Champion 100592 User Manual

OPERATOR'S MANUAL
MODEL #100592
6250W DUAL FUEL GENERATOR
US Patent # D710,802
Made in China - REV 20190515 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.
Specications, 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 A NSI/PGMA G300 (Safety and Performance of Portable Generators).
REGISTER YOUR PRODUCT ONLINE
at championpowerequipment.com
CARBON MONOXIDE AUTO-SHUTOFF
100592 - 6250W DUAL FUEL GENERATOR
TABLE OF CONTENTS
TABLE OF CONTENTS
Introduction ................................................ 3
Safety Definitions Important Safety Instructions
Fuel Safety ...................................................... 6
Safety Labels .................................................... 7
Safety Symbols .................................................. 8
Operation Symbols .............................................. 9
Quickstart Label Symbols......................................10
Controls and Features ...............................11
Generator .......................................................11
Control Panel ...................................................12
Intelligauge .....................................................13
Tools Needed ...................................................14
Assembly ...................................................15
Unpacking ......................................................15
Install the Wheel Kit ............................................15
Add Engine Oil ..................................................15
Add Fuel: Gasoline .............................................16
Add Fuel: Propane (LPG) .......................................17
Grounding ...................................................... 18
Operation ...................................................18
CO Shield™ - Carbon Monoxide (CO)
Detection and Auto-shutoff System ...........................18
Generator Location .............................................19
Surge Protection ...............................................20
Fuel Selector ...................................................20
Starting the Engine: Gasoline ..................................20
Starting the Engine: Propane (LPG) ...........................22
Connecting Electrical Loads ...................................23
Do Not Overload Generator ....................................23
GFCI .............................................................24
Stopping the Engine ............................................24
Moving the Generator ..........................................25
Operation at High Altitude .....................................25
....................................... 3
.................... 4
Maintenance ............................................. 26
Cleaning the Generator ........................................26
Changing the Engine Oil .......................................26
Cleaning and Adjusting the Spark Plug ........................26
Cleaning the Air Filter ..........................................27
Cleaning the Spark Arrestor ...................................27
Adjusting the Governor .........................................27
Maintenance Schedule .........................................27
Storage ..................................................... 28
Short Term Storage (up to 30 days) ...........................28
Mid Term Storage (up to 1 year) ...............................28
Long Term Storage (more than 1 year) ........................29
Removing from Storage ........................................29
Specifications ........................................... 30
Generator Specifications .......................................30
Engine Specifications ..........................................30
Oil Specifications ...............................................30
Fuel Specifications .............................................30
Temperat ure Specificati ons ....................................30
Parts Diagram ..................................................31
Parts List .......................................................32
Engine Parts Diagram ..........................................34
Engine Parts List ...............................................35
Wiring Diagram .................................................37
Troubleshooting ........................................ 38
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100592 - 6250W DUAL FUEL GENERATOR
INTRODUCTION
INTRODUCTION
Congratulations on your purchase of a Champion Power Equipment (CPE) product. CPE designs, builds, and supports all of our products to strict specifications and guidelines. With proper product knowledge, safe use, and regular maintenance, this product should bring years of satisfying service.
Every effort 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. Therefore, it is IMPORTANT to review this product manual and other product materials thoroughly and be fully aware and knowledgeable of the assembly, operation, dangers and maintenance of the product before use. Fully familiarize yourself, and make sure others who plan on operating the product fully familiarize themselves too, with the proper safety and operation procedures 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 the information found on your product’s nameplate label to the table below
SAFETY DEFINITIONS
The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and their explanations, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures.
! DANGER
DANGER indicates a hazardous situation which,if not avoided, will result in death or serious injury.
! WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
! CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
"
NOTICE
NOTICE indicates information considered important, but not hazard-related (e.g., messages relating to property damage).
CPE TECHNICAL SUPPORT TEAM
1-877-338-0999
MODEL NUMBER
100592
SERIAL NUMBER
DATE OF PURCHASE
PURCHASE LOCATION
3
100592 - 6250W DUAL FUEL GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
! WARNING
Cancer and Reproductive Harm – www.P65Warnings.ca.gov
! DANGER
Generator exhaust contains carbon monoxide, a colorless, odorless, poisonous gas. Breathing carbon monoxide will cause nausea, dizziness, fainting or death. If you start to feel dizzy or weak, get to fresh air immediately.
