Champion Power Equipment 100199 Operators Manual

2015-08-26

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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 specications 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 specications 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:

s Product Info & Updates

s Frequently Asked Questions

s Tech Bulletins

s Product Registration

– or –

Call our Customer Care Team Toll-Free at:

1-877-338-0999

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

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

t Installation Manual, Part No. 101049

t Transfer Switch Manual, Part No. 101111

It is also recommended to refer to the reference materials list on

page 16 of the Installation Manual.

Model 100199

CONTENTS

INTRODUCTION ........................... 4

Home standby generator ....................4

SAFETY ................................. 5

Safety Symbol Denitions ...................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

Safety Labels on Unit . . . . . . . . . . . . . . . . . . . . . . . 12

GENERAL INFORMATION ...................13

Component Identication – 8.5 kW Generator. . . . 13

Component Identication – 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 Control Module ........................ 16

Battery Charger .........................17

Emission Requirements ....................17

Specications ...........................18

Fuel System ............................19

Battery Requirements .....................19

Battery Charging ........................19

Model and Serial Number . . . . . . . . . . . . . . . . . . 19

OPERATION .............................20

Enclosure and Access .....................20

Pre-Start Checklist .......................20

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

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

Model 100199

INTRODUCTION

4Part No. 101048

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 liquied

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.

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.

! 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:NIndicates 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

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 qualied 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 unqualied

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 inuence of alcohol

or drugs. Their effects on vision

and judgment make operating a

generator dangerous.

Model 100199

SAFETY

Part No. 101048

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 return the generator to service,

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:

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.

Model 100199

SAFETY

Part No. 101048

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.

BATTERY HAZARDS

! WARNING

Always read and comply with

the battery manufacturer’s

recommendations for procedures

concerning proper battery use and

maintenance.

! 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.

Model 100199

SAFETY

SAFETY, SERIAL/MODEL, NAMEPLATE LABEL LOCATIONS

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

A) Serial number locaon

B) Nameplate

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 enlevé que par

un concessionnaire d’entretien agréé ou un

électricien qualifié ; haute tension 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

100791 100793

100787 100788 100795

101045

101051 100789

100794

4 5

SAFETY LABELS ON UNIT

Model 100199

GENERAL INFORMATION

COMPONENT IDENTIFICATION – 8.5 KW GENERATOR

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

Model 100199

GENERAL INFORMATION

14 Part No. 101048

COMPONENT IDENTIFICATION –

ENGINE

Figure 2

1. Engine Starter

2. Engine Oil Dipstick

3. Spark Plug

4. Fuel Mixture Valve

5. Air Cleaner

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)

MARCHE

ENCENDIDO

OFF

ARRÊT

APAGADO

MAIN CIRCUIT BREAKER

DISJONCTEUR PRINCIPAL

INTERRUPTOR DE CIRCUITO PRINCIPAL

Figure 3

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

MARCHE

ENCENDIDO

OFF

ARRÊT

APAGADO

Figure 4

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.

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:

t The battery was disconnected from the generator

t 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)

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.

APAGADO

ARRÊT

OFF

Manual

Manuel

Manual

ATS

Hz over/under / Hz plus / sous

Hz Más / Menos

Run / Marche

Funcionar

Power / Alimentation

Potencia

High engine temperature

Surchauffe moteur

Alta temperatura del motor

Low oil / Huile basse

Baja de aceite

Over crank

Surdémarrage

Sobre manivela

Exercise / Exercice /

Ejercicio

Low battery /

Batterie faible

Batería baja

Figure 5

MODE SWITCH

t 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.

t OFF – This position shuts down the engine and prevents

automatic operation of the generator.

t Manual – This position allows manual starting of the

engine. Load transfer from the generator output does not

occur unless the utility power is lost.

EXERCISER LED

The green LED will be lit when the generator is performing the

excercise period. When the exercise period has completed, the

LED will turn off.

LOW BATTERY LED

The red 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.

Model 100199

GENERAL INFORMATION

16 Part No. 101048

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.

HIGH ENGINE TEMP LED

The red LED will be lit if the engine operating temperature

is too high. It could be from an excessive load, high ambient

temperature or engine over speeding.

