Champion 100892 Operator'S Manual Download Page 3

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100892 - 4500W OPEN FRAME INvERTER

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 and Dataplate 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

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Control Panel

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Intelligauge

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FCC Statement

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Parts Included

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Assembly

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Unpacking

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Remove Shipping Support Spacers

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Add Engine Oil

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Add Fuel

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Grounding

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Operation

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Generator Location

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Surge Protection

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Starting the Engine

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Connecting Electrical Loads

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Do Not Overload Generator

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Eco (Economy) Mode

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12V DC Automotive Style Outlet

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Parallel Operation

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Stopping the Engine

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Moving the Generator

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Operation at High Altitude

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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

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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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Maintenance Schedule

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Storage

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Short Term Storage (up to 30 days)

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Mid Term Storage (30 days – 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

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Fuel Specifications

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Temperature Specifications

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Parts Diagram

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Parts List

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Engine Parts Diagram

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Engine Parts List

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Wiring Diagram

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Troubleshooting

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Warranty*

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Warranty Qualifications

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Repair/Replacement Warranty

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Do Not Return The Unit To The Place Of Purchase

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Warranty Exclusions

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Other Exclusions

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Limits of Implied Warranty and Consequential Damage

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Contact Information

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Summary of Contents for 100892

Page 1: ... 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 PGMA G300 2015 Compliant This product meets the requirements of the PGMA Portable Generator Manufacturers Association standard ANSI PGMA G300 2015...

Page 2: ...t all carbon monoxide risks you ll be better prepared to protect your family from this colorless oderless threat CARBON MONOXIDE SAFETY THE BIG PICTURE KNOW THE SYMPTOMS Headache Nausea Shortness of breath Dizziness Fatigue STAY ALERT WITH CARBON MONOXIDE DETECTORS POINT FUMES AWAY FROM NEARBY PEOPLE KEEP IT OUTSIDE AND AWAY FROM DOORS WINDOWS AND GARAGES ALWAYS READ THE OPERATOR S MANUAL FIRST MA...

Page 3: ...the Generator 22 Operation at High Altitude 22 Maintenance 22 Cleaning the Generator 23 Changing the Engine Oil 23 Cleaning and Adjusting the Spark Plug 23 Cleaning the Air Filter 24 Cleaning the Spark Arrestor 24 Adjusting the Governor 24 Maintenance Schedule 24 Storage 25 Short Term Storage up to 30 days 25 Mid Term Storage 30 days 1 year 25 Long Term Storage over 1 year 25 Removing from Storage...

Page 4: ...ffort 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 Th...

Page 5: ...ng 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 electrical cords ...

Page 6: ...d 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 NOT mod...

Page 7: ...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 8: ...L OP Rev B Size 78 x 20 mm Artwork Notes 3mm corner radius 2mm safe margin Revision Changes B Changed Octane rating from 85 to 87 20200421 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 Fuel D WARNING DO NOT TOUCH Exhaust gases muff...

Page 9: ...efore 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 caus...

Page 10: ... allow you to more safely operate the product SYMBOL MEANING On Stop or Off ECO Economy Mode Switch Low Oil Overload Reset Switch Hertz Volts Run time SYMBOL MEANING Choke Pull choke knob to CHOKE position Run Push choke knob to RUN position 12V Direct Current Parallel Connection s Circuit Breaker Reset Push RV Ready Receptacle Neutral Floating Neutral circuit IS NOT electrically connected to the ...

Page 11: ... 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 87 and an ethanol content of 10 or less by volu...

Page 12: ...manual for future reference Generator 1 Fuel Valve Used to turn fuel supply on and off to engine 2 Air Filter Protects the engine by filtering dust and debris from the intake air 3 Recoil Starter Used to manually start the engine 4 Control Panel See Control Panel section 5 Gasoline Tank 4 gal 15 2 L 6 Gasoline Gauge 7 Fuel Cap Remove to add fuel 8 Muffler 9 Oil Fill Cap Dipstick Used to check and ...

Page 13: ...e generator against electrical overloads 9 Ground Terminal Consult an electrician for local grounding regulations 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 AC 20A...

Page 14: ...tage and total run time The LCD displays each mode for several seconds and then automatically cycles through MODE DESCRIPTION Frequency H Output frequency in hertz Example 60 0 hertz Voltage V Output voltage of the generator Example 120 volts Total Run Time Hrs Total run time of the generator since first operation Example 16 hours ...

Page 15: ...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 which can be determine...

Page 16: ...ine with oil or gasoline tip the generator onto its side as shown Tip onto the flattened cardboard box the generator came in or other protective surface so as to not scratch the frame 2 Remove the bolts from the orange support spacers and remove the spacers while lightly lifting the engine Bolts and spacers can be discarded 3 Tip the generator upright Add Engine Oil CAUTION DO NOT attempt to crank...

Page 17: ...e clean fresh regular unleaded gasoline with a minimum octane rating of 87 and an ethanol content of 10 or less by volume y b c DO NOT mix oil with gasoline 1 Remove the gasoline cap 2 Slowly add gasoline to the tank Tank is full when gasoline reaches red circle on screen DO NOT OVERFILL Gasoline can expand after filling A minimum of in 6 4 mm of space left in the tank is required for gasoline exp...

Page 18: ...ystem ground connects lower frame cross member below the alternator The system ground is connected to the AC neutral wire See your Specifications section for specified type of grounding OPERATION Generator Location NEVER operate the generator inside any building including garages basements crawlspaces and sheds enclosure or compartment including the generator compartment of a recreational vehicle ...

