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Champion 100637 - User Manual

Champion 100637
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OPERATOR'S MANUAL
MODEL #100637
9000W PORTABLE GENERATOR
Made in China - REV 20200203 Champion Power Equipment, Inc., Santa Fe Springs, CA USA
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.
Specifications, descriptions and illustrations in this manual are as accurate as known at the time of publication, but are subject to change without notice.
This product meets the requirements of the PGMA (Portable Generator Manufacturers’ Association) standard ANSI/PGMA G300-2018 (Safety and Performance of
Portable Generators).
REGISTER YOUR PRODUCT ONLINE
at championpowerequipment.com

Table of Contents

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Summary

Introduction and Safety Definitions

Safety Definitions and Hazard Symbols

Explains hazard symbols (DANGER, WARNING, CAUTION, NOTICE) and their meanings.

Important Safety Instructions

Carbon Monoxide and Outdoor Operation Safety

Details CO dangers, requirement for outdoor use, and ventilation.

Electrical Safety, Wet Conditions, and Medical Use

Covers electrical shock hazards, grounding, wet operation warnings, and medical device restrictions.

Hot Surfaces, Recoil Cord, and Overload Hazards

Warns about hot engine parts, recoil cord dangers, and overloading the generator.

Fuel Safety and Handling Precautions

Details hazards of gasoline, safe handling, refueling, and storage of fuel.

Generator Safety Labels and Symbols Explained

Safety Labels and CO Danger Information

Explains hazard labels, CO danger warnings, and their multilingual content.

CO Shield, Fuel, and Hot Surface Label Details

Describes labels for CO Shield functionality, fuel type, and hot surface warnings.

Generator Dataplate Information and ID

Details the specifications and identification information found on the generator's dataplate.

Interpreting Safety and Operation Symbols

Interpreting General Safety Symbols

Explains symbols for reading manual, clearance, grounding, and electric shock hazards.

Symbol Meanings for Fire, Heat, and Environment

Details symbols related to fire/explosion, hot surface, open flame, and wet conditions.

Operation Symbols Guide

Engine Control and Status Symbols

Covers symbols for starting, stopping, circuit breakers, and ground terminals.

Generator Status and System Fault Symbols

Explains symbols for smart charger, CO warning, system faults, and receptacle types.

Quickstart Guide Labels

Starting and Stopping the Generator

Provides step-by-step guides for starting and stopping using quickstart labels.

Generator Controls and Features

Generator Component Identification

Identifies and describes major generator parts like fuel tank, choke, air filter, and battery.

Control Panel Overview and Receptacles

Details the control panel layout, ignition switch, Intelligauge, breakers, and AC receptacles.

Intelligauge with Power Meter Functions

Describes the Intelligauge displays for voltage, frequency, run time, and output power.

Generator Parts and Tools

Included Generator Parts and Accessories

Lists accessories and assembly parts included with the generator.

Tools Needed for Assembly and Service

Lists necessary tools for assembly and routine maintenance.

Generator Assembly Instructions

Unpacking and Initial Setup Guidance

Instructions for unpacking the generator and preparing the work area.

Wheel Kit and Support Leg Installation

Details the process of attaching the wheels and the support leg.

Battery Connection and Engine Oil Addition

Guides on connecting the battery and adding engine oil, with important cautions.

Engine Oil and Fueling Guidelines

Engine Oil Specifications and Level Check

Recommends oil types, explains checking oil level, and notes the low oil shut-off feature.

Fueling Instructions and Gasoline Guidelines

Guides on adding fuel, specifying octane, ethanol content, and capacity.

Generator Grounding and Electrical Safety

Proper Grounding for Electrical Safety

Explains the importance of grounding and how to properly connect the generator.

Neutral Configuration: Floating vs. Bonded

Differentiates between neutral floating and neutral bonded to frame configurations.

Generator Operation Procedures

CO Shield System Functionality

Explains the CO Shield technology, its indicators, and automatic shutoff feature.

Safe Generator Location and Placement

Specifies safe operating locations, clearance, and ventilation requirements.

Starting the Engine: Electric and Manual Methods

Outlines the steps for starting the generator using both electric and manual methods.

Connecting Loads and Power Management

Connecting Electrical Loads Safely

Guides on connecting loads, avoiding 3-phase, and informing utilities about generator use.

Preventing Overload: Load Calculation

Explains how to calculate running/starting watts and manage loads to prevent overload.

GFCI and Smart Charger Functionality

GFCI Receptacle Testing and Reset

Details the operation, testing, and reset procedure for GFCI receptacles.

Smart Charger Functionality and Indicators

Explains how the smart charger works, its indicator lights, and battery charging.

Engine Shutdown and Altitude Adjustments

Safe Engine Stopping Procedure

Steps to safely shut down the generator, including fuel valve and ignition switch.

Moving the Generator and Altitude Adjustments

Guides on moving the generator and discusses high altitude operation considerations.

Generator Maintenance Guidelines

General Cleaning and Generator Care

Covers keeping the generator clean, safe operation, and avoiding extreme conditions.

Engine Oil Change Procedure

Step-by-step guide on how to drain and refill the engine oil.

