Champion Power Equipment 100152 Operator's Manual for All Serial Numbers in

REV 100152-20221209

DANGER: Not intended for use in critical life support application. DANGER: Generator must be installed and operated outdoors only.

WARNING

Cancer and Reproductive Harm – www.P65Warnings.ca.gov

DISCLAIMERS

All information, illustrations and speciﬁcations in this manual are based on the latest information available at

the time of publishing. The illustrations used in this manual are intended as representative reference views only.

Products are under a continuous improvement policy. Thus, information, illustrations and/or speciﬁcations to explain

and/or exemplify a product, service or maintenance improvement may be changed at any time without notice.

No part of this publication may be reproduced or used in any form by any means – graphic, electronic or

mechanical, including photocopying, recording, taping or information storage and retrieval systems – without the

written permission of Champion Power Equipment (CPE).

Have questions or need assistance?

Do not return this product to the store!

WE ARE HERE TO HELP!

Visit our website:

www.championpowerequipment.com

for more info:

• Product Info & Updates

• Frequently Asked Questions

– or –

Call our Customer Care Team Toll-Free at:

1-877-338-0999

This manual must be used with Champion Power Equipment (CPE) manuals:

• Installation Manual, Part No. 101307

• Transfer Switch Manual, Part No. 101111

It is also recommended to refer to the reference materials list on page 16 of the Installation Manual.

• Tech Bulletins

• Product Registration

*We are always working to improve our products. Therefore, the enclosed product may differ slightly from the image on the cover.

CONTENTS

Model 100152

CONTENTS

INTRODUCTION ...........................5

Home standby generator ....................5

Parts Included ...........................5

General information, Standards and Codes .......6

SAFETY .................................7

Safety Symbol Deﬁnitions ...................7

Installation Hazards. . . . . . . . . . . . . . . . . . . . . . . . 8

Before Starting ...........................9

Operating Hazards ........................9

Accidental Starting .......................10

Carbon Monoxide Hazards ..................10

Electrical Shock Hazards ...................11

Fire/Explosion Hazards ....................11

Burn Hazards ...........................12

Entanglement Hazards ....................12

Battery Hazards .........................12

Emission Requirements ....................19

Speciﬁcations ...........................20

Fuel System ............................21

Battery Requirements .....................21

Battery Charging ........................21

Model and Serial Number ..................21

OPERATION .............................22

Enclosure and Access .....................22

Pre-Start Checklist .......................22

Turning Off the Generator ..................22

MAINTENANCE ...........................23

Scheduled Maintenance Chart ...............23

Engine Oil .............................23

Engine Oil Requirements .................... 23

Checking the Engine Oil Level ................. 23

Changing the Engine Oil ..................... 24

Safety Labels ...........................12

Safety Labels on Unit ....................... 13

Safety, Serial/Model, Nameplate Label Locations ... 14

GENERAL INFORMATION ...................15

Component Identiﬁcation –11 kW Generator. . . . . 15

Component Identiﬁcation – Engine ............16

Control Panel ..........................16

Main Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . 16

Exercise Switch ........................... 16

Set Exercise Time .......................... 17

Hour Meter .............................. 17

Engine Control Module ...................... 17

Reset Fault Code(s) ........................ 17

ATS Control Module ........................18

Battery Charger .........................19

Inspect and Clean Engine Air Cleaner ..........25

Spark Plug .............................25

Battery Maintenance ......................26

Corrosion Protection ......................26

Maintenance After Submersion ..............26

Storage ...............................26

Return to Service after Storage ................ 27

Engine Parts Diagram ....................... 28

Engine Parts List .......................... 29

Enclosure and Assemblies Diagram ............. 32

Enclosure and Assemblies Parts List ............ 33

Top Cover Assembly, Left Diagram .............. 34

Top Cover Assembly, Left Parts List ............. 35

Top Cover Assembly, Right Diagram ............. 36

Top Cover Assembly, Right Parts List ............ 37

Part No. 101305

Model 100152

CONTENTS

Alternator and Exhaust System Diagram .........38

Alternator and Exhaust System Parts List ......... 39

Control Panel Diagram ...................... 40

Control Panel Parts List ..................... 41

Wiring Diagram ........................... 42

TROUBLESHOOTING .......................43

ADDITIONAL INFORMATION .................45

Identify / Select Standby Circuits .............45

Surge Protection .........................45

Customer Familiarization Summary ...........46

HSB, ATS Model & Serial Reference

Back-Up Circuits ........................47

Maintenance and Service Record .............48

Part No. 101305

Model 100152

INTRODUCTION

Congratulations on your purchase of a Champion Power Equipment (CPE) home standby generator. This generator is designed and engineered in the USA to exacting standards of the North American market. This engine-powered generator meets all Environmental Protection Agency (EPA) Phase 3 requirements and is approved by CETLUS as tested to UL2200 and CSA22.2 No. 100 in both the USA and Canada.

With proper use and maintenance, this generator will provide years of satisfying service.

The Champion Staff,

Champion Power Equipment 12039 Smith Ave. Santa Fe Springs, CA 90670

Toll-free: 1-877-338-0999 Mon-Fri 8:30 AM – 5:00 PM (PST/PDT) www.championpowerequipment.com

HOME STANDBY GENERATOR

This home standby generator is intended exclusively for outdoor installation. This generator will operate using either liqueﬁed petroleum gas (LPG) or natural gas (NG).

PARTS INCLUDED

Your HSB ships with the following:

• Operators Manual

• Installation Manual

• Oil Drain Pan

• Flexible Fuel Line

• HSB Enclosure Keys

• Battery Cable Connection

• LPG Low-speed and Main Converting Jets

• Jet Change Tool

• Lock Nut M6

• Washer, Ø6

• Flange bolt, M6 x 15

This generator is designed to supply typical home load such as:

• Induction motors – sump pumps, refrigerators, air conditioners, furnaces

• Electronic items – televisions, computers

• Household lighting

• Microwaves

• This generator is not intended for use in critical life support applications.

Proper sizing of the generator is required to ensure proper operation of appliances. Some appliances require additional wattage to start and must be considered.

Part No. 101305

Model 100152

INTRODUCTION

GENERAL INFORMATION, STANDARDS AND CODES

The following information related to General Information and Standards was gathered from the list of publications related to installing the HSB generator. A multitude of other materials related to generators were also used concerning common practice, knowledgeable installation practices, certiﬁed electrical experience and work related experiences. This information is not all inclusive and the manufacturer strongly recommends the owner and installer become familiar with all pertinent codes, standards and regulations. Always check for the latest publications date to ensure you are current. Have only a qualiﬁed/certiﬁed electrician or installation technician who is knowledgeable about applicable codes, standards and regulations install and service the generator.

NFPA NO. 30, FLAMMABLE AND CONBUSTIBLE LIQUID CODE

National Fire Protection Association

470 Atlantic Avenue, Boston, MA. 02210

NFPA NO. 70, NFPA HANDBOOK OF ELECTRIC CODE

National Fire Protection Association

470 Atlantic Avenue, Boston, Ma. 02210

ARTICLE X, NATIONAL BUILDING CODE

American Insurance Association

85 John Street, New York, N.Y. 10038

AGRICULTURAL WIRING HANDBOOK

Food and Energy Council

909 University Avenue, Columbia, Mo. 65201

ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS

American Society of Agricultural Engineers

2950 Niles Road, St. Joseph, Mi. 49085

NFPA NO. 37, STATIONARY COMBUSTION ENGINES AND GAS TURBINES

National Fire Protection Association

470 Atlantic Avenue, Boston, Ma. 02210

NFPA NO. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES

National Fire Protection Association

470 Atlantic Avenue, Boston, Ma. 02210

NFPA NO. 54, NATIONAL FUEL GAS CODE

National Fire Protection Association

470 Atlantic Avenue, Boston, Ma. 02210

NFPA NO. 58, AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUID PETROLEUM GAS

National Fire Protection Association

470 Atlantic Avenue, Boston, Ma. 02210

Part No. 101305

Model 100152

SAFETY

This is the safety alert symbol. It is used to alert you to potential physical injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

The words DANGER, WARNING, CAUTION and NOTICE are used throughout this manual to highlight important information.

DANGER

Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

SAFETY SYMBOL DEFINITIONS

Black hazard pictorial on yellow equilateral triangle enclosed by black triangular band

Warns that hazard exists and describes its nature and/or consequences

Black hazard pictorial on white circle enclosed by red circular band with red diagonal bar

Depicts action NOT to be taken or action to be stopped in order to avoid hazard

White hazard pictorial on blue circle

Depicts action to be taken in order to avoid hazard

WARNINGS

NOTICE

Indicates a situation that can cause damage to the equipment, personal property and/or the environment, or cause the equipment to operate improperly.

OTE: N Indicates a procedure, practice or condition that

should be followed in order for the generator to function in the manner intended.

Safety alert symbol

Asphyxiation hazard

Electrical shock hazard

Entanglement hazard

Fire hazard

Part No. 101305

Model 100152

SAFETY

INSTALLATION HAZARDS

Explosion hazard

Burn hazard

Sever hazard (rotating blade)

Crush hazard (top)

MANDATORY ACTIONS

WARNING

Have only a qualiﬁed electrician or installation technician who is familiar with applicable codes, standards and regulations install and service the generator.

ALWAYS comply with local, state and national electrical and building codes when installing the generator. NEVER alter the recommended installation in a way that would render the unit noncompliant with these codes.

ALWAYS comply with regulations that Occupational Safety and Health Administration (OSHA) has established.

ENSURE the generator is installed following the manufacturer’s instructions.

Read manufacturer’s instructions

Wear eye protection

Wear personal protective equipment

Do not leave tools in the area

NOTICE

Before welding components on the generator, contact CPE for recommended welding instructions.

WARNING

Not intended for use in critical life support applications.

Part No. 101305

Model 100152

SAFETY

BEFORE STARTING

CAUTION

Before starting, operating and maintaining this generator, be sure to read and understand the content and safety messages in this manual. The operator is responsible for safe operation and maintenance of the generator. Be sure all potential users of the generator also understand these instructions. If any portion of this manual is not understood, contact your dealer for assistance before operating the generator.

The operator is responsible for performing all safety checks, making sure all maintenance is properly performed and making sure the generator is periodically checked by the dealer.

Inspect the generator regularly. Contact your dealer if repairs are needed.

NEVER climb or step on any part or components of the generator. Doing so may result in injury and cause leaking fuel and exhaust.

OPERATING HAZARDS

WARNING

ALWAYS operate the generator following the manufacturer’s instructions. Operating the generator imprudently, neglecting maintenance or being careless can result in injury or possible death.

DO NOT allow children or unqualiﬁed persons to operate or service the generator.

NEVER operate the generator with the covers open. Operate the generator only with the covers closed and secured in place. NEVER leave the covers unlocked.

Remain alert at all times when working on the generator. NEVER work on the generator when physically or mentally fatigued.

Never operate the generator while under the inﬂuence of alcohol or drugs. Their effects on vision and judgment make operating a generator dangerous.

