Champion Global Power Equipment 100455, Operator'S Manual

Page 1: ...erating 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 ...

Page 2: ...tor 16 Eco Mode 16 Parallel Operation 17 Stopping the Engine 17 Maintenance 17 Cleaning the Generator 17 Changing the Engine Oil 17 Cleaning and Adjusting the Spark Plug s 18 Cleaning the Air Filter 18 Cleaning the Spark Arrestor 18 Adjusting the Governor 19 Maintenance Schedule 19 Storage 20 Short Term Storage up to 1 year 20 Long Term Storage more than 1 year 20 Removing from Storage 20 Specific...

Page 3: ...s before 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 th...

Page 4: ...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 be required The operator should contact local fire agencies for laws or regulations relating to f...

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

Page 6: ...G will 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 ...

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

Page 8: ...ls will allow you to more safely operate the product SYMBOL MEANING START STOP Fuel Valve ON Fuel Valve OFF Choke Pull choke knob out to CHOKE position Choke Push choke knob in to RUN position Economy Mode Switch SYMBOL MEANING Low Oil Overload Output OK Ground Terminal Neutral Floating Neutral circuit IS NOT electrically connected to the frame ground of the generator Circuit Breaker Reset Push Pa...

Page 9: ...el vent until engine has cooled for at least 15 minutes ADVERTENCIA Para prevenir el bloqueo de vapor en el tanque del combustible NO apague la válvula de ventilación hasta que el motor se haya enfriado por 15 minutos AVERTISSEMENT Pour empêcher le blocage de la vapeur dans le réservoir de carburant NE PAS éteindre la soupape de ventilation tant que le moteur n a pas refroidi pendant 15 minutes Fu...

Page 10: ... of the controls and features Save this manual for future reference Generator 1 Carrying Handle Used to lift or carry the unit 2 Fuel Lever Vent Turn this valve to the ON position to supply air to the tank 3 Fuel Cap Remove to add fuel 4 Control Panel See Control Panel section 5 Recoil Starter Used to manually start the engine 6 Spark Plug Access Cover 7 Maintenance Cover 8 Muffler 1 6 7 8 2 3 4 5...

Page 11: ... 4 Economy Mode Switch Enables disables automatic idle control 5 Engine Switch Used to START or STOP the generator 6 Choke Used to start the engine 7 Fuel Valve Knob 8 AC Overload Reset Button 9 Parallel Outlets Used for parallel operation 10 Circuit Breakers Push Reset Protects the generator against electrical overloads RECEPTACLES A A 120V AC 20A NEMA 5 20R May be used to supply electrical power...

Page 12: ...tor rotor has a sealed pre lubricated ball bearing that requires no additional lubrication for the life of the bearing NOTICE The recommended oil type is 10W 30 automotive oil 20 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 1 Place the generator on a flat level surface 2 Loosen the cover screws a...

Page 13: ...ew on the gasoline cap and wipe away any spilled fuel CAUTION Use regular unleaded gasoline with a minimum octane rating of 85 and an ethanol content of 10 or less by volume DO NOT mix oil and gasoline Fill tank to approximately in 6 4 mm below the top of the tank to allow for gasoline expansion DO NOT pump gasoline directly into the generator at the pump Use an approved container to transfer the ...

Page 14: ...structions Place the generator in a well ventilated area DO NOT place the generator near vents or intakes where exhaust fumes could be drawn into occupied or confined spaces Carefully consider 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...

Page 15: ...rter Too much choke leads to spark plug fouling engine flooding due to the lack of incoming air This will cause the engine not to start NOTICE For gasoline restarts with hot engine in hot ambient 30 C 86 F Keep the choke in 75 of the CHOKE position for only 1 pull of the recoil starter After first pull push choke to the RUN position for up to 3 more pulls of the recoil starter Too much choke leads...

Page 16: ...arting 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 all devices identified in step 1 Add this number to the number calculated in step 2 Starting wattage is the extra burst of power needed to sta...

Page 17: ...unit on a flat level surface in a clean dry operating environment DO NOT expose the unit to extreme conditions excessive dust dirt moisture or corrosive vapors WARNING Never operate a damaged or defective generator WARNING Improper maintenance will void your warranty NOTICE Maintenance replacement or repair of emission control devices and systems may be performed by any non road engine repair esta...

Page 18: ...e spark plug types in Specifications when replacing the plug 7 Firmly re install the plug 8 Attach the spark plug cable to the spark plug 9 Reinstall the spark plug access cap if applicable and maintenance cover Cleaning the Air Filter 1 Remove the maintenance cover 2 Locate the air filter plastic cover Remove the screw using a Phillips head screwdriver 3 Remove the foam element 4 Wash in liquid d...

