Instruction Manual for AC Generators CPG 90-120 JD · PDF fileChecking voltmeter P4 ......

CPG 90-120 JD

Instruction Manual for AC Generators English

CHICAGO PNEUMATIC - PORTABLE AIR DIVISIONwww.cp.com

CPG 90-120 JDInstruction Manual for AC Generators

Instruction manual ..................................................................................5

Circuit diagrams ....................................................................................47

Printed matter N°1310 3012 23

04/2010

Warranty and Liability Limitation

Use only authorized parts.Any damage or malfunction caused by r-ranty or Product Liability.The manufacturer does not accept any l i-tions or conversions made without the m

Copyright 2010, Chicago Pneumatic.

Any unauthorized use or copying of the This applies in particular to trademarks,

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the use of unauthorized parts is not covered by Wa

iability for any damage arising for modifications, addanufacturer's approval in writing.

contents or any part thereof is prohibited. model denominations, part numbers and drawings.

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Technical specifications for CPG 90-120 John Deere...................................................... 36, 40

Readings on gauges................................... 36, 40Settings of switches.................................... 36, 40Specifications of the engine/alternator/unit ........................................... 36, 40Conversion list of SI units into British units ..................................................... 46Dataplate......................................................... 46

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Contents

Safety precautions for portable generators................................................................6

Leading particulars..............................................12General description .........................................12Bodywork .........................................................13Markings..........................................................13Drain plugs and filler caps..............................14Control and indicator panel Qc1002™...........14Output terminal board .....................................22Triple voltage (3V)...........................................23Spillage free skid .............................................24Engine coolant heater......................................24

Operating instructions.........................................24Installation.......................................................24Connecting the generator ................................24Before starting .................................................26Operating Qc1002™ .......................................26

Maintenance .........................................................2Maintenance schedule .....................................2Engine maintenance ........................................3(*) Measuring the alternator insulation resistance........................................3Engine oil specifications .................................3Engine oil level check......................................3Engine oil and oil filter change .......................3Engine coolant specifications..........................3Coolant check ..................................................3

Storage of the generator......................................3Storage.............................................................3Preparing for operation after storage.............3

Checks and trouble shooting ..............................3Checking voltmeter P4 .................................... 3Checking ammeters P1, P2 and P3 ................. 3Alternator troubleshooting ..............................3Engine troubleshooting ...................................3

Congratulations on the purchase of your AC generator. It is a solid, safe and reliable machine, built accordilatest technology. Follow the instructions in this booklet and we guarantee you years of troublefree operationread the following instructions carefully before starting to use your machine.While every effort has been made to ensure that the information in this manual is correct, Chicago Pneumanot assume responsibility for possible errors. Chicago Pneumatic reserves the right to make changes withonotice.

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safety requirements and ordinances. The following list isa reminder of special safety directives and precautionsmainly applicable to Chicago Pneumatic equipment.Neglecting the safety precautions may endanger peopleas well as environment and machinery:- endanger people due to electrical, mechanical or

chemical influences,- endanger the environment due to leakage of oil,

solvents or other substances,- endanger the machinery due to function failures.All responsibility for any damage or injury resultingfrom neglecting these precautions or by non-observanceof ordinary caution and due care required in handling,operating, maintenance or repair, also if not expresslymentioned in this instruction manual, is disclaimed byChicago Pneumatic.The manufacturer does not accept any liability for anydamage arising from the use of non-original parts and formodifications, additions or conversions made withoutthe manufacturer’s approval in writing.If any statement in this manual does not comply withlocal legislation, the stricter of the two shall be applied.Statements in these safety precautions should not beinterpreted as suggestions, recommendations orinducements that it should be used in violation of anyapplicable laws or regulations.

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Safety precautions for portable generatorsTo be read attentively and acted accordingly before towing, lifting, operating, performing maintenance

IntroductionThe policy of Chicago Pneumatic is to provide the usersof their equipment with safe, reliable and efficientproducts. Factors taken into account are among others:- the intended and predictable future use of the

products, and the environments in which they areexpected to operate,

- applicable rules, codes and regulations,- the expected useful product life, assuming proper

service and maintenance,- providing the manual with up-to-date information.Before handling any product, take time to read therelevant instruction manual. Besides giving detailedoperating instructions, it also gives specific informationabout safety, preventive maintenance, etc.Keep the manual always at the unit location, easyaccessible to the operating personnel.See also the safety precautions of the engine andpossible other equipment, which are separately sentalong or are mentioned on the equipment or parts of theunit.These safety precautions are general and somestatements will therefore not always apply to a particularunit.Only people that have the right skills should be allowedto operate, adjust, perform maintenance or repair onChicago Pneumatic equipment. It is the responsibility ofmanagement to appoint operators with the appropriatetraining and skill for each category of job.

Skill level 1: OperatorAn operator is trained in all aspects of operating the unwith the push-buttons, and is trained to know the safeaspects.Skill level 2: Mechanical technicianA mechanical technician is trained to operate the unit thsame as the operator. In addition, the mechanictechnician is also trained to perform maintenance anrepair, as described in the instruction manual, and allowed to change settings of the control and safesystem. A mechanical technician does not work on livelectrical components.Skill level 3: Electrical technicianAn electrical technician is trained and has the samqualifications as both the operator and the mechanictechnician. In addition, the electrical technician macarry out electrical repairs within the various enclosureof the unit. This includes work on live electriccomponents.Skill level 4: Specialist from the manufacturerThis is a skilled specialist sent by the manufacturer or iagent to perform complex repairs or modifications to thequipment.In general it is recommended that not more than twpeople operate the unit, more operators could lead unsafe operating conditions. Take necessary steps keep unauthorized persons away from the unit aneliminate all possible sources of danger at the unit.When handling, operating, overhauling and/operforming maintenance or repair on Chicago Pneumatequipment, the mechanics are expected to use saengineering practices and to observe all relevant loc

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Safety during transport and installationTo lift a unit, all loose or pivoting parts, e.g. doors andtowbar, shall first be securely fastened.Do not attach cables, chains or ropes directly to thelifting eye; apply a crane hook or lifting shackle meetinglocal safety regulations. Never allow sharp bends inlifting cables, chains or ropes.Helicopter lifting is not allowed. It is strictly forbidden to dwell or stay in the risk zoneunder a lifted load. Never lift the unit over people orresidential areas. Lifting acceleration and retardationshall be kept within safe limits.1 Before towing the unit:

- check the towbar, the brake system and thetowing eye. Also check the coupling of thetowing vehicle,

- check the towing and brake capability of thetowing vehicle,

- check that the towbar, jockey wheel or stand legis safely locked in the raised position,

- ascertain that the towing eye can swivel freely onthe hook,

- check that the wheels are secure and that thetyres are in good condition and inflated correctly,

- connect the signalisation cable, check all lightsand connect the pneumatic brake couplers,

- attach the safety break-away cable or safetychain to the towing vehicle,

- remove wheel chocks, if applied, and disengagethe parking brake.

2 To tow a unit use a towing vehicle of amplecapacity. Refer to the documentation of the towingvehicle.

3 If the unit is to be backed up by the towing vehicle,disengage the overrun brake mechanism (if it is notan automatic mechanism).

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General safety precautions1 The owner is responsible for maintaining the unit in

a safe operating condition. Unit parts andaccessories must be replaced if missing orunsuitable for safe operation.

2 The supervisor, or the responsible person, shall atall times make sure that all instructions regardingmachinery and equipment operation andmaintenance are strictly followed and that themachines with all accessories and safety devices, aswell as the consuming devices, are in good repair,free of abnormal wear or abuse, and are nottampered with.

3 Whenever there is an indication or any suspicionthat an internal part of a machine is overheated, themachine shall be stopped but no inspection coversshall be opened before sufficient cooling time haselapsed; this to avoid the risk of spontaneousignition of oil vapour when air is admitted.

4 Normal ratings (pressures, temperatures, speeds,etc.) shall be durably marked.

5 Operate the unit only for the intended purpose andwithin its rated limits (pressure, temperature,speeds, etc.).

6 The machinery and equipment shall be kept clean,i.e. as free as possible from oil, dust or otherdeposits.

7 To prevent an increase in working temperature,inspect and clean heat transfer surfaces (cooler fins,intercoolers, coolant jackets, etc.) regularly. See themaintenance schedule.

8 All regulating and safety devices shall bemaintained with due care to ensure that theyfunction properly. They may not be put out ofaction.

9 Pressure and temperature gauges shall be checkeregularly with regard to their accuracy. They shabe replaced whenever outside acceptable tolerance

10 Safety devices shall be tested as described in thmaintenance schedule of the instruction manual determine that they are in good operating conditio

11 Mind the markings and information labels on thunit.

12 In the event the safety labels are damaged odestroyed, they must be replaced to ensure operatosafety.

13 Keep the work area neat. Lack of order will increasthe risk of accidents.

14 When working on the unit, wear safety clothinDepending on the kind of activities these are: safeglasses, ear protection, safety helmet (includinvisor), safety gloves, protective clothing, safeshoes. Do not wear the hair long and loose (protelong hair with a hairnet), or wear loose clothing ojewellery.

