Champion 100136 Operator'S Manual Download

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Model 100136

CONTENTS

Part No. 101306 Rev. A

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 39

ADDITIONAL INFORMATION . . . . . . . . . . . . . . . . . 41

Identify / Select Standby Circuits . . . . . . . . . . . . . 41

Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . 41

Customer Familiarization Summary . . . . . . . . . . . 42

HSB, ATS Model & Serial Reference

Back-Up Circuits . . . . . . . . . . . . . . . . . . . . . . . .43

Maintenance and Service Record . . . . . . . . . . . . .44

Summary of Contents for 100136

Page 1: ...REV 100136 20160407 DANGER Not intended for use in critical life support application DANGER Generator must be installed and operated outdoors only ...

Page 2: ...tenance improvement may be changed at any time without notice ALL RIGHTS RESERVED No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Champion Power Equipment CPE Have questions or need assistance Do not return this produ...

Page 3: ... Time 17 Hour Meter 17 Engine Control Module 17 Reset Fault Code s 17 ATS Control Module 18 Battery Charger 19 Emission Requirements 19 Specifications 20 Fuel System 21 Battery Requirements 21 Battery Charging 21 Model and Serial Number 21 OPERATION 22 Enclosure and Access 22 Pre Start Checklist 22 Turning Off the Generator 22 MAINTENANCE 23 Scheduled Maintenance Chart 23 Engine Oil 23 Engine Oil ...

Page 4: ...v A Wiring Diagram 38 TROUBLESHOOTING 39 ADDITIONAL INFORMATION 41 Identify Select Standby Circuits 41 Surge Protection 41 Customer Familiarization Summary 42 HSB ATS Model Serial Reference Back Up Circuits 43 Maintenance and Service Record 44 ...

Page 5: ...owerequipment com HOME STANDBY GENERATOR This home standby generator is intended exclusively for outdoor installation This generator will operate using either liquefied petroleum gas LPG or natural gas NG This generator is designed to supply typical home load such as Induction motors sump pumps refrigerators air conditioners furnaces Electronic items televisions computers Household lighting Microw...

Page 6: ...BLE LIQUID CODE National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA NO 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES National Fire Protection Association 470 Atlantic Avenue Boston Ma 02210 NFPA NO 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES National Fire Protection Association 470 Atlantic Avenue Boston Ma 02210 NFPA NO 54 NATIONAL FUEL GAS CODE Natio...

Page 7: ...ate injury NOTICE Indicates a situation that can cause damage to the equipment personal property and or the environment or cause the equipment to operate improperly OTE N Indicates a procedure practice or condition that should be followed in order for the generator to function in the manner intended SAFETY SYMBOL DEFINITIONS Black hazard pictorial on yellow equilateral triangle enclosed by black t...

Page 8: ...gulations install and service the generator ALWAYS comply with local state and national electrical and building codes when installing the generator NEVER alter the recommended installation in a way that would render the unit noncompliant with these codes ALWAYS comply with regulations that Occupational Safety and Health Administration OSHA has established ENSURE the generator is installed followin...

Page 9: ...erator regularly Contact your dealer if repairs are needed NEVER climb or step on any part or components of the generator Doing so may result in injury and cause leaking fuel and exhaust OPERATING HAZARDS WARNING ALWAYS operate the generator following the manufacturer s instructions Operating the generator imprudently neglecting maintenance or being careless can result in injury or possible death ...

Page 10: ...arbon 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 The generator must be installed and operated outdoors only NEVER install the generator where exhaust fumes could seep inside or be drawn into a potentially occupied building through windows air intake vents or othe...

Page 11: ...al Code NEC State and local codes for proper grounding may also apply Avoid direct contact with an electric shock victim Immediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor using a nonconducting item such as a dry board or rope If the victim is unconscious apply first aid and call 911 immediately FIRE EXPLOSION HAZARDS WAR...

Page 12: ...TTERY HAZARDS WARNING Always read and comply with the battery manufacturer s recommendations for procedures concerning proper battery use and maintenance WARNING Batteries contain sulfuric acid and generate explosive mixtures of hydrogen and oxygen gases Keep any device that may cause sparks or flames away from the battery to prevent explosion Always wear protective glasses or goggles and protecti...

Page 13: ...ion The generator may create sparks while operating Risque d incendie Nettoyez TOUJOURS la surface à proximité du groupe électrogène et enlevez les débris et ou la végétation sèche Le groupe électrogène peut générer des étincelles pendant son fonctionnement Riesgo de incendio SIEMPRE mantenga el área circundante cerca del generador limpia y libre de escombros y o vegetación seca El generador puede...