OPERATE GENERATOR OUTDOORS ONLY IN A WELL VENTILATED AREA AND POINT EXHAUST AWAY.
DO NOT operate the generator inside any building, including garages, basements, crawlspaces and sheds, enclosure or compartment, including the generator compartment of a recreational vehicle.
DO NOT allow exhaust fumes to enter a confined area through windows, doors, vents or other openings.
! DANGER
Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.
NEVER use inside a home or garage, EVEN IF doors and windows are open.
ONLY use OUTSIDE and far away from windows, doors, and vents.
! 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.
! DANGER
Generator produces powerful voltage.
DO NOT touch bare wires or receptacles.
DO NOT use electrical cords that are worn, damaged or frayed. Use only Champion electrical cords for proper application.
DO NOT operate generator in wet weather.
DO NOT allow children or unqualified persons to operate or service the generator.
Use a ground fault circuit interrupter (GFCI) in damp areas and areas containing conductive material such as metal decking.
Connection to your home’s electrical system requires a listed 30A transfer switch installed by a licensed electrician and approved by the local authority having jurisdiction. The connection must isolate the generator from the utility power and must comply with all applicable laws and electrical codes.
Install battery-operated carbon monoxide alarms or plug-in carbon monoxide alarms with battery back-up according to the manufacturer’s instructions.
! WARNING
Although the generator contains a spark arrester, maintain a minimum distance of 5 ft. (1.5 m) from dry vegetation to prevent fires.
! WARNING
Do not use generator for medical and life support uses.
In case of emergency, call 911 immediately.
NEVER use this product to power life support devices or life support appliances.
NEVER use this product to power medical devices or medical appliances.
Inform your electricity provider immediately if you or anyone in your household depends on electrical equipment to live.
Inform your electrical provider immediately if a loss of power would cause you or anyone in your household to experience a medical emergency.
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100592 - 6250W DUAL FUEL GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
! WARNING
Spark from removed spark plug wire can result in fire or electrical shock.
When servicing the generator:
Disconnect the spark plug wire and place it where it cannot contact the plug or any other metal object.
DO NOT check for spark with the plug removed.
Use only approved spark plug testers.
! WARNING
Running engines produce heat. Severe burns can occur on contact. Combustible material can catch fire on contact.
DO NOT touch hot surfaces.
Avoid contact with hot exhaust gases.
Allow equipment to cool before touching.
Maintain at least 3 ft. (91.4 cm) of clearance on all sides to ensure adequate cooling.
Maintain at least 5 ft. (1.5 m) of clearance from combustible materials.
! 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 or void the warranty.
Use the generator only for intended uses.
Operate only on level surfaces.
DO NOT expose generator to excessive moisture, dust, or dirt.
DO NOT allow any material to block the cooling slots.
If connected devices overheat, turn them off and disconnect them from the generator.
DO NOT use the generator if:
– Electrical output is lost
! WARNING
Rapid retraction of the starter cord will pull hand and arm towards the engine faster than you can let go. Unintentional startup can result in entanglement, traumatic amputation or laceration. Broken bones, fractures, bruises or sprains could 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 modify the generator in any way.
– Equipment sparks, smokes or emits flames
– Equipment vibrates excessively
! WARNING
Tamper ing with CO Shield™ could result in a hazardous condition. Removing the CO Shield module will not allow the generator to start.
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100592 - 6250W DUAL FUEL GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
Fuel Safety
! DANGER
GASOLINE, GASOLINE VAPORS AND PROPANE (LPG) ARE HIGHLY FLAMMABLE AND EXPLOSIVE.
Fire or explosion can cause severe burns or death.
Gasoline and gasoline vapors:
– Gasoline is highly flammable and explosive.
– Gasoline can cause a fire or explosion if ignited.
– Gasoline is a liquid fuel but it’s vapors can ignite.
