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OPERATOR'S MANUAL

MODEL #100637

9000W PORTABLE GENERATOR

Made in China - REV 20200203

Champion Power Equipment, Inc., Santa Fe Springs, CA USA

or visit

championpowerequipment.com

SAVE THESE INSTRUCTIONS.

This manual contains important safety precautions which should be read and understood 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 meets the requirements of the PGMA (Portable Generator Manufacturers’ Association) standard ANSI/PGMA G300-2018 (Safety and Performance of
Portable Generators).

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Summary of Contents for 100637

Page 1: ...perating 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 2018 Safety and P...

Page 2: ...erator 23 Operation at High Altitude 23 Maintenance 24 Cleaning the Generator 24 Changing the Engine Oil 24 Cleaning and Adjusting the Spark Plug 25 Cleaning the Air Filter 25 Cleaning the Spark Arrestor 25 Adjusting the Governor 25 Generator Battery 26 Maintenance Schedule 26 Storage 27 Short Term Storage up to 30 days 27 Mid Term Storage 30 days 1 year 27 Long Term Storage over 1 year 27 Removin...

Page 3: ...fort 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 generator The...

Page 4: ...t 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 electrical cords that are worn damaged or frayed...

Page 5: ...ance 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 modify the generator in any way CAUTION Start the generator and allow the...

Page 6: ...om 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 DO NOT a...

Page 7: ...e disclosed to or used by or for outside parties without the explicit consent of Champion Power Equipment CO Shield Action automatic shutoff See CO Shield section C UNLEADED FUEL ONLY Minimum octane rating 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 1032 L OP A K 10...

Page 8: ...fore 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 can cause...

Page 9: ...he product SYMBOL MEANING START ON STOP or OFF Circuit Breaker Reset Push Circuit Breaker Reset Flip Smart Charger Neutral Bonded to Frame Neutral circuit IS electrically connected to the frame ground of the generator Locking Receptacle SYMBOL MEANING Fuel Gasoline Valve ON OFF Choke Run Ground Terminal High CO Warning Move generator to an open outdoor area Move to fresh air and get medical help i...

Page 10: ...e to ON position 4 Press ignition switch to the ON position 5 Move choke lever to CHOKE position 6 Pull the recoil cord 7 Move the choke lever to RUN position 8 Plug in desired device Stopping the Engine 1 Turn off and unplug all connected electrical loads 2 Press the ignition switch to the OFF position 3 Turn the fuel valve to the OFF position Electric Start See page 20 in Operation section 1 2 3...

Page 11: ... fuel supply on and off to engine 4 Air Filter Protects the engine by filtering dust and debris from the intake air 5 Never Flat Wheels 9 5 in 24 1 cm 6 Recoil Starter Used to manually start the engine 7 Oil Fill Cap Dipstick Used to check and fill oil level 8 Battery Provides 12V DC power the starting system 9 Folding Handle Used to move unit by lifting and rolling on wheels Do not use to lift or...

Page 12: ...nitors for accumulation of poisonous carbon monoxide CO gas produced by engine exhaust when the generator is running If CO Shield detects elevated levels of CO gas it automatically shuts off the engine See CO Shield section for more information 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 phase 60 Hz elec...

Page 13: ...requency 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 The output power shown is based on the electrical lo...

Page 14: ...ts Wheels 9 5 in 24 1 cm Never Flat Wheel A 2 Roll Pin B 2 Large R clip C 2 Engine Vibration Mounts Support Leg with Vibration Mounts D 1 Flange Bolt M8 16 E 2 Flange Lock Nut M8 F 2 Battery Bolts Flange Bolt M5 10 G 2 Flange Lock Nut M5 H 2 Tools Needed Metric Wrench or Socket Set Pliers Phillips Screwdriver A B C D E F H G ...

Page 15: ...ide the Roll Pin B through the Wheel A from the outside 3 Slide the Roll Pin through the mount point on the frame 4 Secure with the R clip C 5 Repeat to attach the second Wheel C A B Install the Support Leg 1 Attach the Support Leg 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 E F Connect th...

