OPERATOR'S MANUAL MODEL # 100302 -1 4000W DIGITAL HYBRID PORTABLE GENERATOR REGISTER YOUR PRODUCT ONLINE at championpowerequipment.com or visit championpowerequipment.com SAVE THESE INSTRUCTIONS. This manual contains important safety precautions which should be read and understood before operating the product. Failure to do so could result in serious injury. This manual should remain with the product.
Table of Contents 100302 - 4000W Digital Hybrid Portable Generator -1 TABLE OF CONTENTS Storage................................................ ......... 21 Short Term Storage (up to 30 days).............................. 21 Introduction.................................................... 3 Mid Term Storage (30 days – 1 year).................. .......... 21 Safety Definitions........................................... 3 Long Term Storage (over 1 year).................................
Introduction 100302 - 4000W Digital Hybrid Portable Generator -1 INTRODUCTION SAFETY DEFINITIONS Congratulations on your purchase of a Champion Power Equipment (CPE) product. CPE designs, builds, and supports all of our products to strict specifications and guidelines. With proper product knowledge, safe use, and regular maintenance, this product should bring years of satisfying service. The purpose of safety symbols is to attract your attention to possible dangers.
Important Safety Instructions 100302 - 4000W Digital Hybrid Portable Generator -1 IMPORTANT SAFETY INSTRUCTIONS DANGER Operate equipment with guards in place. WARNING Rotating parts can entangle hands, feet, hair, clothing and/or accessories. Traumatic amputation or severe laceration can result. Cancer and Reproductive Harm – www.P65Warnings.ca.gov DANGER Keep hands and feet away from rotating parts. Generator exhaust contains carbon monoxide, a colorless, odorless, poisonous gas.
Important Safety Instructions 100302 - 4000W Digital Hybrid Portable Generator -1 CAUTION WARNING Spark from removed spark plug wire can result in fire or electrical shock. Start the generator and allow the engine to stabilize before connecting electrical loads. When servicing the generator: Connect electrical equipment in the off position, and then turn them on for operation. Disconnect the spark plug wire and place it where it cannot contact the plug or any other metal object.
Important Safety Instructions 100302 - 4000W Digital Hybrid Portable Generator -1 Fuel Safety When operating the generator: – DO NOT move or tip the generator during operation. DANGER – DO NOT tip the generator or allow fuel or oil to spill. GASOLINE AND GASOLINE VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE. When transporting or servicing the generator: – Make certain that the fuel valve is in the OFF position and the gasoline tank is empty. Fire or explosion can cause severe burns or death.
Important Safety Instructions 100302 - 4000W Digital Hybrid Portable Generator -1 Safety and Dataplate Labels These labels warn you of potential hazards that can cause serious injury. Read them carefully. If a label comes off or becomes hard to read, contact Technical Support Team for possible replacement. C B A D Top Back Side LABEL DESCRIPTION DANGER Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.
Important Safety Instructions 100302 - 4000W Digital Hybrid Portable Generator -1 Safety Symbols Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to more safely operate the product. SYMBOL MEANING Read Operator’s Manual. To reduce the risk of injury, user must read and understand operator’s manual before using this product. Clearance. Keep all objects at least 5 feet (1.5m) from generator.
Important Safety Instructions 100302 - 4000W Digital Hybrid Portable Generator -1 Operation Symbols Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to more safely operate the product. SYMBOL ECO MEANING SYMBOL MEANING On 12V Direct Current Stop or Off Circuit Breaker Reset: Push Choke: knob is pulled out completely for “choke” position.
Important Safety Instructions 100302 - 4000W Digital Hybrid Portable Generator -1 Quickstart Label Symbols Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to more safely operate the product. 1 2 3 4 5 6 7 8 1 2 3 1544-L-OP-A 10W-30 Stopping the Engine Starting the Engine DANGER LPN 1544-L-OP Rev A Size 198 x 25 mm Colors 1.
Controls and Features 100302 - 4000W Digital Hybrid Portable Generator -1 CONTROLS AND FEATURES Read this operator’s manual before operating your generator. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference. Generator 1 8 2 3 7 4 5 6 1. Carrying Handle(s) – Used to lift or carry the unit. 6. Oil Drain Bolt 2. Gasoline Tank – 2.9 gal. (11 L) 7. Control Panel – See Control Panel section. 3.
Controls and Features 100302 - 4000W Digital Hybrid Portable Generator -1 Control Panel 1 4 5 2 7 8 C 6 A B 3 1. Engine Switch – Used to put in START mode or STOP the generator. RECEPTACLES 2. Economy Mode Switch – Enables/disables automatic idle control. A 3. Ground Terminal – Consult an electrician for local grounding regulations. B 4. Output Indicator Light – Remains ON during normal operating conditions. Turns OFF when generator is overloaded. 5.
Assembly 100302 - 4000W Digital Hybrid Portable Generator -1 Parts Included NOTICE Accessories The generator rotor has a sealed, pre-lubricated ball bearing that requires no additional lubrication for the life of the bearing. Dual Port USB Adapter (5v/2.4A)................................... 1 Battery Charging Cables............................................ 1 Oil Funnel............................................................