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 specied time period. The engine will try

to start ve 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.

RUN LED

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

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)

AUTO / AUTO / AUTOMÁTICO

OFF / ARRÊT / APAGADO

TEST / ESSAI / PRUEBA

UTILIDAD

UTILITÉ

UTILITY

CARGA

CHARGER

LOAD

GENSET

Figure 6

TEST/AUTO/OFF SWITCH

t TEST – This position allows verication 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.

t 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.

t OFF – This position will not allow any power to be

delivered to the ATS when the engine is running.

Model 100199

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 /

SIN CARGO

AUTOMATIC BATTERY CHARGER /

CHARGE AUTOMATIQUE DE BATTERIE /

CARGADOR DE BATERÍA AUTOMÁTICO

Output: 24 Vdc 1.6 A

Producción: 24 V C.C. 1,6 A

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

Power: 80-125 Vac 1.0 A 50 / 60 Hz

Potencia: 80 - 125 V C.A. 1,0 A 50 / 60 Hz

Alimentation : 80-125 V c.a. 1,0 A 50 / 60 Hz

LN ADJ

E. O.

POWER / ALIMENTATION /

POTENCIA

OUTPUT / SORTIE /

PRODUCCIÓN

MODEL / MODÈLE / MODELO : 100482

POWER

ALIMENTATION

POTENCIA

Conforms to UL

Std. 1236

RECOGNIZED

COMPONENT

Figure 7

POWER When lit, it indicates the battery is fully

charged.

Small Bar When lit, it indicates the battery is

receiving a trickle charge.

Middle Bar When current output is near 50%, the LED

turns on.

Large Bar When LED light is on, the charger is

operating above 50% capacity.

NO CHARGE

When lit, it indicates a problem with

the battery or battery charger. See

TROUBLESHOOTING on page 35.

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 certied 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:

t Fuel metering system – mixer and fuel regulator

t Air induction system – air cleaner housing and element

t 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.

Model 100199

GENERAL INFORMATION

18 Part No. 101048

SPECIFICATIONS

Home standby generator

Maximum continuous power, LPG 8.5 kW

Maximum continuous power, NG 7.5 kW

Rated voltage 120/240

Amps 70.8/35.4 LPG, 62.5/31.25 NG

Harmonic distortion Less than 5%

Main line circuit breaker 35.5 amp

Phase Single

Frequency 60 Hz

Unit weight 365.1 lb. (165.6 kg)

Size (L x W x H) 49.1 x 28 x 28.3 in. (124.7 x 71 x 72 cm)

Engine

Type Champion OHV

No. of cylinders 1

Displacement 439 cc

Cylinder block Aluminum with cast-iron sleeve

Ignition system Solid state – magneto

Spark plug F7RTC (NGK BPR7ES)

Governor Mechanical

Compression ratio 9.5:1

Starter Electric 24V DC

Oil capacity 1.2 qt (1.1 L)

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

Model 100199

GENERAL INFORMATION

FUEL SYSTEM

The engine is tted with a dual master mixer assembly

carburetion system, which allows it to run on either NG or

LPG. It has been congured at the factory to run on NG. If your

installation requires the engine to run on LPG, orices in the

master mixer assembly carburetor must be changed.

BATTERY REQUIREMENTS

Champion requires two (2) 12 volt batteries with a minimum of

18 Ah with a minimum of 270 CCA each. [battery size: 6-7/8

L x 3-7/16 W x 6-1/8 H inches (175 mm L x 87 mm W x 155

mm H)]. Purchase the batteries locally. Install the positive battery

cable rst.

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 rst. (Figure 8)

Figure 8

! CAUTION

For battery installation, maintenance, and safety

requirements refer to purchased manufacturer battery

installation and safety manual.

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 17.

