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Champion 100403, Operator'S Manual

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Champion 100403 Operator'S Manual Download Page 23

100403 - 1200W PORTABLE GENERATOR

SPECIFICATIONS

23

#

Part Number

Description

Qty.

1

12.403

Engine, 79.8 cc

1

2

12.100001.02

Gasket, Exhaust 

1

3

12.101000.02

Muffler Assembly

1

4

1.848.08

Washer Ø8

2

5

1.93.08

Lock Washer Ø8

2

6

1.6175.08

Nut M8

2

7

46.101300.08

Spark Arrestor 
Assembly

1

8

46.101503.08

Plate, Spark Arrestor

1

9

1.9074.4.0514

Screw/Washer 
Assembly M5 

×

 14

2

10

122.070400.05

Fuel Valve

1

11

113.070011.04

Fuel Pipe 130 mm

1

12

2.06.016

Clamp, Ø8.7 

×

 b8

2

13

113.070100.00

Fuel Tank Cap

1

14

122.070300.02

Fuel Filter

1

15

113.071000.09.48

Fuel Tank, 7L, Yellow

1

16

1.5789.0620.1

Flange Bolt M6 

×

 20, 

Gloss Black

4

17

1.93.06

Lock Washer Ø6

4

18

2.03.004.1

Washer, Ø24 

×

 Ø6.5 

×

 

1.5, Black

4

19

122.070015.01

Mount Vibration, Fuel 
Tank

4

20

113.191100.12

Rotor Assembly, Al, 
Ø160 

×

 58 mm

1

21

113.191002.00

Stator Cover

1

22

113.191200.06

Stator Assembly, Al, 
Ø160 

×

 58 mm

1

23

2.08.148

Flange Bolt/Washer 
Assembly M8 

×

 160

1

24

1.5789.0612

Flange Bolt M6 

×

 12

2

25

12.100100.01

Bracket, Muffler

1

26

115.190002.00

End Housing

1

27

1.16674.0512.2

Flange Bolt M5 

×

 12, 

Flat Black

3

28

2.08.073

Flange Bolt/Washer 
Assembly M6 

×

 90

4

29

122.190003.00.48

Generator End Cover, 
Yellow

1

30

1.862.06

Lock Washer Ø6, 
Toothed 

1

31

5.1900.081

Grounding Line 200 
mm

1

32

1.6177.1.06

Lock Nut M6, Flange 

1

33

1.97.1.06

Washer Ø6

2

34

1.93.06

Lock Washer Ø6

1

#

Part Number

Description

Qty.

35

1.62.06

Butterfly Type Nut M6

1

36

61148.0.6.2

Frame 490 

×

 355 

×

 

398mm

1

37

1.6177.1.08

Lock Nut M8, Flange 

10

38

113.201200.00

Motor Mount, Left

1

39

122.201400.01

Rubber, Support

2

40

1.16674.0812

Flange Bolt M8 

×

 12

2

41

113.201200.01

Motor Mount, Right

1

42

1.5783.0820

Bolt M8 

×

 20

2

43

203.201400.01

Rubber

2

44

113.201200.02

Motor Mount

2

45

1.6177.1.05

Lock Nut M5, Flange 

6

46

113.210002.07

Control Box

1

47

1.5789.0615.1

Flange Bolt M6 

×

 15, 

Gloss Black

4

48

12.061200.00.2

Guide Plate, Rope, 
Black

1

49

1.9074.4.0514.1

Screw/Washer 
Assembly M5 

×

 14, 

Black

4

50

113.200106.00

Protector, Front Cover

1

51

113.22.1.2

Control Panel, Black

1

52

5.1120.010

Receptacle 5-20R, 
Duplex

1

53

1.6177.1.04.1

Lock Nut M4, Flange, 
Black

3

54

5.1870.008

Receptacle Cover, 
5-20R, Duplex

1

55

5.1200.210

10 Amp Circuit 
Breaker, Push Button

1

56

5.1430.008

Intelligauge

1

57

1.848.03.2

Washer Ø3

4

58

1.859.03.2

Lock Washer Ø3

4

59

1.6175.03.2

Nut M3

4

60

5.1010.003.3

Switch, Red

1

61

5.1860.000

Capacitance

1

62

1.9074.4.0414.1

Screw/Washer 
Assembly M4 

×

 14, 

Black

1

63

122.210003.01

Plug, Control Box

1

64

5.1330.014

Sheath, Wire

1

65

122.210003.03

Plug, End Cover

1

66

100403.21.10

Wire Assembly

1

67

100403.21

Control Panel 
Assembly, Complete 
100403

1

Parts List

Summary of Contents for 100403

Page 1: ...ng 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 is rated in accordance with PGMA Portable Generator Manufacturers Association standard PGMA G300 Standard for Testing and Valid...