– Gasoline is a skin irritant and needs to be cleaned up
immediately if spilled on skin or clothes.
– Gasoline has a distinctive odor, this will help detect potential
leaks quickly.
– In any petroleum gas fire, flames should not be extinguished
unless by doing so the fuel supply valve can be turned OFF. This is because if a fire is extinguished and a supply of fuel is not turned OFF, then an explosion hazard could be created.
– Gasoline expands or contracts with ambient temperatures.
Never fill the gasoline tank to full capacity, as gasoline needs room to expand if temperatures rise.
LPG:
– LPG is highly flammable and explosive.
– LPG is under pressure and can cause a fire or explosion if
ignited.
– LPG is heavier than air and can settle in low places while
dissipating.
– LPG has a distinctive odor added to help detect potential
leaks quickly.
– In any petroleum gas fire, flames should not be extinguished
unless the fuel supply valve is turned OFF. This is because if a fire is extinguished and a supply of fuel is not turned OFF, then an explosion hazard could be created.
– When exchanging LPG cylinders, be sure the cylinder valve
is of the same type.
– Always keep the LPG cylinder in an upright position.
– LPG 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:
DO NOT light or smoke cigarettes.
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 station. Use an approved container to transfer the fuel 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 attempt to start a damaged generator.
Make certain that the gasoline cap, air filter, spark plug, fuel lines and exhaust system are properly in place.
Allow spilled gasoline to evaporate fully before attempting to start the engine.
Make certain that the generator is resting firmly on level ground.
When operating the generator:
DO NOT move or tip the generator during operation.
DO NOT tip the generator or allow fuel or oil to spill.
When transporting or servicing the generator:
Make certain that the fuel valve is in the OFF position and the gasoline tank is empty.
For LPG compatible models, be sure that the LPG cylinder is disconnected and stored securely away from the generator.
Disconnect the spark plug wire.
When storing the generator:
Store away from sparks, open flames, pilot lights, heat and other sources of ignition.
Do not store generator, gasoline or LPG cylinders near furnaces, water heaters, or any other appliances that produce heat or have automatic ignitions.
! WARNING
Never use a gasoline container, gasoline tank, LPG connector hose, LPG cylinder or any other fuel item that is broken, cut, torn or damaged.
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100592 - 6250W DUAL FUEL GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
7
Top
A
C
B
Safety Labels
These labels warn you of potential hazards that can cause serious injury. Read them carefully.
If a label comes off or becomes hard to read, contact Technical Support Team for possible replacement.
Back
D
LABEL DESCRIPTION
A
! PELIGRO
El uso de un generador en interiores PUEDE MATARLO EN MINUTOS. El escape del generador contiene monóxido de carbono. Éste es un veneno que no se puede ver ni oler.
NUNCA lo use dentro del hogar ni
el garaje, INCLUSO SI las puertas y ventanas están abiertas .
Úselo LO a la INTEMPERIE
lejos de ventanas, puertas, y oricios de ventilación.
! DANGER
Utiliser un générateur à lintérieur
PEUT VOUS TUER EN QUELQUES MINUTES. Léchappement du
générateur contient du monoxyde de carbone. Il sagit dun poison que vous ne pouvez ni voir ni sentir.
Ne lutilisez JAMAIS dans la
maison ou le garage ME SI les portes et les fenêtres sont ouvertes.
Utilisez-le UNIQUEMENT À
LEXTÉRIEUR, loin des fenêtres, portes et trappes de ventilation.
ONLY use OUTSIDE and far away from windows, doors, and vents.
NEVER use inside a home or garage, EVEN IF doors and windows are open.
! DANGER
Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains
carbon monoxide. This is a poison you cannot see or smell.
1028-L-SF-B
Safety Symbols/
CO Danger
B
1607-L-SF-A
25 ft. / 7 m
AUTOMATIC SHUTOFF YOU MUST: APAGADO AUTOMÁTICO USTED DEBE: ARRÊT AUTOMATIQUE VOUS DEVEZ :
Move generator to an open, outdoor area. Point exhaust away. Dont run generators in enclosed areas (e.g. not in house or garage).
