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15

  

ENGLISH

 

100238

OPERATION

Connecting Electrical Loads

1.  Let the engine stabilize and warm up for a few 

minutes after starting

2.  Plug in and turn on the desired 120 Volt AC single 

phase, 60 Hz electrical loads.

 

– DO NOT connect 3-phase loads to the generator.

 

– DO NOT connect 50 Hz loads to the generator.

 

– DO NOT overload the generator.

Connecting a generator to your electric utility company’s power 
lines or to another power source may be against the law. In 
addition this action, if done incorrectly, could damage your 
generator and appliances and could cause serious injury or even 
death to you or a utility worker who may be working on nearby 
power lines. If you plan to run a portable electric generator 
during an outage, please notify your electric utility company 
immediately and remember to plug your appliances directly into 
the generator. Do not plug the generator into any electric outlet 
in your home. Doing so could create a connection to the utility 
company power lines. You are responsible for ensuring that your 
generator’s electricity does not feed back into the electric utility 
power lines.
If the generator will be connected to a building electrical system, 
consult your local utility company or a qualified electrician. 
Connections must isolate generator power from utility power and 
must comply with all applicable laws and codes.

NOTE

If the engine starts but does not 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.

NOTE

When the battery switch is in the “ON” position, the 
switch will light up if the battery is sending out a 
charge. If the switch does not light up while in the “ON” 
position, check that the battery connection is still good.

NOTE

The supplied 12V 7AH battery does re-charge while the 
engine is running, but it is also recommended that the 
battery be fully charged at least once per month.

NOTE

LPG Cont’d.

If the ignition switch is held down in the “Start” position 
longer than 5 seconds it could damage the starter.

CAUTION

NOTE

Observing frost on LPG containers and regulators 

is common during operation and normally is not an 

indication of a problem. As LPG vaporizes and travels 

from the tank to the generator engine it expands. The 

amount of frost that forms can be affected by the size of 

the container, the amount of fuel being used, the humidity 

of the air and other operating conditions. In unusual 

situations this frost may eventually restrict the flow of LPG 

gas to the generator resulting in deteriorating performance. 

For example, if the tank temperature is reduced to a 

very low level then the rate at which the LPG vaporizes 

is also reduced and may not provide sufficient fuel flow 

to the engine. This is not an indication of a problem with 

the generator but only a problem with the flow of gas 

from the LPG container. If generator performance seems 

to be deteriorating at the same time that ice formation 

is observed on tank valve, hose or regulator then some 

actions may be taken to eliminate this symptom.

 In these rare situations it can be helpful to reduce or 

eliminate the cold fuel system effects by doing one of the 

following:

 

– Exchanging fuel tanks to allow the first tank to warm 

up, repeating as necessary

 

– Placing the LPG container at the end of the generator 

near the handle, where engine fan air flows out from 

the generator. This air is slightly heated by flowing over 

the engine. The container should not be placed in the 

path of the muffler outlet.

 

– The container can be temporarily warmed by pouring 

warm water over the top of the tank.

6.  Push the ignition switch to the “ON” position. 

7.  Push the battery switch to the “ON” position. 

8.  ELECTRIC START: 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. 

9.  RECOIL START: Pull the starter cord slowly until 

resistance is felt and then pull rapidly. 

10. Do not over-choke. As soon as engine starts, gradually 

move the choke lever to the “RUN” position over a 2-5 

second duration.

LPG

1.  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.  Fully open the LPG cylinder fuel knob. 

4.  Turn the LPG fuel valve to the “ON” position. 

5.  Move the choke lever to the “75% Choke” detent turn 

position. (A) 

a.  For restarting a warm engine, move the choke 

lever to the “75% CHOKE” detent position.

A

Summary of Contents for 100238

Page 1: ...hampionpowerequipment com 4100 Starting Watts 3285 Rated Watts LPG 4550 Starting Watts 3650 Rated Watts Gasoline DUAL FUEL GENERATOR SAVE THESE INSTRUCTIONS Important Safety Instructions are included in this manual MADE IN CHINA REV 100238 20150518 Electric Start 100238 MODEL NUMBER U S Patent No D710 802 ...

Page 2: ...hampion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to 40 C 104 F When your product is needed 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 range before operation In any event the...

Page 3: ...ower Management 16 Stopping the Engine 16 Operation at High Altitude 16 Maintenance and Storage 17 Engine Maintenance 17 Oil 17 Spark Plugs 17 Air Filter 17 Spark Arrester 18 Cleaning 18 Adjustments 18 Maintenance Schedule 18 Generator Maintenance 18 Storage 19 Generator Storage 19 Generator Battery 19 Disconnect the Battery 19 Charge the Battery 19 Specifications 20 Engine Specifications 20 Gener...