15 Take precautions against fire. Handle fuel, oil ananti-freeze with care because they are inflammabsubstances. Do not smoke or approach with nakeflame when handling such substances. Keep a firextinguisher in the vicinity.

16a Portable generators (with earthing pin):Earth the generator as well as the load properly.

16b Portable generators IT:Note: This generator is built to supply a shealternating current IT network.Earth the load properly.

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3 When operating in a dust-laden atmosphere, placethe unit so that dust is not carried towards it by thewind. Operation in clean surroundings considerablyextends the intervals for cleaning the air intakefilters and the cores of the coolers.

4 Never remove a filler cap of the coolant system of ahot engine. Wait until the engine has sufficientlycooled down.

5 Never refill fuel while the unit is running, unlessotherwise stated in the Chicago PneumaticInstruction Book (AIB). Keep fuel away from hotparts such as air outlet pipes or the engine exhaust.Do not smoke when fuelling. When fuelling froman automatic pump, an earthing cable should beconnected to the unit to discharge static electricity.Never spill nor leave oil, fuel, coolant or cleansingagent in or around the unit.

6 All doors shall be shut during operation so as not todisturb the cooling air flow inside the bodyworkand/or render the silencing less effective. A doorshould be kept open for a short period only e.g. forinspection or adjustment.

7 Periodically carry out maintenance works accordingto the maintenance schedule.

8 Stationary housing guards are provided on allrotating or reciprocating parts not otherwiseprotected and which may be hazardous topersonnel. Machinery shall never be put intooperation, when such guards have been removed,before the guards are securely reinstalled.

9 Noise, even at reasonable levels, can cause irritationand disturbance which, over a long period of time,may cause severe injuries to the nervous system ofhuman beings.When the sound pressure level, at any point wherepersonnel normally has to attend, is:

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4 Never exceed the maximum towing speed of theunit (mind the local regulations).

5 Place the unit on level ground and apply the parkingbrake before disconnecting the unit from the towingvehicle. Unclip the safety break-away cable orsafety chain. If the unit has no parking brake orjockey wheel, immobilize the unit by placingchocks in front of and/or behind the wheels. Whenthe towbar can be positioned vertically, the lockingdevice must be applied and kept in good order.

6 To lift heavy parts, a hoist of ample capacity, testedand approved according to local safety regulations,shall be used.

7 Lifting hooks, eyes, shackles, etc., shall never bebent and shall only have stress in line with theirdesign load axis. The capacity of a lifting devicediminishes when the lifting force is applied at anangle to its load axis.

8 For maximum safety and efficiency of the liftingapparatus all lifting members shall be applied asnear to perpendicular as possible. If required, alifting beam shall be applied between hoist andload.

9 Never leave a load hanging on a hoist.10 A hoist has to be installed in such a way that the

object will be lifted perpendicular. If that is notpossible, the necessary precautions must be taken toprevent load-swinging, e.g. by using two hoists,each at approximately the same angle not exceeding30° from the vertical.

11 Locate the unit away from walls. Take aprecautions to ensure that hot air exhausted from thengine and driven machine cooling systems cannbe recirculated. If such hot air is taken in by thengine or driven machine cooling fan, this macause overheating of the unit; if taken in focombustion, the engine power will be reduced.

12 Generators shall be stalled on an even, solid flooin a clean location with sufficient ventilation. If thfloor is not level or can vary in inclination, consuChicago Pneumatic.

13 The electrical connections shall correspond to loccodes. The machines shall be earthed and protecteagainst short circuits by fuses or circuit breakers.

14 Never connect the generator outlets to ainstallation which is also connected to a publmains.

15 Before connecting a load, switch off thcorresponding circuit breaker, and check whethfrequency, voltage, current and power factocomply with the ratings of the generator.

Safety during use and operation1 When the unit has to operate in a fire-hazardou

environment, each engine exhaust has to bprovided with a spark arrestor to trap incendiarsparks.

2 The exhaust contains carbon monoxide which is lethal gas. When the unit is used in a confinespace, conduct the engine exhaust to the outsidatmosphere by a pipe of sufficient diameter; do thin such a way that no extra back pressure is createfor the engine. If necessary, install an extractoObserve any existing local regulations. Make sure that the unit has sufficient air intake fooperation. If necessary, install extra air intake duct

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22 Whenever an abnormal condition arises, e.g.excessive vibration, noise, odour, etc., switch thecircuit breakers to OFF and stop the engine. Correctthe faulty condition before restarting.

23 Check the electric cables regularly. Damaged cablesand insufficient tightening of connections maycause electric shocks. Whenever damaged wires ordangerous conditions are observed, switch thecircuit breakers to OFF and stop the engine.Replace the damaged wires or correct the dangerouscondition before restarting. Make sure that allelectric connections are securely tightened.

24 Avoid overloading the generator. The generator isprovided with circuit breakers for overloadprotection. When a breaker has tripped, reduce theconcerned load before restarting.

25 If the generator is used as stand-by for the mainssupply, it must not be operated without controlsystem which automatically disconnects thegenerator from the mains when the mains supply isrestored.

26 Never remove the cover of the output terminalsduring operation. Before connecting ordisconnecting wires, switch off the load and thecircuit breakers, stop the machine and make surethat the machine cannot be started inadvertently orthere is any residual voltage on the power circuit.

27 Running the generator at low load for long periodswill reduce the lifetime of the engine.

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- below 70 dB(A): no action needs to be taken,- above 70 dB(A): noise-protective devices should

be provided for people continuously beingpresent in the room,

- below 85 dB(A): no action needs to be taken foroccasional visitors staying a limited time only,

- above 85 dB(A): room to be classified as a noise-hazardous area and an obvious warning shall beplaced permanently at each entrance to alertpeople entering the room, for even relativelyshort times, about the need to wear earprotectors,

- above 95 dB(A): the warning(s) at theentrance(s) shall be completed with therecommendation that also occasional visitorsshall wear ear protectors,

- above 105 dB(A): special ear protectors that areadequate for this noise level and the spectralcomposition of the noise shall be provided and aspecial warning to that effect shall be placed ateach entrance.

10 Insulation or safety guards of parts the temperatureof which can be in excess of 80°C (175°F) andwhich may be accidentally touched by personnelshall not be removed before the parts have cooled toroom temperature.

11 Never operate the unit in surroundings where thereis a possibility of taking in flammable or toxicfumes.

12 If the working process produces fumes, dust orvibration hazards, etc., take the necessary steps toeliminate the risk of personnel injury.

13 When using compressed air or inert gas to cleandown equipment, do so with caution and use theappropriate protection, at least safety glasses, forthe operator as well as for any bystander. Do notapply compressed air or inert gas to your skin or

direct an air or gas stream at people. Never use it clean dirt from your clothes.

14 When washing parts in or with a cleaning solvenprovide the required ventilation and use appropriaprotection such as a breathing filter, safety glasserubber apron and gloves, etc.

15 Safety shoes should be compulsory in anworkshop and if there is a risk, however small, ofalling objects, wearing of a safety helmet should bincluded.

16 If there is a risk of inhaling hazardous gases, fumeor dust, the respiratory organs must be protected andepending on the nature of the hazard, so must theyes and skin.

17 Remember that where there is visible dust, the fineinvisible particles will almost certainly be presetoo; but the fact that no dust can be seen is not reliable indication that dangerous, invisible dust not present in the air.

18 Never operate the generator in excess of its limits aindicated in the technical specifications and avolong no-load sequences.

19 Never operate the generator in a humid atmospherExcessive moisture causes worsening of thgenerator insulation.

20 Do not open electrical cabinets, cubicles or othequipment while voltage is supplied. If such cannbe avoided, e.g. for measurements, tests oadjustments, have the action carried out by qualified electrician only, with appropriate tooland ascertain that the required bodily protectioagainst electrical hazards is applied.

21 Never touch the power terminals during operatioof the machine.

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17 When repair has been completed, the machine shallbe barred over at least one revolution forreciprocating machines, several revolutions forrotary ones to ensure that there is no mechanicalinterference within the machine or driver. Check thedirection of rotation of electric motors when startingup the machine initially and after any alteration tothe electrical connection(s) or switch gear, to checkthat the oil pump and the fan function properly.

18 Maintenance and repair work should be recorded inan operator’s logbook for all machinery. Frequencyand nature of repairs can reveal unsafe conditions.

19 When hot parts have to be handled, e.g. shrinkfitting, special heat-resistant gloves shall be usedand, if required, other body protection shall beapplied.

20 When using cartridge type breathing filterequipment, ascertain that the correct type ofcartridge is used and that its useful service life is notsurpassed.

