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Champion 100302-1, Operator'S Manual

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100302 - 4000W DIGITAL HYBRID PORTABLE GENERATOR

SPECIfICATIONS

25

-1

Parts List

#

Part Number

Description 

Qty

1

1.5789.0625

Flange Bolt M6 x 25

2

2

1.5789.0620

Flange Bolt M6 x 20

4

3

85.220005.01

Protection Cover, Control Unit

1

4

1.5789.0612

Flange Bolt M6 x 12

5

5

85.221000.04

Control Unit, 3.3KW, 
120V/60Hz, Wireless Parallel

1

6

85.401

Engine 224cc

1

S/N 
<18MAY0401216
85.402
S/N 
18MAY0

7

85.190002.01

End Housing, Motor

1

8

1.5789.0615

Flange Bolt M6 x 15

4

9

85.191200.03

Stator Assembly

1

10

1.9074.14.0650

Bolt/Washer Assembly M6 
x50

3

11

85.191100.03

Rotor Assembly

1

12

2.02.006

Nut M14 x 1.5

1

13

83.190001.01

Fan, Generator 

1

14

85.190003.01

End Cover, Generator 

1

15

1.845.4219

Screw ST4.2 x 19

4

16

85.100100.01.2

Bracket, Muffler

1

17

46.101300.08

Spark Arrester Assembly

1

18

46.101503.08

Plate, Spark Arrester

1

19

1.9074.4.0514

Screw/Washer Assembly M5 
x 14

2

20

85.101000.01.2

Muffler Assembly

1

21

1.5789.0610

Flange Bolt M6 x 10

2

22

85.101203.01.2

Cover, Exhaust Pipe 

1

23

1.6177.1.08

Lock Nut M8, Flange 

18

24

26.100001.00

Gasket, Muffler

1

25

1.5789.0608

Flange Bolt M6 x 8

1

26

23.090006.21

Holder, Air Cleaner

1

27

85.070011.01

Fuel Pipe 140mm

1

28

2.06.007

Clamp, Ø8 x b6

2

29

85.070400.01

Fuel Valve

1

30

85.071000.02.48

Fuel Tank, 11L, Yellow

1

31

122.070015.01

Mount Vibration, Fuel Tank 

4

32

2.03.004.1

Flat Washer, Ø24 x Ø6.5 x 
1.5, Black

4

33

1.93.06

Lock Washer Ø6

4

34

1.5789.0620.1

Flange Bolt M6 x 20, Black

4

35

24.070014.01

Pipe, Reversal Valve, 720mm

1

36

2.06.006

Clamp, Ø7 x Ø1

3

37

24.070800.00

Reversal Valve

1

#

Part Number

Description 

Qty

38

122.070100.07

Fuel Tank Cap

1

39

122.070300.03

Fuel Filter

1

40

85.070014.01

Pipe, Air Cleaner

1

41

122.070700.00

Carbon Canister, 320CC

1

42

1.5789.0612.1

Flange Bolt M6 x 12, Black

2

43

2.05.001

Clamp, Ø8 x 6.5

2

44

61141.2.2

Frame 520 x 461 x 442

1

45

5.1800.003

Rectifier

1

46

85.201600.01

Supporter

1

47

85.201200.01

Motor Mount, 1

1

48

1.5789.0832

Flange Bolt M8 x 32

4

49

85.201200.02

Motor Mount, 2

2

50

85.100007.01

Insulation Board, Motor 
Mount

1

51

85.201200.03

Motor Mount, 3

1

52

122.201400.01

Rubber, Support

4

53

1.6177.1.06

Lock Nut M6, Flange 

1

54

5.1900.093

Grounding Line

1

55

1.862.06

Lock Washer Ø6, Toothed

1

56

5.1000.004.1

Ignition Switch, Black

1

57

5.1010.003.1

Switch, Economy

1

58

5.1110.005

Receptacle, DC 12V

1

59

85.01.1.2

Control Panel, Black

1

60

1.5783.0520.3

Bolt M5 x 20, Green

1

61

1.93.05.3

Lock Washer Ø5, Green

2

62

1.862.05

Lock Washer Ø5, Toothed

1

63

1.6170.05.3

Nut M5, Green

2

64

1.97.1.05.3

Washer Ø5, Green

1

65

1.9074.4.0514.1

Screw/Washer Assembly M5 
x 14, Black

8

66

1.9074.4.0414.1

Screw/Washer Assembly M4 
x 14, Black

6

67

1.6177.1.04.1

Lock Nut M4, Flange, Black

6

68

5.1120.010

Receptacle 5-20R Duplex

1

69

5.1120.036

Receptacle TT-30R

1

70

5.1210.930

30Amp Circuit Breaker, Push 
Button

1

71

5.1210.920

20Amp Circuit Breaker, Push 
Button

1

72

5.1200.308

8Amp Circuit Breaker, Push 
Button

1

73

83.210001.00.3

Connect Port, 125V/25A, Red

1

74

83.210001.00.1

Connect Port, 125V/25A, 
Black

1

75

83.210016.00

Speed Limiter

1

76

1.818.0514.3

Screw, M5 x 14, Green

2

Summary of Contents for 100302-1

Page 1: ...g the product Failure to do so could result in serious injury This manual should remain with the product Specifications descriptions and illustrations in this manual are as accurate as known at the time of publication but are subject to change without notice This product meets the requirements of the PGMA Portable Generator Manufacturers Association standard ANSI PGMA G300 2015 Safety and Performa...

