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Champion 100238, Owner'S Manual & Operating Instructions

The Champion 100238 Owner's Manual & Operating Instructions is a comprehensive guide that ensures trouble-free use of your product. This comprehensive manual is available for free download at our website, offering detailed instructions and important information to maximize the efficiency and longevity of your Champion 100238.

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22

100238

 

ENGLISH

Parts List

# Part Number

Description

Qty

1

27.690

Engine

1

2

124.191100.10

Rotor Assembly, Al, Ø119 x 90 mm

1

3

2.08.103

Flange Bolt M8 x 227

1

4

1.96.08

Washer Ø8

1

5

1.7244.08

Lock Washer Ø8

1

6

124.191200.10

Stator Assembly, Al, Ø190 x 90 mm

1

7

124.191002.02

Stator Cover

1

8

2.08.050

Flange Bolt M6 x 133

4

9

1.97.1.06

Washer Ø6

4

10

1.93.06

Lock Waher Ø6

8

11

124.190002.00

End Housing

1

12

1.16674.0512.2

Flange Bolt M5 x 12

3

13

122.190300.00

Carbon Brush Assembly

1

14

122.190004.01

Pinch, Carbon Brush

1

15

1.5783.0516

Bolt M5 x 16

3

16

1.93.05

Lock Washer Ø5

3

17

122.190200.03

AVR

1

18

1.16674.0516

Flange Bolt M5 x 16

2

19

152.190003.00.48

Generator End Cover, Yellow

1

20

1.97.1.05

Washer Ø5

2

21

122.190400.00

Terminal Block

1

22

1.5789.0620

Flange Bolt M6 x 20

2

23

1.823.0406

Screw M4 x 6

3

24

27.101300.00

Spark Arrester Assembly

1

25

27.101000.00.2

Muffler Assembly

1

26

1.6175.08

Nut M8

2

27

1.93.08

Lock Washer Ø8

2

28

1.848.08

Washer Ø8

2

29

26.100001.00

Gasket, Exhaust

1

30

1.5789.0608

Flange Bolt M6 x 8

2

31

23.090006.21

Holder, Air Cleaner

1

32

122.071000.31.48

Fuel Tank, Yellow

1

33

122.070015.01

Mount Vibration, Fuel Tank

4

34

2.03.004.1

Washer Ø24 x Ø6.5 x 1.5, Black

4

35

1.5789.0620.1

Flange Bolt M6 x 20, Black

4

36

24.070800.00

Reversal Valve

1

37

122.070014.02

Pipe, Reversal Valve, 670 mm

1

38

24.070030.00

Hole, Breather Tube

1

39

2.06.006

Clamp Ø7 x Ø1

2

40

122.070100.07

Fuel Tank Cap

1

41

122.070300.03

Fuel Filter Assembly

1

42

21.070600.01

Connect, Copper

1

43

2.06.016

Clamp Ø8.7 x b8

4

44

122.070011.08

Fuel Pipe 245+25 mm, Fuel Tank 
to Fuel Valve

1

45

152.200702.00

Cover, Handle

1

46

122.200700.03.2

Handle

1

47

1.6177.1.08

Flange Lock Nut M8

14

48

1.5789.0845

Flange Bolt M8 x 45

2

49

62319.0.8.2

Frame

1

50

2.05.001

Clamp Ø8 x 6.5

2

51

122.200800.05.2

Decorative Plate, Black

1

52

1.5789.0612.1

Flange Bolt M6 x 12, Black

2

53

122.201200.05

Mount 2, Motor 

2

54

122.201200.04

Mount 1, Motor

2

55

2.16.001

Pin Ø2 x 33, "R" Shape

2

56

122.201701.07.2

8 in. Wheel, PU, Black

2

57

122.201501.23

Pin Roll, Wheel, Ø16 x Ø10 x 97

2

58

122.200904.00

Strap, Battery

1

59

9.1000.07001

Battery 12V7AH

1

60

152.200013.01

Jacket, 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 Bolt M8 x 25

2

71

2.05.005

Clamp Ø6

1

72

2.05.009

Clamp Ø12.5 x 7

1

73

1.845.3513

Screw ST3.5 x 13

2

74

1.819.1.0330

Screw M3 x 30

1

75

1.6170.03

Nut M3

1

76

5.1050.000

Switch

1

77

1.845.4816

Screw ST4.8 x 16

2

78

122.070400.06

Fuel Valve

1

79

122.070011.09

Fuel Pipe, Fuel Valve to Carburator, 
395+33 mm

1

80

152.070031.01

Jacket, Fuel Hose

1

81

122.210002.24

Control Box

1

82

1.5789.0615.1

Flange Bolt M6 x 15, Black

4

83

1.823.0408

Screw M4 x 8

2

84

122.070025.02

Knob

1

85

1.6182.05

Lock Nut M5

1

86

122.070032.00

Knob Sleeve

1

87

2.08.055

Bolt M6 x 14

3

88

152.201004.00

Lock Catch

2

89

152.200019.00.48

Switch Handle, Yellow

1

90

122.199.1.2

Control Panel, Black

1

91

5.1000.001.3

Ignition Switch, Red

1

92

1.9074.4.0414.1

Screw/Washer Assembly M4 x 14, 
Black

2

93

1.6177.1.04.1

Lock Nut M4, Flange, Black

10

94

5.1430.001

Intelligauge

1

95

1.9074.4.0512.1

Screw M5 x 12, Black

6

96

1.5783.0514.3

Bolt M5 x 14, Green

1

97

1.6170.05.3

Nut M5, Green

2

98

1.97.1.05.3

Washer Ø5, Green

1

99

1.862.05

Lock Washer Ø5

1

100 5.1120.036

Receptacle TT-30

1

101 5.1120.008

Receptacle L5-30R

1

102 5.1120.010

Receptacle 5-20R Duplex

1

103 5.1210.920

20Amp Circuit Breaker, Push 
Button

1

104 5.1210.930

30Amp Circuit Breaker, Push 
Button

1

105 5.1000.000.3

Battery Switch, Red

1

106 5.1800.004

Rectifier

1

107 1.818.0514.2

Screw M5 x 14

3

108 5.1810.003

VFO Diode

1

109 5.1820.001

Charger

1

110 5.1280.003

Fuse 10A

1

111 5.1280.008

Fuse  5A

1

112 122.210003.01

Wire Jacket, Control Box

1

113 5.1330.018

Sheath, Wire, Ø16 x 250mm

1

114 152.210003.02

Plug, End Cover

1

115 9.1500.002

Sleeve, Connector

1

116 26.136000.06

Pressure-reducing Valve

1

117 122.200018.00

Supporter

1

118 2.06.023

Clip Ø20

2

119 152.070012.05

Pipe 40 mm

1

120 2.06.032

Clip Ø17

2

121 122.074000.02

Cut-off Valve

1

122 122.070012.05

Pipe 380 mm

1

123 152.070031.00

Jacket, LPG Hose

1

124 26.130021.06

LPG Hose With Regulator 3.3 ft.

1

125 100238.21.10

Wire Assembly

1

126 100238.21

Control Panel Assembly

1

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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