Part No. 101305

Model 100152

SAFETY

ACCIDENTAL STARTING

WARNING

ALWAYS prevent the generator from starting while the covers are open. The generator may crank and start at any time without notice. Follow these steps in order:

1. Turn the exercise switch to the OFF position.

2. Switch the main circuit breaker to the OFF position.

3. Turn the ATS control module to the OFF position.

4. Turn the engine control module switch to the OFF position.

5. Disconnect the NEGATIVE, NEG or (-) battery cable ﬁrst, and then remove the POSITIVE, POS or (+) battery cable.

To return the generator to service, follow these steps in order:

1. Connect the POSITIVE, POS or (+) battery cable ﬁrst, and then connect the NEGATIVE, NEG or (-) battery cable.

2. Turn the engine control module switch to the ATS position.

3. Turn the ATS control module switch to the AUTO position.

4. Switch the main circuit breaker to the ON position.

5. Turn the exercise switch to the ON position.

CARBON MONOXIDE HAZARDS

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.

• The generator must be installed and operated outdoors only. NEVER install the generator where exhaust fumes could seep inside or be drawn into a potentially occupied building through windows, air intake vents or other openings.

• Avoid breathing exhaust fumes when near an operating generator.

• NEVER alter or add to the exhaust system or do anything that might render the system unsafe or in noncompliance with applicable codes, standards, laws and regulations.

• Install a battery-operated carbon monoxide detector on each level of any building adjacent to the generator following the manufacturer’s instructions.

• NEVER permit even partial blockage of engine cooling ventilation air. Doing so can seriously affect safe operation of the generator.

Carbon monoxide poisoning symptoms include but are not limited to the following:

• Light-headedness, dizziness

• Physical fatigue, weakness in joints and muscles

• Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision

• Stomachache, vomiting, nausea

Part No. 101305

Model 100152

SAFETY

Carbon monoxide poisoning is possible if someone is experiencing any of these symptoms. Seek fresh air immediately. DO NOT sit, lie down or fall asleep. Alert others to the possibility of carbon monoxide poisoning. If the affected person does not improve within minutes of breathing fresh air, call 911 immediately.

ELECTRICAL SHOCK HAZARDS

WARNING

Use extreme caution when near the generator while it is operating. The generator produces dangerous voltage.

• Avoid contact with bare wires, terminals and connections while the generator is operating.

• ALWAYS stand on an insulated dry surface to reduce shock hazard if work must be done on an operating generator.

• NEVER wear jewelry that can conduct electricity when working on the generator.

• NEVER handle any kind of electrical device while hands or feet are wet, while standing in water or while barefoot.

• Proper earth grounding of the frame and external electrical conductive components is required by the National Electrical Code (NEC). State and local codes for proper grounding may also apply.

• Avoid direct contact with an electric shock victim. Immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor using a nonconducting item such as a dry board or rope. If the victim is unconscious, apply ﬁrst aid and call 911 immediately.

FIRE/EXPLOSION HAZARDS

WARNING

NG and LPG are extremely explosive.

• NEVER allow any ﬂames or smoke near the fuel system.

• Wipe up any oil spills immediately.

• NEVER allow any combustible materials to be near the generator or to be left in the generator compartment.

• ALWAYS keep the surrounding area near the generator clean and free of debris.

• Be sure to properly purge the fuel lines and leak-test according to applicable codes before placing the generator in service.

• Be sure to regularly inspect the fuel system for leaks. NEVER operate the generator if a fuel leak is present.

• Install a ﬁre extinguisher near the generator. Keep it properly charged and be familiar with its use. An ABC rated National Fire Protection extinguisher is appropriate for use on standby electric systems. Contact your local ﬁre department with any questions concerning the ﬁre extinguisher.

Part No. 101305

Model 100152

SAFETY

BURN HAZARDS

WARNING

ALWAYS allow hot surfaces to cool to the touch. Running engines produce heat. Severe burns can occur on contact.

• DO NOT touch hot surfaces.

• Avoid contact with hot exhaust components and gases.

ENTANGLEMENT HAZARDS

WARNING

Use extreme caution when near rotating parts. 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.

• Operate equipment with guards in place.

• DO NOT wear loose-ﬁtting clothing, dangling drawstrings or items that could become caught.

WARNING

Batteries contain sulfuric acid and generate explosive mixtures of hydrogen and oxygen gases. Keep any device that may cause sparks or ﬂames away from the battery to prevent explosion.

Always wear protective glasses or goggles and protective clothing when working with batteries. You must follow the battery manufacturer’s instructions on safety, maintenance and installation procedures.

SAFETY LABELS

WARNING

All safety labels must be legible to alert personnel of safety hazards.

• Replace any illegible or missing label immediately. Missing safety labels must be replaced in their original position before the generator is operated.

• DO NOT operate the generator if there are missing or badly worn safety labels.

BATTERY HAZARDS

WARNING

Always read and comply with the battery manufacturer’s recommendations for procedures concerning proper battery use and maintenance.

Part No. 101305

SAFETY LABELS ON UNIT

Model 100152

SAFETY

Poisonous Gas Hazard Generator exhaust

contains carbon monoxide. Breathing carbon monoxide will cause nausea, dizziness, and fainting, and it may cause death.

Risque d’empoisonnement par le gaz Les gaz

d’échappement de groupe électrogène contiennent du monoxyde de carbone. Si l’on respire du monoxyde de carbone, ceci peut provoquer des nausées, un évanouissement et une perte de conscience, et ceci peut provoquer la mort.

Riesgo de gas venenoso El escape del

generador contiene monóxido de carbono. Aspirar monóxido de carbono causará náuseas, mareos, desvanecimiento y hasta la muerte.

Electrical Shock Hazard

Do not remove this access panel. The panel should only be removed by an authorized Service Dealer or a qualified electrician; high voltage inside.

Risque de choc électrique

N’enlevez pas ce panneau d’accès. Le panneau ne devrait être enlevé que par un concess ionnaire d’entretien agréé ou un électricien qualifié ; haut e tension à l’intérieur.

Riesgo de descarga eléctrica

No remueva este tablero de acceso. El tablero sólo deberá s de servicio autorizado o un electricista calificado; alto voltaje al interior.

er removido por un distribuidor

101045

Burn Hazard DO NOT touch hot

surfaces. Avoid contact with exhaust components and gases.

Risque de brûlure NE touchez

PAS les surfaces chaudes. Evitez le contact avec les composants et les gaz d’échappement.

Riesgo de quemaduras NO toque

las superficies calientes. Evite el contacto con los componentes de escape y gases.

101500

4 5

101045

Fire Hazard ALWAYS keep the surrounding

area near generator clean and free of debris and/or dry vegetation. The generator may create sparks while operating.

Risque d’incendie Nettoyez TOUJOURS la

surface à proximité du groupe électrogène et enlevez les débris et/ou la végétation sèche. Le groupe électrogène peut générer des étincelles pendant son fonctionnement.

Riesgo de incendio SIEMPRE mantenga el

área circundante cerca del generador limpia y libre de escombros y/o vegetación seca. El generador puede crear chispas mientras está en funcionamiento.

Burn Hazard DO NOT touch hot

surfaces. Avoid contact with exhaust components and gases.

Risque de brûlure NE touchez

PAS les surfaces chaudes. Evitez le contact avec les composants et les gaz d’échappement.

Riesgo de quemaduras NO toque

las superficies calientes. Evite el contacto con los componentes de escape y gases.

101051

101500

101051 100789

Burn Hazard DO NOT touch hot surfaces. Allow the engine and alternator to cool to the touch before servicing.

Danger de brulure NE

TOUCHEZ PAS les surfaces chaudes. Laissez le moteur et l’alternateur devenir froid au toucher avant d’intervenir.

Riesgo de quemaduras

NO toque las superficies calientes. Deje que el motor y el alternador se enfríen para tocarlos antes de realizarles el mantenimiento.

100794

Electrical Shock Hazard ALWAYS

close and lock generator covers before operating. The generator produces dangerous voltage.

Risque de choc électrique Fermez et

verrouillez TOUJOURS les capots de groupe électrogène avant d’utiliser le groupe. Le groupe électrogène génère des tensions dangereuses.

Riesgo de descarga eléctrica

SIEMPRE cierre y trabe las tapas del generador antes de ponerlo en funcionamiento. El generador produce un voltaje peligroso.

100794

100789

Explosion Hazard Battery gases are explosive.

Keep sparks and flames away from the battery compartment.

Risque d’explosion Les gaz dégagés par la

batterie peuvent exploser. Ecartez les étincelles et les flammes du compartiment batterie.

Riesgo de explosión Los gases de las baterías

son explosivos. Mantenga las chispas y llamas alejadas del compartimento de las baterías.

Read Operator’s Manual Read,

understand and follow all safety messages in Installation and Operator’s manuals.

Lisez le manuel d’utilisation Lisez,

comprenez bien et respectez tous les messages de sécurité dans les manuels d’installation et d’utilisation.

Lea el manual del operador Lea,

comprenda y siga todos los mensajes de seguridad en los manuales de instalación y del operador.

Starting Hazard The generator may crank and start at any time without notice. Prevent the generator from starting while the covers are open. See the safety section of the operator’s manual for further detail.

Risque au démarrage Le groupe électrogène peut tourner et démarrer à tout moment sans préavis. Ne démarrez pas le groupe électrogène lorsque les capots sont ouverts. Consultez la section sécurité du manuel d’utilisation pour plus de détail.

Riesgo de inicio El generador puede encenderse y ponerse en marcha en cualquier momento sin previo aviso. Evite que el generador se ponga en marcha mientras las tapas están abiertas. Vea la sección de seguridad en el manual del operador para más detalles.

101499

Part No. 101305

Model 100152

SAFETY

SAFETY, SERIAL/MODEL, NAMEPLATE LABEL LOCATIONS

The safety labels have speciﬁc placement and must be replaced if they are unreadable, damaged or missing.

(inner part of cover)

Part No. 101305

A) Serial number locaon

B) Nameplate

C) NFPA 37 Compliance

GENERAL INFORMATION

COMPONENT IDENTIFICATION – 11 KW GENERATOR

Model 100152

Figure 1

1. Exhaust System

2. Air Inlet

3. Fuel Regulator/Wire Connections (behind panel)

4. Main Circuit Breaker

5. Hour Meter

6. Exterior Fault Code Indicator Light

7. Exercise Switch

8. ATS Control Module

9. Engine Control Module

10. Batteries (not included)

11. Engine

12. Alternator

Part No. 101305

Model 100152

MARCHE

ENCENDIDO

OFF ARRÊT APAGADO

MAIN CIRCUIT BREAKER

DISJONCTEUR PRINCIPAL

INTERRUPTOR DE CIRCUITO PRINCIPAL

GENERAL INFORMATION

COMPONENT IDENTIFICATION – ENGINE

CONTROL PANEL

MAIN CIRCUIT BREAKER

The 46-amp main circuit breaker protects the generator from circuit overload. The main circuit breaker controls total output of the generator. (Figure 3)

Figure 3

Figure 2

1. Engine Oil Dipstick

2. Air Cleaner

3. Oil Cap

4. Spark Plug (second on opposite side)

5. Oil Filter

EXERCISE SWITCH

The exercise switch incorporates a built-in timer. The generator will automatically perform an exercise period once every seven days (168 hours). At the start of the exercise period, the engine will start and run for 15 minutes. Load transfer from the generator output will not occur unless the utility power is lost. When the switch is in the OFF position, the exercise function is disabled. Refer to Set Exercise Time to reset. (Figure 4)

EXERCISE / EXERCICE

EJERCICIO

ON MARCHE ENCENDIDO

OFF ARRÊT APAGADO

Figure 4

Part No. 101305

Model 100152

GENERAL INFORMATION

SET EXERCISE TIME

To set the exercise time, the engine control module switch must be in the ATS mode. Decide on the desired day and time to exercise the generator. Press the exercise switch to ON. The generator will start and run for 15 minutes and then shut off. The exercise time is now set. The generator will begin the next exercise period exactly 168 hours from when the exercise switch was pressed to the ON position.

