Champion 100544 Operator'S Manual Download

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100544 - 7000W DUAL FUEL GENERATOR

TABLE OF CONTENTS

Introduction

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Safety Definitions

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Important Safety Instructions

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Fuel Safety

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Safety Labels

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Safety Symbols

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Operation Symbols

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Quickstart Label Symbols

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Controls and Features

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Generator

.......................................................

Control Panel

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Side Panel

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Intelligauge with Power and Fuel Life meter

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Bluetooth

License Statement

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FCC Statement for Remote Control Device

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Assembly

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Unpacking

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Install the Wheel Kit

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Connect the Battery

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Add Engine Oil

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Add Fuel: Gasoline

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Add Fuel: Propane (LPG)

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Grounding

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Operation

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Generator Location

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Grounding*

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Surge Protection

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Fuel Selector Dial

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Starting the Engine: Gasoline

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Starting the Engine: Propane (LPG)

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Battery

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Connecting Electrical Loads

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Do Not Overload Generator

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GFCI

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Smart Charger

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Stopping the Engine

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Operation at High Altitude

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iLINK™ Wireless App

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iLINK Wireless App FAQ

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Maintenance

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Cleaning the Generator

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Changing the Engine Oil

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Cleaning and Adjusting the Spark Plug(s)

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Cleaning the Air Filter

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Cleaning the Spark Arrestor

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Adjusting the Governor

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Generator Battery

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Maintenance Schedule

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Storage

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Short Term Storage (up to 1 year)

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Long Term Storage (over 1 year)

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Removing from Storage

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Specifications

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Generator Specifications

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Engine Specifications

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Oil Specifications

...............................................

Fuel Specifications

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Spark Plug Specifications

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Valve Specifications

............................................

Battery Specifications

..........................................

Important Message About Temperature

.......................

Parts Diagram

..................................................

Parts List

.......................................................

Engine Parts Diagram

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Engine Parts List

...............................................

Wiring Diagram

.................................................

Troubleshooting

.........................................

Summary of Contents for 100544

Page 1: ...before operating 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 Tes...

Page 2: ...Engine Propane LPG 21 Battery 22 Connecting Electrical Loads 22 Do Not Overload Generator 22 GFCI 23 Smart Charger 23 Stopping the Engine 23 Operation at High Altitude 24 iLINK Wireless App 24 iLINK Wireless App FAQ 26 Maintenance 27 Cleaning the Generator 27 Changing the Engine Oil 28 Cleaning and Adjusting the Spark Plug s 28 Cleaning the Air Filter 28 Cleaning the Spark Arrestor 28 Adjusting th...

Page 3: ...ays 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 information found on your ...

Page 4: ...fires DANGER Operate equipment with guards in place 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 WARNING Do not use generator for medical and life su...

Page 5: ...d result When starting engine pull the starter 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 NOT mo...

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: ... of 85 Maximum 10 ethanol GASOLINA 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 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 re...

Page 8: ...fe 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 st...

Page 9: ... meaning Proper interpretation of these symbols will allow you to more safely operate the product SYMBOL MEANING Engine ON Stop Fuel Selection Propane Fuel Selection Gasoline Smart Charger Locking Receptacle SYMBOL MEANING Circuit Breaker Reset Push Bluetooth Connection Propane Fuel Source Turn off fuel source when generator is not in use Propane Tank Inlet Ground Terminal ...

Page 10: ...ision Changes B Added words increased height C Increased size of TM in iLINK logo 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 K 109 CG1 CG6 376 152 2945 186 Starting the Engine DANGER Move generator outside Only use outside and f...

Page 11: ...c start only 3 Side Panel See Side Panel section 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 Never Flat Wheels 9 5 in 24 1 cm 7 Oil Fill Cap Dipstick Used to check and fill oil level 8 Quick Drain Tube Used to quickly drain engine oil 9 Battery Provides 12V DC power the starting system 10 Folding Handle Used...

Page 12: ...DC Smart Charger Plug 4 Circuit Breakers Push Reset Protects the generator against electrical overloads 5 Start Stop Push Button iLINK Broadcast Indicator 6 Fuel Selection Dial Used to select and turn on gasoline or propane LPG fuel source 7 LPG Connection RECEPTACLES A Y 120 240V AC 30A Locking NEMA L14 30R May be used to supply electrical power for operation of 120 240 Volt AC 30 Amp single phas...

Page 13: ...ts 50 output Frequency H Output frequency in hertz Example 60 0 hertz 75 output Example 60 0 hertz 100 output Run Time R Run time of the generator for the current session Example 6 hours no output Total Run Time Total run time of the generator since first operation Example 16 hours 25 output Output The output power will be displayed at all times on the bottom except when the remaining fuel run tim...

Page 14: ...ing fuel level Fuel Level Shows the fuel level remaining in the tank Example 11 5 hours fuel life 100 fuel level Example 3 0 hours fuel life 25 fuel level As the fuel decreases fewer lights are shown until there is approximately 10 fuel remaining at which time the top display will flash FUEL This indicates that the fuel tank needs to be refilled shortly or will run out ...