21 Make sure that oil, solvents and other substanceslikely to pollute the environment are properlydisposed of.

22 Before clearing the generator for use aftermaintenance or overhaul, submit it to a testrun,check that the AC power performance is correct andthat the control and shutdown devices functioncorrectly.

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Safety during maintenance and repairMaintenance, overhaul and repair work shall only becarried out by adequately trained personnel; if required,under supervision of someone qualified for the job.1 Use only the correct tools for maintenance and

repair work, and only tools which are in goodcondition.

2 Parts shall only be replaced by genuine ChicagoPneumatic replacement parts.

3 All maintenance work, other than routine attention,shall only be undertaken when the unit is stopped.Steps shall be taken to prevent inadvertent starting.In addition, a warning sign bearing a legend such as“work in progress; do not start” shall be attached tothe starting equipment. On engine-driven units the battery shall bedisconnected and removed or the terminals coveredby insulating caps. On electrically driven units the main switch shall belocked in open position and the fuses shall be takenout. A warning sign bearing a legend such as “workin progress; do not supply voltage” shall be attachedto the fuse box or main switch.

4 Prior to stripping an engine or other machine orundertaking major overhaul on it, prevent allmovable parts from rolling over or moving.

5 Make sure that no tools, loose parts or rags are leftin or on the machine. Never leave rags or looseclothing near the engine air intake.

6 Never use flammable solvents for cleaning (fire-risk).

7 Take safety precautions against toxic vapours ofcleaning liquids.

8 Never use machine parts as a climbing aid.

9 Observe scrupulous cleanliness during maintenancand repair. Keep away dirt, cover the parts anexposed openings with a clean cloth, paper or tape

10 Never weld on or perform any operation involvinheat near the fuel or oil systems. Fuel and oil tankmust be completely purged, e.g. by steam-cleaninbefore carrying out such operations. Never weld oor in any way modify, pressure vessels. Disconnethe alternator cables during arc welding on the uni

11 Support the towbar and the axle(s) securely working underneath the unit or when removing wheel. Do not rely on jacks.

12 Do not remove any of, or tamper with, the sounddamping material. Keep the material free of dirt anliquids such as fuel, oil and cleansing agents. If ansound-damping material is damaged, replace it prevent the sound pressure level from increasing.

13 Use only lubricating oils and greases recommendeor approved by Chicago Pneumatic or the machinmanufacturer. Ascertain that the selected lubricancomply with all applicable safety regulationespecially with regard to explosion or fire-risk anthe possibility of decomposition or generation ohazardous gases. Never mix synthetic with mineroil.

14 Protect the engine, alternator, air intake filteelectrical and regulating components, etc., prevent moisture ingress, e.g. when steam-cleaning

15 When performing any operation involving heaflames or sparks on a machine, the surroundincomponents shall first be screened with nonflammable material.

16 Never use a light source with open flame foinspecting the interior of a machine.

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Tool applications safetyApply the proper tool for each job. With the knowledgeof correct tool use and knowing the limitations of tools,along with some common sense, many accidents can beprevented.Special service tools are available for specific jobs andshould be used when recommended. The use of thesetools will save time and prevent damage to parts.

Battery safety precautionsBatteriesWhen servicing batteries, always wear protectingclothing and glasses.1 The electrolyte in batteries is a sulphuric acid

solution which is fatal if it hits your eyes, and whichcan cause burns if it contacts your skin. Therefore,be careful when handling batteries, e.g. whenchecking the charge condition.

2 Install a sign prohibiting fire, open flame andsmoking at the post where batteries are beingcharged.

3 When batteries are being charged, an explosive gasmixture forms in the cells and might escape throughthe vent holes in the plugs.Thus an explosive atmosphere may form around thebattery if ventilation is poor, and can remain in andaround the battery for several hours after it has beencharged. Therefore:- never smoke near batteries being, or having

recently been, charged,- never break live circuits at battery terminals,

because a spark usually occurs.

4 When connecting an auxiliary battery (AB) parallel to the unit battery (CB) with booster cableconnect the + pole of AB to the + pole of CB, theconnect the - pole of CB to the mass of the uniDisconnect in the reverse order.

vailable or as stand-by in cases of interruption of the mains.and 60 Hz, 240 V - 1 phase. The CPG 90-120 John Deerearts is given in the diagram below.

Lifting beamGuiding rodSide doorsEngine exhaustData plateSide door, access to control and indicator panelOutput terminal boardHole for forkliftAlternator

F Air filterCoupling

H Drain and access hole (in the frame)CW Drain Cooling Water

EngineFan

F Filler cap fuelO Filler cap engine oilW Filler cap cooling water

Fuel filterFrame

1 BatteryD Oil DrainF Oil filterLD Engine oil level dipstick

Selector Switch

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Leading particularsGeneral descriptionThe CPG 90-120 John Deere is an AC generator, built for continuous running at sites where no electricity is aThe generator can run in 3 different modes: 60 Hz, 480 V - 3 phase, 60 Hz, 208 V - 3 phase lower voltage generator is driven by a water-cooled diesel engine, manufactured by John Deere. An overview of the main p

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Indicates that the alternator should not be cleaned with high pressurised water.

Indicates the battery switch.

Indicates that the unit may start automatically and that the instruction book has to be consulted prior to use.

Indicates the partnumbers of the different service paks and of the engine oil. These parts can be ordered to the factory.

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BodyworkThe alternator, the engine, the cooling system, etc. areenclosed in a sound-insulated bodywork that can beopened by means of side doors (and service plates).The generator’s lifting eye is located in the middle ofthe roof. The recesses in the roof have guiding rods atboth sides.

To be able to lift the generator by means of a forklift,rectangular holes are provided in the frame.The earthing rod, connected to the generator’s earthterminal is located at the side of the frame.

MarkingsA brief description of all markings provided on thegenerator is given hereafter.

Never use the guiding rods to lift thegenerator.

Indicates that an electric voltage, dangerous to life, is present. Never touch the electric terminals during operation.

Indicates that the engine exhaust is a hot and harmful gas, which is toxic in case of inhalation. Always make sure that the unit is operated outside or in a well-ventilated room.

Indicates that these parts can become very hot during operation (e.g. engine,cooler, etc.). Always make sure that these parts are cooled down before touching them.

Indicates that the guiding rods may notbe used to lift the generator. Always use the lifting rod in the roof of the generator to lift it.

Indicates a lifting point of the generator.

Indicates that the generator may be refuelled with diesel fuel only.

Indicates the drain for the engine oil.

Indicates the drain for the coolant.

Indicates the drain plug for the enginefuel.

Indicates the different earthing connections on the generator.

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A1 .......Qc1002™ display

F10 ......Fuse

The fuse activates when the current from thebattery to the engine control circuit exceedsits setting. The fuse can be reset by pushingthe button.

H0 .......Panel light

S2........Emergency stop button

Push the button to stop the generator in caseof an emergency. When the button ispressed, it must be unlocked, before thegenerator can be restarted. The emergencystop button can be secured in the lockedposition with the key, to avoid unauthorizeduse.

S20......ON/OFF switch

Position O: No voltage is applied to theQc1002™ module, the generator will notstart.Position I: Voltage is applied to theQc1002™ module, it is possible to start upthe generator.

X25 .....Terminal strip

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Drain plugs and filler capsThe drain holes for the engine oil, the coolant and theplug for the fuel, are located and labelled on the frameat the service side.The drain flexible for engine oil can be brought to theoutside of the generator through the drain hole.

Control and indicator panel Qc1002™

General description Qc1002™ contropanel

The drain hole can also be used toguide external fuel tank connections.

Following LEDs are used on the Qc1002™

Power Green LED indicates that the unit is powered up.

Remote Green LED indicates that the Remote Mode is selected.

Start/Stop Green LED indicates that the engine is running.

Alarm Flashing red LED indicates that an alarm is present. A continuous red LED indicates that the alarm has been acknowledged by the user. The exact alarm is shown on the display.

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Qc1002™ Module

The Qc1002™ module is located inside the controlpanel. This control module will carry out allnecessary tasks to control and protect a generator,regardless of the use of the generator.This means that the Qc1002™ module can be used forseveral applications.

Pushbutton and LED functions

Following pushbuttons are used on the Qc1002™

ENTER: Is used to select and confirm changed settings in the Parameter list.

UP: Is used to scroll through the display information and to adjust parameter value upwards.

DOWN: Is used to scroll through the display information and to adjust parameter value downwards.

BACK: Is used to leave the Alarm pop-up window, to leave the Parameter list and to leave menu's without change.

REMOTE MODE: Is used to activate the remote mode. The LED indicates if the gen-set is put in Remote Mode.

START: Is used to start the unit in Manual Mode.

STOP: Is used to stop the unit in Manual or Remote Mode (without cooldown). When the unit is stopped with the STOP button in Remote mode, it will automatically go to Manual Mode.

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LOG list display

This view shows the alarm memory and gives accessto it.An overview is given in “LOG list” on page 21.