If you choose to change the current exercise time setting, choose the new day and time and cycle the exercise switch from off to on and it will begin the cycle again. (Figure 4)

The exercise time will have to be reset if:

• The battery was disconnected from the generator

• The switch was moved to the OFF position for maintenance

HOUR METER

The generator is equipped with an hour meter that will display the generator actual run and exercise times.

ENGINE CONTROL MODULE

The engine control module contains the ATS/OFF/Manual mode switch and the LEDs that indicate if a generator operation is being performed or if there is an active alarm. (Figure 5)

If the exterior fault code indicator light is on, open the enclosure to view the engine control module. Determine what the fault code is and remedy the situation or have the generator serviced by an authorized Service Dealer or contact Champion Customer Service at 1-877-338-0999.

RESET FAULT CODE(S)

ATS

Exercise / Exercice / Ejercicio

Low battery / Batería baja

Hz over/under / Hz plus / sous Hz Más / Menos

High engine temperature Surchauffe moteur Alta temperatura del motor

Low oil / Huile basse Baja de aceite

Over crank Surdémarrage Sobre manivela

Run / Marche Funcionar

Power / Alimentation Potencia

MODE SWITCH

• ATS – This position allows for fully automatic operation. If utility power is lost, the generator will automatically start up. It also allows the generator to automatically perform the exercise period.

• OFF – This position shuts down the engine and prevents automatic operation of the generator.

• Manual – This position allows manual starting of the engine. Load transfer from the generator output does not occur unless the utility power is lost.

EXERCISE LED The GREEN LED will be ﬂashing when the HSB is performing the

weekly exercise cycle. When the exercise period has completed, the LED will stay lit and the HSB will resume standby monitoring.

Batterie faible

ATS ATS

Figure 5

OFF

ARRÊT

APAGADO

Manual Manuel Manual

There is also an exterior fault code indicator light located on the back of the enclosure. This should be checked weekly to make sure there are no active fault codes.

The fault code(s) can be reset by placing the Engine Control Module (Figure 5) in the OFF position. This will reset fault LED, however if a fault code(s) re-occurs it must be addressed.

LOW BATTERY LED The yellow LED will be lit if the battery voltage fell below 21.0

volts for at least one minute while the engine was running. If battery voltage rises above 21.1 volts, the LED will turn off. Battery voltage is not monitored when cranking the engine.

Part No. 101305

Model 100152

GENERAL INFORMATION

HIGH ENGINE TEMP LED The red LED will be lit if the engine operating temperature

exceeds the factory preset limits. If excessive operating temperature is detected, the HSB will shut down and re-start will be disabled. The RED LEDs on the module and enclosure exterior are lit.

This failure could be the result of an excessive load or high ambient temperatures. Should this fault occur do the following;

1. Open the enclosure doors to increase air ﬂow throughout the unit

2. Check oil level, add oil if required

3. Inspect the interior and exterior of the enclosure for debris, leaves, ect., and remove them to increase air ﬂow around and inside the unit.

4. Once the engine temperature falls into the normal operating range, generally 30 minutes, follow the reset procedures in the manuals speciﬁc to your model to clear and correct fault.

5. Close the enclosure doors and the unit is ready to run.

HZ OVER / UNDER SPEED LED The red LED will be lit if the engine was operating above or

below its preset speed limit. The engine will shut down, and the LED will remain lit until the generator is repaired and operating correctly. Appliances connected to the generator circuit could be damaged from high generator output if the engine is allowed to operate above its preset limit. If this failure occurs, contact an authorized Service Dealer or contact Champion Customer Service at 1-877-338-0999.

LOW OIL LED The red LED will be lit if the engine oil level has dropped below

the safe operating level. When this happens, the engine will shut down. Check the engine oil level before attempting to restart the engine. The engine will not start until the problem is corrected.

OVER CRANK LED The red LED will be lit if the engine tried to start but was

unable to start in the speciﬁed time period. The engine will try to start ﬁve times and if unsuccessful the light will turn on. This may occur on initial start-up, the fuel system needs to be fully pressurized to start and operate. Follow reset procedure on page

15.

POWER LED The green LED will be lit indicating the generator is working

correctly and loads can be connected to it.

ATS CONTROL MODULE

The ATS control module contains the TEST/AUTO/OFF switch and LEDs that indicate type of power delivery. (Figure 6)

UTILITY UTILITÉ

UTILIDAD

TEST / ESSAI / PRUEBA

AUTO / AUTO / AUTOMÁTICO

OFF / ARRÊT / APAGADO

TEST/AUTO/OFF SWITCH

• TEST – This position allows veriﬁcation that the generator power delivery circuit is functional. With the switch in the TEST position, the engine will start and the ATS will transfer. The GENSET LED, ATS LED (middle LED) and LOAD LED should be lit, indicating the generator power delivery circuit is functional.

• AUTO – This position allows automatic delivery of power from the generator if there is a utility outage. With the switch in the AUTO position and the engine not running, the UTILITY LED, ATS LED (middle LED) and LOAD LED should be lit, indicating the household is using utility provided power.

• OFF – This position will not allow any power to be delivered to the ATS when the engine is running.

LOAD

CHARGER

CARGA

Figure 6

GENSET GENSET GENSET

RUN LED The green LED will be lit indicating the engine is running.

Part No. 101305

Model 100152

GENERAL INFORMATION

BATTERY CHARGER

The LEDs on the battery charger indicate the state of the battery’s charge level. Battery charger rating 24 Vdc 1.6A. (Figure 7)

NO CHARGE / PAS DE CHARGE /

POWER

ALIMENTATION

RECOGNIZED COMPONENT

Conforms to UL

Std. 1236

Power: 80-125 Vac 1.0 A 50 / 60 Hz Alimentation : 80-125 V c.a. 1,0 A 50 / 60 Hz Potencia: 80 - 125 V C.A. 1,0 A 50 / 60 Hz

POWER / ALIMENTATION /

MODEL / MODÈLE / MODELO : 100482

POTENCIA

L N ADJ

POTENCIA

AUTOMATIC BATTERY CHARGER /

CHARGE AUTOMATIQUE DE BATTERIE /

CARGADOR DE BATERÍA AUTOMÁTICO

Figure 7

SIN CARGA

Output: 24 Vdc 1.6 A

Sortie : 24 V c.c. 1,6 A

Producción: 24 V C.C. 1,6 A

OUTPUT / SORTIE /

PRODUCCIÓN

E. O.

EMISSION REQUIREMENTS

This engine-powered generator meets all United States Environmental Protection Agency (EPA) Phase 3 requirements and is approved in both the USA and Canada.

This generator is certiﬁed to operate on pipeline NG and LPG (vapor) fuel for use as a stationary engine for standby power generation. Federal and/or local laws may be violated if it is used for any other purpose.

The maintenance schedule must be followed to ensure that the engine complies with the applicable emission standards for the duration of the engine’s life.

The following components on the engine consist of the emission control system:

• Fuel metering system – mixer and fuel regulator

• Air induction system – air cleaner housing and element

• Ignition system – spark plug and ignition module

The emissions compliance period for which the engine has been shown to meet federal emission requirements is stated on the emission compliance label attached to the engine. Emission Control System Warranty found at the end of this manual.

POWER Lit to indicate the battery is fully charged.

Small Bar

Lit to indicate the battery is receiving a trickle charge

Middle Bar Lit to indicate current output is near 50%.

Large Bar

Lit to indicate the charger is operating above 50% capacity.

Lit to indicate a battery charging problem.

NO CHARGE

If this LED is lit, the LED on the Engine Controller module, “LOW BATTERY” will also be lit.

Part No. 101305

Model 100152

GENERAL INFORMATION

SPECIFICATIONS

Home standby generator

Maximum continuous power, LPG/NG 11 kW Rated voltage 120/240 Amps 91.6/45.8 LPG (propane), NG (natural gas) Harmonic distortion Less than 5% Main line circuit breaker 46 amp Phase Single Frequency 60 Hz Unit weight 425.5 lb. (193 kg) Size (L x W x H) 49 x 28 x 28 in. (124.5 x 71 x 71 cm)

Engine

Type Milwaukee Series OHV Commercial V-Twin No. of cylinders 2 Displacement 717 cc Cylinder block Aluminum with cast iron sleeves Ignition system Solid state – magneto Spark plug F7RTC (NGK BPR7ES) Governor Mechanical Starter Electric 24V DC Oil capacity 1.6 qt (1.5 L) Oil Type 5W-30 Full Synthetic* RPM 3600

Controls

Mode switch auto Auto start on utility failure Mode switch manual Starts on demand Mode switch off Stops unit/control and charger active Ready to run/maintenance messages Standard Programmable start delay Standard Engine start sequence Standard Starter lockout Standard Battery charger/low battery indicator Standard Charger fault Standard AVR over voltage protection Standard

Low oil protection Standard Safety fused Standard Overcrank/overspeed/underspeed protection Standard

*Unit ships without oil. Add oil before starting the HSB.

Part No. 101305

Model 100152

GENERAL INFORMATION

FUEL SYSTEM

The engine is ﬁtted with a dual master mixer assembly carburetion system, which allows it to run on either NG or LPG. It has been conﬁgured at the factory to run on NG. If your installation requires the engine to run on LPG, oriﬁces in the master mixer assembly carburetor must be changed.

BATTERY REQUIREMENTS

Two (2) 12 volt Group U1 batteries with a minimum of 350 CCA each. Battery size: 7 (196mm L x 131mm W x 185mm H). This is based on testing in extreme cold and heat -22° F (-30° C) to 104 ° F (40° C). Purchase batteries locally. Install positive cable ﬁrst..

Install a cable from the positive (+) terminal of one battery to the negative (–) terminal of the other battery. Always connect the positive (+) battery cable to the generator ﬁrst. (Figure 8)

3/4

L x 5

3/16

W x 7

5/16

H inches

To Starter

BATTERY CHARGING

The generator is equipped with an automatic battery charger. The charger will sense the battery’s state of charge and automatically charge the battery when required. LED lights on the charger display the battery state of charge. See Figure 7 on page 19.

MODEL AND SERIAL NUMBER

The model and serial number plate is afﬁxed to the generator above the control panel. Have this information if calling for service or ordering parts. (Figure 9)

MAX LOAD UNBALANCE MAX DÉSÉQUILIBRE DE CHARGE MAX DESEQUILIBRIO DE LA CARGA50% 50 % 50 %

RATED AMBIENT TEMP TEMPÉRATURE AMBIANTE NOMINALE TEMPERATURA AMBIENTE NOMINAL25-40 ºC 25-40 ºC 25-40 ºC

INSULATION CLASS

FOR STANDBY SERVICE

RAINPROOF ENCLOSURE FITTED

NEUTRAL

H H H

FLOATING NEUTRE FLOTTANT NEUTRO FLOTANTE

BOÎTIER ÉTANCHE À LA PLUIE ÉQUIPÉ

POWER FACTOR 1.0 FACTEUR DE PUISSANCE 1,0 FACTOR DE POTENCIA 1,0

RATED ENGINE SPEED

3600 r/min

RÉGIME MOTEUR NOMINAL

RATED CURRENT 91.6 A / 45.8 A (LPG,NG) COURANT NOMINALE 91,6 A / 45,8 A (GPL,GN) CORRIENTE NOMINAL 91,6 A / 45,8 A (GLP,GN)

RATED FREQUENCY

60 Hz

FRÉQUENCE NOMINALE

RATED VOLTAGE 120/240~,single-phase TENSION NOMINALE 120 / 240~,monophasées

STATIONARY ENGINE DRIVEN GENERATOR / STATIONNAIRE GÉNÉRATEUR ENTRAÎNÉ PAR UN MOTEUR /

GENERADOR ACCIONADO POR MOTOR ESTACIONARIO

To Ground

Figure 8

U1 battery post style

CAUTION

For battery installation, maintenance, and safety requirements refer to purchased manufacturer battery installation and safety manual.

