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Champion 100203, Owner'S Manual & Operating Instructions

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20

100203

 

ENGLISH

Parts List

#

Part Number

Description

Qty

1

122.070100.07

Fuel Tank Cap

1

2

122.070300.03

Fuel Filter

1

3

24.070800.00

Reversal Valve

1

4

2.06.006

Clamp Ø7 x Ø1

1

5

24.070030.00

Hole, Breather Tube

1

6

152.070014.06

Pipe, Reversal Valve, 730 mm

1

7

2.05.001

Clamp Ø8 x b6.5

2

8

1.5789.0620.1

Flange Bolt M6 x 20, Black

4

9

1.93.06

Lock Waher Ø6

4

10

2.03.004.1

Flat Washer, Ø24 x Ø6.5 x 1.5, 

Black

4

11

122.070015.01

Mount Vibration, Fuel Tank

4

12

152.071000.40.48

Fuel Tank, 29L, Yellow

1

13

122.070400.05

Fuel Valve

1

14

2.06.007

Clamp Ø8 x b6

2

15

152.070011.07

Pipe, Fuel, 195 mm

1

16

45.090006.20

Holder, Air Cleaner

1

17

1.6177.1.06

Lock Nut M6, Flange 

2

18

1.6177.1.08

Lock Nut M8, Flange 

10

19

47.100001.00

Gasket, Exhaust

1

20

46.101000.01.2

Muffler Assembly

1

21

46.101300.00

Spark Arrester Assembly

1

22

1.9074.4.0510

Screw/Washer Assembly M5 x 10

3

23

1.16674.0820

Flange Bolt M8 x 20

2

24

152.190300.00

Carbon Brush Assembly

1

25

122.190004.01

Pinch, Carbon Brush

1

26

1.93.05

Lock Washer Ø5

2

27

1.9074.15.0520

Bolt/Washer Assembly M5 x 20

1

28

122.190400.00

Terminal Block

1

29

152.190003.00.48

Generator End Cover, Yellow

1

30

1.16674.0512.2

Flange Bolt M5 x 12

3

31

1.9074.17.0516

Screw/Washer Assembly M5 x 16

2

32

1.97.1.05

Washer Ø5

2

33

1.16674.0516

Flange Bolt M5 x 16

2

34

153.190200.04

AVR, CSA

1

35

152.190002.00

End Housing

1

36

2.08.069

Flange Bolt/Washer Assembly 

M6 x 194

4

37

2.08.071

Bolt M5 x 229

2

38

1.6175.05

Nut M5

2

39

154.191002.00

Stator Cover

1

40

155.191200.00

Stator Assembly, Cu, Ø204 x 

158 mm, CSA

1

41

2.08.070

Flange Bolt/Washer Assembly 

M10 x 280

1

42

155.191100.00

Rotor Assembly, Cu, Ø204 x 158 

mm, CSA

1

43

1.5789.0608

Flange Bolt M6 x 8

2

44

152.192300.01

Air Guide

1

45

48.603

Engine, 459cc

1

46

5.1900.029

Grounding Line 150 mm

1

47

1.5789.0612

Flange Bolt M6 x 12

1

48

1.862.06

Lock Washer Ø6, Toothed

2

49

152.100007.00

Insulation Board, Motor Mount

1

50

11.110008.00

"R" Shape 

2

51

152.200703.04

Long Pin, Handle

2

52

1.894.1.08

Circlip Ø8

2

53

152.200703.02

Short Pin, Handle

2

54

152.200701.02.2

Handle, U Shape

1

55

152.200702.02

Cover, Handle

1

56

65251.0.10.2

Frame, 700 x 541 x 600

1

57

1.6177.1.10

Lock Nut M10, Flange 

4

58

152.201200.03

Motor Mount 1

2

#

Part Number

Description

Qty

59

122.201501.25

Pin Roll, Wheel,  Ø16 x Ø10 x 

107

2

60

152.201701.09.48

9.5 in. Wheel, PU, Yellow

2

61

2.16.001

Pin Ø2 x 33, "R" Shape 

2

62

152.201200.04

Motor Mount 2

2

63

1.5789.0816

Flange Bolt M8 x 16

2

64

152.200002.01.2

Support Leg 84 mm

1

65

152.201400.00

Rubber, Support

2

66

1.5789.0825

Flange Bolt M8 x 25

2

67

1.9074.3.0510

Screw/Washer Assembly M5 x 10

2

68

1.6177.1.05

Lock Nut M5, Flange 

2

69

9.1000.150

Battery 12V15AH

1

70

152.200904.00

Pinch, Rubber

1

71

152.200013.02.3

Jacket, Wire, Red

2

72

5.1900.024

Red Wire, 480 mm, Battery, CSA

1

73

152.200013.02

Jacket, Wire, Black

1

74

5.1900.025

Black Wire, 320 mm, Battery, 

CSA

1