Page 19: ...ustment needs Maintenance Schedule Follow the service intervals indicated in the following maintenance schedule Service your generator more frequently when operating in adverse conditions Contact our Technical Support Team at 1 877 338 0999 to locate the nearest CPE certified service dealer for your generator or engine maintenance needs EVERY 8 HOURS OR DAILY Check oil level Clean around air intak...

Page 20: ...buretor drain bolt and be sure to properly dispose of the drained gasoline according to local regulations or guidelines 7 Option 2 Run Dry 7a Turn engine switch to the ON position and start the generator 7b With the generator running turn the fuel valve to the OFF position and allow the generator to run until the engine stops from complete fuel starvation This may take a few minutes 7c Turn engine...

Page 21: ...sassembled and cleaned or replaced If no gasoline leaks are found turn the fuel valve to the OFF position 5 Check engine oil level and add clean fresh oil if needed See Oil Specifications for proper oil type 6 Check and clear air filter of any obstructions such as bugs or cobwebs If necessary clean air filter according to Cleaning the Air Filter 7 Start the generator according to Starting the Engi...

Page 22: ...1 gal 3 8 L Spark Plug Specifications OEM Type NHSP E6RTC Replacement Type NGK BPR6HS or equivalent Gap 0 024 0 028 in 0 6 0 7 mm Valve Specifications Intake Clearance 0 004 in 0 1 mm Exhaust Clearance 0 004 in 0 1 mm NOTICE A technical bulletin regarding valve adjustment procedures is available at www championpowerequipment com Temperature Specifications Starting Temperature Range F C 5 to 104 15...

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

Page 24: ... Ø4 Green 1 30 81 130200 00 Pull Choke Assembly 1 31 1 818 0412 3 Screw M4 12 Green 1 32 81 070001 00 Knob Fuel Valve 1 33 5 1010 003 1 Switch Black 2 Part Number Description Qty 34 81 211100 00 2 Operate Panel Black 1 35 81 126000 00 Ignition Assembly 1 36 81 210200 01 Toroid Coil Component Square 1 37 81 211001 00 Control Box Operation Panel 1 38 81 210200 00 Toroid Coil Component Round 1 39 81 ...

Page 25: ...19 20 1 21 22 23 24 25 26 27 28 13 29 30 31 32 33 34 35 3637 1 1 38 39 40 41 42 43 44 45 47 46 48 49 50 51 52 53 54 55 56 57 58 59 13 60 61 62 63 64 65 19 47 66 67 68 69 70 71 72 58 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 3 13 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 3 87 47 86 64 66 85 84 83 82 107 ...

Page 26: ...er Seal Sleeve 1 37 81 190001 00 Cooling Fan Rotor 1 Part Number Description Qty 38 2 09 007 Circlip Ø13 5 Ø1 2 39 81 050003 00 Pin Piston 1 40 81 050200 00 Connecting Rod 1 41 81 050300 00 Piston Ring Set 1 42 81 050005 00 Piston 1 43 81 040100 00 Camshaft 1 44 81 040013 00 Lifter Valve 2 45 81 040005 00 Push Rod 2 46 2 15 005 E6RTC Spark Plug E6RTC 1 47 2 01 027 Stud Bolt M6 27 6 48 1 845 4817 T...

Page 27: ...08 Flange Bolt M6 8 1 90 81 030035 00 Oil Nipple 1 91 1 9074 4 0535 Screw M5 35 2 92 1 818 0306 1 Screw M3 6 2 93 1 9074 3 0510 Screw M5 10 1 94 81 130007 00 Clamp Board Choke Control Line 1 95 81 130010 00 Spring Connecter 1 96 81 131000 00 Carburetor 1 81 131000 02 97 2 06 010 Clamp Ø10 5 Ø1 2 98 81 132200 00 Stepper Motor 1 99 1 9074 1 0408 Screw M4 8 2 100 81 132100 00 Stepper Motor Base 1 101...

Page 28: ...OP SW L W G B Y R YELLOW BLACK BLUE GREEN RED WHITE Br WHITE BLUE GREEN YELLOW WHITE GREEN BROWN BLACK WHITE B W W L G Y W G ENGINE IGNITION COIL G 5 20R AC COIL SUB COIL C W B W O L Y A G Y O B W C W O Y L C B G Y L R R R Y Y R W B L TCI UNIT G Y G Y G Y C CARNATION A AMETHYST O ORANGE OUTPUT PANEL CONTROL PANEL CIRCUIT BREAKER 20A W W R Red Black 1 2 5 3 4 4 5 6 7 8 3 9 2 10 1 6 RESET SW ...

Page 29: ... 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 Loose wiring Inspect and tighten wirin...

Page 30: ...ent 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 majeure events beyond the m...

Page 31: ... 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 CPE recommends that you retain all your receipts covering maintenance on your small off road engine SORE but CPE cannot den...

Page 32: ...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 33: ...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...