Service timer 1 & Service timer 2 display

This view shows both Service timers. The servicetimer indication is shown when service time has runout. It can be removed by resetting the timers oracknowledging the Service timer indication.The service timer indications count upwards and givean alarm when the set value is reached.Resetting the Service Timers can be done through theParameter display.

LOG List

Service 1Service 2

59h59h

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Qc1002™ Menu Overview

At Qc1002™, the LCD will show followinginformation:

– in Normal condition (scroll through theinformation using UP and DOWN):• Status (eg: preheat, crank, cooldown, extended

stop time, …) (pop-up: this display is onlyshown when a Special status comes up)

• Controller type & version• Parameter list• Alarm list• LOG list• Service Timer 1 & Service Timer 2• Battery Voltage• Coolant temperature• Oil pressure• RPM (speed)• Fuel level• Voltage - frequency - running hours

– in Alarm condition (scroll through theinformation using UP and DOWN):• a list of all active Alarms

It's possible to scroll through the views, using the UPand DOWN buttons. The scrolling is continuous. If a Special status comes up, the Status Display isshown. If an Alarm comes up, the Alarm Display is shown.

Controller type and version display

This view shows the controller type and the ASWversion number.

Parameter display

This view shows a number of Parameter settings angives access to them.An overview is given in “Parameter list” on page 18

Alarm list display

This view shows the number of active alarms angives access to them.An overview is given in “Alarm Display (pop-uwindow)” on page 20.

Qc1002 CANv1.00.0

Parameter

Alarm List0 Alarm(s)

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Qc1002™ Menu Description

Status Display (pop-up window)

In case special statuses are entered, a pop-up windowwill automatically be entered for as long as the statusis active.The background screen is not updated when the statuspop-up window is active.

These special statuses are:

PREHEAT

START OFF/EXTENDED STOP TIMER

COOLDOWN

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Battery Voltage display

This view shows the Battery voltage and the runninghours.

Coolant temperature display

This view shows the Coolant temperature and therunning hours.See also “Parameter list” on page 18 for selectionbetween °C and °F.

Oil pressure display

This view shows the Oil pressure and the runninghours.See also “Parameter list” on page 18 for selectionbetween bar and psi.

Fuel level display

This view shows the Fuel level and the running hour

Voltage - frequency - running hours display

This view shows the voltage, frequency and runninhours.

Engine speed display

This view shows the engine speed and running hour

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144˚FWater00168.1h

58psiOil00168.1h

75%Fuel00168.1h

60Hz480V00168.1h

1800RPM00168.1h

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– Generator Undervoltage: failclass, enable, delay,setpoint

– Generator Overvoltage: failclass, enable, delay,setpoint

– Engine CAN communication

This menu is used to select the type of engineelectronics, the Qc1002™ controller shouldcommunicate with via the Canbus.

It's possible to scroll between configuration menu'sby using the pushbuttons UP and DOWN.Pushing the ENTER button activates theconfiguration menu which is shown at the display.

- 18 -

If a special status has elapsed, the active view will beentered again automatically.If an Alarm comes up, the Alarm Display is shown.

Parameter list

The Parameter Menu's are pre-programmed!A password will be asked for when an attempt tochange a setting is about to be done (user password =2003).By entering the parameter list, pushbutton REMOTEis disposed of its normal operations and will notperform any functionality.Menu's shown on the Parameter list LCD:

– Running hours adjust

This menu is used to adjust the amount of runninghours. The running hours can only be raised, notlowered.

– Unit Type

– Service Timer 2 reset

– Service Timer 1 reset

These menus are used to reset the service timerWhen a service timer alarm occurs and acknowledged, the service timer will be resautomatically.

– Diagnostics Menu

This menu is used to power up the enginelectronics without starting the engine. When thsetting is switched ‘on’, electric power will bsupplied to the engine electronics after half minute delay. The unit can not be started as lonas this parameter is switched ‘on’.

– Unit Menu

This menu is used to select whether tempreaturand pressure should appear in °C/bar or °F/psi.

– Language selection

Icons is the default factory set language, but other languages can be selected: English, FrencGerman, Italian, Spanish and Cyrillic (RussianAll information in the Parameter List display always in English.

– Generator Underfrequency: failclass, enabldelay, setpoint

– Generator Overfrequency: failclass, enable, delasetpoint

DIAGNOSTIC

Unit type 6 for CPG 90-120 JohnDeere!

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Highlight

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Highlight

ARORWalsh

Highlight

- 19 -

This is the described menu flow for changing the unit type:

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LOW FUEL LEVEL

LOW COOLANT LEVEL

GENERATOR OVERVOLTAGE

GENERATOR UNDER-VOLTAGE

GENERATOR OVER-FREQUENCY

GENERATOR UNDER-FREQUENCY

- 20 -

Alarm Display (pop-up window)

In case an Alarm occurs, a pop-up window willautomatically be displayed for as long as the alarm isactive, no matter which view is active. The flashingred alarm LED will light up. The alarm icons will beshown together with an acknowledgement check-box.Push the ENTER button to acknowledge the alarm.When the alarm has been acknowledged, a V-marking will appear in the check-box and the redalarm LED will light up continuously.

The Alarm Display can always be left by pushing theBACK button.If more than one alarm comes up, it's possible to scrollthrough the alarm messages with the UP and DOWNpushbuttons. The newest alarm will be placed at thebottom of the list (meaning that the older alarm staysat the display when a newer alarm comes up).If one or more than one alarm is present, an arrow atthe right of the display will be shown.

Following general groups of Alarms exist

– Warning: Alarm LED lights up + Alarm pop-uappears on the display + Alarm relay empowered (if configured)

– Trip of GB: ‘Warning’ actions + GeneratoContactor opens

– Trip and Stop: ‘Trip of GB’ actions + unit stopafter Cooldown

– Shutdown: ‘Trip of GB’ actions + unit stopimmediately

List of possible alarms:

An alarm should always beacknowledged before solving theproblem that causes the alarm.

LOW OIL PRESSURE

HIGH COOLANT TEMPERATURE

CHARGING ALTERNATOR

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Remote start operation

Installation wirings:

– X25.1 & X25.2 to be wired for the remote startswitch.

– X25.3 & X25.4 to be wired for the remotecontactor (open/close).

Fail classes

All the activated alarms of the Qc1002™ have theirown pre-defined fail class.All alarms are enabled according to one of these threestatuses:

– disabled alarm, no supervision of alarm (OFF)

– enabled alarm, supervision of alarm all the time(ON)

– running alarm, only supervision when themachine is running (RUN)

- 21 -

LOG list

The unit will keep an event log of the latest 30 eventEvents are:

– shutdowns

– service timer 1/2 reset

– unit type changesTogether with each event, the running hours at thtime of the event will be stored.

SERVICE TIMER 1

SERVICE TIMER 2

ENGINE ALARM

EMERGENCY STOP

START FAILURE

STOP FAILURE

1 Controller type

2 Event number

3 Event

4 Running hours

Time: 00001h

EVENT LOG #04 WaterQc1002

1

3

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Q3 .......Circuit breaker for X3

Interrupts the power supply to X3 when ashort-circuit occurs at the load side, or whenthe overcurrent protection (50 A) isactivated. When activated, Q3 interrupts 2phases towards X3. It can be activated againafter eliminating the problem.





Circuit breakers Q1.1 do not onlyinterrupt the power supply towardssocket X1 but also towards X2, X3,X4 and X5.Make sure to switch on circuitbreakers Q1.1, Q2, Q3, Q4 and Q5after starting the generator whenpower supply is done by means ofX2, X3, X4 or X5.

- 22 -

Output terminal boardThe output terminal board is situated below thecontrol and indicator panel.

S2 ....... Emergency stop button

X1 ....... Terminal board

Provides a more easy connection of cables.

X2 ....... Single phase outlet socket (240V) Socket rated to 50A.

Provides L1,L2, neutral and earthing.

X3 ....... Single phase outlet socket (240V) Socket rated to 50A.

Provides L1,L2, neutral and earthing.

X4 .......Single phase GFCI outlet socket (120V). Socket rated to 20A.

X5 .......Single phase GFCI outlet socket (120V). Socket rated to 20A.

Q1.1 ....Circuit breaker for low voltage, high current

Interrupts the low voltage power suppltowards X1 when a short-circuit occurs the load side or when the overcurrenprotection (364 A) is activated. It must breset manually after eliminating thproblem.

Q1.2 ....Circuit breaker for high voltage, low current

Interrupts the high voltage power suppltowards X1 when a short-circuit occurs the load side or when the overcurrenprotection (172 A) is activated. It must breset manually after eliminating thproblem.


Interrupts the power supply to X2 when short-circuit occurs at the load side, or whethe overcurrent protection (50 A) activated. When activated, Q2 interrupts onphase towards X2. It can be activated agaiafter eliminating the problem.