75

152.209.4.2

Control Panel, Black

1

76

5.1240.937

37.5Amp Circuit Breaker, Double 

Pole, CSA

1

77

5.1870.007

Receptacle Cover, Receptacle 

14-50R

1

78

5.1120.044

Receptacle 14-50R

1

79

1.5783.0622.3

Bolt M6 x 22, Green

1

80

1.6175.06.3

Nut M6, Green

2

81

1.97.1.06.3

Washer Ø6, Green

2

82

1.93.06.3

Lock Washer Ø6, Green

2

83

1.9074.4.0514.1

Screw/Washer Assembly M5 x 

14, Black

5

84

5.1120.027

Receptacle 5-20R Duplex, CSA

2

85

5.1870.008

Receptacle Cover, Receptacle 

5-20R, Duplex

2

86

5.1210.920

20Amp Circuit Breaker, Push 

Button, CSA

2

87

5.1120.026

Receptacle  L14-30R, CSA

1

88

5.1870.003

Receptacle Cover, Receptacle 

L14-30R

1

89

1.6177.1.04.1

Flange Lock Nut M4, Black

10

90

5.1280.003

Fuse, 10A

1

91

1.818.0514.2

Screw M5 x 14

4

92

5.1810.000

Over Voltage Protector, CSA

1

93

5.1800.000

Rectifier

1

94

5.1000.001.3

Ignition Switch, Red

1

95

5.1440.008

Intelligauge, With Power Meter

1

96

5.1110.006

Receptacle, Battery Charger

1

97

5.1240.930

30Amp Circuit Breaker, Double 

Pole, CSA

1

98

1.9074.4.0306.1

Screw/Washer Assembly M3 x 

6, Black

8

99

152.210002.19

Control Box

1

100

1.5789.0615.1

Flange Bolt M6 x 15, Black

4

101

152.210003.01

Wire Jacket, Control Box

1

102

5.1320.24

Conduit, Plastic, 155 mm, CSA

1

103

152.210003.03

Plug, End Cover, CSA

1

104

100203.21.10

Wire Assembly

1

105

100203.21

Control Panel Assembly

1

106

5.1820.007

Smart Charger

1

Summary of Contents for 100203

Page 1: ... o ne Year Limited Warrant y ne Year Limited Warrant y n a n n a n T wo Year Limited Warrant y T wo Year Limited Warrant y u x a n s u x a n s G a r a n t í a G a r a n t í a T h ree Year Limited Warran t y T h ree Year Limited Warran t y G a r a n t í G a r a n t í o i s a n s o i s a n s T wo Year Limited Warrant y G a rantie limitée de deux a n s T wo Year Limited Warrant y G a rantie limitée d...

Page 2: ...cover AN IMPORTANT MESSAGE ABOUT TEMPERATURE Your Champion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to 40 C 104 F When necessary your product may be operated at temperatures ranging from 15 C 5 F to 50 C 122 F for short periods If the product is exposed to temperatures outside this range during storage it should be brought back within this r...

Page 3: ... 13 Do Not Overload Generator 14 Capacity 14 Power Management 14 Operation at High Altitude 14 Maintenance and Storage 15 Engine Maintenance 15 Oil 15 Spark Plugs 15 Air Filter 15 Spark Arrester 16 Cleaning 16 Adjustments 16 Maintenance Schedule 16 Generator Maintenance 16 Storage 17 Generator Storage 17 Generator Battery 17 Disconnect the Battery 17 Charge the Battery 17 Specifications 18 Engine ...

Page 4: ...e to ensure the accuracy and completeness of the information in this manual and we reserve the right to change alter and or improve the product and this document at any time without prior notice Since CPE CET highly value how our products are designed manufactured operated and serviced and also highly value your safety and the safety of others we would like you to take the time to review this prod...

Page 5: ...us situation which if not avoided may result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage CAUTION DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury DANGER WARNING indicates a potentially hazardous situation w...