Page 2: ...ot Overload Generator 16 Stopping the Engine 16 Maintenance 17 Cleaning the Generator 17 Changing the Engine Oil 17 Cleaning and Adjusting the Spark Plug s 17 Cleaning the Air Filter 18 Cleaning the Spark Arrestor 18 Adjusting the Governor 18 Maintenance Schedule 18 Storage 19 Short Term Storage up to 1 year 19 Long Term Storage over 1 year 20 Removing from Storage 20 Specifications 21 Generator S...

Page 3: ...ore each use Please always exercise common sense and always err on the side of caution when operating the product to ensure no accident property damage or injury occurs We want you to continue to use and be satisfied with your CPE product for years to come When contacting CPE about parts and or service you will need to supply the complete model and serial numbers of your product Transcribe the inf...

Page 4: ... 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 Operate equipment with guards in place DO NOT wear loose fitting clothing dangling drawstrings or items that could become caught WARNING Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrestor may...

Page 5: ...ne 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 speed DO NOT modify the generator in any way CAUTION Improper treatment or use of the generator can damage it shorten its life and void your warranty Use the...

Page 6: ...ll burn skin if it comes in contact with it Keep any and all LPG away from skin at all times When adding or removing gasoline Turn the generator off and let it cool for at least two minutes before removing the gasoline cap Loosen the cap slowly to relieve pressure in the tank Only fill or drain gasoline outdoors in a well ventilated area DO NOT pump gasoline directly into the generator at the gas ...

Page 7: ...e 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 can cause severe burns or death Operation of this equipment may create sparks that can sta...

Page 8: ...evel ground when checking Check Fuel Level Use clean fresh regular unleaded gasoline with a minimum octane rating of 85 and an ethanol content of less than 10 by volume Fuel Valve ON Engine Switch ON Press the Engine Switch to ON position Choke Move choke lever to CHOKE position Recoil Starter Pull recoil starter to start the engine Choke Move choke lever to RUN position Plug In Plug in desired de...

Page 9: ...NA REGULAR SOLAMENTE 85 octanos como mínimo Máximo de etanol de 10 ESSENCE SANS PLOMB SEULEMENT Indice d octane minimal de 85 Maximum 10 d éthanol 1032 L OP A Fuel D WARNING DO NOT TOUCH Exhaust gases muffler and engine components are extremely HOT and cause burns ADVERTENCIA NO TOCAR Los gases de escape el silenciador y los compnonentes del motor están extremadamente CALIENTES y causan quemaduras...

Page 10: ...ank 1 9 gal 7 L 2 Choke Used to start the engine 3 Fuel Valve Used to turn fuel supply on and off to engine 4 Air Filter Protects the engine by filtering dust and debris from the intake air 5 Recoil Starter Used to manually start the engine 6 Oil Fill Cap Dipstick Used to check and fill oil level 7 Control Panel See Control Panel section 8 Carrying Handle s Used to lift or carry the unit 9 Ground ...

Page 11: ... against electrical overloads 2 Intelligauge Three mode digital meter for displaying running time voltage and hertz 3 Engine Switch Used to START or STOP the generator RECEPTACLES A A 120V AC 20A NEMA 5 20R May be used to supply electrical power for operation of 120 Volt AC 20 Amp single phase 60 Hz electrical loads 2 A 3 1 ...

Page 12: ...ps 1 2 for the remaining mount 2 total A D Ac 3 2 G S D B R E O Attach the Alternator Vibration Mounts 1 Thread the flange bolt C through the vibration mount B and then through the frame alternator side 2 Firmly secure the bolt to the frame with the M8 lock nut D DO NOT over tighten 3 Repeat steps 1 2 for the remaining mount 2 total B C D Add Engine Oil CAUTION DO NOT attempt to crank or start the...

Page 13: ...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 5º C 41º F Add Fuel 1 Use clean fresh regular unleaded gasoline with a minimum octane rating of 85 and an ethanol content of less than 10 by volume y b c 2 DO NOT mix oil with gasoline 3 Remove the gasoline cap 4 Slowly add...

Page 14: ... or compartment including the generator compartment of a recreational vehicle Please 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 while not in operation Generators must have at least 5 ft 1 5 m of ...

Page 15: ... 3 Turn the gasoline fuel valve to the ON position 4 Move the choke to the CHOKE position 5 For restarting a warm engine move the choke to 75 of the CHOKE position 6 Push the engine switch to the ON position 7 Pull the starter cord slowly until resistance is felt and then pull rapidly 8 Do not over choke As soon as engine starts move the choke to the RUN position over a 2 5 second duration NOTICE ...

Page 16: ...dentified in step 1 Add this number to the number calculated in step 2 Starting wattage is the extra burst of power needed to start some electric driven equipment Following the steps listed under Power Management will guarantee that only one device will be starting at a time Power Management Use the following formula to convert voltage and amperage to watts Volts Amps Watts To prolong the life of ...