MODEL AND SERIAL NUMBER

The model and serial number plate is afxed to the generator

above the control panel. Have this information if calling for

service or ordering parts. (Figure 9)

CHAMPION POWER EQUIPMENT

12039 Smith Ave., Santa Fe Springs, CA 90670 USA P/N 100970

CARCASA A PRUEBA DE LLUVIA EQUIPADO

BOÎTIER ÉTANCHE À LA PLUIE ÉQUIPÉ

RAINPROOF ENCLOSURE FITTED

RATED CURRENT 70.8 A / 35.4 A (LPG) COURANT NOMINALE 70,8 A / 35,4 A (GPL) CORRIENTE NOMINAL 70,8 A / 35,4 A (LPG)

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

RATED FREQUENCY 60 Hz FRÉQUENCE NOMINALE 60 Hz FRECUENCIA NOMINAL 60 Hz

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

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

RATED ENGINE SPEED 3600 r/min RÉGIME MOTEUR NOMINAL 3600 r/min VELOCIDAD NOMINAL DEL MOTOR 3600 r/min

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

AISLANTE CLASEISOLATION DE CLASSE

INSULATION CLASS H H H

Conforms to UL Std.

No. 2200

Certified to

CAN/CSA Standard

C22.2 No. 100

FOR STANDBY SERVICE PARA EL SERVICIO SUPLENTEPOUR LE SERVICE DE SECOURS

NEUTRAL FLOATING NEUTRE FLOTTANT NEUTRO FLOTANTE

100199

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

ESTACIONARIO ACCIONADA POR EL MOTOR GENERADOR

MODEL

MODELO

MODÈLE

Figure 9

To Starter

To Ground 2

Model 100199

OPERATION

Part No. 101048

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.

Figure 10

PRE-START CHECKLIST

To make sure the generator is ready for proper operation, the

following items should be checked:

t Fuel valve is in the ON position

t No fault code LEDs are lit

t Battery is at full charge

t ATS control module is in the AUTO position

t Engine control module is in the ATS position

t 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.

Model 100199

MAINTENANCE

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.

SCHEDULED MAINTENANCE

CHART

First

5Hours of

Operation

Weekly Monthly

Every

2Years

or 100

Hours of

Operation

Change

engine oil √√**

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

√***

* 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.

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 gure 12,

page 22.

Figure 11

Model 100199

MAINTENANCE

22 Part No. 101048

NOTICE

DO NOT overll 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 overll.

Figure 12

5. Install the dipstick.

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

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.

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)

Figure 13

1. Oil Drain Hose

2. Hose Clamp

3. Retaining Pin

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

empty.

8. Reinstall the hose onto the retaining pin and reposition

hose clamp.

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

Figure 12.

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

11. Turn the ATS to the AUTO position.

Model 100199

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.

Figure 14

1. Air Cleaner Cover

Clips

2. Paper Element

3. Air Cleaner Cover

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.

6. Install paper element in the air cleaner housing with the

pleats facing towards the air cleaner cover.

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

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

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).

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.

Model 100199

MAINTENANCE

24 Part No. 101048

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 uid 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

! WARNING

Never try to start or operate the

generator if it has been submerged

underwater or exposed to a ood.

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.

If the house or building has been exposed to a ood, it should

be inspected by a certied 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

rst.

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

page 22.

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.

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 rst. After the

positive cable is connected, then

the negative (-) battery cable can

be attached. This minimizes the

possibility of electrical contact.

5. Connect the positive (+) battery cable to the positive

(+) battery terminal rst 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

14 and 15.