12039 Smith Ave., Santa Fe Springs, CA 90670 USA

CHAMPION POWER EQUIPMENT

CARCASA A PRUEBA DE LLUVIA EQUIPADO

P/N 101502

AISLANTE CLASEISOLATION DE CLASSE

PARA EL SERVICIO SUPLENTEPOUR LE SERVICE DE SECOURS

CAN/CSA Standard

C22.2 No. 100

Certified to

No. 2200

Conforms to UL Std.

Figure 9

3600 r/min

VELOCIDAD NOMINAL DEL MOTOR

3600 r/min

60 Hz

TENSIÓN NOMINAL

FRECUENCIA NOMINAL

120 / 240~,monofásicas

60 Hz

MODÈLE

100152

MODELO

MODEL

Part No. 101305

Model 100152

OPERATION

Before operating the generator, review SAFETY section starting on page 7.

ENCLOSURE AND ACCESS

Open the enclosure to gain access to the generator and its components. (Figure 10) Unlock the handles. Turn the handles and lift the hoods up and to the outside.

Figure 10

PRE-START CHECKLIST

To make sure the generator is ready for proper operation, the following items should be checked:

• Fuel valve is in the ON position

• No fault code LEDs are lit

• Battery is at full charge

• ATS control module is in the AUTO position

• Engine control module is in the ATS position

• Transfer switch lever is in the Utility Power position

TURNING OFF THE GENERATOR

If you need to shut off the generator when it is running, turn the engine control module switch to the OFF position. This will shut off the engine. With the engine control module in the OFF position, the generator will not start, even if there is loss of utility power.

Part No. 101305

Model 100152

MAINTENANCE

Before performing maintenance procedures, review SAFETY section starting on page 7.

Ensure that the ATS and Engine Switches are in the OFF position before performing any maintenance or cleaning.

SCHEDULED MAINTENANCE CHART

Every

Change engine oil

Change the engine oil ﬁlter

Check engine oil level

Inspect fuel lines and connections

Check exterior fault code indicator light

Inspect and clean enclosure louvers

Inspect and clean battery terminals

Inspect and clean engine air cleaner

Inspect engine spark plug

Complete inspection of generator and engine tune-up

First

5Hours of

Operation

√**** √****

Weekly Monthly

√ √**

√*

√

2Years

or 100

Hours of

Operation

√**

√

√***

ENGINE OIL

ENGINE OIL REQUIREMENTS

Use American Petroleum Institute (API) Service Class SN or better. Do not use special additives. All temperatures full synthetic 5W-30.

CHECKING THE ENGINE OIL LEVEL

Check the oil level daily when the generator is running for an extended period of time.

1. If the generator is running during a utility outage, turn off all household loads.

2. Turn the engine control module switch to the OFF position.

3. Remove the dipstick. Wipe it dry with a clean cloth and completely reinsert it into the dipstick tube. See ﬁgure 12, page 24.

* Monthly or 24 hours of continuous operation

** Service sooner if operating in high ambient temperatures or a

dusty and dirty environment.

*** Maintenance should be performed by your service dealer.

**** If so equiped

Figure 11

Part No. 101305

Model 100152

MAINTENANCE

NOTICE

DO NOT overﬁll the engine with engine oil. Damage to the engine may occur.

4. Remove the dipstick. The oil level should be at the FULL mark. If necessary, add oil. DO NOT overﬁll.

Figure 12

5. Install the dipstick.

6. Turn the engine control module switch to its prior position.

NOTICE

Always be environmentally responsible. Consult the local authorities or reclamations facility for proper disposal of engine oil waste.

5. Position drain pan under alternator.

6. Loosen hose clamp on oil drain hose and slide drain hose off retaining pin. (Figure 13)

CHANGING THE ENGINE OIL

WARNING

Always wear protective glasses or goggles and protective clothing when changing hot engine oil.

1. Turn the ATS to the OFF position.

2. Turn the engine control module switch to the MANUAL position.

3. Allow the engine to run until it reaches operating temperature.

4. Turn the engine control module switch to the OFF position.

Figure 13

1. Oil Drain Hose

2. Hose Clamp

7. Position drain hose into drain pan and allow crankcase to empty.

8. With the oil drained, remove oil ﬁlter by turning counterclockwise.

9. Apply a light coat of clean engine oil to the gasket of the new oil ﬁlter.

10. Screw the new oil ﬁlter on (turning clockwise) by hand until the gasket contacts the engine block.

11. Screw the ﬁlter an additional 3/4 turn.

12. Reinstall the hose onto the retaining pin and reposition hose clamp.

13. Fill the engine with the proper amount of engine oil. See

Figure 12.

14. Turn the engine control module switch to its prior position.

15. Turn the ATS to the AUTO position.

3. Retaining Pin

Part No. 101305

Model 100152

MAINTENANCE

INSPECT AND CLEAN ENGINE AIR CLEANER

1. Turn the engine control module switch to the OFF position.

2. Unsnap the clips holding the air cleaner cover in place and remove the air cleaner cover.

3. Remove the paper element.

SPARK PLUG

1. Turn the ATS to the OFF position.

2. Turn the engine control module switch to the OFF position.

3. Remove the spark plug cable from the spark plug.

4. Clean the area around the spark plug to keep dirt out of the engine and remove the spark plug.

5. Inspect the spark plug electrode and replace the plug if the electrode shows signs of deterioration.

6. Check the gap before installing the spark plug. The spark plug gap should be 0.028 – 0.031 in. (0.7 – 0.8 mm).

Figure 14

1. Air Cleaner Cover Clips

2. Paper Element

4. Inspect the paper element for any rips or tears. Replace if damaged.

5. Hold the paper element up to a light. You should be able to see light through the paper element, if not replace the element. Inspect air cleaner cover, remove any dirt or debris.

6. Fit paper element over air cleaner base inlet lip. Push element gently downward to fully seat element into air cleaner base.

7. Install the cover and snap the clips in place.

8. Turn the engine control module switch to its prior position.

3. Air Cleaner Base

0.028 - 0.031 in. (0.7 - 0.8 mm)

Figure 15

7. Carefully thread the spark plug into the engine and tighten to 20-30 N-m (14.8-22.1 lbf-ft).

8. Re-connect the spark plug cable.

9. Turn the engine control module switch to its prior position.

10. Turn the ATS to the AUTO position.

Part No. 101305

Model 100152

MAINTENANCE

BATTERY MAINTENANCE

1. Turn the engine control module switch to the OFF position.

2. Inspect the battery cables and terminals for corrosion.

3. Check that the cables are securely fastened to the terminals.

4. Check the ground lug and make sure the connections are tight.

5. Check the ﬂuid level of the battery, unless sealed. If low, top off the level using distilled water only.

Follow all battery instructions provided by the battery manufacture.

CORROSION PROTECTION

NOTICE

Never use a pressure washer to wash the interior of the generator with water.

Wash the outside of the enclosure using a mild soap and water. Use an automotive-type wax and wax the outside of the enclosure to protect it from the elements. If used in a salt water/coastal area, the enclosure should be washed more frequently to prevent corrosion. Spray light oil on the hinges for the enclosure doors.

MAINTENANCE AFTER SUBMERSION

If the house or building has been exposed to a ﬂood, it should be inspected by a certiﬁed electrician for any electrical problems that may occur if the generator is put back into service or if utility power is restored.

STORAGE

If the generator is not going to be used for several months and not exercised every 7 days, it should be prepared for storage.

1. Manually start the engine and run it for several minutes to allow it to warm up.

2. With the engine running, turn the fuel shutoff valve to the closed position and let the engine continue to run until it shuts down.

3. Once the engine has shut down, turn the engine control module switch and the ATS control module switch to the OFF position.

4. Switch the generator’s main circuit breaker to the OFF (OPEN) position.

5. Turn off the utility power to the transfer switch.

6. Disconnect the battery cables. Remove the negative cable ﬁrst.

7. Change the engine oil. See CHANGING THE ENGINE OIL on page 24.

8. Remove the spark plug and spray fogging oil into the spark plug hole. Install the spark plug and tighten.

9. Thoroughly wash and wax the exterior of the generator enclosure. Do not use a pressure washer.

WARNING

Never try to start or operate the generator if it has been submerged underwater or exposed to a ﬂood.

If the generator has been in conditions where it became submerged underwater, the generator must be inspected and maintenance must be performed before returning the generator to service.

Turn engine control module and ATS control module to the OFF position. Have a authorized Champion Dealer inspect the generator and perform any necessary maintenance.

Part No. 101305

RETURN TO SERVICE AFTER

STORAGE

1. Make sure the utility power to the transfer switch is off.

2. The engine control module switch and the ATS control module switch should be in the OFF position.

3. Check the engine oil level. Add oil if needed.

4. Recharge the batteries to 100% state of charge. If the batteries will not fully charge, replace the batteries.

WARNING

Always connect the positive (+) battery cable ﬁrst. After the positive cable is connected, then the negative (-) battery cable can be attached. This minimizes the possibility of electrical contact.

Model 100152

MAINTENANCE

5. Connect the positive (+) battery cable to the positive (+) battery terminal ﬁrst and then connect the negative battery cable to the negative (-) battery terminal.

6. Clean and wipe down the generator with mild soap and water.

7. Turn the fuel shutoff valve to the ON position.

8. Turn the engine control module switch to the manual position. The engine should start. Run the engine for 15 minutes to allow it to warm up. The fuel system might require more than one start cycle to fully pressurize the fuel system for operation.

9. Make sure there are not any active fault codes.

10. Turn the engine control module switch to the OFF position to shut off the engine.

11. Turn the ATS module switch to the AUTO position.

12. Turn on the utility power to the transfer switch. The utility LEDs on the ATS module should be lit.

13. Turn the engine control module switch to the ATS position.

14. Set the exercise time. See EXERCISE SWITCH on pages

16 and 17.