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Depending on which mode the generator is runningin, circuit breaker Q1.1 or Q1.2 will be operational.Circuit breakers Q1.1 and Q1.2 cannot be switched onat the same time. This is prevented by means of theauxiliary voltage selection relays S10b and S10c(refer to the circuit diagram).The selection between the three voltage modes isperformed by means of S10.

S10......Output voltage selection switch

Allows to select a 1 phase output voltage, a3 phase high output voltage or a 3 phase lowoutput voltage. Selector switch S10 islocated on the alternator.

Changing the output voltage is onlyallowed after shutdown.After changing the output voltage bymeans of the selection switch S10,adjust the output voltage by means ofpotentiometer R12 to the requiredvalue.

- 23 -

Triple voltage (3V)The generator can run in three different modes:

– 1 phase

When using this selection, the generator providesa 240/277 V output voltage.

– 3 phase, lower voltage


– 3 phase, higher voltage


Q1.1 ....Circuit breaker for low voltage, high current

Interrupts the low voltage power suppltowards X1 when a short-circuit occurs the load side or when the overcurrenprotection is activated. It must be resmanually after eliminating the problem.

Q1.2 ....Circuit breaker for high voltage, low current

Interrupts the high voltage power suppltowards X1 when a short-circuit occurs the load side or when the overcurrenprotection is activated. It must be resmanually after eliminating the problem.

R12 .....Output voltage adjust potentiometer

Allows to adjust the output voltage.

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cooling air is not recirculated. If necessary,consult Chicago Pneumatic.

– Leave enough space for operation, inspection andmaintenance (at least 1 meter at each side).

– Check that the inner earthing system is incompliance with the local legislation.

– Use coolant for the engine cooling system. Referto the Engine instruction book for the propercoolant mixture.

– Check the tightness of the bolts and nuts.

– Install the earthing rod as near as possible to thegenerator and measure its diffusion resistance(max. 1 kΩ) in order not to have a contact voltagehigher than 25 V at 30 mA leakage current.

– Check that the cable end of the earthing rod isconnected to the earth terminal.

Connecting the generator

Precautions for non-linear and sensitive loads

The most common non-linear, 3-phase loads arethyristor/rectifier-controlled loads, such as convertorssupplying voltage to variable speed motors,uninterruptable power supplies and Telecomsupplies. Gas-discharge lighting arranged in single-phase circuits generate high 3rd harmonics and riskfor excessive neutral current.

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Non-linear loads draw currents withhigh contents in harmonics, causingdistortion in the wave form of thevoltage generated by the alternator.

- 24 -

Spillage free skidA spillage free skid with forklift slots allows thecustomer to transport the generator easily with aforklift.It avoids accidental spilling of engine fluids.

Engine coolant heaterTo make sure that the engine can start and accept loadimmediately, an external cooling water heater(2000 W, 240 V) is provided which keeps the enginetemperature between 38°C (100°F) and 49°C(120°F).

Operating instructions

Installation

– Place the generator on a horizontal, even and solifloor. The generator can operate in a slant positionot exceeding 15° (in both senses: front/rear anleft/right).

– The generator should be kept with the dooclosed, in order to avoid the ingress of water andust. Dust ingress reduces the lifetime of filteand may reduce your generator's performance.

– Check that the engine exhaust is not directetowards people. If the generator is operateindoors, install an exhaust pipe of sufficiendiameter to duct the engine exhaust towards thoutside. Check for sufficient ventilation so that th

In your own interest, always strictlyobserve all relevant safetyinstructions.Do not operate the generator in excesof the limitations mentioned in theTechnical Specifications.Local rules concerning the setting upof low voltage power installation(below 1000 V) must be respectedwhen connecting site distributionpanels, switch gear or loads to thegenerator.

For information about indooinstallation, consult your locaChicago Pneumatic dealer.

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Protection

– Check whether frequency, voltage and currentcomply with the ratings of the generator.

– Provide for the load cable, without excessivelength, and lay it out in a safe way withoutforming coils.

– Open the door of the control and indicator paneland the transparent door in front of the terminalboard X1.

– Provide the wire ends with cable lugs suited forthe cable terminals.

– Loosen the cable clamp and push the wire ends ofthe load cable through the orifice and clamp.

– Connect the wires to the proper terminals (L1, L2,L3, N and PE) of X1 and tighten the boltssecurely.

– Tighten the cable clamp.

– Close the transparent door in front of X1.

For safety reasons, it is necessary toprovide an isolating switch or circuitbreaker in each load circuit. Locallegislation may impose the use ofisolating devices which can be locked.

- 25 -

Loads most sensitive to voltage distortion includeincandescent lamps, discharge lamps, computers, X-ray equipment, audio amplifiers and elevators.Consult Chicago Pneumatic for measures against theadverse influence of non-linear loads.

Quality, minimum section and maximum length of cables

The cable connected to the terminal board of thegenerator must be selected in accordance with locallegislation. The type of cable, its rated voltage andcurrent carrying capacity are determined byinstallation conditions, stress and ambienttemperature. For flexible wiring, rubber-sheathed,flexible core conductors of the type H07 RN-F(Cenelec HD.22) or better must be used.The following table indicates the maximum allowable3-phase currents (in A), in an ambient temperature of40°C (104°F), for cable types (multiple and singlecore PVC insulated conductors and H07 RN-Fmultiple core conductors) and wire sections as listed,in accordance with VDE 0298 installation methodC3. Local regulations remain applicable if they arestricter than those proposed below.

The lowest acceptable wire section and thcorresponding maximum cable or conductor lengtfor multiple core cable or H07 RN-F, at rated currenfor a voltage drop e lower than 5% and at a powefactor of 0.80, are respectively 10 mm² (0.39 in²) an146 m (179 ft). In case electric motors must be starteoversizing the cable is advisable.The voltage drop across a cable can be determined afollows:

e = Voltage drop (V)I = Rated current (A)L = Length of conductors (m)R = Resistance (Ω/km to VDE 0102)X = Reactance (Ω/km to VDE 0102)

Connecting the load

Site distribution panel

If outlet sockets are required, they must be mounteon a site distribution panel supplied from the terminboard of the generator and in compliance with locregulations for power installations on building sites

Wire section Max. current (A) (mm²) Multiple core Single core H07 RN-F

25 94 101 8835 114 123 11050 138 155 13870 176 191 17095 212 228 205

120 245 273 239150 282 314 275185 323 358 313

240 379 421 371300 429 477 428

Wire section Max. current (A) (mm²) Multiple core Single core H07 RN-F

e 3 I L R ϕcos⋅ X ϕsin⋅+( )⋅ ⋅ ⋅1000

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– Switch on circuit breaker Q1.1/Q1.2 .

– Put the remote start/stop switch in position start.

– The unit starts a preheating cycle which takes 12seconds.

– After the preheating period, the unit will start. Thestarting attempt will take maximum 12 seconds.

During operation Qc1002™

Following points should be carried out regularly:

– Check the engine gauges and the lamps for normalreadings.

– Check for leakage of oil, fuel or coolant.

– Avoid long low-load periods (< 30%). In this case,an output drop and higher oil consumption of theengine could occur.

– Check, by means of the generator gauges, that thevoltage between the phases is identical and thatthe rated current in the third phase (L3) is notexceeded.

– When single-phase loads are connected to thegenerator output terminals, keep all loads well-balanced.

Avoid to let the engine run out of fuel.If it happened, priming will speed upthe starting.

- 26 -

Before starting– With the generator standing level, check the

engine oil level and top up if necessary. The oillevel must be near to, but not exceed the high markon the engine oil level dipstick.

– Check the coolant level in the expansion tank ofthe engine cooling system. The coolant level mustbe near to the FULL mark. Add coolant ifnecessary.

– Drain any coolant and sediment from the fuel pre-filter. Check the fuel level and top up if necessary.It is recommended to fill the tank after the day’soperation to prevent coolantdamp in a nearlyempty tank from condensing.

– Check the vacuum indicator of the air filter. If thered part shows completely, replace the filterelement.

– Press the vacuator valve of the air filter to removedust.

– Check the generator for leakage, tightness of wireterminals, etc. Correct if necessary.

– Check that fuse F10 has not tripped and that theemergency stop is in the OUT position.

– Check that the load is switched off.

– Check that circuit breaker Q1.1/Q1.2 are switchedoff.

Operating Qc1002™

Starting Qc1002™

To start up the unit locally, proceed as follows:

– Switch on the battery switch.

– Switch off circuit breaker Q1.1/Q1.2 . This is nonecessary when a plant contactor is installebetween Q1.1/Q1.2 and the load.

– Put switch S20 in position I (ON). Voltage applied to the Qc1002™ module.

– The unit can be started manually by pressing thSTART button on the Qc1002™ module.

– The unit starts a preheating cycle which takes 1seconds.

– After the preheating period, the unit will start. Thstarting attempt will take maximum 12 seconds.

– Switch on circuit breaker Q1.1/Q1.2 in case ncontactor is installed.