Model 100199

MAINTENANCE

26 Part No. 101048

100

101

104

103

102

345

14 15 16 17 18

91 92

93 94 95

82 81

105

106

ENGINE PARTS

Model 100199

MAINTENANCE

# Part Number Description Qty

11.5789.0612 Flange Bolt M6 × 12 12

247.080100.01.2 Fan Cover, Black 1

32.02.007 Nut M16 × 1.5 1

41.5789.0629 Flange Bolt M6 × 29 2

547.080005.00 Plate, Fan 1

646.123000.01 Ignition Coil 1

747.080001.00 Cooling Fan 1

846.120100.05 Flywheel, Electric Start 1

92.11.007 Oil Seal, Ø35 × Ø52 × 8 2

10 45.030032.00 Sheath, Wire 1

11 1.9074.4.0306 Screw M3 × 6 2

12 5.1050.001 Sensor, Oil Temperature 1

13 2.08.039 Drain Bolt, M12 × 1.5 × 15 1

14 2.03.023 Washer, Ø12.5 × Ø20 × 2 2

15 47.030100.04 Crankcase 1

16 45.127000.02 Oil Level Sensor 1

17 1.5789.0615 Flange Bolt M6 × 15 2

18 1.276.6202 Bearing 6202 2

19 47.050006.00 Weight Balancer 1

20 47.050100.01 Crankshaft 1

21 46.030008.00 Gasket, Crankcase Cover 1

22 2.04.001 Dowel Pin, Ø9 × 14 2

23 46.080600.00 Air Guide, Right Side 1

24 1.276.6207 Bearing 6207 1

25 47.031100.00 Tube, Oil Fill 1

26 47.031300.00.48 Dipstick Assembly, Yellow 1

27 45.030007.03 Cover, Crankcase, LPG/NG 1

28 1.5789.0840.0.8 Flange Bolt M8 × 40 7

29 2.03.021.1 Washer, Ø6.4 × Ø13 × 1, Black 1

30 45.110013.00 Shaft, Governor Gear 1

31 45.110100.00 Gear, Governor 1

32 21.110011.00 Clip, Governor Gear 1

33 45.110012.00 Bushing, Governor Gear 1

34 47.050200.00 Connecting Rod 1

35 47.050005.01 Piston 1

36 2.09.004 Circlip, Ø21 × Ø1 2

37 45.050003.00 Pin, Piston 1

38 46.050303.02 Ring, Oil 1

39 46.050302.02 Ring, Second Piston 1

40 46.050301.02 Ring, First Piston 1

41 2.04.004 Dowel Pin, Ø12 × 20 2

42 47.030009.00 Gasket, Cylinder Head 1

43 46.080400.00 Air Guide, Lower 1

44 47.010100.04 Cylinder Head 1

45 2.01.010 Stud Bolt M8 × 35 2

46 2.15.008(F7RTC) Spark Plug, F7RTC 1

47 2.08.122 Flange Bolt M10 × 100 4

48 46.020002.00 Gasket, Cylinder Head Cover 1

49 47.021000.00 Cylinder Head Cover, CPE 1

50 45.020001.02 Breather Tube 1

51 47.020100.00 Bolt, Cylinder Head Cover 1

52 45.032000.00 Fuel Guide Assembly 1

53 2.06.013 Clamp, Ø13.5 × b10 1

54 45.030200.00 Support 1

55 47.041000.02 Camshaft 1

56 47.040004.00 Lifter, Valve 2

57 47.040002.00 Valve, Intake 1

58 47.040006.00 Valve, Exhaust 1

59 46.040005.00 Push Rod 2

60 45.040015.00 Retainer, Valve Spring 2

61 45.040017.00 Oil Seal, Valve 2

# Part Number Description Qty

62 45.040003.00 Spring, Valve 2

63 23.040010.00 Bolt, Rocker Arm 2

64 45.040001.00 Retainer, Intake Valve Spring 1

65 45.040007.00 Retainer, Exhaust Valve Spring 1

66 45.040008.00 Rotator, Exhaust Valve 1

67 46.040004.00 Guide Plate, Push Rod 1

68 46.040016.00 Shaft, Rocker Arm 1

69 46.040201.00 Retainer, Rocker Arm 1

70 46.040009.00 Rocker Arm, Intake Valve 1

71 46.040018.00 Rocker Arm, Exhaust Valve 1

72 1.97.1.06 Washer Ø6 2