Page 15: ...e in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception whi...

Page 16: ...D to the generator frame with Flange Bolts E and Flange Lock Nuts F 2 Slowly tip the generator back down so that it rests on the Wheels and Support Leg D F E 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 Flange Bolt G and secure with the Flange Lock Nut H 3 Repeat for the black battery lead G H A...

Page 17: ...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 Gasoline 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 18: ...ttings with a solution of soap and water Bubbles which appear or bubbles which grow indicate that a leak exists If a leak exists at a fitting then turn off the valve on the cylinder and tighten the fitting Turn the valve back on and recheck the fitting with the soap and water solution If the leak continues or if the leak is not at a fitting then do not use the generator and contact customer servic...

Page 19: ...east 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 muffler DO NOT conta...

Page 20: ...n a level surface 4 On the left side operator panel rotate the fuel selector dial to GASOLINE iLINK App Start see iLINK Wireless App section pg 24 for details on set up and first use 1 Press the START STOP button once The button will flash amber 2 Start app on smart device and follow instructions 3 Press START on app screen The generator will attempt to start There will be up to 6 starting attempt...

Page 21: ...is on a level surface 4 Connect LPG cylinder See page 18 Add Fuel Propane LPG 5 Fully open fuel valve on propane cylinder 6 On the side operator panel rotate the fuel selector dial to PROPANE iLINK App Start see iLINK Wireless App section pg 24 for details on set up and first use 1 Press the START STOP button once The button will flash amber 2 Start app on smart device and follow instructions 3 Pr...

Page 22: ...he 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 Do No...

Page 23: ...ctricity The indicator light will also turn back on GFCI does not protect against circuit overloads To ensure proper operation of the GFCI duplex perform this test monthly 1 With the generator running plug a lamp into the GFCI receptacle Turn the lamp on 2 Press the TEST C button located on the front of the receptacle to trip the device This should immediately stop the flow of electricity and shut...

Page 24: ...application of the high altitude carburetor main jet is listed in the table below In order to select the correct high altitude main jet it is necessary to identify the carburetor model For this purpose a code is stamped on the side of the carburetor Select the correct high altitude jet part number corresponding to the carburetor code found on your particular carburetor Carb Code High Alt Jet Part ...

Page 25: ...tor s Dashboard 7 If you ever need to come back to the My Generators screen or to view add additional generators press the home icon Dashboard 1 With iLINK you are able to start stop and monitor your generator from the Dashboard screen 2 Monitoring includes 2a Output displays the generator wattage output in percent 2b Fuel Life Hours displays the time remaining until the gasoline tank is empty bas...

Page 26: ...eater than 12 hours 3a Turn off and unplug all electrical loads 3b Let the generator run at no load for several minutes 3c Turn the fuel select dial to the OFF position If running on propane LPG shut off propane at the source Disconnecting From Your Generator 1 From the Dashboard screen click the Menu icon 2 Click Disconnect NOTICE Disconnecting the app from your generator while it is running will...

Page 27: ...ultaneously Disconnect one device before connecting another to the generator The generator name photo and PIN code remains the same on each device Can I have more than one generator paired to my iLINK app Certainly you may pair as many as 20 Champion model 100544 generators depending on your smart device memory Will iLINK automatically disconnect from the generator if my device is out of range Yes...

Page 28: ...while checking Cleaning and Adjusting the Spark Plug s 1 Remove the spark plug cable from the spark plug 2 Use a spark plug socket tool not included or a 13 16 in 21 mm socket 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 Make certain the spark plug gap is 0 028 0 031 in 0 7 0 8 mm SPARK PLUG GAP 5 Ref...

Page 29: ...ld be fully charged at least once per month If the battery is not able to start the engine it can be started by manually 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 Bat...

Page 30: ...soline in the carburetor however may gum up and clog the carburetor if it isn t used or drained within 2 4 weeks 1 Be sure all appliances are disconnected from the generator 2 Add a properly formulated fuel stabilizer to the gasoline tank 3 Turn the fuel select dial to gasoline 4 Start and run the generator for 10 minutes so the treated gasoline cycles through the fuel system and carburetor 5 Turn...

Page 31: ...e If any leaks are found the carburetor will need to be disassembled and cleaned or replaced If no gasoline leaks are found turn the fuel select dial to OFF 4 Check engine oil level and add clean fresh oil if needed See Oil Specifications for proper oil type 5 Check and clear air filter of any obstructions such as bugs or cobwebs If necessary clean air filter according to Cleaning the Air Filter 6...

Page 32: ... of 85 and an ethanol content of 10 or less by volume DO NOT USE E15 or E85 DO NOT OVERFILL Gasoline Capacity 8 5 gal 32 L Dual Fuel models ONLY Use only an approved LPG cylinder equipped with an OPD overfilling prevention device valve Spark Plug Specifications OEM Type NHSP F6RTC Replacement Type NGK BPR6ES or equivalent Gap 0 028 0 031 in 0 7 0 8 mm Valve Specifications Intake Clearance 0 005 0 ...