Page 14: ...1306 Rev A SAFETY SERIAL MODEL NAMEPLATE LABEL LOCATIONS The safety labels have specific placement and must be replaced if they are unreadable damaged or missing inner part of cover A B 2 6 5 3 4 1 A Serial number location B Nameplate ...

Page 15: ...2 5 KW GENERATOR Figure 1 1 Exhaust System 2 Air Inlet 3 Fuel Regulator Wire Connections behind panel 4 Main Circuit Breaker 5 Hour Meter 6 Exterior Fault Code Indicator Light 7 Exercise Switch 8 ATS Control Module 9 Engine Control Module 10 Batteries not included 11 Engine 12 Alternator 1 2 9 4 5 7 3 8 6 10 11 12 ...

Page 16: ...O MAIN CIRCUIT BREAKER DISJONCTEUR PRINCIPAL INTERRUPTOR DE CIRCUITO PRINCIPAL Figure 3 EXERCISE SWITCH The exercise switch incorporates a built in timer The generator will automatically perform an exercise period once every seven days 168 hours At the start of the exercise period the engine will start and run for 15 minutes Load transfer from the generator output will not occur unless the utility...

Page 17: ...vice at 1 877 338 0999 RESET FAULT CODE S There is also an exterior fault code indicator light located on the back of the enclosure This should be checked weekly to make sure there are no active fault codes The fault code s can be reset by placing the Engine Control Module Figure 5 in the OFF position This will reset fault LED however if a fault code s re occurs it must be addressed APAGADO ARRÊT ...

Page 18: ...opped below the safe operating level When this happens the engine will shut down Check the engine oil level before attempting to restart the engine The engine will not start until the problem is corrected OVER CRANK LED The red LED will be lit if the engine tried to start but was unable to start in the specified time period The engine will try to start five times and if unsuccessful the light will...

Page 19: ...ating above 50 capacity NO CHARGE Lit to indicate a battery charging problem If this LED is lit the LED on the Engine Controller module LOW BATTERY will also be lit EMISSION REQUIREMENTS This engine powered generator meets all United States Environmental Protection Agency EPA Phase 3 requirements and is approved in both the USA and Canada This generator is certified to operate on pipeline NG and L...

Page 20: ...ment 717 cc Cylinder block Aluminum with cast iron sleeves Ignition system Solid state magneto Spark plug F7RTC NGK BPR7ES Governor Mechanical Starter Electric 24V DC Oil capacity 1 5 qt 1 4 L RPM 3600 Controls Mode switch auto Auto start on utility failure Mode switch manual Starts on demand Mode switch off Stops unit control and charger active Ready to run maintenance messages Standard Programma...

Page 21: ...7 on page 19 MODEL AND SERIAL NUMBER The model and serial number plate is affixed to the generator above the control panel Have this information if calling for service or ordering parts Figure 9 CHAMPION POWER EQUIPMENT 12039 Smith Ave Santa Fe Springs CA 90670 USA P N 101501 CARCASA A PRUEBA DE LLUVIA EQUIPADO BOÎTIER ÉTANCHE À LA PLUIE ÉQUIPÉ RAINPROOF ENCLOSURE FITTED RATED CURRENT 104 A 52 A L...

Page 22: ...oper operation the following items should be checked Fuel valve is in the ON position No fault code LEDs are lit Battery is at full charge ATS control module is in the AUTO position Engine control module is in the ATS position Transfer switch lever is in the Utility Power position TURNING OFF THE GENERATOR If you need to shut off the generator when it is running turn the engine control module swit...

Page 23: ...nspect engine spark plug Complete inspection of generator and engine tune up Monthly or 24 hours of continuous operation Service sooner if operating in high ambient temperatures or a dusty and dirty environment Maintenance should be performed by your service dealer If so equiped ENGINE OIL ENGINE OIL REQUIREMENTS Use American Petroleum Institute API Service Class SN or better Do not use special ad...

Page 24: ...nmentally responsible Consult the local authorities or reclamations facility for proper disposal of engine oil waste 5 Position drain pan under alternator 6 Loosen hose clamp on oil drain hose and slide drain hose off retaining pin Figure 13 1 2 3 Figure 13 1 Oil Drain Hose 2 Hose Clamp 3 Retaining Pin 7 Position drain hose into drain pan and allow crankcase to empty 8 With the oil drained remove ...

Page 25: ...wnward to fully seat element into air cleaner base 7 Install the cover and snap the clips in place 8 Turn the engine control module switch to its prior position SPARK PLUG 1 Turn the ATS to the OFF position 2 Turn the engine control module switch to the OFF position 3 Remove the spark plug cable from the spark plug 4 Clean the area around the spark plug to keep dirt out of the engine and remove th...

