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.
Model 100199 CONTENTS CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Home standby generator . . . . . . . . . . . . . . . . . . . . 4 Battery Requirements . . . . . . . . . . . . . . . . . . . . . 19 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . 19 Safety Symbol Definitions . . . . . . . . . . . . . . . . .
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.
Model 100199 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.
Model 100199 SAFETY INSTALLATION HAZARDS Explosion hazard Burn hazard ! ! 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.
Model 100199 SAFETY BEFORE STARTING ! OPERATING HAZARDS 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.
Model 100199 SAFETY ACCIDENTAL STARTING CARBON MONOXIDE HAZARDS 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.
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.
Model 100199 SAFETY BURN HAZARDS ! ! 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 allow hot surfaces to cool to the touch. Running engines produce heat. Severe burns can occur on contact. t DO NOT touch hot surfaces. Always wear protective glasses or goggles and protective clothing when working with batteries.
Model 100199 SAFETY SAFETY, SERIAL/MODEL, NAMEPLATE LABEL LOCATIONS The safety labels have specific placement and must be replaced if they are unreadable, damaged or missing. 4 3 ! 5 2 A 1 B 6 A) Serial number location B) Nameplate © 2015 Champion Power Equipment Part No.
Model 100199 SAFETY SAFETY LABELS ON UNIT ! ! 1 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.
Model 100199 GENERAL INFORMATION COMPONENT IDENTIFICATION – 8.5 KW GENERATOR 6 5 4 7 2 1 8 9 3 10 11 12 Figure 1 1. Exhaust System 7. Exercise Switch 2. Air Inlet 8. ATS Control Module 3. Fuel Regulator/Wire Connections (behind panel) 9. Engine Control Module 4. Main Circuit Breaker 11. Engine 5. Hour Meter 12. Alternator 6. Exterior Fault Code Indicator Light © 2015 Champion Power Equipment 10. Batteries (not included) Part No.
Model 100199 GENERAL INFORMATION COMPONENT IDENTIFICATION – ENGINE 2 CONTROL PANEL MAIN CIRCUIT BREAKER The 35.5-amp main circuit breaker protects the generator from circuit overload. The main circuit breaker controls total output of the generator. (Figure 3) 3 1 4 MAIN CIRCUIT BREAKER DISJONCTEUR PRINCIPAL INTERRUPTOR DE CIRCUITO PRINCIPAL ON MARCHE ENCENDIDO 5 OFF ARRÊT APAGADO Figure 3 Figure 2 1. Engine Starter 4. Fuel Mixture Valve 2. Engine Oil Dipstick 5. Air Cleaner 3.
Model 100199 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.
Model 100199 GENERAL INFORMATION 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.
Model 100199 GENERAL INFORMATION BATTERY CHARGER EMISSION REQUIREMENTS The LEDs on the battery charger indicate the state of the battery’s charge level. Battery charger rating 24 Vdc 1.6A. (Figure 7) This engine-powered generator meets all United States Environmental Protection Agency (EPA) Phase 3 requirements and is approved in both the USA and Canada. POWER ALIMENTATION POTENCIA RECOGNIZED COMPONENT NO CHARGE / PAS DE CHARGE / SIN CARGO E. O.
Model 100199 GENERAL INFORMATION SPECIFICATIONS Home standby generator Maximum continuous power, LPG 8.5 kW Maximum continuous power, NG 7.5 kW Rated voltage 120/240 Amps Harmonic distortion Main line circuit breaker 70.8/35.4 LPG, 62.5/31.25 NG Less than 5% 35.5 amp Phase Single Frequency 60 Hz Unit weight Size (L x W x H) 365.1 lb. (165.6 kg) 49.1 x 28 x 28.3 in. (124.7 x 71 x 72 cm) Engine Type No.
Model 100199 GENERAL INFORMATION FUEL SYSTEM BATTERY CHARGING 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. The generator is equipped with an automatic battery charger.
Model 100199 OPERATION Before operating the generator, review SAFETY section starting on page 5. 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.
