Champion Power Equipment 100199, 100177, 100174 Operator's Manual
REV 100199-20150409
CALIFORNIA PROPOSITION 65 WARNING
Certain components in this product and its related accessories contain chemicals known to the state of California
to cause cancer, birth defects or other reproductive harm. Wash hands after handling.
CALIFORNIA PROPOSITION 65 WARNING
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth
defects or other reproductive harm.
DISCLAIMERS
All information, illustrations and specications 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 specications to explain
and/or exemplify a product, service or maintenance improvement may be changed at any time without notice.
ALL RIGHTS RESERVED
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:
s Product Info & Updates
s 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:
t Installation Manual, Part No. 101049
t Tr ansfe r Swi tc h Ma nu al, Par t No. 101 111
It is also recommended to refer to the reference materials list on
page 16 of the Installation Manual.
s Tech Bulletins
s 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 100199
CONTENTS
INTRODUCTION ........................... 4
Home standby generator . . . . . . . . . . . . . . . . . . . . 4
SAFETY ................................. 5
Safety Symbol Denitions . . . . . . . . . . . . . . . . . . . 5
Installation Hazards. . . . . . . . . . . . . . . . . . . . . . . . 6
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operating Hazards . . . . . . . . . . . . . . . . . . . . . . . . 7
Accidental Starting . . . . . . . . . . . . . . . . . . . . . . . . 8
Carbon Monoxide Hazards . . . . . . . . . . . . . . . . . . . 8
Electrical Shock Hazards . . . . . . . . . . . . . . . . . . . . 9
Fire/Explosion Hazards . . . . . . . . . . . . . . . . . . . . . 9
Burn Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Entanglement Hazards . . . . . . . . . . . . . . . . . . . . 10
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety, Serial/Model, Nameplate Label Locations . . . 11
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Battery Requirements . . . . . . . . . . . . . . . . . . . . . 19
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . 19
Model and Serial Number . . . . . . . . . . . . . . . . . . 19
OPERATION ............................. 20
Enclosure and Access . . . . . . . . . . . . . . . . . . . . . 20
Pre-Start Checklist . . . . . . . . . . . . . . . . . . . . . . . 20
Turn ing O ff the G ener at or . . . . . . . . . . . . . . . . . . 20
MAINTENANCE ........................... 21
Scheduled Maintenance Chart . . . . . . . . . . . . . . . 21
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine Oil Requirements . . . . . . . . . . . . . . . . . . . . 21
Checking the Engine Oil Level . . . . . . . . . . . . . . . . . 21
Changing the Engine Oil Level . . . . . . . . . . . . . . . . . 22
Inspect and Clean Engine Air Cleaner . . . . . . . . . . 23
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safety Labels on Unit . . . . . . . . . . . . . . . . . . . . . . . 12
GENERAL INFORMATION ................... 13
Component Identication – 8.5 kW Generator. . . . 13
Component Identication – Engine . . . . . . . . . . . . 14
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . 14
Exercise Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Set Exercise Time . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine Control Module . . . . . . . . . . . . . . . . . . . . . . 15
Reset Fault Code(s) . . . . . . . . . . . . . . . . . . . . . . . . 15
ATS Contr ol Module . . . . . . . . . . . . . . . . . . . . . . . . 16
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . 17
Emission Requirements . . . . . . . . . . . . . . . . . . . . 17
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . 24
Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . 24
Maintenance After Submersion . . . . . . . . . . . . . . 24
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Return to Service after Storage . . . . . . . . . . . . . . . . 25
Engine Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . 26
Engine Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Enclosure and Assemblies Diagram . . . . . . . . . . . . . 28
Enclosure and Assemblies Parts List . . . . . . . . . . . . 29
Alternator and Exhaust System Diagram . . . . . . . . . 30
Alternator and Exhaust System Parts List . . . . . . . . . 31
Control Panel Diagram . . . . . . . . . . . . . . . . . . . . . . 32
Control Panel Parts List . . . . . . . . . . . . . . . . . . . . . 33
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TROUBLESHOOTING ....................... 35
© 2015 Champion Power Equipment Part No. 101048
3
Model 100199
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- 877-3 38-09 99
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 liquied
petroleum gas (LPG) or natural gas (NG).
This generator is designed to supply typical home load such as:
t Induction motors – sump pumps, refrigerators, air
conditioners, furnaces
t Electronic items – televisions, computers
t Household lighting
t Microwaves
t 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. 101048
4
5
Model 100199
SAFETY
© 2015 Champion Power Equipment Part No. 101048
!
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.
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 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
!