Mover el generador a un área abierta a la intemperie. Apunte el escape alejado. No corra los generadores en áreas cerradas (ej. no en una casa o garaje).
placer le générateur vers un espace exrieur en plein air. Garder léchappement loin. Ne pas faire fonctionner les générateurs dans un espace clos (ex., pas dans une maison ou un garage).
ACTION LABEL ETIQUETA DE ACCIÓN ÉTIQUETTE D'ACTION
EXHAUST
EL ESCAPE
L’E C H A P P E M E N T
POINT AWAY DIRIJA ALEJADO DIRIGER LOIN
Move to fresh air and get medical help if sick, dizzy or weak.
Mueva al aire fresco y obtenga asistencia medica si está enfermo, mareado, o débil.
Aller à l'air frais et obtenir de l'aide médicale si malade, étourdi ou faible.
CO Shield
Action automatic
shutoff
*See CO Shield
section
C
UNLEA DED FUEL ONLY. Minimum oct ane rating of 85. Ma ximum 10% ethanol.
GASOL INA REGU LAR SOLAMEN TE. 85 octanos como mínimo . Máximo de etanol d e 10%.
ESSENC E SANS PLOMB SEULEMENT. Indice doctane minimal de 85. Maximum 10 % d'éthanol.
1032-L- OP-A
Fuel
D
! WARNING
DO NOT TOUCH!
Exhaust gases, mufer 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 required. The operator should contact local re agencies for laws and regulations relating to re prevention requirements. If installed, clean every 100 hours or every season.
! ADVERTENCIA
¡NO TOCAR! Los gas es de escape, el silenciador y los compnonentes del motor están extremadamente CALIENTES y causan quemaduras.
La operacn de este equipo puede producir chispas que pueden provocar incendios alrededor de la vegetacn seca. Un supresor de chispas puede que sea necesario. El operador debe comunicarse con las agencias locales de bomberos para las leyes y reglamentos relativos a los requisitos de prevención de incendios. Si está instalado, limpie cada 100 horas o cada temporada.
! AVERTISSEMENT
NE PAS TOUCHER! Les gaz déchappement, le silencieux et les pièces du moteur sont extrêmement CHAU DS et peuvent causer des brûlures.
Cet équipement peut créer des étincelles et provoquer un incendie dans la végétation sèche. Un pare-étincelles peut être requis. Lopérateur doit communiquer avec le service dincendie local pour connaître les lois et les règlements en matière de prévention des incendies. Si elle est installée, nettoyez toutes les 100 heures ou chaque saison.
1035-L-SF- B
Hot Surface
100592 - 6250W DUAL FUEL GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
Safety Symbols
Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to more safely operate the product.
SYMBOL MEANING
Read Operator’s Manual. To reduce the risk of injury, user must read and understand operator’s
manual before using this product.
Clearance. Keep all objects at least 5 feet (1.5m) from generator. Heat from the muffler and exhaust gas can ignite combustible objects.
Ground. Consult with local electrician to determine grounding requirements before 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 severe burns or death. Keep generator at least 5 feet (1.5m) from all objects to prevent combustion.
Hot Surface. To reduce the risk of injury or damage, avoid contact with any hot surface.
Open Flame Alert. Fuel and its vapors are extremely flammable and explosive. Keep fuel away from
smoking, open flames, sparks, pilot lights, heat, and other ignition sources.
Wet Conditions Alert. Do not expose to rain or use in damp locations.
8
100592 - 6250W DUAL FUEL GENERATOR
IMPORTANT SAFETY INSTRUCTIONS
Operation Symbols
Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to more safely operate the product.
SYMBOL MEANING
ON
STOP or OFF
High CO Warning. Move generator to
an open, outdoor area. Move to fresh air and get medical help if sick, dizzy or weak.
System Fault. Electrical issue, tampering, end of life.
Locking Receptacle
Neutral Bonded to Frame. Neutral
circuit IS electrically connected to the frame/ground of the generator.