To start up the unit from a remote location, proceed as follows:

– Put the starter switch S20 in position I (ONVoltage is applied to the Qc1002™ module.

– The unit can be started from a remote location bpressing the remote mode button on thQc1002™ module.

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- 27 -

If circuit breakers are activated during operation,switch off the load and stop the generator. Check and,if necessary, decrease the load.

Stopping Qc1002™

To stop the unit locally, proceed as follows:

– Switch off the load.

– Switch off circuit breaker Q1.1/Q1.2 .

– Let the engine run for about 5 minutes.

– Stop the engine by using the STOP button on theQc1002™ module.

– Put switch S20 in position O (OFF) to shut downthe voltage apply towards the Qc1002™ module.

– Lock the side doors and the door of the indicatorsand control panel to avoid unauthorized access.

To stop the unit when the Qc1002™ module is in position , proceed asfollows:

– Switch off the load.

– Stop the engine by putting the remote start/stoswitch in position stop or by using the STObutton on the Qc1002™ module. When the unit stopped with the STOP button in Remote mode, will automatically go to Manual Mode.

– Put the starter switch S20 in position O (OFF) tshut down the voltage apply towards thQc1002™ module.

– Lock the side doors and the door of the indicatoand control panel to avoid unauthorized access.

The generator’s doors may onlyremain opened for short periodsduring operation, to carry out checksfor example.

- 28 -

MaintenanceMaintenance schedule

Before carrying out any maintenance activity, check that the start switch is in position O and that no electrical power is present on the terminals.

yliaDeludehcs ecnanetniaMEvery 250 hr or

6 months

Every 1000 hr or yearly

Service pak - 1310 3004 45 1310 3004 46

For the most important subassemblies, Chicago Pneumatic has developed service kits that combine all wear parts. These service kits offer you the benefits of genuine parts, save on administration costs and are offered at reduced price, compared to the loose components. Refer to the parts list for more information on the contents of the service kits.

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Replace engine oil (1) x

Replace engine oil filter (1) x

Check/clean radiator/cooler fins x x

Check tension and condition of the drive belt (4) x

Grease door hinges and locks x

Replace fuel filter element x

Replace fuel prefilter element x

Check electrolyte level and terminals of battery x

- 29 -

Check engine mounts

Check crankcase ventilation system

Check condition of cooling fan assembly

Pressure test cooling system

Check engine electrical ground connection

Replace air filter element

Replace safety cartridge

Measure alternator insulation resistance (*)

Check glycol level in coolant

Check PH level of engine coolant

Check and adjust engine inlet and outlet valves

Check alternator and starter motor

Check electrical system for security of cables and wear x

Test thermostats x

Test glow plugs x

Verify that safety circuits work x

Inspection by Chicago Pneumatic Service technician

Generators in standby application have to be tested on aregular basis. At least once a month the engine should run forminimum 30 minutes at a high load ( 50% - 70% ) that theengine reaches its operating temperature.

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Engine oil specifications

High-quality, mineral, hydraulic or synthesizedhydrocarbon oil with rust and oxidation inhibitors,anti-foam and anti-wear properties is recommended.The viscosity grade should correspond to the ambienttemperature and ISO 3448, as follows.

Specifications GENOIL

GENOIL from Chicago Pneumatic is the ONLY oiltested and approved for use in all engines built intoChicago Pneumatic compressors and generators.Extensive laboratory and field endurance tests onChicago Pneumatic equipment have proven GENOILto match all lubrication demands in varied conditions.It meets stringent quality control specifications toensure your equipment will run smoothly andreliably.The quality lubricant additives in GENOIL allow forextended oil change intervals without any loss inperformance or longevity.

It is strongly recommended to useChicago Pneumatic brandedlubrication oils.

Engine Type of lubricant

between -25°C (-13°F) and 40°C (104°F) GENOIL 15W40

- 30 -

Notes:

In highly dusty environments, these service intervalsdo not apply. Check and/or replace filters and cleanradiator on a regular basis.

(1) During engine break-in, change the oil and oilfilter for the first time after max. 100 hours ofoperation. Use GENOIL 15W40 only.

(2) Rocker cover gaskets can be re-used after valveclearence.

(3) Replace crankshaft damper every 4500 Hrs or 60months, whichever occurs first.

Engine maintenanceRefer to the engine’s operator manual for fullmaintenance schedule.

(*) Measuring the alternator insulationresistanceA 500 V megger is required to measure the alternatoinsulation resistance.If the N-terminal is connected to the earthing systemit must be disconnected from the earth terminaDisconnect the AVR.Connect the megger between the earth terminal anterminal L1 and generate a voltage of 500 V. Thscale must indicate a resistance of at least 5 MΩ.Refer to the alternator operating and maintenancinstructions for more details.

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Engine coolant specifications

The use of the correct coolant is important for goodheat transfer and protection of liquid-cooled engines.Coolants used in these engines must be mixtures ofgood quality water (distilled or de-ionised), specialcoolant additives and if necessary freeze protection.Coolant that is not to manufacturer's specification willresult in mechanical damage of the engine.The freezing point of the coolant must be lower thanthe freezing point that can occur in the area. Thedifference must be at least 5°C (41°F). If the coolantfreezes, it may crack the cylinder block, radiator orcoolant pump.Consult the engine's operation manual and follow themanufacturer's directions.

Never remove the cooling system fillercap while coolant is hot.The system may be under pressure.Remove the cap slowly and only whencoolant is at ambient temperature. Asudden release of pressure from aheated cooling system can result inpersonal injury from the splash of hotcoolant.It is strongly recommended to useChicago Pneumatic branded coolant.

Never mix different coolants andmix the coolant components outsidethe cooling system.

- 31 -

GENOIL provides wear protection under extremeconditions. Powerful oxidation resistance, highchemical stability and rust- inhibiting additives helpreduce corrosion, even within engines left idle forextended periods.GENOIL contains high quality anti-oxidants tocontrol deposits, sludge and contaminants that tend tobuild up under very high temperatures.GENOIL's detergent additives keep sludge formingparticles in a fine suspension instead of allowing themto clog your filter and accumulate in the valve/rockercover area.GENOIL releases excess heat efficiently, whilstmaintaining excellent bore-polish protection to limitoil consumption.GENOIL has an excellent Total Base Number (TBN)retention and more alkalinity to control acidformation.GENOIL prevents Soot build-up.GENOIL is optimized for the latest low emissionEURO -3 & -2, EPA TIER II & III engines running onlow sulphur diesel for lower oil and fuel consumption.

GENOIL 15W40

GENOIL 15W40 is a Synthetic ultra highperformance diesel engine oil with a high viscosity-index. Chicago Pneumatic GENOIL 15W40 isdesigned to provide excellent lubrication from start-up in temperatures as low as -25°C (-13°F).

Engine oil level checkConsult the Engine Operation Manual for the ospecifications, viscosity recommendations and ochange intervals.For intervals, see section “Maintenance schedule” opage 28.Check engine oil level according to the instructions ithe Engine Operation Manual and if necessary top uwith oil.

Engine oil and oil filter changeSee section “Maintenance schedule” on page 28.

Liter US gal

Imp gal cu.ft Order

number

can 5 1.3 1.1 0.175 1626 2262 00

can 20 5.3 4.4 0.7 1626 2263 00

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Coolant check

Monitoring coolant condition

In order to guarantee the lifetime and quality of theproduct, thus to optimise engine protection, regularcoolant-condition-analysis is advisable.The quality of the product can be determined by threeparameters.

Visual check

– Verify the outlook of the coolant regarding colourand make sure that no loose particles are floatingaround.

pH measurement

– Check the pH value of the coolant using a pH-measuring device.

– Typical value for EG = 8.6.

– If the pH-level is below 7 or above 9.5, the coolantshould be replaced.

Glycol concentration measurement

– To optimise the unique engine protection featuresof the GENCOOL EG the concentration of theGlycol in the water should be always above 33vol.%.

– Mixtures with more than 68 vol.% mix ratio inwater are not recommended, as this will lead tohigh engine operating temperatures.

– A refractometer can be ordered from ChicagoPneumatic with part number 2913 0028 00.

- 32 -

Specifications GENCOOL EG

GENCOOL EG is the only coolant that has beentested and approved by all engine manufacturerscurrently in use in Chicago Pneumatic compressorsand generators.Chicago Pneumatic's GENCOOL EG extended lifecoolant is the new range of organic coolants purposedesigned to meet the needs of modern engines.GENCOOL EG can help prevent leaks caused bycorrosion. GENCOOL EG is also fully compatiblewith all sealants and gasket types developed to joindifferent materials used within an engine.GENCOOL EG is a ready to use Ethylene Glycolbased coolant, premixed in an optimum 50/50dilution ratio, for antifreeze protection guaranteed to-40°C (-40°F).Because GENCOOL EG inhibits corrosion, depositformation is minimized. This effectively eliminatesthe problem of restricted flow through the enginecoolant ducts and the radiator, minimizing the risk forengine overheating and possible failure.It reduces water pump seal wear and has excellentstability when subjected to sustained high operatingtemperatures.GENCOOL EG is free of nitride and amines toprotect your health and the environment. Longerservice life reduces the amount of coolant producedand needing disposal to minimise environmentalimpact.