Page 33: ...18 19 21 22 23 24 25 26 27 28 29 30 40 20 1 2 3 4 5 6 7 8 11 12 64 66 67 68 69 70 29 74 75 78 80 81 82 83 73 76 77 84 85 86 87 89 90 91 92 95 96 93 94 97 72 71 98 99 100 101 102 103 98 104 105 107 108 109 110 111 112 113 114 115 116 78 117 119 121 120 122 123 124 125 126 127 128 129 130 131 118 132 133 136 137 138 139 140 5 5 32 106 134 123 141 142 135 118 88 48 9 79 10 65 23 ...

Page 34: ...Air Cleaner 1 32 1 6177 1 06 Lock Nut M6 Flange 2 33 1 848 08 Washer Ø8 2 34 1 93 08 Lock Washer Ø8 2 35 1 6175 08 Nut M8 2 36 46 100001 07 Gasket Exhaust 1 Part Number Description Qty 37 46 101000 01 2 Muffler Assembly 1 38 1 9074 4 0510 Screw Washer Assembly M5 10 3 39 46 101300 00 Spark Arrester Assembly 1 40 1 16674 0820 Flange Bolt M8 20 2 41 1 6175 05 Nut M5 2 42 1 97 1 05 Washer Ø5 2 43 1 9...

Page 35: ...1 97 1 06 2 Washer Ø6 2 103 1 62 06 Butterfly Type Nut M6 1 104 152 200002 14 2 Support Leg 72 mm 1 105 1 5789 0816 Flange Bolt M8 16 2 Part Number Description Qty 106 152 201400 00 Rubber Support 2 107 1 5789 0825 Flange Bolt M8 25 2 108 1 9074 3 0510 Screw Washer Assembly M5 10 2 109 1 6177 1 05 Lock Nut M5 Flange 2 110 9 1000 150 Battery 12V15AH 1 111 152 200904 00 Pinch Rubber 1 112 152 200013...

Page 36: ...PECIFICATIONS 36 Part Number Description Qty 138 152 210003 03 Plug End Cover CSA 1 139 100544 21 10 Wire Assembly 1 140 100544 21 Control Panel Assembly 1 141 47 130021 01 LPG Hose with regulator 3 3 ft 1 142 5 1820 007 Smart Charger 1 ...

Page 37: ... 7 8 9 11 12 13 14 15 16 17 18 19 20 24 25 26 27 28 29 30 31 33 34 35 12 36 30 37 38 23 39 41 42 43 44 46 47 48 49 50 51 52 53 12 54 55 57 58 59 60 61 62 65 66 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 86 87 88 67 83 84 56 94 95 96 111 89 97 98 99 100 101 23 93 89 112 63 32 92 113 114 90 91 115 21 22 117 118 119 120 121 116 122 12 12 ...

Page 38: ...00 Air Guide Right Side 1 36 1 276 6207 Bearing 6207 1 37 46 031000 01 48 Oil Dipstick Assembly Yellow 1 Part Number Description Qty 38 45 030007 00 Cover Crankcase 1 39 1 5789 0840 0 8 Flange Bolt M8 40 7 40 2 03 021 1 Washer Ø6 4 Ø13 1 Black 1 41 45 110013 00 Shaft Governor Gear 1 42 45 110100 00 Gear Governor 1 43 21 110011 00 Clip Governor Gear 1 44 45 110012 00 Bushing Governor Gear Steel 1 4...

Page 39: ...Cleaner 1 96 46 091200 04 Cover Air Cleaner 1 97 1 5789 0835 Flange Bolt M8 35 2 98 45 125100 00 Starter Motor Assembly 1 99 45 125200 03 Relay Starter 1 100 1 93 05 Lock Washer Ø5 2 101 1 16674 0516 Flange Bolt M5 16 2 102 45 110001 00 Shaft Governor Arm 1 103 2 03 019 Washer Ø8 2 Ø17 0 8 1 104 2 11 006 Oil Seal Ø7 Ø14 5 1 105 45 110008 00 Pin Shaft 1 106 45 110003 01 Arm Governor 1 107 2 08 040 ...

Page 40: ...14 30R L Y Y L L B W W R L B R G Y B B W G Y W DCW INTELLIGAUGE CIRCUIT BREAKER CIRCUIT BREAKER 20A 20A R G Y W B R FUEL CUT SOLENOIL B G B G G _ R G Y INPUT 12V W G W L B W G Y 1 2 3 4 5 6 1 2 3 4 6 8 10 12 5 7 9 11 1 2 1 2 4 3 G Y G G G G G R L Y C O LPG CUT SOLENOIL a b e f c d LPG OFF GAS BUTTON R R B B 1 2 3 4 5 6 R FUEL SENSOR B Y L R G PILOT LAMP BUTTON START L R B Y G W L O Y R C L B O Y R...

Page 41: ... surface Generator cannot supply enough power or overheating Generator is overloaded Review 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 ...

Page 42: ...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 43: ...iagnosis 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 ...

Page 44: ...shall 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 s...

Page 45: ...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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