Page 19: ...switch to the ON position 5 Pull choke knob out to the CHOKE position 6 Pull the recoil cord slowly until resistance is felt and then pull rapidly 7 As engine warms up push the choke knob in to the RUN position NOTICE Keep choke in CHOKE position for only 1 pull of the recoil cord After first pull press the choke knob in to the RUN position for up to the next 3 pulls of the recoil cord Too much ch...

Page 20: ...and must comply with all applicable laws and codes Do Not Overload Generator Capacity Follow these simple steps to calculate the running and starting watts necessary for your purposes 1 Select the electrical devices you plan on running at the same time 2 Total the running watts of these items This is the amount of power you need to keep your items running 3 Identify the highest starting wattage of...

Page 21: ...or is running It will not give the battery a boost of power The vehicle or the generator may be damaged Charge only vented wet lead acid batteries Other types of batteries may burst causing personal injury or damage NOTICE Be sure all electric devices including the lines and plug connections are in good condition before connection to the generator Parallel Operation The Champion model 100892 is pa...

Page 22: ... altitude range for the application of the high altitude carburetor main jet is listed in the following table 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 ...

Page 23: ... oil drain bolt with a 10 mm socket or wrench DRAIN BOLT 2 Allow the oil to drain completely into an appropriate container 3 Replace the oil drain bolt 4 Add oil according to Add Engine Oil in Assembly section DO NOT OVERFILL Oil not included for routine maintenance 5 Dispose of used oil at an approved waste management facility NOTICE Once oil has been added a visual check should show oil about 1 ...

Page 24: ...ered 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 the factory set governor will void your warranty The air fuel mixture is not adjustable Tampering...

Page 25: ...t and run the generator for 10 minutes so the treated gasoline cycles through the fuel system 5 Option 1 Drain Gasoline from Carburetor 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...

Page 26: ...7 338 0999 If the gasoline tank and carburetor were properly emptied of all gasoline prior to the generator being stored follow the below 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 gasolin...

Page 27: ... 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 87 and an ethanol content of 10 or les...

Page 28: ...100892 4500W Open Frame Inverter Specifications 28 Parts Diagram ...

Page 29: ...er Module 1 31 100011267 0003 Flange Bolt M6 x 22 GB5789 2 32 100011268 0003 Flange Bolt M6 x 25 GB5789 2 Part Number Description Qty 33 100710871 Inverter Module 120V 60Hz 1 34 100142008 0001 Frame 530 x 453 x 480 1 35 100136320 Fuel Valve 1 36 100005138 Clamp Ø9 5 x 8 1 37 100142005 0001 Fuel Tank 15 2 Yellow 1 38 100711814 Bushing Ø9 x Ø6 5 x 10 4 39 100711813 Vibration Mounting Fuel Tank 4 40 ...

Page 30: ...8 GB6170 4 69 100011452 0002 Flange Nut M6 GB6177 1 4 70 100093522 Damping Pad 4 71 100011267 0002 Flange Bolt M6 x 22 4 72 100011446 0001 Flange Nut M4 6 73 100011419 0003 Flange Nut M5 1 74 100009075 Sheath Connection Tube 1 75 100155004 Battery Charging Cables 1 76 100155005 Dual Port USB Adapter 5v 2 4A 1 ...

Page 31: ...100892 4500W Open Frame Inverter Specifications 31 Engine Parts Diagram ...

Page 32: ...34 100033258 Clamp Stepping Motor Guide 1 35 100052405 Spring 1 36 100713488 Gasket Air Filter Base 2 Part Number Description Qty 37 100142011 Choke Lever Rack 1 38 100153222 Air Filter Assembly 1 39 100156312 Air Filter Base 1 40 100005078 Air Filter Baffle 1 41 100004771 Air Filter Element 1 42 100087055 Air Filter Cover 1 43 100004949 Air Filter Bolt 1 44 100011463 0002 Flange Nut M6 2 45 10000...

Page 33: ...83 100011540 0007 Flange Bolt M6 x 50 3 84 100126953 Rotor Assembly Permanent Magneto Ø180 x 64 mm 1 85 100087582 Cooling Fan 1 86 100087581 Pulley Starter 1 87 100011459 0003 Flange Nut M14 x 1 5 1 88 100153289 0003 Recoil Starter Assembly 1 89 100128650 0001 Fan Cover Black 1 90 100156547 0001 Recoil Starter Black 1 91 100010894 0002 Washer Ø6 3 92 100011565 0002 Flange Bolt M6 x 10 GB16674 1 3 ...

Page 34: ...100892 4500W Open Frame Inverter Specifications 34 Wiring Diagram ...

Page 35: ...k 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 is open...

Page 36: ...erly 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 due to a...

Page 37: ...n system catalytic converter and other exhaust emission related assemblies Where a warrantable condition exits CPE will repair your small off road engine SORE at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE This exhaust and evaporative emission control system is warranted for two years If any exhaust and evaporative emission related part on your engine or equ...

Page 38: ...ted 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 exhaust and evaporative emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to th...

Page 39: ...ive Controls Fuel Tank Fuel Cap Fuel Lines for liquid fuel and fuel vapors Fuel Line Fittings Clamps Pressure Relief Valves Control Valves Control Solenoids Electronic Controls Vacuum Control Diaphragms Control Cables Control Linkages Purge Valves Gaskets Liquid Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector TO OBTAIN WARRANTY SERVICE You must take your ...

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