To ensure protection against corrosion, cavitation anformation of deposits, the concentration of thadditives in the coolant must be kept between certailimits, as stated by the manufacturer's guidelineTopping up the coolant with water only, changes thconcentration and is therefore not allowed.Liquid-cooled engines are factory-filled with thtype of coolant mixture.

Liter US gal

Imp gal cu.ft Order

number

can 5 1.3 1.1 0.175 1626 2255 00

can 5 1.3 1.1 0.175 1626 2257 00

can 20 5.3 4.4 0.7 1626 2256 00

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Storage of the generatorStorage– Store the generator in a dry, frost-free room which

is well ventilated.

– Run the engine regularly, e.g. once a week, until itis warmed up. If this is impossible, extraprecautions must be taken:• Consult the engine’s operator manual.• Remove the battery. Store it in a dry, frost-free

room. Keep the battery clean and its terminalslightly covered with petroleum jelly. Rechargethe battery regularly.

• Clean the generator and protect all electricalcomponents against moisture.

• Place silica gel bags, VCI paper (VolatileCorrosion Inhibitor) or another drying agentinside the generator and close the doors.

• Stick sheets of VCI paper with adhesive tapeon the bodywork to close off all openings.

• Wrap the generator, except the bottom, with aplastic bag.

- 33 -

Topping up of coolant

– Verify if the engine cooling system is in a goodcondition (no leaks, clean,...).

– Check the condition of the coolant.

– If the condition of the coolant is outside the limits,the complete coolant should be replaced (seesection “Replacing the coolant”).

– Always top-up with GENCOOL EG.

– Topping up the coolant with water only, changesthe concentration of additives and is therefore notallowed.

Replacing the coolant

Drain

– Completely drain the entire cooling system.

– Used coolant must be disposed or recycled inaccordance with laws and local regulations.

Flush

– Flush twice with clean water. Used coolant mube disposed or recycled in accordance with lawand local regulations.

– From the Chicago Pneumatic Instruction boodetermine the amount of GENCOOL EG requireand pour into the radiator top tank.

– It should be clearly understood that the risk focontamination is reduced in case of propecleaning.

– In case a certain content of ‘other’ coolant remainin the system, the coolant with the loweproperties influences the quality of the ‘mixedcoolant.

Fill

– To assure proper operation and the release otrapped air, run the engine until normal enginoperation temperature is reached. Turn off thengine and allow to cool.

– Recheck coolant level and add if necessary.

In case of a mix of different coolantproducts this type of measurementmight provide incorrect values.

Checking voltmeter P4– Put a voltmeter in parallel with voltmeter P4 on

the control panel.

– Check that the read-out of both voltmeters is thesame.

– Stop the generator and disconnect one terminal.

– Check that the internal resistance of the voltmeteris high.

Checking ammeters P1, P2 and P3– Measure by means of a clamp-on probe the

outgoing current during the load.

– Compare the measured currents with the currentson the corresponding ammeters. Both readingsshould be the same.

Engine troubleshootingRefer to the engine’s operator manual for the enginetroubleshooting. An extensive Enginetroubleshooting manual is available at John Deere.For more information contact John Deere.

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- 34 -

Preparing for operation after storageBefore operating the generator again, remove thewrapping, VCI paper and silica gel bags and check thegenerator thoroughly (go through the checklist“Before starting” on page 26).

– Consult the engine’s operator manual.

– Check that the insulation resistance of thegenerator exceeds 5 MΩ.

– Replace the fuel filter and fill the fuel tank. Ventthe fuel system.

– Reinstall and connect the battery, if necessaryafter being recharged.

– Submit the generator to a test run.

Checks and trouble shootingNever perform a test run withconnected power cables. Never touchan electrical connector without avoltage check.When a failure occurs, always reporwhat you experienced before, duringand after the failure. Information withregard to the load (type, size, powerfactor, etc.), vibrations, exhaust gacolour, insulation check, odoursoutput voltage, leaks and damagedparts, ambient temperature, daily andnormal maintenance and altitudemight be helpful to quickly locate theproblem. Also report any informationregarding the humidity and locationof the generator (e.g. close to sea).

ction.ternator by applying a 12V battery voltage with a 30 W ries on the + and - terminals of the electronic regulator, e polarities.ction cables, measure winding resistances and compare entioned in the alternator manual.

e.ncy/voltage regulator.

ngs.e.gulator.e potentiometer.igh, power factor lower than 0.8; speed lower than 10% d.gulator.s, disconnect cables.e potentiometer.gulator.rity of rotation.ility of regulator by acting on STABILITY r.

- 35 -

Alternator troubleshooting

Symptom Possible cause Corrective aAlternator gives 0 Volt Blown fuse. Replace fuse

No residual voltage. Excite the alresistor in serespecting th

After being excited the alternator still gives 0 Volt.

Connections are interrupted. Check connewith values m

Low voltage at no load Voltage potentiometer out of setting. Reset voltagIntervention of protection. Check frequeWinding failure. Check windi

High voltage at no load Voltage potentiometer out of setting. Reset voltagFailed regulator. Substitute re

Lower than rated voltage at load Voltage potentiometer out of setting. Reset voltagIntervention by protection. Current too h

of rated speeFailed regulator. Substitute reRotating bridge failure. Check diode

Higher than rated voltage at load Voltage potentiometer out of setting. Reset voltagFailed regulator. Substitute re

Unstable voltage Speed variation in engine. Check regulaRegulator out of setting. Regulate stab

potentiomete

ctivates at (Metric).5 bar10°C

US Metric

60 Hz 60 Hz 1800 rpm 1800 rpm

PRP PRP100 kPa 100 kPa

30% 30%77°F 25°C

122°F 50°C13,000 ft 4000 m

85% 85%0 °F -18 °C

-13°F -25°C

72 kW 72 kW60 kW 60 kW0,80 0,801.0 1.0

- 36 -

Technical specifications for CPG 90 John DeereReadings on gauges

Settings of switches

Specifications of the engine/alternator/unit

Gauge Reading UnitAmmeter L1-3 (P1-3) Below max. rating AVoltmeter (P4) Depends upon selector switch V

Switch Function Activates at (US) AEngine oil pressure Shut down 7.25 psi 0Engine coolant temperature Shut down 230°F 1

Reference conditions 1) Rated frequencyRated speedGenerator service dutyAbsolute inlet pressureRelative air humidityAir inlet temperature

Limitations 2) Maximum ambient temperature Altitude capabilityRelative air humidity maximumMinimum starting temperature unaidedMinimum starting temperature aided

Performance data 2) 3) 5) Rated active power (PRP) 3 phpRated active power (PRP) 1phRated power factor (lagging) 3phaseRated power factor (lagging) 1phase

US Metric90 kVA 90 kVA60 kVA 60 kVA480 V 480 V208 V 208 V240 V 240 V108 A 108 A250 A 250 A250 A 250 A

G2 G2<1 % <1 %

isochronous isochronous41 lb/h 18.6/14 kg/h

0.57 lb/kWh 0.258 kg/kWh25.8 h 25.8 h

69 dB(A) 69 dB(A)69 dB(A) 69 dB(A)

160 US gal 605 l85 % 85 %

PRP PRPland use land usesingle single

manual/auto manual/autounspecified unspecified

transportable/D transportable/Dmobile/E mobile/E

fully resilient fully resilientopen air open air

IP 54 IP 54earthed earthed

- 37 -

Rated PRP power (PRP) 3ph Rated PRP power (PRP)1phRated voltage 3ph. line to lineRated voltage 3ph. line to line lower voltageRated voltage 1ph. line to lineRated current 3phRated current 3ph lower voltageRated current 1ph.Performance class (acc.ISO 8528-5:1993)Frequency droop

Fuel consumption at full load/no loadSpecific fuel consumptionFuel autonomy at full load with standard tankMaximum sound power level (LWA)measured according to 2000/14/EC ONDSound Level @ 23 Feet @ 75% Load Capacity of fuel tankSingle step load acceptance

Application data Mode of operationSiteOperationStart-up and control modeStart-up timeMobility/Config. acc. to ISO 8528-1:1993