Page 4: ... 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 are 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: ...r 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 Use approved transfer equipment to isolate generator from your electric utility and Notify your utility company before connecting your generator to y...

Page 7: ...r s running capacity can damage the generator and or electrical devices connected to it DO NOT overload the generator Start 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 DO NOT tamper with the governed s...

Page 8: ...LAMMABLE AND EXPLOSIVE Fire or explosion can cause severe burns or death Unintentional startup can result in entanglement traumatic amputation or laceration DANGER When adding or removing gasoline Turn the generator off and let it cool for at least two minutes before removing the fuel cap Loosen the cap slowly to relieve pressure in the tank Only fill or drain fuel outdoors in a well ventilated ar...

Page 9: ...ity fuel tank 2 Choke Used to start the engine 3 Air Cleaner Protects the engine by filtering dust and debris from the intake air 4 Recoil Starter Used to manually start the engine 5 LPG Hose Connector 6 Oil Filler Cap Check and fill engine oil level 7 Battery Used to start the engine electrically 8 Power Panel See Power Panel section 9 Fuel Selector Switch Used to select fuel source Generator Con...

Page 10: ...nal Consult an electrician for local grounding regulations 7 120 Volt AC 30 Amp Receptacle NEMA TT 30 May be used to supply electrical power for the operation of 120 Volt AC single phase 60 Hz electrical loads 8 120 Volt AC 30 Amp Twist Lock Receptacle NEMA L5 30R May be used to supply electrical power for the operation of 120 Volt AC single phase 60 Hz electrical loads 9 120 Volt AC 20 Amp Duplex...

Page 11: ...l Kit 8 in 20 3 cm Wheel 2 Pin Roll Ø16 x Ø10 x 97 for Wheel 2 R Shape Pin 2 Handle 1 Flange Bolt M8x45 for Handle 2 Support Leg w Vibration Mounts 1 Flange Bolt M8x16 for Support Leg 2 Flange Lock Nut M8 4 Other Oil 0 6 qt 0 6 L LPG Hose With Regulator 3 3 ft 1 m 1 Oil Funnel 1 Controls and Features ...

Page 12: ...tor frame with flange bolt M8x16 and flange lock nuts M8 2 Tip the generator slowly so that it rests on the wheels and support leg The wheel kit is not intended for over the road use CAUTION Install the Handle 1 Place the handle over the mounting channel on the frame 2 Secure the handle to the frame using the two handle bolts M8x45 3 Place a flange lock nut M8 on the end of each bolt and fasten se...

Page 13: ...mended 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 Full synthetic 5W 30 oil will aid in starting in cold ambient 5ºC 41ºF 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 the ru...

Page 14: ...thanol 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 Slowly add fuel to the tank DO NOT OVERFILL Fuel can expand after filling A minimum of in 6 4 mm of space left in the tank is required for fuel expansion more than in 6 4 mm is recommended Fuel can be forced out of the tank as a result of expansion if it is overfilled an...

Page 15: ... not been plugged or kept closed must also be purged The purging process should be done by a LPG supplier Cylinders from an exchange supplier should have been purged and filled properly already Always position the cylinder so the connection between the valve and the LPG inlet won t cause sharp bends or kinks in the hose NOTE Connecting Liquid Petroleum Gas LPG Cylinder 1 Make sure the fuel valve o...

Page 16: ...itioning generator Failure to follow proper safety precautions may void manufacturer s warranty 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 WARNING WARNING During operation the muffler and exhaust fumes pr...

Page 17: ...ices plugged in or turned on 3 Turn the gasoline fuel valve to the ON position 4 Move the choke lever to the 100 CHOKE detent position a For restarting a warm engine move the choke lever to the 75 CHOKE detent position 5 Push the ignition switch to the ON position 6 Push the battery switch to the ON position 7 ELECTRIC START Press and hold the ignition switch to the START position Release as the e...

Page 18: ...tion of a problem As LPG vaporizes and travels from the tank to the generator engine it expands The amount of frost that forms can be affected by the size of the container the amount of fuel being used the humidity of the air and other operating conditions In unusual situations this frost may eventually restrict the flow of LPG gas to the generator resulting in deteriorating performance For exampl...

Page 19: ...justing the engine 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 ...