73 22.040012.00 Screw, Valve Adjustment 2

74 1.6177.1.06 Flange Lock Nut M6 2

75 21.040021.00 Lock Nut, M6 × 0.5 2

76 2.01.008 Stud Bolt M6 × M8 × 105 2

77 46.130002.20 Gasket, Insulator 1

78 45.130001.00 Insulator, Carburetor 1

79 46.130003.20 Gasket, Carburetor 1

80 161.133000.00 Master Mixer Assembly, LPG/NG 1

81 46.130004.20 Gasket, Air Cleaner 1

82 1.6177.06 Flange Nut M6 3

83 46.091100.03 Base, Air Cleaner 1

84 45.091002.20 Seal, Air Cleaner 1

85 45.091001.20 Separator, Air Cleaner 1

86 47.091300.00 Element, Air Filter Ul Paper 1

87 47.091200.00 Cover, Air Cleaner 1

88 47.091000.00 Air Cleaner Assembly 1

89 47.090004.00 Pipe, Air Cleaner 1

90 46.080300.20 Air Guide, Upper 1

91 1.5789.0835 Flange Bolt M8 × 35 2

92 46.125100.03 Starter Motor Assembly 1

93 45.125200.00 Relay, Starter 1

94 1.93.05 Lock Washer Ø5 2

95 1.16674.0516 Flange Bolt M5 × 16 2

96 45.110001.00 Shaft, Governor Arm 1

97 2.03.019 Washer, Ø8.2 × Ø17 × 0.8 1

98 2.11.006 Oil Seal, Ø7 × Ø14 × 5 1

99 45.110008.00 Pin, Shaft 1

100 45.110003.00 Arm, Governor 1

101 2.08.040 Bolt, Governor Arm, M6 × 21 1

102 45.110006.00 Rod, Governor 1

103 45.110005.00 Spring, Throttle Return 1

104 45.110007.00 Spring, Governor 1

105 161.133029.00 Metering Jet, Main, LPG 1

161.133029.01 Metering Jet, Main, NG 1

106 161.133030.00 Metering Jet, Idle, LPG 1

161.133030.01 Metering Jet, Idle, NG 1

Model 100199

MAINTENANCE

28 Part No. 101048

ENCLOSURE AND ASSEMBLIES

10 9

15 14

27 28 29 30 31 32 33 34 35 36 37

42 43 44

50 49 47 46

66 67 68

24 25

70 71

Model 100199

MAINTENANCE

# Part Number Description Qty

11.6177.1.06 Flange Lock Nut M6 23

21.5789.0615 Flange bolt, M6 X 15 5

3161.200507.00 Curb Chain Assembly, Cover 2

4161.200500.01.24 Top Cover Assembly, Right,

Silk Grey 1

5161.200110.00 Hook Lock Assembly 2

6161.200110.00.01 Key, Hook Lock 2

7161.200021.16 Seal, Access Cover 1

881.200503.00 Plug 1

91.16674.0820 Flange bolt, M8 X 20 7

10 1.16674.0812 Flange bolt, M8 X 12 23

11 161.200402.00.24 Access Cover, Electric Cabinet,

Silk Grey 1

12 161.200109.03 Rubber Strip, 575 mm 2

13 161.200401.00.24 Rear Cover, Silk Grey 1

14 5.1460.015 Indicator Light, 24 v 1

15 161.192100.00 Supporter, Air Guide, Alternator 1

16 1.862.06 Toothed Lock Washer, Ø6 3

17 5.1560.000 Ground Wire Teminal, Ø6, UL 1

18 161.200021.05 Acoustic Panel, Rear Center

Chamber 1

19 9.3410.02 Locking Nylon cable ties, 5 X

500 mm 1

20 161.192300.00 Air Guide, Alternator 1

21 161.200500.00.24 Top Cover Assembly, Left, Silk

Grey 1

22 161.200021.17 Seal Strip, Top Cover, Long,

625 X 50 X 25 mm 1

23 161.201600.02.1 Gutter, Black 1

24 161.100006.00 Spring , Mufﬂer 3

25 2.08.119 Flange Bolt M8 X 35, Mufﬂer 3

26 161.1010005.01.2 Supportor, Mufﬂer, Bottom,

Black 1

27 161.200021.13 Acoustic Panel, Mufﬂer Cover,

Front 1