Choke
SYMBOL MEANING
Ground Terminal
Propane Valve ON/OFF
Fuel/Gasoline Valve ON/OFF
Propane Operation
Gasoline Operation
Propane Inlet
Propane Fuel Source. Turn off fuel
source when generator is not in use.
Run
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100592 - 6250W DUAL FUEL GENERATOR
1604-L-OP -A
!
10W-30
"
1 4
5 6 7 8 1 3
2A
2B
3A
2A
2B
3B
b c
"
+
+
+
+
IMPORTANT SAFETY INSTRUCTIONS
Quickstart Label Symbols
Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to more safely operate the product.
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. Add fuel. 2a. If operating on gasoline, check gasoline level.
When adding gasoline, use a minimum octane rating of 85 and an ethanol content of 10% or less by volume.
2b. If operating on propane, connect propane tank.
Open valve on propane tank.
3. Fuel Selector 3a. Slide Fuel Selector to the left for gasoline operation.
Then turn the fuel valve to the “ON” position.
3b. Slide Fuel Selector to the right for LPG operation. Then
turn the fuel valve to the “ON” position.
4. Press engine switch to the “ON” position.
Stopping the Engine
1. Tur n of f a nd unplug a ll conn ected elec tric al loads .
2. Fuel Valve 2a. If operating on gasoline, turn the fuel valve to the
“OFF” position.
2b. If operating on LPG, turn the fuel valve to the “OFF”
position on the generator and on the tank.
3. Press the engine switch to the “OFF” position.
5. Move choke lever to “CHOKE” position.
6. Pull the recoil starter.
7. Move the choke lever to “RUN” position.
8. Plug in desired device.
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100592 - 6250W DUAL FUEL GENERATOR
CONTROLS AND FEATURES
11
CONTROLS AND FEATURES
Read this operators manual before operating your generator. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference.
Generator
1. Gasoline Tank – 6 gal. (22.9 L)
2. Choke – Used to start the engine.
3. Air Filter Protects the engine by ltering dust and debris
from the intake air.
4. Never Flat Wheels – 8 in. (20.3 cm)
5. Recoil Starter – Used to manually start the engine.
6. Oil Fill Cap/Dipstick Used to check and ll oil level.
7. Folding Handle Used to move unit by lifting and rolling on wheels. Do not use to lift or carry the unit.
8. Control Panel See Control Panel section.
9. Ground Terminal Consult an electrician for local grounding regulations.
1
3
2
4
5
6
8
7
9
100592 - 6250W DUAL FUEL GENERATOR
Control Panel
CONTROLS AND FEATURES
1
2
1. Fuel Selector – Used to select and turn on gasoline or
propane (LPG) fuel source.
2. LPG Inlet – Used to connect LPG fuel source to generator.
3. Engine Switch – Used to put in START mode or STOP the
generator. When operating by propane, this switch will NOT stop the engine.
4. Intelligauge – Three mode digital meter for displaying
total run time, voltage and hertz.
5. CO Shield red shutoff LED
3
5
A
A
Y
B
C
B
RECEPTACLES
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 electrical loads.
(4×) 120V AC, 20A GFCI (NEMA 5-20R) May be used to supply electrical power for operation of 120 Volt AC, 20 Amp, single phase, 60 Hz electrical loads.
4
6
7
8
6. CO Shield yellow service LED
The CO Shield technology monitors 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
7. Circuit Breakers (Push Reset) – Protects the generator
against electrical overloads.
8. Circuit Breakers (Flip Reset) – Protects the generator
against electrical overloads.
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100592 - 6250W DUAL FUEL GENERATOR
Intelligauge
Three mode digital meter for displaying voltage, hertz, and total run time.
Push SELECT button on right side of gauge to display different modes.
MODE DESCRIPTION
CONTROLS AND FEATURES
V
Hz
H
Output voltage of the generator.
Voltage (V)
Frequency (Hz)
Tot al Run Time(H)
Example: 120 volts
Example: 60.0 hertz
Example: 80 hours
V
Hz
120
H
Output frequency in hertz.
V
Hz
60.0
H
Tot al run time o f the generato r since first operatio n.
V
Hz
80.0
H
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