Page 6: ...ator GFCI in damp areas and areas containing conductive material such as metal decking Use approved transfer equipment to isolate generator from your electric utility and notify your utility company before connecting your generator to your power system DANGER Sparks can result in fire or electrical shock When servicing the generator Disconnect the spark plug wire and place it where it cannot conta...

Page 7: ...ent in the off position and then turn them on for operation Turn electrical equipment off before stopping the generator DO NOT tamper with the governed speed DO NOT modify the generator in any way CAUTION Fuel and fuel vapours are highly flammable and extremely explosive Fire or explosion can cause severe burns or death Unintentional startup can result in entanglement traumatic amputation or lacer...

Page 8: ... to be printed shown in 50 process magenta Revision Changes This artwork belongs to Champion Power Equipment The contents are confidential and privileged and shall not be disclosed to or used by or for outside parties without the explicit consent of Champion Power Equipment F WARNING DO NOT TOUCH Exhaust gases muffler and engine components are extremely HOT and cause burns Operation of this equipm...

Page 9: ... Fuel Valve Turn this valve to the ON position to supply fuel to the engine 4 Air Cleaner Protects the engine by filtering dust and debris from the intake air 5 Recoil Starter Used to start the engine 6 Low Oil Sensor Senses the level of oil in the crankcase and shuts the engine down if the level falls too low 7 Oil Filler Cap Check and fill engine oil level 8 Battery Used to start the engine 9 Po...

Page 10: ...nd or 240 Volt AC single phase 60 Hz electrical loads 5 Ground Terminal Consult an electrician for local grounding regulations 6 120V 20A Duplex 2 NEMA 5 20R May be used to supply electrical power for the operation of 120 Volt AC single phase 60 Hz electrical loads 7 Circuit Breakers Protect the generator against electrical overload 8 120 240V 30A Twist Lock Receptacle NEMA L14 30R May be used to ...

Page 11: ...parts Wheel Kit 24 1 cm 9 5 in Wheel 2 Pin Roll Ø16 x Ø10 x 107 for Wheel 2 R Shape Pin 2 Support Leg w Vibration Mounts 1 Flange Bolt M8x16 for Support Leg 2 Flange Lock Nut M8 2 Other Smart Charger 1 Oil Funnel 1 Flange Bolt M5x10 for Battery 2 Flange Nut M5 2 Controls and Features Battery Bolts ...

Page 12: ...all the wheel kit and support leg Install the Wheel Kit Install the Support Leg 1 Attach the support leg to the generator frame with flange bolts M8x16 and flange lock nuts M8 2 Tip the generator slowly so that it rests on the wheels and support leg Connect the Battery 1 Remove the protective cover from the red lead on the battery 2 Attach the red lead to the red terminal on the battery with the f...

Page 13: ...quires no additional lubrication for the life of the bearing NOTE The recommended oil type is 10W 30 automotive oil NOTE Synthetic oil may be used after the 5 hour initial break in period Using synthetic oil does not increase the recommended oil change interval NOTE We consider the first 5 hours of run time to be the break in period for the unit During the break in period stay at or below 50 of th...

Page 14: ...t is advisable to always shut off the fuel supply run the engine to fuel starvation and drain the tank when the equipment is not in use for more than 30 days NOTE Add Fuel Cont d Add Fuel 1 Use clean fresh regular unleaded fuel with a minimum octane rating of 85 and an ethanol content of less than 10 by volume 2 DO NOT mix oil with fuel 3 Clean the area around the fuel cap 4 Remove the fuel cap 5 ...

Page 15: ...ase consult your local authority In some areas generators must be registered with the local utility Generators used at construction sites may be subject to additional rules and regulations Generators should be on a flat level surface at all times even when not in operation Generators must have at least 1 5 m 5 ft of clearance from all combustible material In addition to clearance from all combusti...

Page 16: ...abilize internal temperatures of the engine and generator 3 Turn the fuel valve to the OFF position 4 Let the engine run until fuel starvation has stopped the engine This usually takes a few minutes 5 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 engine is not in use If the engine will not be used ...

Page 17: ...g engine configuration at a given altitude may increase its emissions and decrease fuel efficiency and performance WARNING Operation at High Altitude 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 3 for every 304 8 m 1 000 ft of elevation above sea lev...