28 161.200021.18 Seal Strip, Top Cover, Short,

50 X 320 X 25 mm 1

29 2.02.032 Cage Nut, M8 5

30 161.200017.03.24 Mufﬂer Cover, Back, Silk Grey 1

31 161.200021.15 Foams, Mufﬂer Cover, Back 2

32 161.200021.14 Acoustic Panel, Mufﬂer Cover,

side 1

33 161.200021.06 Acoustic Panel, Mufﬂer Cover,

top 1

# Part Number Description Qty

34 1.5789.0612 Flange Bolt, M6 X 12 6

35 2.03.004 Washer, Ø24 X Ø6.5 X 1.5 4

36 161.200017.02 Thermal Bafﬂe 1

37 161.200017.00.24 Mufﬂer Cover, Top, Silk Grey 1

38 161.1010005.00.2 Supportor, Mufﬂer, Top, Black 1

39 100199.901 Generator Assembly 1

40 2.06.035 Clamp, Ø23.5 1

41 100199.902 Control Panel Assembly 1

42 161.200021.02 Seal Strip, Right/Left Cover 2

43 161.200302.00.24 Right Cover Assembly, Silk Grey 1

44 161.201900.00 Hinge 4

45 5.1320.018 Plastic Conduit, CSA, 100 mm 1

46 161.134100.00 Solenoid Valve, LPG/NG 1

47 161.133106.01 Nipple, NPT 3/4 1

48 161.133106.00 Nipple, NPT 3/8 1

49 161.136000.00 Pressure Reducing Valve, LPG/

NG 1

50 161.200018.00 Supportor, Pressure Reducing

Valve 1

51 1.5789.0629 Flange bolt, M6 X 29 2

52 1.5781.0825 Bolt, M8 X 25 8

53 161.200601.00.24 Base Center, Silk Grey 1

54 1.823.0414 Screw, M4 X 14 2

55 161.210011.00 Terminal Block, 60A 1

56 161.200017.01.24 Mufﬂer Cover, Front, Silk Grey 1

57 161.200021.03 Acoustic Panel, Left Firewall 1

58 161.200005.01.24 Firewall, Left, Silk Grey 1

59 1.6177.1.08 Flange Lock Nut, M8 9

60 161.192300.01.2 Fan Cover, Rotor, Black 1

61 161.200021.12 Foams, Fan Cover 1

62 161.200109.01 Rubber Strip, 1120 mm 1

63 161.200201.00.24 Left Cover, Silk Grey 1

64 161.200023.00.1 Oil Container, Black 1

65 161.130021.01 LPG Hose With NPT3/4 Nipple 1

66 161.200109.02 Rubber Strip, 530mm 2

67 161.200101.00.24 Front Cover , Silk Grey 1

68 161.200021.11 Foams, Front Cover 1

69 161.201800.00 Plastic Pallet, PP 1

70 1.6182.08 Nut, M8 2

71 5.1900.074 Battery Jump Wire, 225 mm,

6AWG 1

Model 100199

MAINTENANCE

30 Part No. 101048

11 12 13

20 21 22 23

28 29 30 31

32 33

34 35 36 37 38 39 40

26 27

ALTERNATOR AND EXHAUST SYSTEM

Model 100199

MAINTENANCE

# Part Number Description Qty

1161.200021.00 Foams Ring, Engine Fan 1

21.5789.0608 Flange Bolt, M6 X 8 3

3161.200024.00.1 Supportor, Air Guide Cover 1

447.692 Engine 1

5161.190007.00 Crankcase Cover 1

61.5789.1022 Flange Bolt, M10 X 22 4

7161.191100.00 Rotor Component, Ø175 X

Ø225 X 120 1

8161.191002.00 Stator Cover 1

9161.191200.00 Stator Assembly, Ø230 X 120 1

10 161.190002.00 End Housing 1

11 2.08.110 Bolt, M8 X 170 4

12 1.93.08 Lock Washer, Ø8 9

13 1.848.08 Washer, Ø8 6

14 161.190300.00 Carbon Brush Assembly 1

15 122.190004.01 Pinch, Carbon Brush 1

16 1.93.05 Lock Washer, Ø5 1

17 1.5783.0520 Bolt, M5 X 20 1

18 161.190001.00 Rotor Fan, 8KW 1

19 1.5789.0629 Flange Bolt, M6 X 29 4

20 2.08.113 Flange Bolt, M10 X 340 1