Engine Component Maintenance

Spark Plug Service and Adjustment

Instructions for removing, cleaning, gapping, and reinstalling the spark plug.

Air Filter and Spark Arrestor Cleaning

Details cleaning the air filter element and the spark arrestor screen.

Battery and Maintenance Schedule

Generator Battery Maintenance and Care

Discusses battery charging, maintenance, and storage recommendations.

Preventative Maintenance Schedule

Provides a table outlining maintenance tasks based on operating hours or time.

Generator Storage Procedures

Short and Mid-Term Storage Guidance

Instructions for preparing the generator for short and medium-term storage.

Long-Term Storage Procedures

Procedures for draining the fuel tank and carburetor for storage exceeding one year.

Removing Generator from Storage

Steps to prepare the generator for use after a period of storage.

Generator Technical Specifications

Generator, Engine, and Fuel Specs

Lists model, start type, voltage, amps, engine details, and fuel capacity.

Oil, Battery, and Temperature Specifications

Details oil type, battery specs, operating temperature ranges, and warnings.

ICES-002 Compliance Notice

Provides compliance information for Industry Canada regarding device interference.

Parts Identification and Diagrams

Generator Parts Diagram

A visual representation of the generator's main external components with numerical labels.

Generator Parts List Details

Lists part numbers, descriptions, and quantities for external generator components.

Engine Component Identification

Engine Parts Diagram Overview

A visual layout of the generator's engine internal parts with numerical identifiers.

Engine Parts List: Recoil to Governor

Lists parts related to the recoil starter, piston, rings, and governor system.

Engine Parts List: Carburetor to Starter

Details parts for the carburetor, air cleaner, ignition coil, and starter motor.

Generator Wiring Diagram Explained

Electrical System Wiring Schematic

Illustrates the electrical connections for the generator, including components and color coding.

Generator Troubleshooting Guide

Engine Start and Performance Issues

Addresses problems like engine not starting, running roughly, and fuel-related issues.

Engine Shutdown, CO Shield, and Output Problems

Covers engine shutdown, CO Shield faults, no AC output, and overloading.

Troubleshooting Hunting Engines and Breakers

Addresses hunting engines, repeated circuit breaker tripping, and provides support contacts.

Champion Generator Warranty Information

Warranty Qualifications, Terms, and Exclusions

Details registration, repair terms, and conditions not covered by the warranty.

Emission Control System Warranty Details

Owner Responsibilities and Manufacturer Coverage

Outlines owner's role in maintenance and the manufacturer's emission control warranty.

ECS Warranty Applicability and Part Coverage

Defines the ECS warranty scope, period, and lists covered emission-related parts.

Obtaining Emission Warranty Service

Provides instructions on how to get emission warranty service and contact information.

Summary

Introduction and Safety Definitions

Safety Definitions and Hazard Symbols

Explains hazard symbols (DANGER, WARNING, CAUTION, NOTICE) and their meanings.

Important Safety Instructions

Carbon Monoxide and Outdoor Operation Safety

Details CO dangers, requirement for outdoor use, and ventilation.

Electrical Safety, Wet Conditions, and Medical Use

Covers electrical shock hazards, grounding, wet operation warnings, and medical device restrictions.

Hot Surfaces, Recoil Cord, and Overload Hazards

Warns about hot engine parts, recoil cord dangers, and overloading the generator.

Fuel Safety and Handling Precautions

Details hazards of gasoline, safe handling, refueling, and storage of fuel.

Generator Safety Labels and Symbols Explained

Safety Labels and CO Danger Information

Explains hazard labels, CO danger warnings, and their multilingual content.

CO Shield, Fuel, and Hot Surface Label Details

Describes labels for CO Shield functionality, fuel type, and hot surface warnings.

Generator Dataplate Information and ID

Details the specifications and identification information found on the generator's dataplate.

Interpreting Safety and Operation Symbols

Interpreting General Safety Symbols

Explains symbols for reading manual, clearance, grounding, and electric shock hazards.

Symbol Meanings for Fire, Heat, and Environment

Details symbols related to fire/explosion, hot surface, open flame, and wet conditions.

Operation Symbols Guide

Engine Control and Status Symbols

Covers symbols for starting, stopping, circuit breakers, and ground terminals.

Generator Status and System Fault Symbols

Explains symbols for smart charger, CO warning, system faults, and receptacle types.

Quickstart Guide Labels

Starting and Stopping the Generator

Provides step-by-step guides for starting and stopping using quickstart labels.

Generator Controls and Features

Generator Component Identification

Identifies and describes major generator parts like fuel tank, choke, air filter, and battery.

Control Panel Overview and Receptacles

Details the control panel layout, ignition switch, Intelligauge, breakers, and AC receptacles.

Intelligauge with Power Meter Functions

Describes the Intelligauge displays for voltage, frequency, run time, and output power.

Generator Parts and Tools

Included Generator Parts and Accessories

Lists accessories and assembly parts included with the generator.

Tools Needed for Assembly and Service

Lists necessary tools for assembly and routine maintenance.