Page 26: ...nce must be performed before returning the generator to service Turn engine control module and ATS control module to the OFF position Have a authorized Champion Dealer inspect the generator and perform any necessary maintenance If the house or building has been exposed to a flood it should be inspected by a certified electrician for any electrical problems that may occur if the generator is put ba...

Page 27: ...tive battery terminal first and then connect the negative battery cable to the negative battery terminal 6 Clean and wipe down the generator with mild soap and water 7 Turn the fuel shutoff valve to the ON position 8 Turn the engine control module switch to the manual position The engine should start Run the engine for 15 minutes to allow it to warm up The fuel system might require more than one s...

Page 28: ...104 105 106 107 108 109 110 111 112 113 114 115 116 128 127 124 123 121 120 119 118 122 98 99 78 79 77 76 74 84 85 83 82 81 80 86 90 91 88 89 10 19 20 21 22 5 4 6 7 14 15 16 10 11 12 13 8 9 2 1 130 129 126 133 134 135 136 137 138 139 140 143 142 141 93 83 92 103 3 94 75 17 131 132 144 125 87 2 1 3 4 5 61 60 18 17 33 34 32 31 30 29 28 26 27 25 24 23 97 96 95 39 38 117 1 2 28 1 2 3 4 26 ...

Page 29: ...48 2 14 005 Key Flywheel 1 49 717 051101 04 Assy Crankshaft Taper PTO 1 50 2 03 026 Washer Crankshaft Thrust 1 Part Number Description Qty 51 101454 Camshaft Assembly 1 52 717 050200 00 Assy Connecting Rod 2 53 2 09 009 Retainer Piston Pin 4 54 100968 Pin Piston 17 X 53 8 2 55 101396 Piston 78Mm 2 75Mm Dish Ceramic Crown 2 56 100784 Ring Assy Oil Control 2 57 717 050302 00 Ring Piston 2Nd 2 58 717...

Page 30: ...ll 1 119 21 040021 00 Jam Nut M6 X 0 5Mm Pitch 4 120 1 6170 08 Hex Nut Gb6170 M8 4 121 717 040016 00 Sleeve Rocker Arm 4 122 2 08 086 Bolt M8 X 1 25 Hhw Special 4 123 717 040005 00 Push Rod 4 124 45 040002 00 Valve Intake 2 125 101734 Bolt Hex Flange M10 X 80 6 126 717 080300 02 Air Guide Assy Inner Cyl 2 1 127 717 010100 20 Cyl Head 2 Purchased Assy 1 128 717 030009 00 Gasket Assy Cylinder Head 2...

Page 31: ...Model 100136 MAINTENANCE 31 2015 Champion Power Equipment Part No 101306 Rev A PAGE INTENTIONALLY LEFT BLANK ...

Page 32: ...A ENCLOSURE AND ASSEMBLIES 1 2 3 4 7 9 8 10 11 12 14 13 15 16 19 20 21 22 23 24 28 29 30 31 32 33 34 35 36 37 39 40 42 43 44 45 38 27 50 49 47 46 48 53 58 59 60 62 63 64 43 65 66 67 51 52 61 25 26 55 57 68 5 6 70 71 72 73 17 54 41 18 56 74 75 76 69 ...

Page 33: ...1 34 1 5789 0612 Flange Bolt M6 x 12 8 35 2 03 004 Washer Ø24 x Ø6 5 x 1 5 4 36 163 200017 01 Thermal Baffle 1 37 163 200017 00 24 Muffler Cover Top Silk Grey 1 Part Number Description Qty 38 161 1010005 00 2 Supportor Muffler Top Black 1 39 100136 901 Generator Assembly 1 40 2 06 035 Clamp Ø23 5 1 41 2 06 037 Clamp Ø28 1 42 100136 902 Control Panel Assembly 1 43 161 200021 02 Seal Strip Right Lef...

Page 34: ...Model 100136 MAINTENANCE 34 Part No 101306 Rev A 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 22 26 27 28 29 30 19 17 20 21 23 25 31 32 34 37 1 35 36 33 24 ALTERNATOR AND EXHAUST SYSTEM ...

Page 35: ... Assembly M10 x 375 1 16 161 190019 00 Flange Plate Fan 1 17 163 101000 00 Muffler Assembly 1 18 163 101001 00 Exhaust Pipe 1 19 2 03 004 Washer Ø24 x Ø6 5 x 1 5 6 Part Number Description Qty 20 1 5789 0615 Flange bolt M6 x 15 6 21 1 93 06 Lock Washer Ø6 6 22 163 080009 00 2 Air Guide Muffler Pipe Above 1 23 1 9074 17 0612 Screw Washer Assembly M6 x 12 6 24 717 100001 00 Gasket Exhaust Pipe 2 25 1...