21 1.7244.10 Lock Washer, Ø10 3

22 2.03.050 Washer, Ø25 X Ø10.2 X 2.7 1

23 161.190019.00 Flange Plate, Fan 1

24 161.080009.01.2 Air Guide, Mufﬂer Pipe, Front 1

# Part Number Description Qty

25 161.080009.00.2 Air Guide, Mufﬂer Pipe, Back 1

26 1.93.06 Lock Washer, Ø6 5

27 2.03.004 Washer, Ø24 X Ø6.5 X 1.5 5

28 1.5789.0615 Flange bolt, M6 X 15 5

29 161.101002.00 Gasket, Mufﬂer 1

30 1.16674.0825 Flange Bolt, M8 X 25 1

31 161.101000.00 Mufﬂer Assembly 1

32 1.6177.1.06 Flange Lock Nut M6 1

33 45.090006.20 Holder, Air Cleaner 1

34 1.6177.1.10 Flange Lock Nut, M10 4

35 161.201600.01 Supportor, End Housing 1

36 161.200605.00 Motor Mount 4

37 1.6177.1.08 Flange Lock Nut, M8 8

38 161.201600.00 Supportor, Engine 1

39 2.06.023 Clamp, Ø20 1

40 161.130021.00 Pipe, LPG/NG 1

41 1.6175.08 Nut, M8 2

42 47.100001.00 Gasket, Exhaust Pipe 1

43 161.101001.00 Exhaust Pipe 1

44 1.96.08 Washer, Ø8 1

45 1.6187.1.10 Lock Nut M10, Flange, Metal 2

46 1.6170.10 Nut, M10 2

47 1.5789.0608 Flange bolt, M6 X 8 6

Model 100199

MAINTENANCE

32 Part No. 101048

CONTROL PANEL

24 25

26 27

29 30 31

3435

Model 100199

MAINTENANCE

# Part Number Description Qty

15.1810.000 Over Voltage Protector 1

21.818.0514 Screw, M5X14 1

3161.210011.00 Terminal Block, 60A 1

42.02.032 Cage Nut, M8 7

5161.200004.00.24 Cover, Electric Cabinet, Silk Grey 1

65.1000.006.3 Switch, UL, Red 1

75.1420.002 Hour Meter 1

85.1240.935 AC 35.5A Breaker, Double Pole,

UL 1

91.9074.3.0510 Screw, M5X10 4

10 5.1850.004 ATS Controller, ATS100 1

11 5.1850.003 Engine Controller, GTR128 1

12 1.5789.0550 Flange Bolt, M5X50 4

13 2.13.028 Bushing, Ø5.5×Ø14×25 4

14 5.1850.005 Relay Module, Engine 1

15 2.08.068 Flange Bolt, M5X13 4

16 161.200020.00 Grille 1

17 2.02.030 Cage Nut M5 8

18 161.200005.00.24 Firewall, Right, Silk Grey 1

# Part Number Description Qty

19 161.200109.01 Rubber Strip 1120mm 1

20 161.200021.04 Foams, Right Firewall 1

21 1.16674.0812 Flange Bolt, M8×12 3

22 2.02.031 Cage Nut, M6 2

23 161.190200.00 AVR, TT91-15U 1

24 2.13.029 Bushing, Ø7×Ø14×50 2

25 1.5789.0675 Flange Bolt, M6X75 2

26 5.1820.003 Charger, Battery, 24V 1

27 1.9074.3.0408 Screw, M4X8 2

28 5.1860.004 Electrical Resistance, GH-RX24-

50W 1

29 1.9074.4.0306 Screw, M3X6 6

30 1.823.0414 Screw, M4X14 4

31 161.210011.01 Terminal Block, 15A 1

32 5.1320.017 Plastic Conduit, CSA, 50mm 1

33 100199.21.10.V1.1 Wire Assembly 1

34 161.230003.00 Label, Panel,100199 1

35 161.230004.00 Label, Nameplate 1

Model 100199

MAINTENANCE

34 Part No. 101048

WIRING DIAGRAM

F.D2

Low Oil Level/Pressure

High Engine Temperature

Exercise

ATS

F.D1

Motor

100666

DC 24V

B+

B-

5A 5A

Valve

Alarm

Stop

Magnetize

Charge

Freq. Freq. ATS IN.1 WATROILALTFUEL Start Stop B+ B-

100417

250VAC 5A

40A

100667

DC 24V

5A5A

B+

B-

Start ATS

Gen-set Close

Gen-set C.B

Utility C.B.