Part No. 101305

Model 100152

MAINTENANCE

ENGINE PARTS

117

116

115

114

113

118

119

120

144

143

142

131

134

135

136

137

138

139

112

111

110

109

121

122

123

124

140

141

129

130

108

107

106

105

125

127

126

104

103

102

101

100

128

132

333432

6 2

Part No. 101305

133

Model 100152

MAINTENANCE

# Part Number Description Qty

101027

2.08.083

717.070004.00 Bracket, Fuel Pump

1. 6 177. 2 0 Nut, M20 x 1.5 Flange

1.5789.0 816 Hex Flange Bolt, M8 x 16

61.080005.00 Plate, Fan

717.080001.00 Fan, Cooling

717.123000.03

100922 Flywheel Assembly

1.5789.0629 Hex Flange Bolt, M6 x 29

717.123000.04

2.06.009 Clamp, Ø17 x Ø1.5

100303 Tube, Breather

1.166 74.06 40 Hex Small Flange Bolt, M6 x 40

717.130012.00 Intake Manifold

717.130011.00 Gasket, Intake Manifold

1.166 74.06 2 0 Hex Flange Bolt, M6 x 20

100 4 86 Cover, Breather

100 504 Gasket, Breather Cover

1.82 3.0 410 Screw, Small Pan Head M4 x 10

101767 Retainer, Reed Valve

100 69 3 Reed Valve

101482 Protective Sleeve

100 342 Hose, Gaseous Fuel Id 12.7

100 825 Clamp Hose Id Ø16-Ø25

100 25 8 Gasket, Carburetor

61.130001.00 Insulator, Carburetor

100 662 Mixer Assembly

1 100928 Main Jet - Right 2 100929 Main Jet - Left

3 100910 Slow Jet - Right 4 100910 Slow Jet - Left 1 100909 Main Jet - Right 2 100310 Main Jet - Left

LPG

3 101032 Slow Jet - Right 4 100671 Slow Jet - Left

717.090005.00 Gasket, Ac Assembly

101020 Base Assembly, Air Cleaner

1.5789.068 8 Hex Flange Bolt, M6 x 88

100 275 Air Filter Assembly

10100 4 Seal, Ac Base

101847 Cover, Ac Base

100 829 Pin, Dowel Ø10 x 14

101115

1.166 74.08 110 Hex Small Flange Bolt, M8 x 110

100 937 Switch, Thermal Shutdown

1.823.0306.1 Screw, M3 x 6

2.08.039 Bolt, Drain, M12 x 1.5 x 15

2.03.023

10 0 374 Crankcase Component

1.5789.0612 Hex Flange Bolt M6 x 12

61.120800.00 Diode Assembly, Engine Stop

2.12.004 Grommet Ø9.5 x 10

100 470

Cover, Fan, Rotating Screen With Oil Cooler Ribs

Bolt, Hex Flange M6 x 12 6

Ignition Coil Assembly, Cylinder 1, EMC

Ignition Coil Assembly, Cylinder 2, EMC

Motor Assembly, 24V Solenoid Shift Starter

Washer, Drain Bolt, Ø12.5 x Ø20 x 2

Air Board, Assembly, Internal Oil Cooler

# Part Number Description Qty

1 1 3 1 1

1 4

2 1 4 1 2 4 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 2

2 1 2 1

1 1

717.080500.00

2.14.005 Key, Flywheel, 4 x 5.5 x 12.5

717.051101.04 Assembly, Crankshaft - Taper Pto

2.03.026

10145 4 Camshaft Assembly

717.050200.00 Assembly, Connecting Rod

2.09.009 Retainer, Piston Pin, Ø17 x Ø1

100 968 Pin, Piston, Ø17 x 53.8 mm

102024

102289 Ring Assembly, Oil Control

10228 6 Ring, Piston, 2nd

102285 Ring, Top Piston

45.110012.00 Bushing, Governor Gear

2.03.053 Washer, Ø6.2 x Ø17 x 0.8

21.110011.00 Clip, Retaining

61.110100.0 0 Gear Assy, Governor

2.03.054 Washer, Ø6.2 x Ø15 x 1

45.110013.00 Shaft, Governor Gear

1.5789.0620 Hex Flange Bolt, M6 x 20

61.150300.00 Oil Filter Component

2.04.002 Location Pin Ø8 x 14

100 59 6 O-Ring Ø12 x Ø3.5

100 261 Gasket, Crankcase Cover

100726 Tube, Oil Dipstick Assembly

100 26 8 Cover, Crankcase

1.5789.0850 Hex Flange Bolt, M8 x 50

2.11.010 Seal, Pto Oil, Ø38 x Ø58 x 9

61.030011.00 Plug, Crankcase Cover

100 69 9 Blade Assembly, Oil Dipstick

1.30 8.9.5 Ball Ø9.5, Steel Check Valve

61.150004.00 Spring, Compression

61.151000.00 Pump Assembly, Oil

1.70.0616 Screw, M6 x 16, Socket Head Cap

10176 6 Filter, Oil

1024 4 6 Switch, Low Oil Shut-Down 0.6 Bar

1.166 74.06 2 5 Hex Small Flange Bolt, M6 x 25

101719

100 8 47 Clamp Ø17, Oil Hose

100 942 Hose 2, Oil Line

100941 Hose 1, Oil Line

2.07.004 O-Ring Ø12 x Ø2.5

1.5789.0620 Hex Flange Bolt, M6 x 20

10172 3 Oil Cooler Assy, Internal Mount

717.080600.00

1.5789.0608 Hex Flange Bolt, M6 x 8

1.16674.0 616 Hex Small Flange Bolt, M6 x 16

2.04.005 Pin, Ø8 x 10, Location

101478 Follower Assembly, Camshaft

1 101475 Follower Pivot Assembly, Camshaft

2 2.03.021.1

3 1004 85 Follower, Camshaft 4 61.040019.01 Follower, Camshaft 5 61.041001.00 Spring, Support

Air Guide, Outer Cylinder 1 Assembly

Washer, Crankshaft Thrust, Ø39 x Ø54 x 1.2

Piston, 78 mm, 2.75 mm, Dish Ceramic Crown

Base Assembly, Oil Filter With Oil Cooler And Oil Pressure Switch

Air Guide, Outer, Cylinder 2 Assembly

Washer, Governor Shaft, Ø6.4 x Ø13 x 1

1 1

1 2 4 2

2 2 2 1 1 3 1 1 1 3 1 2 1 1 1 1 9 2 1 1 1 1 1 2 1 1 4

4 1 1 2 2 1

2 1 1 1 1

2 2 2

Part No. 101305

Model 100152

MAINTENANCE

# Part Number Description Qty

45.030200.00 Retainer, Oil Drain Hose

2.06.013 Hose Clamp, Ø13.5 x b10

45.032000.00 Hose, Oil Drain

1.276.6003.1 Bearing, Roller Ø35 x Ø17 x 10

717.030026.01 Plug, Npt1/8-27 Hexagon Socket

2.04.004 Pin, Ø12 x 20 Location

100

100170 Bracket, Governor Spring

101

2.01.010 Bolt M8 x 35, Exhaust Stud

102

717.010003.00 Lift Strap

103

1.166 74.08 2 0 Hex Small Flange Bolt, M8 x 20

104

2.0 8 .122 Bolt, Hex Flange M10 x 95

105

100179 Valve, Exhaust

106

717.040015.00 Shim, Valve Spring

107

101881 Oil Seal, Valve Stem

108

45.040003.00 Spring, Valve

109

45.040001.00 Retainer, Intake Valve

110

717.040202.00 Bracket, Rocker Arm

111

1.70.1.0816 Screw, M8 x 16 Socket Head Cap

112

22.040012.00 Adjusting, Lash

113

717.040200.02 Rocker Arm

114

10164 4 Gasket, Rocker Cover

115

1.5789.0625 Hex Flange Bolt, M6 x 25

116

102357 Cap, Oil Fill Assembly

117

1 2.07.001 Seal, Cap Oil Fill, Ø25.5 x Ø3.5 2 101813 Cap, Oil Fill 102261 Rocker Cover Assembly, Oil Fill