Safety alert symbol
Asphyxiation hazard
Electrical shock hazard
Entanglement hazard
Fire hazard
6
Model 100199
SAFETY
Part No. 101048
Explosion hazard
Burn hazard
Sever hazard (rotating blade)
Crush hazard (top)
MANDATORY ACTIONS
Read manufacturer’s instructions
Wear eye protection
Wear personal protective equipment
Do not leave tools in the area
INSTALLATION HAZARDS
!
WARNING
!
Have only a qualied 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.
NOTICE
Before welding components on the generator, contact CPE
for recommended welding instructions.
!
WARNING
!
Not intended for use in critical life
support applications.
Model 100199
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 unqualied
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 inuence of alcohol
or drugs. Their effects on vision
and judgment make operating a
generator dangerous.
© 2015 Champion Power Equipment Part No. 101048
7
Model 100199
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 rst, and
then remove the POSITIVE,
POS or (+) battery cable.
To r eturn t he g en erat or to s er vice,
follow these steps in order:
1. Connect the POSITIVE, POS
or (+) battery cable rst, 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.
t 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.
t Avoid breathing exhaust fumes
when near an operating generator.
t 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.
t Install a battery-operated carbon
monoxide detector on each
level of any building adjacent
to the generator following the
manufacturer’s instructions.
t 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:
Part No. 101048
8
t Light-headedness, dizziness
t Physical fatigue, weakness in joints and muscles
t Sleepiness, mental fatigue, inability to concentrate or
speak clearly, blurred vision
t Stomachache, vomiting, nausea
Model 100199
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.
t Avoid contact with bare wires,
terminals and connections while
the generator is operating.
t ALWAYS stand on an insulated dry
surface to reduce shock hazard
if work must be done on an
operating generator.
t NEVER wear jewelry that can
conduct electricity when working
on the generator.
t NEVER handle any kind of
electrical device while hands or
feet are wet, while standing in
water or while barefoot.
t 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.
t 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 rst aid and
call 911 immediately.
FIRE/EXPLOSION HAZARDS
!
WARNING
NG and LPG are extremely explosive.
t NEVER allow any ames or smoke
near the fuel system.
t Wipe up any oil spills immediately.
t NEVER allow any combustible
materials to be near the generator
or to be left in the generator
compartment.
t ALWAYS keep the surrounding
area near the generator clean and
free of debris.
t Be sure to properly purge the fuel
lines and leak-test according to
applicable codes before placing
the generator in service.
t Be sure to regularly inspect the
fuel system for leaks. NEVER
operate the generator if a fuel leak
is present.
t Install a re 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 re department with any
questions concerning the re
extinguisher.
© 2015 Champion Power Equipment Part No. 101048
9
Model 100199
SAFETY
BURN HAZARDS
!
WARNING
ALWAYS allow hot surfaces to cool to
the touch. Running engines produce
heat. Severe burns can occur on
contact.
t DO NOT touch hot surfaces.
t 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.
t Keep hands and feet away from
rotating parts.
t Tie up long hair and remove
jewelry.
t Operate equipment with guards in
place.
t DO NOT wear loose-tting
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 ames 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.
!
t Replace any illegible or missing
label immediately. Missing safety
labels must be replaced in their
original position before the
generator is operated.
t DO NOT operate the generator if
there are missing or badly worn
safety labels.
BATTERY HAZARDS
!
Always read and comply with
the battery manufacturer’s
recommendations for procedures
concerning proper battery use and
maintenance.
Part No. 101048
10
WARNING
11
Model 100199
SAFETY
© 2015 Champion Power Equipment Part No. 101048
SAFETY, SERIAL/MODEL, NAMEPLATE LABEL LOCATIONS
The safety labels have specic placement and must be replaced if they are unreadable, damaged or missing.
!
6
2
1
4
5
3
A) Serial number locaon
B) Nameplate
A
B
12
Model 100199
SAFETY
Part No. 101048
100788
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.
100795
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.
100787
!
!
!
!
!
!
100791
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.
100793
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.
!
!
!
!
100792
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.
!
!
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
!
!
!
100789
!
!
!
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.
101045
!
!
!
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
Riesgo de descarga eléctrica
N’enlevez pas ce panneau d’accès.
Le panneau ne devrait être enle vé que par
un concessionnaire d’entretien agréé ou un
électricien qualifié ; haute tensio n à l’intérieur.
No remueva este tablero de acceso. El tablero
sólo deberá ser removido por un distribuidor
de servicio autorizado o un electricista
calificado; alto voltaje al interior.
!
!
!
101051
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.
100792
1
100791 100793
100787 100788 100795
101045
101051 100789
100794
2
3
6
4 5
SAFETY LABELS ON UNIT
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