Generator Assembly Instructions

Unpacking and Initial Setup Guidance

Instructions for unpacking the generator and preparing the work area.

Wheel Kit and Support Leg Installation

Details the process of attaching the wheels and the support leg.

Battery Connection and Engine Oil Addition

Guides on connecting the battery and adding engine oil, with important cautions.

Engine Oil and Fueling Guidelines

Engine Oil Specifications and Level Check

Recommends oil types, explains checking oil level, and notes the low oil shut-off feature.

Fueling Instructions and Gasoline Guidelines

Guides on adding fuel, specifying octane, ethanol content, and capacity.

Generator Grounding and Electrical Safety

Proper Grounding for Electrical Safety

Explains the importance of grounding and how to properly connect the generator.

Neutral Configuration: Floating vs. Bonded

Differentiates between neutral floating and neutral bonded to frame configurations.

Generator Operation Procedures

CO Shield System Functionality

Explains the CO Shield technology, its indicators, and automatic shutoff feature.

Safe Generator Location and Placement

Specifies safe operating locations, clearance, and ventilation requirements.

Starting the Engine: Electric and Manual Methods

Outlines the steps for starting the generator using both electric and manual methods.

Connecting Loads and Power Management

Connecting Electrical Loads Safely

Guides on connecting loads, avoiding 3-phase, and informing utilities about generator use.

Preventing Overload: Load Calculation

Explains how to calculate running/starting watts and manage loads to prevent overload.

GFCI and Smart Charger Functionality

GFCI Receptacle Testing and Reset

Details the operation, testing, and reset procedure for GFCI receptacles.

Smart Charger Functionality and Indicators

Explains how the smart charger works, its indicator lights, and battery charging.

Engine Shutdown and Altitude Adjustments

Safe Engine Stopping Procedure

Steps to safely shut down the generator, including fuel valve and ignition switch.

Moving the Generator and Altitude Adjustments

Guides on moving the generator and discusses high altitude operation considerations.

Generator Maintenance Guidelines

General Cleaning and Generator Care

Covers keeping the generator clean, safe operation, and avoiding extreme conditions.

Engine Oil Change Procedure

Step-by-step guide on how to drain and refill the engine oil.

Engine Component Maintenance

Spark Plug Service and Adjustment

Instructions for removing, cleaning, gapping, and reinstalling the spark plug.

Air Filter and Spark Arrestor Cleaning

Details cleaning the air filter element and the spark arrestor screen.

Battery and Maintenance Schedule

Generator Battery Maintenance and Care

Discusses battery charging, maintenance, and storage recommendations.

Preventative Maintenance Schedule

Provides a table outlining maintenance tasks based on operating hours or time.

Generator Storage Procedures

Short and Mid-Term Storage Guidance

Instructions for preparing the generator for short and medium-term storage.

Long-Term Storage Procedures

Procedures for draining the fuel tank and carburetor for storage exceeding one year.

Removing Generator from Storage

Steps to prepare the generator for use after a period of storage.

Generator Technical Specifications

Generator, Engine, and Fuel Specs

Lists model, start type, voltage, amps, engine details, and fuel capacity.

Oil, Battery, and Temperature Specifications

Details oil type, battery specs, operating temperature ranges, and warnings.

ICES-002 Compliance Notice

Provides compliance information for Industry Canada regarding device interference.

Parts Identification and Diagrams

Generator Parts Diagram

A visual representation of the generator's main external components with numerical labels.

Generator Parts List Details

Lists part numbers, descriptions, and quantities for external generator components.

Engine Component Identification

Engine Parts Diagram Overview

A visual layout of the generator's engine internal parts with numerical identifiers.

Engine Parts List: Recoil to Governor

Lists parts related to the recoil starter, piston, rings, and governor system.

Engine Parts List: Carburetor to Starter

Details parts for the carburetor, air cleaner, ignition coil, and starter motor.

Generator Wiring Diagram Explained

Electrical System Wiring Schematic

Illustrates the electrical connections for the generator, including components and color coding.

Generator Troubleshooting Guide

Engine Start and Performance Issues

Addresses problems like engine not starting, running roughly, and fuel-related issues.

Engine Shutdown, CO Shield, and Output Problems

Covers engine shutdown, CO Shield faults, no AC output, and overloading.

Troubleshooting Hunting Engines and Breakers

Addresses hunting engines, repeated circuit breaker tripping, and provides support contacts.

Champion Generator Warranty Information

Warranty Qualifications, Terms, and Exclusions

Details registration, repair terms, and conditions not covered by the warranty.

Emission Control System Warranty Details

Owner Responsibilities and Manufacturer Coverage

Outlines owner's role in maintenance and the manufacturer's emission control warranty.

ECS Warranty Applicability and Part Coverage

Defines the ECS warranty scope, period, and lists covered emission-related parts.

Obtaining Emission Warranty Service

Provides instructions on how to get emission warranty service and contact information.

Champion 100637 Specifications

General IconGeneral
Engine Type4-Stroke OHV
Frequency60 Hz
Run Time at 50% Load8 hours
Outlets120V 30A RV (TT-30R), 120V 20A Household (5-20R)
Voltage120 V

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