Assembly 100302 - 4000W Digital Hybrid Portable Generator -1 CAUTION CAUTION Use unleaded gasoline with a minimum octane rating of 85 and an ethanol content of 10% or less by volume. This engine is equipped with a low oil shut-off and will stop when the oil level in the crankcase falls below the threshold level. DO NOT light cigarettes or smoke when filling the tank. DO NOT mix oil and gasoline. NOTICE DO NOT overfill the tank. Fill tank to approximately ¼ in. (6.
Operation 100302 - 4000W Digital Hybrid Portable Generator -1 Grounding location that will not allow for adequate cooling of the generator and/or the muffler. DO NOT contain generators during operation. Allow generators to properly cool before transport or storage. Your generator must be properly connected to an appropriate ground to help prevent electric shock. Place the generator in a well-ventilated area.
Operation 100302 - 4000W Digital Hybrid Portable Generator -1 NOTICE OFF For gas starting in cold ambient < 59°F (15°C): The choke must be in 100% of the “CHOKE” position for manual start procedures. Do not over-choke. As soon as engine starts, push the choke knob in the “RUN” position. OFF ON NOTICE If the engine starts but does not continue to run make certain that the generator is on a flat, level surface.
Operation 100302 - 4000W Digital Hybrid Portable Generator -1 Do Not Overload Generator Capacity Follow these simple steps to calculate the running and starting watts necessary for your purposes: 1. Select the electrical devices you plan on running at the same time. 2. Total the running watts of these items. This is the amount of power you need to keep your items running. 3. Identify the highest starting wattage of all devices identified in step 1. Add this number to the number calculated in step 2.
Operation 100302 - 4000W Digital Hybrid Portable Generator -1 Important: The 12V DC outlet is ONLY to be used with the supplied 12V DC battery charging cable. The 12V DC output is unregulated and will damage other 12V DC products. When using the 12V DC outlet, turn the Economy mode switch to the “OFF” position. Be sure all electric devices including the lines and plug connections are in good condition before connection to the generator.
Maintenance 100302 - 4000W Digital Hybrid Portable Generator -1 WARNING 4. Inspect all air vents and cooling slots to ensure that they are clean and unobstructed. Operation using the alternative main jet at elevations lower than the recommended minimum altitude can damage the engine. For operation at lower elevations, the originally supplied standard main jet must be used.
Maintenance 100302 - 4000W Digital Hybrid Portable Generator -1 5. Refer to the spark plug types in Specifications when replacing the plug. NOTICE Federal and local laws and administrative requirements indicate when and where spark arrestors are required. When ordered, spark arrestors are required for operation of this generator in National Forest lands.
Storage 100302 - 4000W Digital Hybrid Portable Generator -1 3. Turn the fuel valve to the “ON” position. EVERY 250 HOURS 4. Start and run the generator for 10 minutes so the treated gasoline cycles through the fuel system. Clean combustion chamber* Check/adjust valve clearance* 5. Option 1: Drain Gasoline from Carburetor 5a. Turn engine switch to the “OFF” position and allow generator to cool completely before continuing. EVERY 3 YEARS Replace fuel line* 5b. Turn the fuel valve to the “OFF”.
Storage 100302 - 4000W Digital Hybrid Portable Generator -1 Removing from Storage If the generator has been improperly stored for a long period of time with gasoline in the gasoline tank and/or carburetor, all fuel must be drained and the carburetor must be thoroughly cleaned. This process involves technically advanced tasks. For assistance please call our Technical Support Team at 1-877-338-0999.
Specifications 100302 - 4000W Digital Hybrid Portable Generator -1 SPECIFICATIONS Recommended Engine Oil Type 10W-30 Generator Specifications 5W-30 Generator Model......................................... 100302 -1 10W-40 5W-30 Synthetic Start Type.................................................... Manual °F -20 °C -28.9 Watts (Starting/Running)............................... 4000/3500 0 -17.8 20 -6.7 40 4.4 60 15.6 80 26.7 100 37.8 120 48.9 Ambient temperature Volts AC. . .............
4 49 46 23 47 48 45 44 43 23 42 64 41 63 53 54 55 4 62 52 51 50 23 61 56 57 58 59 60 65 66 74 73 40 1 24 75 3 76 4 5 65 77 78 72 71 70 69 68 2 79 67 80 6 81 82 7 26 39 2 25 38 9 27 28 29 83 10 24 11 23 37 12 36 13 8 22 8 21 30 31 34 33 32 35 14 4 15 16 18 17 19 20 84 85 100302 - 4000W Digital Hybrid Portable Generator -1 Specifications Parts Diagram
Specifications 100302 - 4000W Digital Hybrid Portable Generator -1 Parts List # 1 2 3 4 Part Number 1.5789.0625 1.5789.0620 85.220005.01 1.5789.0612 5 85.221000.04 7 8 9 85.401 S/N <18MAY0401216 85.402 S/N 18MAY0401216 + 85.190002.01 1.5789.0615 85.191200.03 10 1.9074.14.0650 11 12 13 14 15 16 17 18 85.191100.03 2.02.006 83.190001.01 85.190003.01 1.845.4219 85.100100.01.2 46.101300.08 46.101503.08 19 1.9074.4.0514 20 21 22 23 24 25 26 27 28 29 30 31 85.101000.01.2 1.5789.0610 85.101203.01.