118

21.040 021.00 Jam Nut, M6 x 0.5 mm Pitch

119

1.6170. 0 8 Hex Nut, Gb6170, M8

120

717.040016.00 Sleeve, Rocker Arm

121

2.08.086 Bolt, M8 x 1.25 Hhw Special

122

717.040005.00 Push Rod

123

45.040002.00 Valve, Intake

124

2.08.014 Bolt, Hex Flange M10 x 80

125

717.080300.02

126

717.010100.2 0 Head Assembly, Cylinder 2

127

717.030009.00 Gasket Assembly, Cylinder Head

128

717.010100.10 Head Assembly, Cylinder 1

129

717.080300.01

130

2.11.0 0 6 Shaft Oil Seal, Ø7 x Ø14 x 5

131

2.15.0 08 Spark Plug, F7RTC

132

10226 3 Rocker Cover Assembly

133

102428 Spring, Link Take Up

134

100 22 3 Link, Governor

135

2.0 8 .107 Bolt, Governor Arm

136

2.03.019 Washer, Ø8.2 x Ø17 x 0.8

137

61.110008.00 Pin, Shaft

138

1.58 01.0810 Bearing, Roller

139

1.97.1.08 Washer Ø8

140

61.110001.00 Shaft, Governor

141

100 432 Spring, Governor

142

100178 Lever, Governor Arm

143

1. 6 177. 0 6 Nut, M6 Hexagon Flange

144

Air Guide Assembly, Inner Cylinder 2

Air Guide, Inner Cylinder 1 Assembly

1 1 1 1 1 4 1 4 2 2 2 2 2 4 4 4 4 4 4 4 2 8 1 1 1 1 4 4 4 4 4 2 6

1 2 1

1 2 1 1 1 1 1 2 2 2 1 1 1 1

Part No. 101305

Model 100152

MAINTENANCE

PAGE INTENTIONALLY LEFT BLANK

Part No. 101305

Model 100152

MAINTENANCE

ENCLOSURE AND ASSEMBLIES

，See Figure B

Part No. 101305

，See Figure A

6869

7172

Model 100152

MAINTENANCE

# Part Number Description Qty

1.6177.1.06 Lock Nut M6, Flange 24

1.5789.0615 Flange bolt, M6 x 15

161.200507.00 Curb Chain Assembly, Cover

162.200500.61.24

161.200110.00 Hook Lock Assembly

161.2 0 0021.16 .6

1.166 74.08 2 0 Flange bolt, M8 x 20

1.166 74.08 12 Flange bolt, M8 x 12

161.200402.60.24

161.2 0 0109.6 3

162.200401.60.24

5.14 60.015 Indicator Light, 24 v

161.192100.6 0

1.862.0 6 Toothed Lock Washer, Ø6

5.1560.000 Ground Wire Teminal, Ø6, UL

717.090004.21 Pipe, Air Cleaner

2.06.036 Clamp, Ø75

162.200 021.01.6

9.3410. 02 Nylon Cable Ties, 5 x 500 mm

161.192300.00 Air Guide, Alternator

163.200500.60.24

161.20 00 21.17.6

161.2 01600.0 2.1 Gutter, Black

161.100006.00 Spring, Mufﬂer

2.08.119 Flange Bolt M8 x 35, Mufﬂer

163.1010005.00.2

161.20 00 21.13.6

161.20 00 21.18.6

2.02.032 Cage Nut, M8

161.200017.63.24

161.20 00 21.15.6

163.200021.03.6

1.5789.0612 Flange Bolt, M6 x 12

2.03.004 Washer, Ø24 x Ø6.5 x 1.5

163.200 017.01 Thermal Bafﬂe

163.200017.60.24

161.1010005.00.2 Supportor, Mufﬂer, Top, Black

Top Cover Assembly, Right, Silk Grey, Flame Retardant and textured, See Figure B

Seal, Access Cover, Flame Retardant

Access Cover, Electric Cabinet, Silk Grey, Flame Retardant and textured

Rubber Strip, 575 mm, Flame Retardant

Rear Cover, Silk Grey, Flame Retardant and textured

Supporter, Air Guide, Alternator, Flame Retardant

Acoustic Panel, Rear Center Chamber, Flame Retardant

Top Cover Assembly, Left, Silk Grey, Flame Retardant and textured, See Figure A

Seal Strip, Top Cover, Long, 625 x 50 x 25 mm, Flame Retardant

Supportor, Mufﬂer, Bottom, Black

Acoustic Panel, Mufﬂer Cover, Front, Flame Retardant

Seal Strip, Top Cover, Short, 50 x 320 x 25 mm, Flame Retardant

Mufﬂer Cover, Back, Silk Grey, Flame Retardant and textured

Foams, Mufﬂer Cover, Back, Flame Retardant

Acoustic Panel, Mufﬂer Cover, top, Flame Retardant

Mufﬂer Cover, Top, Silk Grey, Flame Retardant and textured

# Part Number Description Qty

100152.901 Generator Assembly

5 1 1 1

1 1

1 3 3

8 4 1

2.06.037 Clamp, Ø28

10015 2.9 02 Control Panel Assembly

161.20 00 21.02.6

161.200300.60.24

161.201900.00 Hinge

161.130021.02 Galvanized Pipe, NPT 3 /4

5.1910.0 0 4 Wiring

2.06.015 Cla mp, Ø16 - Ø25

161.1360 0 0.04.1

161.200018.00

1.5789.0629 Flange bolt, M6 x 29

1.5783.0825 Bolt, M8 x 25

161.20 06 01.60.24

2.0 8 .133 Male Female bolt, M5 x 50

1.16674.0 516 Flange bolt, M5 x 16

161.210018.00 Cover,Terminal Block

161.210011.02 Terminal Block, 60A, 90° Angle

161.200 017.61.24

163.200021.00.6

163.200005.61.24

1.6177.1.08 Flange Lock Nut, M8

163.192300.00.2 Fan Cover, Rotor, Black

161.200200.60.24

161.2 0 0109.62

161.200101.60.24

161.20 00 21.11.6

161.201800.00 Plastic Pallet, PP

163.200021.10.6

163 .130021. 01 LPG Hose With NPT3/4 Nipple

9.1120.001 Screwdriver, Jet

5.19 0 0.0 74

161.200023.00.1 Oil Container, Black

1.6182.0 6 Lock Nut M6, Flange

1.97.1.06 Wa she r, Ø6

161.080007.00 Cap, Ø35

1.5789.0620 Flange bolt, M6 x 20

1.97.1.08 Wa she r, Ø8

2.03.065 Insulating Washer, Ø8 × Ø17

2.03.064 Insulating Washer, Ø6 × Ø12

Seal Strip, Right/Left Cover, Flame Retardant

Right Cover Assembly, Silk Grey, Flame Retardant and textured

Pressure Reducing Valve, LPG/ NG

Supportor, Pressure Reducing Valve

Base Center, Silk Grey, Flame Retardant and textured

Mufﬂer Cover, Front, Silk Grey, Flame Retardant and textured

Acoustic Panel, Left Firewall, Flame Retardant

Firewall, Left, Silk Grey, Flame Retardant and textured

Left Cover, Silk Grey, Flame Retardant and textured

Rubber Strip, 530 mm, Flame Retardant

Front Cover , Silk Grey, Flame Retardant and textured

Foams, Front Cover, Flame Retardant

Foams, Heat Insulation, Flame Retardant

Battery Jump Wire, 275 mm, 6 AWG

1 1 1

4 1 1 1

2 8

2 2 1 1

1 1

1 4 4 2 4 4

Part No. 101305

Model 100152

MAINTENANCE

TOP COVER ASSEMBLY, LEFT

5 1

13 2 1

1 1

0 1

Part No. 101305

# Part Number Description Qty

161.200109.00

161.200500.00.24 Top Cover, Left 1

161.200110.00 Handle Assembly 1

2.13.027 Bushing, Ø10.5 × Ø16×7.5 1

161.201004.00 Locking Plate 1

163.200021.06

161.20 00 21.19

161.20 00 21.20 Acoustic Panel, Cover, Top 1

163.200021.08 Acoustic Panel, Left Cover, Top 1

161.20 00 21.01 Seal, Gutter 1

161.200110.00.07 Rubber Gasket, Handle 1

161.200110.00.02 Locking Washer, Ø5 2

161.200110.00.03 Bolt, M5X12 2

161.200110.00.04 Wave Washer Ø10 1

161.200110.00.05 Locking Washer, Ø10 2

161.200110.00.06 Nut, M10 3

161.200110. 00.01 Key, Handle 1

Seal Strip, 20x1150x8mm, Gutter

Acoustic Panel, Left Cover, Side

Seal Strip, Top Cover, 32x560x15mm

Model 100152

MAINTENANCE

Part No. 101305

Model 100152

MAINTENANCE

TOP COVER ASSEMBLY, RIGHT

1 5

1 4 3 1

1 2

1 1

1 6

1 7

8 9 1 0

Part No. 101305

# Part Number Description Qty

161.20 0500.01.24 Top Cover Assembly, Right 1

161.200109.00

163.200021.07

161.20 00 21.20 Acoustic Panel, Cover, Top 1

161.20 00 21.10

161.20 00 21.01

161.20 00 21.19

161.200110.00 Handle Assembly 1

2.13.027 Bushing, Ø10.5 × Ø16×7.5 1

161.201004.00 Locking Plate 1

161.200110.00.07 Rubber Gasket, Handle 1

161.200110.00.02 Locking Washer, Ø5 2

161.200110.00.03 Bolt, M5X12 2

161.200110.00.04 Wave Washer, Ø10 1

161.200110.00.05 Locking Washer, Ø10 2

161.200110.00.06 Nut, M10 3

161.200110. 00.01 Key, Handle 1

Seal Strip, 20x1150x8mm, Gutter

Acoustic Panel, Right Cover, Side

Acoustic Panel, Right Cover, Top

Seal Strip, 20x1150x8mm, Gutter

Seal Strip Top Cover, 32 x 560 x 15

Model 100152

MAINTENANCE

Part No. 101305

Model 100152

MAINTENANCE

ALTERNATOR AND EXHAUST SYSTEM

2018 21 22 24

19 23

Part No. 101305

Model 100152

MAINTENANCE

# Part Number Description Qty

162.200021.00.6

100185 Engine 1

161.190007.00 Front Housing, Stator 1

1.5789.1022 Flange Bolt, M10 x 22 4

162.191100.00 Rotor Component, Ø135 x 145 1

162.191002.00 Stator Cover 1

162.191200.00 Stator Assembly, Ø230 x 145 1

161.190002.00 End Housing, Stator 1

2.08.111 Bolt Assembly, M8 x 195 4

161.190300.00 Carbon Brush Assembly 1

122.190004.01 Pinch, Carbon Brush 1

1.93.05 Lock Washer, Ø5 1

1.5783.0520 Bolt, M5 x 20 1

164.190001.00 Rotor Fan, 12.5 KW, Aluminum 1

1.5789.0629 Flange Bolt, M6 x 29 4

2.08.114

164.19 0019.00 Flange Plate, Fan 1

163.101000.00 Mufﬂer Assembly 1

Foams Ring, Engine Fan, Flame Retardant

Flange Bolt Assembly, M10 x 360

# Part Number Description Qty

162.1010 01.00 Exhaust Pipe 1

2.03.004 Washer, Ø24 x Ø6.5 x 1.5 6

1.5789.0615 Flange bolt, M6 x 15 6

1.93.06 Lock Washer, Ø6 6

163.080009.00.2 Air Guide, Mufﬂer Pipe, Above 1

1.9074.17.0612

717.100001.00 Gasket, Exhaust Pipe 2

1.6187.1.08 Nut, M8 4

1.6177.1.10 Flange Lock Nut, M10 4

161.2 01600.01 Supportor, End Housing 1

161.200605.00 Motor Mount 4

1.6177.1.08 Flange Lock Nut, M8 4

161.2 01600.0 0 Supportor, Engine 1

163.080009.01.2 Air Guide, Mufﬂer Pipe, Bottom 1

1.96.08 Washer, Ø8 1

1.93.08 Lock Washer, Ø8 1

1.166 74.08 2 5 Flange Bolt, M8 x 25 1

1.724 4 .10 Lock Washer, Ø10 2

1.6187.1.10 Nut, M10 4

161.101002. 00 Gasket, Mufﬂer 1

Screw/ Washer Assembly, M6 x 12

Part No. 101305

Model 100152

MAINTENANCE

CONTROL PANEL

37-2

37-1

37-3

Part No. 101305

Model 100152

MAINTENANCE

# Part Number Description Qty

5.1600.010 Connector, Ten Holes, Male 1

5.1610. 010 Connector, Ten Holes, Female 1

5.1810.0 07 Over Voltage Protector 1

1.818.0514 Screw, M5 x 14 3

161.210011.02 Terminal Block, 60A, 90° Angle 1

2.02.032 Cage Nut, M8 7

163.200004.60.24

5.1000.006.3 Switch, UL, Red 1

5.1420.0 02 Hour Meter 1

5.1241. 946

5.1850 .004 .Y ATS Controller, 100667Y 1

5.1850 .003 .Y Generator Controller,100666Y 1

1.5789.0550 Flange Bolt, M5 x 50 4

2.13.028 Bushing, Ø5.5 x Ø14 x 25 4

5.18 50.00 5 Relay Module, Engine 1

2.08.068 Flange Bolt, M5 x 13 4

161.200020.00 Grille 1

2.02.030 Cage Nut M5 8

163.200005.60.24

163.2 00109.6 0

163.200021.01.6

Cover, Electric Cabinet, Silk Grey, Flame Retardant and textured

46Amp Circuit Breaker, Double Pole, UL

Firewall, Right, Silk Grey, Flame Retardant and textured

Rubber Strip, 1000 mm, Flame Retardant

Foams, Right Firewall, Flame Retardant

# Part Number Description Qty

1.166 74.08 12 Flange Bolt, M8 × 12 3

163.210003.00 Grommet, Wire 1

2.02.031 Cage Nut, M6 2

161.1902 00.04 AVR, TT916U-402 1

2.13.029 Bushing, Ø7 × Ø14 × 50 2

1.5789.0675 Flange Bolt, M6 x 75 2

5.18 20.0 0 3 Charger, Battery, 24V 1

1.9074.4.0414.2 Screw, M4 x 14 3

163.200004.61.24

1.9074.4.0306 Screw, M3 x 6 4

164.200018.00.24 Supportor, Switch, Silk Grey 1

1.82 3.0 412 Screw, M4 x 12 2

161.210017.00

5.1000.008.1 Switch, Black 1

5.1320. 017 Plastic Conduit, CSA, 50mm 1

100 237.21.10.V1.0 Wire Assembly 1

37-1 5.1910.00 5 Battery Cable Positive, Red 37-2 5.1910.0 06 Battery Cable Negative, Black 37-3 5.19 0 0.0 74 Battery Transfer Cable, Black

162.230004.00.V1.0 Decal, Nameplate, 100152 1

163.230003.00.V1.0 Decal, Control Panel, 100136 1

100237.230005.00 Decal, ATS Selector 1

5.1050 .0 09 Switch, UL, Black

100237.21.20

Cover, Charger, Silk Grey, Flame Retardant and textured

Supportor, Ten Holes, Connector

Wire Assembly, Shutdown Switch

1 1 1

Part No. 101305

Model 100152

MAINTENANCE

WIRING DIAGRAM

Terminal Block #1 Ter minal Block #2

B+

Neutral line

Power Winding

Sampling Winding

B-

DC 24V

Low Oil Level/Pressure

Utility position micro switch

BATTERY CHARGER

ATS

Generator transfer signal

Utility transfer signal

Load bus L2

B/W

RG B

GND

N/C

MODEL:100482

P/N 5.1820.003

L N

GND

B-

B+

ALT FUEL Start Stop

N/C

ATS IN.1 WATR OIL

Freq. Freq.