Page 2: ...at High Altitude 18 Maintenance 19 Cleaning the Generator 19 Changing the Engine Oil 19 Cleaning and Adjusting the Spark Plug 19 Cleaning the Air Filter 20 Cleaning the Spark Arrestor 20 Adjusting the Governor 20 Maintenance Schedule 20 Storage 21 Short Term Storage up to 30 days 21 Mid Term Storage 30 days 1 year 21 Long Term Storage over 1 year 21 Removing from Storage 22 Specifications 23 Gener...

Page 3: ...Every effort has been made to ensure the accuracy and completeness of the information in this manual at the time of publication and we reserve the right to change alter and or improve the product and this document at any time without prior notice CPE highly values how our products are designed manufactured operated and serviced as well as providing safety to the operator and those around the gener...

Page 4: ...e Rotating parts can entangle hands feet hair clothing and or accessories Traumatic amputation or severe laceration can result Keep hands and feet away from rotating parts Tie up long hair and remove jewelry DO NOT wear loose fitting clothing dangling drawstrings or items that could become caught DANGER Generator produces powerful voltage DO NOT touch bare wires or receptacles DO NOT use electrica...

Page 5: ...ins could result When starting engine pull the recoil cord slowly until resistance is felt and then pull rapidly to avoid kickback DO NOT start or stop the engine with electrical devices plugged in and turned on CAUTION Exceeding the generator s running capacity can damage the generator and or electrical devices connected to it DO NOT overload the generator DO NOT tamper with the governed speed DO...

Page 6: ...ssure from the gasoline tank Only fill or drain gasoline outdoors in a well ventilated area DO NOT pump gasoline directly into the generator at the gas station Always use an approved fuel container to transfer the gasoline to the generator DO NOT overfill the gasoline tank Always keep gasoline away from sparks open flames pilot lights heat and other sources of ignition When starting the generator ...

Page 7: ...d privileged and shall not be disclosed to or used by or for outside parties without the explicit consent of Champion Power Equipment Fuel C WARNING DO NOT TOUCH Exhaust gases muffler and engine components are extremely HOT and cause burns Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrestor may be required The operator should contact local fire...

Page 8: ...ements before operation Electric Shock Failure to use in dry conditions and to observe safe practices can result in electric shock Improper connections to a building can allow current to backfeed into utility lines creating an electrocution hazard A transfer switch must be used when connecting to a building Fire Explosion Fuel and its vapors are extremely flammable and explosive Fire or explosion ...

Page 9: ...e safely operate the product SYMBOL MEANING On Stop or Off Choke knob is pulled out completely for choke position Run knob is pushed in completely for run position ECO Economy Mode Switch Output OK Overload Low Oil SYMBOL MEANING 12V Direct Current Circuit Breaker Reset Push RV Ready Receptacle Parallel Connection s Ground Terminal Neutral Floating Neutral circuit IS NOT electrically connected to ...

Page 10: ... to or used by or for outside parties without the explicit consent of Champion Power Equipment K 376 186 152 CG1 2945 Colors Starting the Engine DANGER Move generator outside and far away from windows doors and intake ventilation covers 1 Check oil level Recommended oil is 10W 30 2 Check gasoline level When adding gasoline use a minimum octane rating of 85 and an ethanol content of 10 or less by v...

Page 11: ...on of the controls and features Save this manual for future reference Generator 1 Carrying Handle s Used to lift or carry the unit 2 Gasoline Tank 2 9 gal 11 L 3 Fuel Valve Used to turn fuel supply on and off to engine 4 Recoil Starter Used to manually start the engine 5 Choke Used to start the engine 6 Oil Drain Bolt 7 Control Panel See Control Panel section 8 Fuel Cap Remove to add fuel 1 4 5 6 ...

