL Br Br AVR R W B W 27A DIODE W 250V 27A DOUBLE POLE B B R G/Y W B/G W/G R W Y G/Y CIRCUIT BREAKER 20A FUEL CUT SOLENOIL B/G W/G Transition G/Y L14-30R B 5-20R DUPLEX A
TROUBLESHOOTING 100462 - 6500W PORTABLE GENERATOR TROUBLESHOOTING Problem Generator will not start. Generator will not start; Generator starts but runs roughly. Generator shuts down during operation. Generator cannot supply enough power or overheating. No AC output. Generator gallops. Cause Solution No fuel. Add fuel. Faulty spark plug. Replace spark plug. Unit loaded during start up. Remove load from unit. Low oil level. Fill crankcase to the proper level.
WARRANTY* Other Exclusions CHAMPION POWER EQUIPMENT 3 YEAR LIMITED WARRANTY This warranty excludes: Warranty Qualifications To register your product for warranty and FREE lifetime call center technical support 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.
CHAMPION POWER EQUIPMENT, INC. (CPE) AND THE UNITED STATES ENVIRONMENT PROTECTION AGENCY (U.S. EPA) EMISSION CONTROL SYSTEM WARRANTY Your 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 2020 small off-road engine (SORE) and engine powered equipment.
EMISSION CONTROL SYSTEM WARRANTY The 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.
EMISSION-RELATED PARTS INCLUDE THE FOLLOWING: (using those portions of the list applicable to the engine) Systems covered by this warranty Parts Description Fuel Metering System Fuel regulator, Carburetor and internal parts Air Induction System Air cleaner, Intake manifold Ignition System Spark plug and parts, Magneto ignition system Exhaust System Exhaust manifold, catalytic converter Miscellaneous Parts Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed systems.