Model 100199 MAINTENANCE ENGINE OIL Before performing maintenance procedures, review SAFETY section starting on page 5. Ensure that the ATS and Engine Switches are in the OFF position before performing any maintenance or cleaning. Use American Petroleum Institute (API) Service Class SN or better. Do not use special additives. All temperatures full synthetic 5W-30.
Model 100199 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. 4. Turn the engine control module switch to the OFF 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.
Model 100199 MAINTENANCE INSPECT AND CLEAN ENGINE AIR CLEANER SPARK PLUG 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. 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.
Model 100199 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.
Model 100199 MAINTENANCE 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.
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Model 100199 MAINTENANCE # Part Number Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 1.5789.0612 47.080100.01.2 2.02.007 1.5789.0629 47.080005.00 46.123000.01 47.080001.00 46.120100.05 2.11.007 45.030032.00 1.9074.4.0306 5.1050.001 2.08.039 2.03.023 47.030100.04 45.127000.02 1.5789.0615 1.276.6202 47.050006.00 47.050100.01 46.030008.00 2.04.001 46.080600.00 1.276.
Part No.
Model 100199 MAINTENANCE # Part Number Description 1 2 3 1.6177.1.06 1.5789.0615 161.200507.00 4 161.200500.01.24 5 6 7 8 9 10 161.200110.00 161.200110.00.01 161.200021.16 81.200503.00 1.16674.0820 1.16674.0812 11 161.200402.00.24 12 13 14 15 16 17 161.200109.03 161.200401.00.24 5.1460.015 161.192100.00 1.862.06 5.1560.
Part No.
Model 100199 MAINTENANCE # Part Number Description 1 2 3 4 5 6 161.200021.00 1.5789.0608 161.200024.00.1 47.692 161.190007.00 1.5789.1022 7 161.191100.
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Model 100199 MAINTENANCE # Part Number Description 1 2 3 4 5 6 7 5.1810.000 1.818.0514 161.210011.00 2.02.032 161.200004.00.24 5.1000.006.3 5.1420.002 8 5.1240.935 Over Voltage Protector Screw, M5X14 Terminal Block, 60A Cage Nut, M8 Cover, Electric Cabinet, Silk Grey Switch, UL, Red Hour Meter AC 35.5A Breaker, Double Pole, UL Screw, M5X10 ATS Controller, ATS100 Engine Controller, GTR128 Flange Bolt, M5X50 Bushing, Ø5.
Battery R B O G O/B Thermal Switch G Br Y G GND PART NO:100199.21.V1.1 GND B 24V R Fuel Valve Y L R B Br GND Start Motor G L/B B+ W B+ Red Black Brown Yellow Blue M R P Pu G O W 50W10Ω Power Resistance G/B B/W Fuel Valve N/C Stop ALT FUEL Start IN.1 WATR OIL N/C R/B L/B Freq. Freq. ATS 8 7 6 L G/B Stop Charge Magnetize Stop 5 4 B/W G ALT FUEL Start N/C Valve Alarm 3 2 IN.1 WATR OIL 100666 Motor B- Freq. Freq. ATS F.D2 F.
Model 100199 TROUBLESHOOTING Before performing troubleshooting procedures, review SAFETY section starting on page 5. Problem Generator will not start Generator starts but runs rough Cause Solution Fuel valve turned off Turn fuel valve on. Battery not charged Charge battery. Faulty spark plug Replace spark plug. Engine control module switch off Turn switch to ATS or manual. Active fault code Check fault codes.
Champion Power Equipment, Inc. (CPE), United States Environment Protection Agency (U.S. EPA) and Environment Canada (EC) Emission Control System Warranty Your Champion Power Equipment (CPE) engine complies with U.S. EPA and EC emission regulations. YOUR WARRANTY RIGHTS AND OBLIGATIONS: The US EPA, EC AND CPE are pleased to explain the Federal Emission Control Systems Warranty on your 2015 small off-road engine and engine powered equipment.
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. 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.
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.
Champion Power Equipment 12039 Smith Ave.