Page 12: ...er output parallel kit sold separately 8 Circuit Breakers Push Reset Protects the generator against electrical overloads RECEPTACLES A z 12V DC 8A Automotive May be used to supply electrical power for operation of 12 Volt DC 8 Amp electrical loads B t 120V AC 30A RV NEMA TT 30R May be used to supply electrical power for operation of 120 Volt AC 30 Amp single phase 60 Hz electrical loads C A 2 120V...

Page 13: ...g to follow these instructions will void your warranty NOTICE The generator rotor has a sealed pre lubricated ball bearing that requires no additional lubrication for the life of the bearing NOTICE The recommended oil type for typical use is 10W 30 automotive oil If running generator in extreme temperatures refer to the following chart for recommended oil type 20 0 20 40 60 Ambient temperature Rec...

Page 14: ... the generator 3 Screw on the gasoline cap and wipe away any spilled fuel CAUTION Use unleaded gasoline with a minimum octane rating of 85 and an ethanol content of 10 or less by volume DO NOT light cigarettes or smoke when filling the tank DO NOT mix oil and gasoline DO NOT overfill the tank Fill tank to approximately in 6 4 mm below the top of the tank to allow for gasoline expansion DO NOT pump...

Page 15: ...must also have at least 3 ft 91 4 cm of clearance on all sides to allow for adequate cooling maintenance and servicing Generators should never be started or operated in the back of a SUV camper trailer in the bed of a truck regular flat or otherwise under staircases stairwells next to walls or buildings or in any other location that will not allow for adequate cooling of the generator and or the m...

Page 16: ...he 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 Connecting Electrical Loads Let the engine stabilize and warm up for a few minutes after starting 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...

Page 17: ...witch can be activated to turn on economy control in order to minimize fuel consumption and noise while operating the unit during times of reduced electrical output Eco Mode allows the engine speed to idle during periods of non use The engine speed returns to normal when an electrical load is connected When the economy switch is off the engine runs at normal speed continuously CAUTION For periods ...

Page 18: ...ch to the OFF position Important Always ensure that the fuel valve and the engine switch are in the OFF position when the generator is not in use NOTICE If the engine will not be used for a period of two 2 weeks or longer please see the Storage section for proper engine and fuel storage Moving the Generator ALWAYS turn the generator off and ensure the fuel valve is closed ALWAYS make sure engine a...

Page 19: ... slots and damage the generator windings It can also contaminate the fuel system 1 Use a damp cloth to clean exterior surfaces of the generator 2 Use a soft bristle brush to remove dirt and oil 3 Use an air compressor 25 PSI to clear dirt and debris from the generator 4 Inspect all air vents and cooling slots to ensure that they are clean and unobstructed To prevent accidental starting remove and ...

Page 20: ...aws and administrative requirements indicate when and where spark arrestors are required When ordered spark arrestors 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 arrestor Adjusting the Governor WARNING Tampering with ...

Page 21: ...5a Turn engine switch to the OFF position and allow generator to cool completely before continuing 5b Turn the fuel valve to the OFF 5c Use the drain bolt on the carburetor to empty any excess gasoline from the carburetor into an appropriate container Use a funnel and appropriate hose if necessary under the carburetor drain bolt to avoid spillage 5d When gasoline stops flowing from the carburetor ...

Page 22: ...w steps when removing from storage 1 Be sure the engine switch is in the OFF position 2 Add gasoline to the generator according to Add Fuel 3 Turn the fuel valve to the ON position 4 After 5 minutes check the carburetor and air filter areas for any leaking gasoline If any leaks are found the carburetor will need to be disassembled and cleaned or replaced If no gasoline leaks are found turn the fue...

Page 23: ... 0 20 40 60 Ambient temperature Recommended Engine Oil Type 80 100 120 28 9 F C 17 8 6 7 4 4 15 6 26 7 37 8 48 9 10W 30 5W 30 Synthetic 10W 40 5W 30 NOTICE Temperature will affect engine oil and engine performance Change the type of engine oil used based on the temperature to suit the engine needs Fuel Specifications Use unleaded gasoline with a minimum octane rating of 85 and an ethanol content o...

Page 24: ...Diagram 2 3 1 4 5 6 7 9 10 11 14 15 16 20 22 23 24 17 18 19 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 4 41 43 44 45 4 46 47 23 48 49 23 23 50 52 59 60 61 62 63 64 66 68 69 70 71 72 56 57 58 73 74 75 76 77 78 79 80 81 82 12 13 67 83 84 85 53 54 55 4 65 65 51 8 2 42 8 21 ...