Page 18: ... dipstick to add oil 5 Add up to 1 1 L 1 2 qt of oil and replace oil fill cap dipstick DO NOT OVERFILL 6 Dispose of used oil at an approved waste management facility Spark Plugs 1 Remove the spark plug cable from the spark plug 2 Use the spark plug tool not included to remove the plug 3 Inspect the electrode on the plug It must be clean and not worn to produce the spark required for ignition 4 Mak...

Page 19: ... damage the generator windings CAUTION Maintenance Schedule Follow the service intervals indicated in the following maintenance schedule Service your generator more frequently when operating in adverse conditions Contact our help line at 1 877 338 0999 to locate the nearest Champion Power Equipment certified service dealer for your generator or engine maintenance needs Spark Arrester 1 Allow the e...

Page 20: ...Reattach the spark plug 11 Store the unit in a clean dry place out of direct sunlight Generator Battery This product is equipped with an automatic battery charging circuit The battery will receive charging voltage when 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...

Page 21: ...plug NGK BPR6ES or equivalent Make certain the spark plug gap is 0 7 0 8 mm or 0 028 0 031 in An Important Message About Temperature Your Champion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to 40 C 104 F When necessary your product may be operated at temperatures ranging from 15 C 5 F to 50 C 122 F for short periods If the product is exposed t...

Page 22: ... 38 39 40 41 26 32 42 44 45 19 20 23 1 2 3 8 9 10 11 12 13 14 15 46 47 48 17 50 51 52 53 54 55 56 57 59 60 61 62 63 64 65 66 21 22 57 67 68 69 70 71 72 74 58 4 5 6 7 43 43 75 76 77 78 48 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 18 18 73 30 49 ...

Page 23: ...2 200703 02 Short Pin Handle 2 54 152 200701 02 2 Handle U Shape 1 55 152 200702 02 Cover Handle 1 56 65251 0 10 2 Frame 700 x 541 x 600 1 57 1 6177 1 10 Lock Nut M10 Flange 4 58 152 201200 03 Motor Mount 1 2 Part Number Description Qty 59 122 201501 25 Pin Roll Wheel Ø16 x Ø10 x 107 2 60 152 201701 09 48 9 5 in Wheel PU Yellow 2 61 2 16 001 Pin Ø2 x 33 R Shape 2 62 152 201200 04 Motor Mount 2 2 6...

Page 24: ... 22 21 23 23 39 30 37 38 36 12 34 35 33 32 28 29 30 31 26 27 63 24 25 12 100 101 99 98 97 102 103 104 105 106 107 91 112 110 108 109 12 111 89 90 91 85 86 87 88 95 96 93 94 113 92 40 41 42 43 44 45 46 47 48 49 50 51 52 53 12 54 55 56 57 58 59 60 61 62 80 81 82 83 84 78 79 75 76 74 77 72 73 68 69 71 70 67 65 66 64 116 117 ...

Page 25: ...ge Bolt M10 95 4 59 46 020002 00 Gasket Cylinder Head Cover 1 Part Number Description Qty 60 47 021000 00 Cover Cylinder Head 1 61 45 020001 02 Breather Tube 1 62 47 020100 00 Bolt Cylinder Head Cover 1 63 2 08 039 Drain Bolt M12 1 5 15 1 64 48 041000 00 Camshaft 1 65 48 040013 00 Lifter Intake Valve 1 66 47 040002 00 Valve Intake 1 67 47 040006 00 Valve Exhaust 1 68 46 040005 00 Push Rod 2 69 45 ...

Page 26: ...L SW MW2 CONTROL BOX BLOCK COMBINATION SW L Y Y L L W R R L B R M Br W W L G Y CHARGE COIL BATTERY STARTER DIODE Br B G B G R B 3 4 2 1 6 5 OFF ON ST COMBINATION SWITCH G Y B G Y W W Br Br DCW 6 5 4 3 2 1 B W B W B ST OFF ON FUSE 10A CIRCUIT BREAKER CIRCUIT BREAKER 20A 20A R B NO USE W G W G B G Y B G Y B Transition W Y B DUPLEX A DUPLEX B 14 50R R W W R R 30A 37 5A 250V 37 5A DOUBLE POLE Intellig...

Page 27: ...own during operation Out of fuel Fill fuel tank Low oil level Fill crankcase to the proper level Place generator on a flat level surface Generator cannot supply enough power or overheats Generator is overloaded Review load and adjust See Power Management Insufficient ventilation Check for air restriction Move to a well ventilated area No AC output Cable not properly connected Check all connections...

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