Page 20: ...plug into the engine 7 Use a spark plug socket not included to firmly install the plug 8 Attach the spark plug wire to the plug For service or parts assistance contact our help line at 1 877 338 0999 NOTE Maintenance replacement or repair of emission control devices and systems may be performed by any non road engine repair establishment or individual NOTE WARNING WARNING Improper maintenance will...

Page 21: ...e and Storage Federal and local laws and administrative requirements indicate when and where spark arresters are required When ordered spark arresters 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 arrester NOTE To be pe...

Page 22: ...nually 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 Battery 1 Remove the protective cover from the black negative battery lead 2 Disconnect the black negative lead from ...

Page 23: ...e Clearance Intake 0 13 0 17 mm 0 005 0 007 in Exhaust 0 18 0 22 mm 0 007 0 009 in Note Tech bulletin regarding the valve adjustment procedure is on www championpowerequipment com Spark Plugs OEM spark plug NHSP F6RTC Replacement spark 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 p...

Page 24: ...6 88 89 87 112 113 114 115 116 117 118 119 120 121 124 82 122 123 72 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 12 19 15 16 20 21 22 23 24 25 26 27 28 29 30 31 10 30 49 50 51 52 47 53 54 55 56 57 58 59 60 61 62 63 64 65 67 47 69 70 90 91 95 92 93 96 97 98 99 100 94 101 102 103 104 105 106 107 108 109 110 111 71 68 43 125 126 66 38 ...

Page 25: ...ket Wire 3 61 5 1900 010 Red Wire Battery 190 mm 1 62 5 1900 011 Black Wire Battery 190 mm 1 63 1 6177 1 06 Lock Nut M6 Flange 1 64 5 1900 026 Grounding Line 150mm 1 Part Number Description Qty 65 1 862 06 Lock Washer Ø6 Toothed 1 66 1 5789 0612 Flange Bolt M6 x 12 1 67 1 5789 0816 Flange Bolt M8 x 16 2 68 152 200002 00 2 Support Leg 60 mm 1 69 152 201400 00 Rubber Support 2 70 1 5789 0825 Flange ...

Page 26: ...37 38 12 40 41 42 43 44 46 47 21 22 23 24 31 34 36 39 53 52 102 51 50 49 55 56 57 58 54 60 62 61 63 65 66 67 68 69 70 71 72 74 25 93 94 95 92 91 90 97 78 79 80 82 83 84 85 86 87 88 76 59 12 77 96 33 81 73 106 54 45 103 104 98 107 15 20 48 14 101 51 100 64 16 99 89 19 11 18 17 19 28 109 108 105 75 26 110 ...

Page 27: ...tion Coil Silicon Rubber 1 54 1 5789 0625 Flange Bolt M6 25 3 55 23 110005 01 Spring Throttle Return 1 56 23 110007 00 Spring Governor 1 57 2 08 040 Bolt M6 21 Governor Arm 1 58 21 110008 00 Pin Shaft 1 59 27 111000 20 Control Assembly 1 60 25 040013 00 Lifter Valve 2 Part Number Description Qty 61 2 04 001 Dowel Pin Ø9 14 2 62 27 041000 01 Camshaft 1 63 2 14 012 Woodruff Key 4 7 5 19 1 64 2 08 03...

Page 28: ...N SWITCH 6 5 4 3 2 1 B W B W FUSE 10A Y VFO SWITCH DCW FUEL CUT SOLENOIL B G B G W G W G G G Y G Y 3 4 5 2 1 6 a b d e G Y Charger Br G Y SWITCH lb l la G Y EARTH TERMINAL G Y Module L B W B G G G G Y Br W G W G B B G Y G Y Y W G W FUSE 5A R CIRCUIT BREAKER EXW FW MW1 L Y Y AVR Br 30A R w G Y G Y Y Y L L R W w 120V 20A CIRCUIT BREAKER L5 30R R R R R R w B MW2 w W intelligauge 120V 5 20R G Y R W GA...

Page 29: ... Generator shuts down during operation Out of fuel Fill the gasoline tank or fill LPG cylinder Low oil level Fill crankcase to the proper level Place generator on a flat level surface Generator cannot supply enough power or overheating 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 C...

Page 30: ...tor is deemed to have been misused neglected involved in an accident abused loaded beyond the generator s limits modified installed improperly or connected incorrectly to any electrical component Installation Use and Maintenance Cont d Normal maintenance such as spark plugs air filters adjustments fuel system cleaning and obstruction due to buildup is not covered by this warranty Other Exclusions ...

Page 31: ...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 32: ...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 33: ...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...

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