Specifications 100302 - 4000W Digital Hybrid Portable Generator -1 # 77 78 79 80 81 82 83 84 85 Part Number 85.061200.01.2 85.200106.01 85.130300.01 85.210002.01 1.5789.0615.1 100302.21.10 100302.21 9.1700.008 9.1600.009 Description Guide Plate, Rope, Black Protector, Front Cover Pull Choke Assembly Control Box Flange Bolt M6 x 15, Black Wire Assembly Control Panel Assembly Plug, USB 5V/2.
97 96 19 17 2 3 4 5 6 27 7 8 9 10 15 18 57 25 21 22 12 53 13 23 54 51 55 48 89 35 37 64 20 24 52 103 14 16 38 12 56 40 41 19 30 45 60 61 62 32 42 63 34 31 100 29 28 27 99 98 39 43 44 50 71 70 69 68 67 66 65 36 33 77 58 72 74 73 76 49 82 80 79 78 101 83 81 11 46 102 92 85 84 77 26 91 88 87 86 59 90 36 73 75 47 93 74 78 94 81 39 79 25 95 26 80 91 1 100302 - 4000W Digital Hybrid Portable Generator -1 Specifications Engine Parts Diag
Specifications 100302 - 4000W Digital Hybrid Portable Generator -1 Engine Parts List # Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1.5789.0615 85.061100.00.2 21.061005.00 2.10.003.1 21.061001.01 45.060003.00 45.060002.00 45.060009.00 45.060007.00 45.060008.00 24.040004.00 1.5789.0612 85.080100.01.48 85.091100.01 21.061300.00 24.130004.20 85.061000.01 85.091000.01 85.131000.02 20 2.03.016 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 2.02.006 23.060001.01 27.
Specifications 100302 - 4000W Digital Hybrid Portable Generator -1 # Part Number 79 21.040003.00 80 21.040007.00 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 21.040001.00 21.040008.00 24.040202.00 22.040009.00 22.040012.00 21.040021.00 1.97.1.06 1.6177.1.06 1.5789.0620 24.040201.00 23.040010.00 27.040005.00 21.020002.01 24.021000.00 23.020001.02 27.131017.01 27.131017.01.01 1.6177.1.05 85.130005.04 2.13.034 1.823.0306.1 24.040200.00 27.010000.00 2.08.
G G BLACK B Br BROWN Y YELLOW B/W BLACK WHITE L BLUE W/G WHITE GREEN G GREEN G/Y GREEN YELLOW R RED W/L WHITE BLUE W WHITE O ORANGE C CARNATION A AMETHYST SUB COIL AC COIL DC COIL GENERATOR Y Y R B R + Y Red Black O Y L C C _ O R R W R G/Y W/L Y W G B B/W OIL LEVEL SW W/L G B Y G/Y TT-30R CIRCUIT BREAKER 20A ECO.SW STOP.
Troubleshooting 100302 - 4000W Digital Hybrid Portable Generator -1 TROUBLESHOOTING Problem Cause Solution No fuel. Add fuel. Faulty spark plug. Clean and adjust spark plug or replace. Fill crankcase to the proper level. Low oil level. Engine will not start. Engine starts but runs roughly. Engine shuts down during operation. Generator cannot supply enough power or overheating. Engine is running but no AC output. Engine hunts or falters. Repeated circuit breaker tripping.
WARRANTY 100302 - 4000W Digital Hybrid Portable Generator -1 WARRANTY* Other Exclusions CHAMPION POWER EQUIPMENT 3 YEAR LIMITED WARRANTY This warranty excludes: – Cosmetic defects such as paint, decals, etc. – Wear items such as filter elements, o-rings, etc. Warranty Qualifications – Accessory parts such as starting batteries, and storage covers. To register your product for warranty and FREE lifetime call center technical support please visit: https://www.championpowerequipment.
CHAMPION POWER EQUIPMENT, INC. (CPE), THE UNITED STATES ENVIRONMENT PROTECTION AGENCY (U.S. EPA) AND THE CALIFORNIA AIR RESOURCES BOARD (CARB) EMISSION CONTROL SYSTEM WARRANTY Your Champion Power Equipment (CPE) engine complies with both the U.S. EPA and state of California Air Resources Board (CARB) Exhaust and Evaporative emissions regulations.
EXHAUST AND EVAPORATIVE EMISSION CONTROL SYSTEM WARRANTY The following are specific provisions relative to your Exhaust and Evaporative Emission Control System (ECS) Warranty Coverage. 1. APPLICABILITY: This warranty shall apply to 1995 and later model year California small off-road engines (SORE) (for other states, 1997 and later model year engines).
EMISSION-RELATED PARTS INCLUDE THE FOLLOWING: (using those portions of the list applicable to the engine) Systems covered by this warranty Parts Description 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.