Page 17: ...ean and unobstructed To prevent accidental starting remove and ground the spark plug wire before performing any service Changing the Engine Oil Change oil when the engine is warm Refer to the oil specification to select the proper grade for your operating environment 1 Remove the oil drain plug with a 12 mm socket not included and extension 2 Allow the oil to drain completely into an appropriate c...

Page 18: ...degraded engine performance Type 1 Type 2 NOTICE Federal and local laws 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 ...

Page 19: ...asoline 4 Start and run the generator for 10 minutes so the treated gasoline cycles through the fuel system and carburetor 5 Turn engine switch to the OFF position and allow generator to cool completely before continuing 6 Option 1 Drain Gasoline all models 6a Turn the fuel valve to the OFF position or for Dual Fuel models ONLY set the fuel selector switch for operation on LPG and be sure any LPG ...

Page 20: ...carburetor were properly emptied of all gasoline prior to the generator being stored follow the below steps when removing from storage 1 Add gasoline to the generator according to Add Fuel Gasoline 2 Be sure the engine switch is in the OFF position 3 Turn the fuel valve to the ON position or for Dual Fuel models ONLY set the fuel selector switch for operation on gasoline 4 After 5 minutes check th...

Page 21: ...he engine needs Fuel Specifications Use regular unleaded gasoline with a minimum octane rating of 85 and an ethanol content of less than 10 by volume DO NOT USE E15 or E85 DO NOT OVERFILL Gasoline Capacity 1 9 gal 7 L Spark Plug Specifications OEM Type NHSP E6RTC Replacement Type NGK BPR6HS or equivalent Gap 0 028 0 031 in 0 7 0 8 mm Valve Specifications Intake Clearance 0 005 0 007 in 0 13 0 17 m...

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

Page 23: ...hed 1 31 5 1900 081 Grounding Line 200 mm 1 32 1 6177 1 06 Lock Nut M6 Flange 1 33 1 97 1 06 Washer Ø6 2 34 1 93 06 Lock Washer Ø6 1 Part Number Description Qty 35 1 62 06 Butterfly Type Nut M6 1 36 61148 0 6 2 Frame 490 355 398mm 1 37 1 6177 1 08 Lock Nut M8 Flange 10 38 113 201200 00 Motor Mount Left 1 39 122 201400 01 Rubber Support 2 40 1 16674 0812 Flange Bolt M8 12 2 41 113 201200 01 Motor M...

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

Page 25: ...over 1 35 2 04 002 Dowel Pin Ø8 14 4 Part Number Description Qty 36 15 031000 00 48 Oil Dipstick Assembly Yellow 1 37 15 030007 00 Cover Crankcase 1 38 1 5789 0625 0 8 Flange Bolt M6 25 6 39 12 050200 00 Connecting Rod 1 40 12 050005 02 Piston 1 41 2 09 005 Circlip Ø16 Ø1 2 42 12 050003 01 Pin Piston 1 43 11 050303 00 Ring Oil 1 44 11 050302 00 Ring Second Piston 1 45 11 050301 00 Ring First Pisto...

Page 26: ...1 896 06 Circlip Ø6 1 77 2 03 019 Washer Ø8 2 Ø17 0 8 1 78 12 110008 00 Pin Shaft 1 79 12 110003 00 Arm Governor 1 80 12 110007 21 Spring Governor 1 81 12 110005 00 Spring Throttle Return 1 82 12 110006 00 Rod Governor 1 83 15 040009 00 Rocker Arm 2 84 1 5789 0612 Flange Bolt M6 12 5 85 1 5789 0615 Flange Bolt M6 15 4 ...

Page 27: ...LOCK SPARKING PLUG GREEN YELLOW W G R B Y YELLOW BLACK GREEN WHITE RED G Y GENERATOR BLOCK EXW FW Y Y IGNITION COIL B W G Y W CONTROL BOX BLOCK ENG SW Y G Y CIRCUIT BREAKER MW R 10A Y Y G Y B C Y TRANSITION OIL LEVEL SW B B Y B R L BLUE R 120V 5 20R R w Intelligauge V H Hz W ...

Page 28: ...w load and adjust See Connecting Electrical Loads Insufficient ventilation Check for air restriction Move to a well ventilated area No AC output Cable not properly connected Check all connections Connected device is defective Replace defective device Circuit breaker is open Reset circuit breaker Faulty brush assembly Replace brush assembly Service Center Faulty AVR auto voltage regulator Replace A...

Page 29: ...equired 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 due to acts of God and other force majeure events beyond the manufacturer s control Problems caused by parts that are not origina...

Page 30: ... parts and labor For engines less than or equal to 80cc only the fuel tank and fuel line is subject to the evaporative emission control warranty requirements of this section MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE This emission control system is warranted for two years subject to provisions set forth below If during the warranty period emission related part on your engine is defec...

Page 31: ... 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 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 schedu...

Page 32: ...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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