Page 16: ...s below the threshold level NOTICE The first 5 hours of run time are the break in period for the unit During the break in period stay at or below 50 of the running watt rating and vary the load occasionally to allow stator windings to heat and cool Adjusting the load will also cause engine speed to vary slightly and help seat piston rings After the 5 hour break in period change the oil NOTICE Synt...

Page 17: ...line improperly stored gasoline and or improperly formulated stabilizers are not covered by manufacturer s warranty It is advisable to always shut off the gasoline supply and run the engine to starvation after each use See Storage instructions for extended non use Grounding Your generator must be properly connected to an appropriate ground to help prevent electric shock WARNING Failure to properly...

Page 18: ... to or used by or for outside parties without the explicit consent of Champion Power Equipment When you approach the generator to investigate a shut off a blinking red LED light in the CO Shield area provides notification that the generator shut off due to an accumulating CO hazard The red LED light will blink for at least five 5 minutes after a shutoff event AUTOMATIC SHUTOFF SERVICE AUTOMATIC SH...

Page 19: ...r wind and air currents when positioning generator Failure to follow proper safety precautions may void manufacturer s warranty WARNING 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 During operation ...

Page 20: ... seconds it could damage the starter Manual Start 1 Push the ignition switch to the ON position 2 Move the choke to the CHOKE position 2a For restarting a warm engine move the choke to 75 of the CHOKE position 3 Pull the recoil cord slowly until resistance is felt and then pull rapidly 4 Do not over choke As soon as engine starts move the choke to the RUN position over a 2 5 second duration NOTICE...

Page 21: ... WARNING 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 pleas...

Page 22: ... it has been serviced or replaced 3 Press the RESET button located on the front of the receptacle to restore the flow of electricity If the indicator light does not come back on or if the GFCI cannot be reset then it must be replaced A B C NOTICE In any electrical application some current will flow through the protective ground conductor to the ground this is called leakage current It takes 4 mA 0...

Page 23: ...titudes is lower than at sea level Engine power is reduced as the air mass and air fuel ratio decrease Engine power and generator output will be reduced approximately 3 for every 1000 ft of elevation above sea level 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 ...

Page 24: ...ots 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 gro...

Page 25: ...the two or three screws varies by model holding the cover plate which retains the spark arrestor to the muffler 3 Remove the spark arrestor screen 4 Carefully remove the carbon deposits from the spark arrestor screen with a wire brush Type 1 Type 2 See your model s parts list for specified type of spark arrestor 5 Replace the spark arrestor if it is damaged 6 Position the spark arrestor on the muf...

Page 26: ...2 for the red battery lead 4 Store the battery in a cool dry place Charge the Battery For a generator equipped with batteries for electric starting proper battery maintenance and storage should be followed A trickle charger or battery maintainer should be used to charge the battery while the generator is in storage Maximum charging rate should not exceed 1 5 amps Follow the instructions included w...

Page 27: ...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 replace and tighten the carburetor drain bolt and be sure to properly dispose of the drained gasoline according to local regu...

Page 28: ...emoving from storage 1 Be sure the ignition switch is in the OFF position 2 Add gasoline to the generator according to Add Fuel Gasoline 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 fuel v...

Page 29: ...ngine 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 of 10 or less by volume DO NOT USE E15 or E85 DO NOT OVERFILL Gasoline Capacity 7 7 gal 29 L Battery Specifications Type Rechargeable Non Spillable Lead Acid Volts 12 Capacity 15 Ah Temperature Spe...

Page 30: ...36 37 38 39 40 41 26 32 42 44 45 19 20 23 1 2 3 8 9 10 11 12 13 14 15 46 47 48 17 51 52 53 54 55 56 57 58 60 61 62 63 64 65 66 67 21 22 58 68 69 70 71 72 73 75 59 4 5 6 7 43 43 76 77 78 79 80 81 82 83 84 85 87 88 89 90 91 92 96 97 98 99 100 101 102 103 104 105 106 107 108 18 18 74 30 50 9 49 86 94 95 93 ...