GW G

1 2

Transfer common

Micro switch common

Load bus L1

Hour Meter

P/N 5.1850.005

100417

40A

B+ B-

ALT FUEL Start Stop

N/C

O/B

O G/B B/W L/B W

ATS IN.1 WATR OIL

Freq. Freq.

250VAC 5A

SWITCH

L/B

Gen-AC Detect

Load AC Detect

Utility AC Detect

Utility C.B.

Gen-set C.B

3 1 5

4 2 6

SWITCH

Not Connect

N/C

Orange/Black

O/B

Green

Switch "1" -ATS50/ATS100

Green/Black

G/B

Orange

OWP

B R

P BrY

G/B

3 1

4 2

Switch

Emergency

Switch "OFF" -Shutdown

Switch "ON" -Work

Switch "2" -ATS200

Red/Black

Blue/Black

Black/White

L/B

R/B

B/W

Pink

Purple

White

B/W

R G GRR

Start ATS

B-

Gen-set Close

5A5A

Utility Close

100667

P/N 5.1850.004

Utility Close

B-

B+

DC 24V

GND

Over Voltage Protector

GND

Iginition Coil

Fuel Valve

GGG

Low Oil Pres sure Switch

Thermal Switch

Exercise Swi tch

GND

Start Motor

GND

To ATS

Ground line

Generator line L2

Generator line L1

Connector Assembly

Circuit Breaker

Power Winding

STATOR

Excitation Winding

Y W L L

123

B/W

Motor

5A 5A

High Engine Temperature

Exercise

O/B

OFF O N

Valve

ATS

121413

O G/B

Interior E mergency Swit ch

G/B W

100666&100666Y

Indicator DC24V

GND

B R

ROTOR

Carbon Brush

LLWG

GND

Alarm

F.D1

N/C

L/B

R/B

Stop

Charge

Magnetize

P/N 5.1850.003.Y

F.D2

Utility line L1

Generator position micro switch

Utility line L2

G/B

AVR

GND

Part No. 101305

24V Battery

Red

Blue

Black

Brown

BBrY

Yellow

GND

PART NO:101526.REV 1.4

Model 100152

TROUBLESHOOTING

TROUBLESHOOTING HSB

The number one problem which relates to starting, output and performance is “Fuel Pressure Insufﬁcient”. Utility fuel regulator and pipe sized to small which can be compounded by pipe run distance to long for the size of pipe installed. Conﬁrm fuel pressure to the fuel regulator during No-load and Load operation.

ENGINE WILL NOT CRANK/TURN OVER

1. HSB set in “OFF” mode. Place the HSB controllers in the proper AUTO and ATS start positions.

2. Battery not connected or loose, Connect the batteries according to owner’s manual, clean and tighten the corroded posts or wires. battery connections

3. Battery(s) not charged or low charge. Recharge or replace battery(s).

4. Check for active fault code. Identify fault code, correct and reset.

5. Defective starter solenoid *

6. Defective starter *

GENERATOR WILL CRANK/TURN OVER BUT WILL NOT START

1. Check for active fault code. Identify fault code, correct and reset.

2. Fuel valve(s) turned off. Turn on fuel supply.

3. Fuel pressure insufﬁcient*. Manometer check, conﬁrm fuel pressure to fuel regulator*.

4. Weak battery(s). Recharge or replace battery(s)

5. Low oil level. Check for oil leaks. Check the oil level and add oil if necessary.

6. Spark plug wire is disconnected. Connect spark plug wire.

7. Defective fuel solenoid/regulator. *

ENGINE STARTS, RUNS ROUGH

1. Fuel pressure insufﬁcient*. Manometer check, conﬁrm fuel pressure to fuel regulator*.

2. Wrong fuel jets. Check jets for NG or LPG, change to correct Master Mixer fuel jets.

3. Faulty spark plug, loose spark plug wire. Change spark plug, set gap, connect wire.

4. Plugged air cleaner Clean or replace air cleaner.

5. Generator overloaded*. Remove one or more loads*.

6. Shorted circuit *

HSB STARTS, THEN SUDDENLY STOPS

1. Check for active fault code. Identify fault code, correct and reset.

2. Fuel supply insufﬁcient* Manometer check, conﬁrm fuel pressure to fuel regulator*.

3. Low oil, pressure shut down. Check for oil leaks. Check the oil level and add oil if necessary.

4. Generator over loaded. Turn off standby circuits for house, reset fault, place unit back into AUTO and ATS mode. Turn on standby circuits for house. If problem returns contact Champion or Champion service dealer*.

5. Engine high/over temperature shut down. Check all intake and exhaust ventilation around the HSB, remove all debris. Let HSB sit for 30 minutes to cool down.

Part No. 101305

Model 100152

TROUBLESHOOTING

NO AC OUTPUT

1. HSB set in “TEST” mode. Place HSB in AUTO and ATS mode.

2. Circuit breaker in “OFF” position. Turn on breaker.

3. ATS control in “OFF” mode. Place ATS module in ATS mode.

4. Main circuit breaker in “OFF” position. Turn on breaker.

5. Transfer switch breaker in “OFF” position. Turn on breaker.

6. Standby breakers set in “OFF” position. Turn on breaker.

7. Line circuit tripping breaker because of short circuit *

8. Line circuit tripping breaker because of overload *

9. Poor wiring connections*

10. ATS problems*

LED INDICATORS

In all cases when the LED is GREEN, this is an indicator that the HSB is performing properly.

In all cases when the LED is RED, this is an indicator that the HSB has registered a fault and must be corrected. Only the “LOW BATTERY LED” will not latch out or shut down the HSB. All other RED LED faults will latch out, shut down, disable starting and light the RED LEDS on the Engine Control Module and the exterior fault code light on the backside of the HSB.

RESET FAULT CODE(S)

There is an exterior fault code indicator light located on the back of the enclosure. This should be checked weekly to make sure there are no active fault codes.

The fault code(s) can be reset by placing the Engine Control Module in the OFF position for 10 seconds and then placed into ATS mode. This will reset fault LED, however if a fault code(s) re-occurs it must be addressed.

BATTERY(S) NO OR LOW LEVEL CHARGED, BATTERY(S) DEAD, NEEDS REPLACEMENT, THE EXERCISE TIME MUST BE RESET ONCE THE BATTERY(S) HAVE BEEN DISCONNECTED.

*Contact Champion Power Equipment, Technical Service toll free 1-877-338-0999,

tech@championpowerequipment.com or your nearest Champion dealer.

www.championpowerequipment.com

Part No. 101305

Model 100152

ADDITIONAL INFORMATION

IDENTIFY/SELECT STANDBY CIRCUITS

Identify the basic needs

It is very important to understand what items the home owner wants powered by the HSB during a utility failure. The selection of these items will indicate which circuits will be selected for connection to the ATS so that they are powered by the HSB. Unforeseen power outages can last from minutes to days, so it is important to focus circuit selections on those that power household items that are deemed essential and within the output capability of the HSB

An authorized or certiﬁed dealer or electrician can come to your home and measure the loads with a clamp-on AMP meter which would provide accurate load demands for each circuit tested.

Once you have identiﬁed the customer needs, you can properly size the HSB by referring to the sizing guide provided by Champion, www.championpowerequipment.com or call Champion 1-877-338-0999.

Circuits must be protected by the same size breaker. For example, a 15 amp 120 volt circuit in the ATS will replace a 15 amp 120 volt circuit in the main utility distribution panel. When tied together or backed up, the breakers must be the same size.

SURGE PROTECTION

CAUTION

Voltage ﬂuctuation may impair the proper functioning of sensitive electronic equipment.

Electronic devices, including computers and many programmable appliances use components that are designed to operate within a narrow voltage range and may be affected by momentary voltage ﬂuctuations. While there is no way to prevent voltage ﬂuctuations, you can take steps to protect sensitive electronic equipment.

1. Install UL1449, CSA-listed, plug-in surge suppressors on the outlets feeding your sensitive equipment. Surge suppressors come in single or multi-outlet styles. They’re designed to protect against virtually all short-duration voltage ﬂuctuations.

Part No. 101305

Model 100152

ADDITIONAL INFORMATION

CUSTOMER FAMILIARIZATION SUMMARY

It’s important to educate the home owner on proper maintenance, operation and service call procedures. A properly educated home owner can reduce unnecessary service trips and phone calls.

Ensure that the installation of the HSB and ATS has been correctly performed as outlined by the manufacturer and that it meets all applicable codes.

Test and conﬁrm proper operation of the HSB and ATS system as outlined in the appropriate installation and owner’s manuals.

Educate the home owner on the location and operation of;

1. Full ﬂow shutoff valve

2. Automatic operation of the HSB system

3. Engine Control Module and LED indicators

4. ATS Module and LED indicators

5. Battery Charger and LED indicators

6. Exterior fault code indicator LED on the backside of the HSB

7. ATS operation

8. Exercise scheduled time of operation

9. Scheduled Maintenance

10. Fill out and provide the customer a copy of the HSB, ATS model & serial number reference. This information is extremely important for part purchases and service information, these numbers are speciﬁc to each HSB and ATS.

11. Fill out and provide the customer a copy of the ATS backup circuits.

12. Fill out the Circuit Label inside the ATS..

It’s always a good business practice to place business cards in the Owner’s and Installation manuals and place dealer stickers on the HSB and ATS for the customer’s reference.

NOTICE

By law it is required in many states to have a Carbon Monoxide (CO) detector in operating condition in your home. Carbon Monoxide detector(s) must be installed and maintained indoors according to the manufacturer’s instructions. A CO monitor is an electric device that detects hazardous levels of CO. When there is a buildup of CO, the monitor will alert the occupants by ﬂashing a visual light indicator and an audible alarm. Smoke alarms cannot detect CO gas.

CO gas is odorless, colorless and tasteless and is unlikely to be noticed until a person is overcome. Standby generators emit carbon monoxide (CO) gas in the engine exhaust.

Part No. 101305

Model 100152

ADDITIONAL INFORMATION

HSB, ATS MODEL & SERIAL REFERENCE ATS BACK-UP CIRCUITS

HSB Model Number _____________________________________

HSB Serial Number _____________________________________

Fuel Type LPG______________ NG________________

ATS Model Number ______________________________________

ATS Serial Number ______________________________________

ATS circuits powered ______________________________________

____________________________ ____________________________

Date Installed _____________________________________

Dealer/Installer _____________________________________________________

Address _____________________________________________________

_____________________________________________________

Phone _____________________________________________________

Cell _____________________________________________________

Purchased from _____________________________________________________

Part No. 101305

Model 100152

ADDITIONAL INFORMATION

MAINTENANCE AND SERVICE RECORD

Keeping accurate records when any service is preformed is important. Records replace guessing when a repair was done or when it should be scheduled. Hour Meter notation as well as the date provides better time period records. To maintain the overall performance throughout the life of the product follow the scheduled maintenance chart contained in your owner’s manual or refer to www. championpowerequipment.com. Genuine Champion parts must be used to ensure warranty coverage.

Date Hour Meter Service Preformed _________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ _________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ ______________

Record the name, address and phone number of your authorized Champion dealer

__________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________

Part No. 101305

Champion Power Equipment

12039 Smith Ave.

Santa Fe Springs, CA 90670 USA

Made in China

10 YEAR LIMITED WARRANTY*

Basic Warranty Provisions

Champion Air-Cooled 8.5kW – 20kW Home Standby Units USA and Canadian Models

For a period of 10 years or 2000 hours (whichever occurs ﬁrst) from successful activation by an Authorized Champion Home Standby Dealer, Champion Power Equipment will, at its option, repair or replace any part(s) which upon examination, inspection and testing by Champion Power Equipment or an Authorized Champion Home Standby Dealer is found to be defective under normal use and service, in accordance with the Warranty Schedule set forth below.

Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/Certiﬁed Champion Home Standby Service Dealer. This warranty applies only to Champion Power Equipment automatic standby generators used in “Standby” applications as Champion has deﬁned Standby. Scheduled Maintenance, as outlined by the generator owner’s manual is required. This Scheduled Maintenance should be performed by a knowledgeable, experience operator or an Authorized/Certiﬁed Champion Home Standby Service Dealer.

– Steel enclosures are warranted against rusting for the ﬁrst

year of ownership only. Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty. Nicks, scrapes, dents or scratches to the painted enclosure should be repaired promptly by the owner.

– All warranty expense allowances are subject to the conditions

deﬁned in Champion Power Equipment “Home Standby” Warranty Policy and Procedures Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

– Original installation or start-up costs

– Champion Home Standby generators that utilize non-Champion

Power Equipment replacement parts

– Costs of normal maintenance (i.e. tune-ups, associated part(s),

adjustments, loose/leaking clamps, installation and start-up)

– Units sold, rated or used for “Prime Power”, “Trailer Mounted”

or “Rental Unit” applications

– Damage to generator system (including transfer switch)

caused by improper installation or costs necessary to correct installation

WARRANTY SCHEDULE

Years 1 and 2 – Limited comprehensive coverage on mileage, labor and parts

Years 3 through 10 – Limited comprehensive coverage on parts only

GUIDELINES:

– Warranty begins upon the successful activation of the unit.

– Unit should be Registered and Proof of Purchase and

Maintenance must be available.

– Warranty is transferable between ownership of original

installation site.

– Warranty only applies to permanently wired and mounted

units.

– Any and all warranty repairs and/or concerns must be

performed and/or addressed by an Authorized/Certiﬁed Champion Home Standby Service Dealer. Repairs or diagnostics performed by individuals other than Authorized/ Certiﬁed Champion Home Standby Service Dealers not authorized in writing by Champion Power Equipment will not be covered.

– A Champion approved Transfer Switch is highly recommended

to be used in conjunction with the generator set. The Champion Transfer Switch is covered under its own, separate warranty listed in the Transfer Switch Instruction Manual and is not covered under this warranty schedule.

– If a Non-Champion approved Transfer Switch is substituted

for use and directly causes damage to the generator set, no warranty coverage shall apply.

– Units used for Prime Power in place of existing utility power

(where utility power is present) or in place of utility power where utility power service does not normally exist. Prime power includes any application that does not use the utility grid for electric power (example: Solar power)

– Fuel connections other than conventional utility company

supplied natural gas systems or conventional LP vapor withdrawal systems

– Any failure caused by contaminated fuels, oils or lack of proper

fuels, oils or failure to perform scheduled maintenance and service the air ﬁlter

– Steel enclosures that are rusting due to the improper

installation, location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised

– Failures due, but not limited, to normal wear and tear,

accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the Champion engines need periodic part(s) service and ﬂuid replacement to perform as designed.

– Failures caused by any external cause or act of God, such as

collision, theft, vandalism, riot or wars, nuclear holocaust, ﬁre, freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or ﬂood, tornado or hurricane

– Damage related to rodent and/or insect infestation

– Covered warranty labor rates are based on normal working

hours. Overtime, holiday, or emergency labor costs for repairs outside of normal business hours will be the responsibility of the customer

– Any incidental, consequential or indirect damages caused by

defects in materials or workmanship, or any delay in repair or replacement of the defective part(s)

– Failure due to misapplication to provide sufﬁcient cooling air

and to regularly exercise the generator under load

– Telephone, cellular phone, facsimile, internet access or other

communication expenses

– Living or travel expenses of person(s) performing service,

except as speciﬁcally included within the terms of a speciﬁc unit warranty period

– Expenses related to “customer instruction” or troubleshooting

where no manufacturing defect is found

– Rental equipment used while warranty repairs are being

performed and/or overnight freight costs for replacement part(s)

– Costs incurred for equipment used for removal and/or

reinstallation of generator, (i.e.: cranes, hoists, lifts, etc.)

– Planes, ferries, railroad, buses, helicopters, snowmobiles,

snow-cats, off-road vehicles or any other mode of transport deemed abnormal

Contact Information

Address

Champion Power Equipment, Inc.

Customer Service 12039 Smith Avenue Santa Fe Springs, CA 90670 USA www.championpowerequipment.com

Customer Service and Techinical Support

Toll Free: 1-877-338-0999 hsb@cpeauto.com Fax no.: 1-562-236-9429

– Starting batteries, fuses, light bulbs, engine ﬂuids, and spark

plugs

THIS WARRANTY AND THE ATTACHED U.S. EPA WARRANTY ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/ owner.

CHAMPION POWER EQUIPMENT’S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL CHAMPION POWER EQUIPMENT BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF CHAMPION POWER EQUIPMENT’S NEGLIGENCE.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/owner. Purchaser/owner agrees to make no claims against Champion Power Equipment based on negligence. This warranty gives purchaser/owner speciﬁc legal rights. Purchaser/ owner also may have other rights that vary from state to state.

To obtain warranty service or your nearest Champion Home Standby Dealer call Champion Power Equipment Customer Service toll free 1-877-338-0999.

*Except as other wise stipulated in any of the following enclosed Emission Control System Warranties (when applicable) for the Emission Control System: U.S. Environmental Protection Agency (EPA) and/or California Air Resources Board (CA RB).

CHAMPION POWER EQUIPMENT, INC. (CPE)

AND THE UNITED STATES ENVIRONMENT PROTECTION AGENCY (U.S. EPA)

EMISSION CONTROL SYSTEM WARRANTY

our Champion Power Equipment (CPE) engine complies with U.S. EPA emission regulations.

YOUR WARRANTY RIGHTS AND OBLIGATIONS:

TThhe Ue US ES EPPA AA and CPPE aE arre pe plleeaasseed td to eo exxppllaaiin tn thhe Fe Feeddeerraal El Emmiissssioion Cn Coonnttrrol Sol Syysstteemms Ws Waarrrraanntty oy on yn yoouur 2r 20021 s22 smmaalll ol offff--rrooaad ed ennggiinne (e (SSOORREE)) a

nd engine powered equipment. New engines and equipment must be designed, built and equipped, at the time of sale, to meet U.S. EPA regulations for small off-road engines (SORE). CPE warrants the emission control system on your small off-road engine (SORE) and equipment for the period of time listed below, provided there has been no abuse, neglect, unapproved modiﬁcation, or improper maintenance of your equipment.

Your emission control system may include parts such as the carburetor, fuel-injection system, the ignition system, catalytic converter and fuel lines. Also included may be hoses, belts, connectors and other 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.

ANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

his emission control 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.

WNER WARRANTY RESPONSIBILITIES:

s 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 deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the small off-road engine (SORE) owner, you should however be aware that CPE may deny you warranty coverage if your small, off-road engine (SORE) or a part has failed due to abuse, neglect, improper maintenance or unapproved modiﬁcations.

You are responsible for presenting your small off-road engine (SORE) to an Authorized CPE service outlet or alternate service outlet as described in (3)(f.) below, CPE dealer or CPE, Santa Fe Springs, Ca. as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact:

Champion Power Equipment, Inc.

Customer Service 12039 Smith Ave.

Santa Fe Springs, CA 90670

1-877-338-0999

tech@championpowerequipment.com

EMISSION CONTROL SYSTEM WARRANTY

The following are speciﬁc provisions relative to your Emission Control System (ECS) Warranty Coverage.

1. APPLICABILITY: This warranty shall apply to 1997 and later model year small off-road engines (SORE). The ECS Warranty Period shall

begin on the date the new engine or equipment is delivered to its original, end-use purchaser, and shall continue for 24 consecutive months thereafter.

2. GENERAL EMISSIONS WARRANTY COVERAGE

CPE warrants to the original, end-use purchaser of the new engine or equipment and to each subsequent purchaser that each of its small off-road engines (SORE) is:

2a. Designed, built and equipped so as to conform to U.S. EPA emissions standards for spark-ignited engines at or below 19 kilowatts.

2b. Free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects

to the part as described in the engine manufacturer’s application for certiﬁcation for a period of two years.

3. THE WARRANTY ON EMISSION-RELATED PARTS WILL BE INTERPRETED AS FOLLOWS:

3a. Any warranted part that is not scheduled for replacement as required maintenance in the Owners Manual shall be warranted for

the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by CPE according to Subsection “d” below. Any such part repaired or replaced under the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period.

3b. Any warranted, emissions-related part which is scheduled only for regular inspection as speciﬁed in the Owners Manual shall be

warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary”, shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

3c. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner’s Manual 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 emissionsrelated 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 replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the

owner at a CPE Authorized Service Outlet.

3e. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in

fact defective, provided that such diagnostic work is performed at a CPE Authorized Service Outlet.

3f. CPE shall pay for covered emissions warranty repairs at non-authorized service outlets under the following circumstances:

i. The service is required in a population center with a population over 100,000 according to U.S. Census 2000 without a CPE

Authorized Service Outlet AND

ii. The service is required more than 100 miles from a CPE Authorized Service Outlet. The 100 mile limitation does not apply in the

following states: Alaska, Arizona, Colorado, Hawaii, Idaho, Montana, Nebraska, Nevada, New Mexico, Oregon, Texas, Utah and Wyoming.

3g. CPE shall be liable for damages to other original engine components or approved modiﬁcations proximately caused by a failure

under warranty of an emission-related part covered by the ECS Warranty.

3h. Throughout the ECS Warranty Period, CPE shall maintain a supply of warranted emission-related parts sufﬁcient to meet the

expected demand for such emission-related parts.

3i. Any CPE Authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty

maintenance or repair and will be provided without charge to the owner. Such use shall not reduce CPE’s warranty obligation.

3j. Unapproved add-on or modiﬁed parts may not be used to modify or repair a CPE engine. Such use voids this ECS Warranty and

shall be sufﬁcient grounds for disallowing an ECS Warranty claim. CPE shall not be liable hereunder for failures of any warranted parts of a CPE engine caused by the use of such an unapproved add-on or modiﬁed part.

EMISSION-RELATED PARTS INCLUDE THE FOLLOWING: (using those portions of the list applicable to the engine)

Systems covered by this

warranty

Fuel Metering System Fuel regulator, Carburetor and internal parts

Air Induction System Air cleaner, Intake manifold

Ignition System Spark plug and parts, Magneto ignition system

Exhaust System Exhaust manifold, catalytic converter

Miscellaneous Parts Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed systems.

Evaporative Emissions Fuel Tank, Fuel Cap, Fuel Line (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, Vapor Hoses, Liquid/ Vapor Separator, Carbon Canister, Canister Mounting Brackets, Carburetor Purge Port Connector

Parts Description

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. Alternate service locations deﬁned in Section (3)(f.) above must be approved by CPE prior to service. Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used.

If you have any questions regarding your warranty rights and responsibilities, or to obtain warranty service, please write or call Customer Service at Champion Power Equipment, Inc.

Champion Power Equipment, Inc.

12039 Smith Ave.

Santa Fe Springs, CA 90670

1-877-338-0999

Attn.: Customer Service

tech@championpowerequipment.com

Champion Power Equipment 100152 Operator's Manual for All Serial Numbers in

Specifications and Main Features

Frequently Asked Questions

User Manual