Utility Close

11 Utility AC Detect

12 Utility AC Detect

14 Load AC Detect

13 Load AC Detect

16 Gen-A C Detect

15 Gen-A C Detect

24V

Battery

GND

Fuel Valve

GND

Start Motor

GND

Iginition Coil

GND

To ATS

Transfer common

Generator transfer signal

Generator position micro sw itch

Utility transfer signal

Micro switch common

Utility line L2

Utility line L1

Utility position micro sw itch

Load bus L2

Load bus L1

Neutral line

Indicator Light DC24V

L N

BATTERY CHARGER

MODEL:100482

GND

N/C

GND

Circuit Breaker

N/C

50W10Ω Power Resistance

GND

Hour Meter

STATOR

Power Winding

Excitation Winding

Sampling Winding

Carbon Brush

ROTOR

To ATS

Terminal Block #1 Terminal Block #2

AVR

Over Voltage Protector

GND

O/B

OG/B

B/W

L/B

R/B

BBr

O/B Y

OG/B B/W L/B WG

R G G

RG B

B R

G/B P BrY

B/W

Pu O

B/W

G/B

B R

L/B

Red

Black

Brown

Yellow

Blue

Green

Orange

White

Pink

Purple

O/B

G/B

R/B

B/W

Orange/Black

Green/Black

L/B

Red/Black

Black/White

Blue/Black

Terminal Block #3

Not Connect

N/C

Low Oil Level/Pressure Switch

Thermal Switch

Exercise Switch

LLWG

PART NO:100199.21.V1.1

N/C

Ground line

Generator line L2

Generator line L1

Model 100199

TROUBLESHOOTING

Before performing troubleshooting procedures, review SAFETY

section starting on page 5.

Problem Cause Solution

Generator will not

start

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.

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.

Generator starts

but runs rough

Faulty spark plug Replace spark

plug.

Plugged air cleaner Clean or replace

air cleaner.

Fuel pressure

incorrect

Contact authorized

service dealer.

No generator

output

ATS control module

switch off

Turn switch to

auto.

Main circuit

breaker is off

Turn breaker to on.

Transfer switch

turned off

Turn transfer

switch on.

Champion Power Equipment

Toll-free: 1-877-338-0999

Mon-Fri 8:30 AM – 5:00 PM (PST/PDT)

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. New engines and equipment must be designed, built and

equipped, at the time of sale, to meet U.S. EPA regulations for small non-road engines. CPE warrants the emission

control system on your small off-road engine 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 at no cost to you

including diagnosis, parts and labor.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

This emission control system is warranted for two years, subject to provisions set forth below. If, during the

warranty period, emission related part on your engine is defective in materials or workmanship, the part will be

repaired or replaced by CPE.

OWNER WARRANTY RESPONSIBILITIES:

As the small off-road engine 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, 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 owner, you should however be aware that CPE may deny you warranty coverage if

your small, off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved

modifications.

You are responsible for presenting your small off-road engine 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. 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 is:

a. Designed, built and equipped so as to conform to U.S. EPA emissions standards for spark-ignited

engines at or below 19 kilowatts.

b. 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:

a. 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.

b. 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.

c. 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 emissions-related 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.

d. 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.

e. 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.

f. 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.

g. 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.

h. 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.

i. 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.

j. 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

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.

Evaporative Emissions

Fuel Tank, Fuel Cap, Fuel Line, Fuel Line Fittings, Clamps, Pressure

Relief Valves, Control Valves, Control Solenoids, Electronic Controls,

Vacuum Control Diaphragms, Control Cables, Control Linkages, Purge

Valves, Vapor Hoses, Liquid/Vapor Separator, Carbon Canister, Canister

Mounting Brackets, Carburetor Purge Port Connector

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

12039 Smith Ave.

Santa Fe Springs, CA 90670 USA

Made in China

Champion Power Equipment 100199 Operators Manual

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