Page 31: ...74 0516 Flange Bolt M5 16 2 34 153 190200 04 AVR CSA 1 35 152 190002 00 End Housing 1 36 2 08 069 Bolt M6 194 4 Part Number Description Qty 37 2 08 071 Bolt M5 229 2 38 1 6175 05 Nut M5 2 39 154 191002 00 Stator Cover 1 40 155 191200 03 Stator Assembly Cu Ø204 158 mm CSA 1 41 2 08 070 Bolt M10 280 1 42 155 191100 00 Rotor Assembly Cu Ø204 158 mm CSA 1 43 1 5789 0608 Flange Bolt M6 8 2 44 152 19230...

Page 32: ...1870 003 Receptacle Cover Receptacle L14 30R 1 88 1 6177 1 04 1 Lock Nut M4 Flange Black 11 89 5 1280 003 Fuse 10A 1 90 1 818 0514 2 Screw M5 14 4 91 5 1810 000 Over Voltage Protector CSA 1 92 5 1800 000 Rectifier 1 93 1 845 3513 Screw ST3 5 13 1 94 1 845 4216 Screw ST4 2 16 2 95 5 1830 022 Module CO Shutdown 1 96 5 1000 001 3 Switch Red 1 97 5 1440 008 Intelligauge With Power Meter 1 Part Number ...

Page 33: ... 2 16 20 22 21 23 23 39 30 37 38 36 12 34 35 33 32 28 29 30 31 26 27 63 24 25 12 100 101 99 98 97 102 103 104 105 106 107 91 112 110 108 109 12 111 89 90 91 85 86 87 88 95 96 93 94 113 92 40 41 42 43 44 45 46 47 48 49 50 51 52 53 12 54 55 56 57 58 59 60 61 62 80 81 82 83 84 78 79 75 76 74 77 72 73 68 69 71 70 67 65 66 64 116 117 ...

Page 34: ...45 030007 00 Cover Crankcase 1 39 1 5789 0840 Flange Bolt M8 40 7 40 2 03 021 1 Washer Ø6 4 Ø13 1 Black 1 Part Number Description Qty 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 1 45 47 050200 00 Connecting Rod 1 46 48 050005 00 Piston 1 47 2 09 004 Circlip Ø21 Ø1 2 48 45 050003 00 Pin Piston 1 49 ...

Page 35: ...over 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 Three Gear 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 Bolt M6 21 Gover...

Page 36: ...ION SW L Y Y L L W R R L B R M Br W W L G Y CHARGE COIL BATTERY STARTER Br B G B G R B 3 4 2 1 6 5 OFF ON ST COMBINATION SWITCH G Y B G Y W W Br Br DCW1 6 5 4 3 2 1 B W B W B ST OFF ON FUSE 10A 20A C B 20A C B R B NO USE W G W G B G Y B G Y B Y B R W W R R 30A 37 5A 37 5A 2P C B R G Y B B B B B B B B R R _ R G Y 30A 2P C B B B G BLACK GREEN W 1 2 3 4 6 8 10 5 7 9 R Y IGNITION COIL B B R DCW2 Br Br...

Page 37: ... and buildings Move to fresh air and get medical help if sick dizzy or weak If equipped CO Shield shutoff due system fault if the yellow LED light blinks on the panel Start to confirm yellow LED light blinks when if generator shuts off If CO Shield continues sense the fault and shuts off contact technical support Clogged spark arrestor Clean spark arrestor Engine starts and shuts off right away If...

Page 38: ...act the help line Other Contact the help line Engine hunts or falters Engine governor defective Contact the help line Dirty fuel valve Clean the fuel valve Carburetor is dirty and running lean Contact the help line Choke in wrong position Move choke until it stops under RUN position or push in completely Repeated circuit breaker tripping Overload Review load and adjust See Connecting Electrical Lo...

Page 39: ... 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 due to acts of God and other force majeu...

Page 40: ...ol system is warranted for two years subject to provisions set forth below If during the warranty period an 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 SORE owner you are responsible for the performance of the required maintenance listed in your Owner s Manual...

Page 41: ...eplacement 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 3d Repair or ...

Page 42: ...nister Mounting Brackets 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 bu...

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