Page 36: ...Model 100136 MAINTENANCE 36 Part No 101306 Rev A CONTROL PANEL 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 24 26 27 28 31 32 33 34 5 36 13 22 25 3 4 35 1 2 37 38 32 4 30 29 23 ...

Page 37: ...2 08 068 Flange Bolt M5 x 13 4 17 161 200020 00 Grille 1 18 2 02 030 Cage Nut M5 8 19 163 200005 00 24 Firewall Right Silk Grey 1 Part Number Description Qty 20 163 200109 00 Rubber Strip 1040 mm 1 21 163 200021 01 Foams Right Firewall 1 22 1 16674 0812 Flange Bolt M8 12 3 23 163 210003 00 Grommet Wire 1 24 2 02 031 Cage Nut M6 2 25 161 190200 00 AVR TT91 15U 1 26 2 13 029 Bushing Ø7 Ø14 50 2 27 1...

Page 38: ...signal Micro switch common 5 12 11 6 2 1 3 10 9 7 Utility line L2 Utility line L1 Utility position micro switch Load bus L2 Load bus L1 Neutral line Indicator Light DC24V L N BATTERY CHARGER MODEL 100482 GND N C GND Circuit N C N C 50W10Ω Power Resistance GND L1 L2 Hour Meter 44 33 22 11 STATOR Power Winding Power Winding Excitation Winding Sampling Winding Carbon Brush ROTOR CB To ATS Terminal Bl...

Page 39: ...m fuel pressure to fuel regulator 4 Weak battery s Recharge or replace battery s 5 Low oil level Check for oil leaks Check the oil level and add oil if necessary 6 Spark plug wire is disconnected Connect spark plug wire 7 Defective fuel solenoid regulator ENGINE STARTS RUNS ROUGH 1 Fuel pressure insufficient Manometer check confirm fuel pressure to fuel regulator 2 Wrong fuel jets Check jets for N...

Page 40: ...rected Only the LOW BATTERY LED will not latch out or shut down the HSB All other RED LED faults will latch out shut down disable starting and light the RED LEDS on the Engine Control Module and the exterior fault code light on the backside of the HSB RESET FAULT CODE S There is an exterior fault code indicator light located on the back of the enclosure This should be checked weekly to make sure t...

Page 41: ...y size the HSB by referring to the sizing guide provided by Champion www championpowerequipment com or call Champion 1 877 338 0999 Circuits must be protected by the same size breaker For example a 15 amp 120 volt circuit in the ATS will replace a 15 amp 120 volt circuit in the main utility distribution panel When tied together or backed up the breakers must be the same size SURGE PROTECTION CAUTI...

Page 42: ...l out and provide the customer a copy of the HSB ATS model serial number reference This information is extremely important for part purchases and service information these numbers are specific to each HSB and ATS 11 Fill out and provide the customer a copy of the ATS back up circuits 12 Fill out the Circuit Label inside the ATS It s always a good business practice to place business cards in the Ow...

Page 43: ..._______ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ Date Installed _____________________________________ Dealer Installer ___...

Page 44: ...___________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ ___________________________________________________________________________...

Page 45: ...Champion Power Equipment 12039 Smith Ave Santa Fe Springs CA 90670 USA Made in China ...

Page 46: ...ted comprehensive coverage on engine short block and alternator rotor and stator parts only GUIDELINES Warranty begins upon the successful activation of the unit Unit should be Registered and Proof of Purchase and Maintenance must be available Warranty is transferable between ownership of original installation site Warranty only applies to permanently wired and mounted units Any and all warranty r...

Page 47: ...wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Champion engines need periodic part s service and fluid replacement to perform as designed Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood to...

Page 48: ...PART S AS STATED ABOVE IN NO EVENT SHALL CHAMPION POWER EQUIPMENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF CHAMPION POWER EQUIPMENT S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitations may not apply to purchaser owner Purchaser owner agrees to make no claims against...

Page 49: ...ol system is warranted for two years subject to provisions set forth below If during the warranty period 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 owner you are responsible for the performance of the required maintenance listed in your Owner s Manual CPE rec...

Page 50: ...cement 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 emissions related 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 d Repair or repla...

Page 51: ...kets 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 Alterna...

Page 52: ...trol system is warranted for two years subject to provisions set forth below If during the warranty period 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 owner you are responsible for the performance of the required maintenance listed in your Owner s Manual CPE r...

Page 53: ...all be warranted for the remainder of the ECS Warranty Period c 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 ...

Page 54: ...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 ...

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