Page 25: ...Black 4 35 24 070014 01 Pipe Reversal Valve 720mm 1 36 2 06 006 Clamp Ø7 x Ø1 3 37 24 070800 00 Reversal Valve 1 Part Number Description Qty 38 122 070100 07 Fuel Tank Cap 1 39 122 070300 03 Fuel Filter 1 40 85 070014 01 Pipe Air Cleaner 1 41 122 070700 00 Carbon Canister 320CC 1 42 1 5789 0612 1 Flange Bolt M6 x 12 Black 2 43 2 05 001 Clamp Ø8 x 6 5 2 44 61141 2 2 Frame 520 x 461 x 442 1 45 5 180...

Page 26: ...Guide Plate Rope Black 1 78 85 200106 01 Protector Front Cover 1 79 85 130300 01 Pull Choke Assembly 1 80 85 210002 01 Control Box 1 81 1 5789 0615 1 Flange Bolt M6 x 15 Black 4 82 100302 21 10 Wire Assembly 1 83 100302 21 Control Panel Assembly 1 84 9 1700 008 Plug USB 5V 2 4A 1 85 9 1600 009 Cables 12V 2m CSA 1 ...

Page 27: ...5 6 7 8 9 10 12 13 25 35 37 38 12 40 41 42 43 44 46 47 21 22 23 24 32 34 36 39 51 52 60 62 61 63 65 66 67 68 69 70 71 72 74 25 93 94 95 92 91 90 26 78 79 80 82 83 84 85 86 87 88 76 77 1 33 81 73 15 20 48 14 55 45 54 64 53 11 18 17 89 75 49 50 59 58 77 28 29 100 19 16 56 57 27 96 19 31 99 98 30 101 ...

Page 28: ...t M6 x 90 2 37 85 030100 01 Crankcase 1 38 21 127000 02 Oil Level Sensor 1 39 26 010100 01 Cylinder Head 224cc 1 40 27 050200 00 Connecting Rod 1 41 85 050100 01 Crankshaft 1 42 1 276 6205 Bearing 6205 2 43 24 030008 00 Gasket Crankcase Cover 1 Part Number Description Qty 44 46 031000 00 48 Oil Dipstick Assembly Yellow 1 45 1 6177 06 Flange Nut M6 2 46 85 030007 02 Cover Crankcase 1 S N 18MAY04012...

Page 29: ...M6 x 0 5 Lock 2 87 1 97 1 06 Washer Ø6 2 88 1 6177 1 06 Lock Nut M6 Flange 2 89 1 5789 0620 Flange Bolt M6 x 20 1 90 24 040201 00 Retainer Rocker Arm 1 91 23 040010 00 Bolt Rocker Arm 2 92 27 040005 00 Push Rod 2 93 21 020002 01 Gasket Cylinder Head Cover 1 94 24 021000 00 Cover Cylinder Head 1 95 23 020001 02 Breather Tube 112 35 mm 1 96 27 131017 01 Main Jet Standard 1 27 131017 01 01 Main Jet A...

Page 30: ...E Br WHITE BLUE GREEN YELLOW WHITE GREEN BROWN BLACK WHITE B W W L G Y W G GENERATOR ENGINE RECEPTACLE AC COIL SUB COIL W B W O B W G W Y O Y L C B G G R R R Y Y R W B L G Y G Y G Y C CARNATION A AMETHYST O ORANGE OUTPUT PANEL Y 120V 5 20R R W R R R W G Y B B O W L G C C CIRCUIT BREAKER 20A CIRCUIT BREAKER 30A R W Red Black W R W L W L G IGNITION COIL G Y B W W G Y Y _ DC12V R R B Y Y R C R CIRCUI...

Page 31: ...ged spark arrestor Clean spark arrestor Generator cannot supply enough power or overheating Generator is overloaded Review load and adjust See Connecting Electrical Loads Dirty air filter Clean or replace air filter Choke in wrong position Move choke until it stops under RUN position or push in completely Engine is running but no AC output Poor cord connection Check all connections Circuit breaker...

Page 32: ...d improperly or connected incorrectly to any electrical component Normal maintenance is not covered by this warranty and is not required to be performed at a facility or by a person authorized by CPE Other Exclusions This warranty excludes Cosmetic defects such as paint decals etc Wear items such as filter elements o rings etc Accessory parts such as starting batteries and storage covers Failures ...

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