MountingClimatic exposureDegree of protection (cubicle)Status of neutral

Technical specifications for CPG 90 John Deere

US Metric

IEC 34-1 IEC 34-1

ISO 8528-3 ISO 8528-3

NEWAGE NEWAGEUCI 224 G1 UCI 224 G1

90 kVA 90 kVABR BR

23 IP 23 IPH HH H12 12

ISO 3046 ISO 3046ISO 8528-2 ISO 8528-2

JOHN DEERE JOHN DEERE126 hp 94 kWICXN ICXNwater water

direct injection direct injectionturbo turbo

4 44.5 l 4.5 l

electronic electronic2.2 US gal 8.5 l4.2 US gal 16 l

12 Vdc 12 Vdc

- 38 -

Design data 4)Alternator

Standard

Make ModelRated output, class H temp. rise

Rating type acc. ISO 8528-3Degree of protectionInsulation class statorInsulation class rotorNumber of wires

Engine Standard

MakeRated net output

Rating type acc. ISO 3046-7CoolantCombustion systemAspiration

Number of cylindersSwept volumeSpeed governingCapacity of oil sumpCapacity of cooling systemElectrical system


US Metric

3 3125A 125 A3.5xIn 3.5xIn

3 3250 A 250 A3.5xIn 3.5xIn

GFCI duplex (2x) GFCI duplex (2x)2p + E 2p + E

20 A 125 V 20 A 125 V

Temp power (2x) Temp power (2x)2p + N + E 2p + N + E

50 A 125/250 V 50 A 125/250 V

- 39 -

Power circuit Circuit-breaker, 3 phaseNumber of poles Thermal release ItMagnetic release Im

Circuit-breaker, 3 phase, lower voltage (208 V)Number of polesThermal release It Magnetic release Im

Outlet sockets


ctivates at (Metric).5 bar03°C

US Metric

60 Hz 60 Hz 1800 rpm 1800 rpm

PRP PRP100 kPa 100 kPa

30% 30%77°F 25°C

122°F 50°C13,000 ft 4000 m

85% 85%0 °F -2 °C

-13°F -25°C

95 kW 95 kW72 kW 72 kW

0,80 0,801.0 1.0

- 40 -

Technical specifications for CPG 120 John DeereReadings on gauges

Settings of switches

Specifications of the engine/alternator/unit

Gauge Reading UnitAmmeter L1-3 (P1-3) Below max. rating AVoltmeter (P4) Depends upon selector switch V

Switch Function Activates at (US) AEngine oil pressure Shut down 7.25 psi 0Engine coolant temperature Shut down 217.40°F 1

Reference conditions 1) Rated frequencyRated speedGenerator service dutyAbsolute inlet pressureRelative air humidityAir inlet temperature

Limitations 2) Maximum ambient temperature Altitude capabilityRelative air humidity maximumMinimum starting temperature unaidedMinimum starting temperature aided

Performance data 2) 3) 5) Rated active power (PRP) 3 phpRated active power (PRP) 1phRated power factor (lagging) 3phaseRated power factor (lagging) 1phase

US Metric120 kVA 120 kVA72 kVA 72 kVA480 V 480 V208 V 208 V240 V 240 V144 A 144 A333 A 333 A333 A 333 A

G2 G2<1 % <1 %

isochronous isochronous44.6 lb/h 20.3/4.5 kg/h

0.47 lb/kWh 0.214 kg/kWh24 h 24 h

dB(A) Preliminary 69 dB(A) dB(A) Preliminary 69 dB(A)

160 US gal 605 l85 % 85 %

PRP PRPland use land usesingle single

manual/auto manual/autounspecified unspecified

transportable/D transportable/Dmobile/E mobile/E

fully resilient fully resilientopen air open air

IP 54 IP 54earthed earthed

- 41 -

Rated PRP power (PRP) 3ph Rated PRP power (PRP)1phRated voltage 3ph. line to lineRated voltage 3ph. line to line lower voltageRated voltage 1ph. line to lineRated current 3phRated current 3ph lower voltageRated current 1ph.Performance class (acc.ISO 8528-5:1993)Frequency droop

Fuel consumption at full load/no loadSpecific fuel consumptionFuel autonomy at full load with standard tankMaximum sound power level (LWA)measured according to 2000/14/EC OND 69Sound Level @ 23 Feet @ 75% Load 69Capacity of fuel tankSingle step load acceptance

Application data Mode of operationSiteOperationStart-up and control modeStart-up timeMobility/Config. acc. to ISO 8528-1:1993

MountingClimatic exposureDegree of protection (cubicle)Status of neutral


US Metric

IEC 34-1 IEC 34-1

ISO 8528-3 ISO 8528-3

NEWAGE NEWAGEUCI 274 C UCI 274 C125 kVA 125 kVA

BR BR23 IP 23 IP

H HH H12 12

ISO 3046 ISO 3046ISO 8528-2 ISO 8528-2

JOHN DEERE JOHN DEEREHF 285 HF 285140 hp 104 kWICXN ICXNwater water

direct injection direct injectionturbo turbo

4 44.5 l 4.5 l

electronic electronic2.2 US gal 8.5 l4.2 US gal 16 l

12 Vdc 12 Vdc

- 42 -

Design data 4)Alternator

Standard

Make ModelRated output, class H temp. rise

Rating type acc. ISO 8528-3Degree of protectionInsulation class statorInsulation class rotorNumber of wires

Engine Standard

MakeModelRated net output

Rating type acc. ISO 3046-7CoolantCombustion systemAspirationNumber of cylindersSwept volumeSpeed governingCapacity of oil sumpCapacity of cooling systemElectrical system


US Metric

3 3150A 150 A3.5xIn 3.5xIn

3 3333 A 333 A3.5xIn 3.5xIn

GFCI duplex (2x) GFCI duplex (2x)2p + E 2p + E

20 A 125 V 20 A 125 V

Temp power (2x) Temp power (2x)2p + N + E 2p + N + E

50 A 125/250 V 50 A 125/250 V

- 43 -

Circuit-breaker, 3 phaseNumber of poles Thermal release ItMagnetic release Im

Circuit-breaker, 3 phase, lower voltage (208 V)Number of polesThermal release It Magnetic release Im

Outlet sockets

Power circuit


delivering (at variable load), in the event of a s running). No overload is permitted on these

y be run for an unlimited number of hours per load is permitted for 1 hour in 12 hours. The 0%.

- 44 -

Notes

1) Reference conditions for engine performance to ISO 3046-1.2) See derating diagram or consult the factory for other conditions.3) At reference conditions unless otherwise stated.4) Rating definition (ISO 8528-1):

LTP: Limited Time Power is the maximum electrical power which a generating set is capable of utility power failure (for up to 500 hours per year of which a maximum of 300 hours is continuouratings. The alternator is peak continuous rated (as defined in ISO 8528-3) at 25°C.

PRP: Prime Power is the maximum power available during a variable power sequence, which mayear, between stated maintenance intervals and under the stated ambient conditions. A 10% overpermissible average power output during a 24h period shall not exceed the stated load factor of 7

5) Specific mass fuel used: 0.86 kg/l.(a) optional equipment(b) thermal release is higher at 25°C

5 40 45 50 5500 100 97 94 9100 100 97 94 9100 100 97 94 917 97 94 91 884 94 91 88 868 88 85 83 808 88 85 83 802 82 80 77 752 82 80 77 75

5 40 45 50 550 100 97 94 910 100 97 94 910 100 97 94 91

7 97 94 91 884 94 91 88 868 88 85 83 808 88 85 83 802 82 80 77 752 82 80 77 75

- 45 -

Generating setNominal power output (kVA) at 40°C, 1000m: 33.0kVA

When nominal power is lower then 33kVA => 30kVA, the derating factor is different!

For use of generator outside theseconditions, please contact Chicago Pneumatic.

derating factor %0 5 10 15 20 25 30 3

0 100 100 100 100 100 100 100 1500 100 100 100 100 100 100 100 11000 100 100 100 100 100 100 100 11500 97 97 97 97 97 97 97 92000 94 94 94 94 94 94 94 92500 88 88 88 88 88 88 88 83000 88 88 88 88 88 88 88 83500 82 82 82 82 82 82 82 84000 82 82 82 82 82 82 82 8

temperature (°C)

heig

ht (m

)

derating factor %0 5 10 15 20 25 30 3

0 100 100 100 100 100 100 100 10500 100 100 100 100 100 100 100 101000 100 100 100 100 100 100 100 101500 97 97 97 97 97 97 97 92000 94 94 94 94 94 94 94 92500 88 88 88 88 88 88 88 83000 88 88 88 88 88 88 88 83500 82 82 82 82 82 82 82 84000 82 82 82 82 82 82 82 8

heig

ht (m

)

temperature (°C)

- 46 -

Conversion list of SI units into British units

A temperature difference of 1°C = a temperaturedifference of 1.8°F.

Dataplate

1 bar = 14.504 psi1 g = 0.035 oz1 kg = 2.205 lb1 km/h = 0.621 mile/h1 kW = 1.341 hp (UK and US)1 l = 0.264 US gal1 l = 0.220 lmp gal (UK)1 l = 0.035 cu.ft1 m = 3.281 ft1 mm = 0.039 in1 m³/min = 35.315 cfm1 mbar = 0.401 in wc1 N = 0.225 lbf1 Nm = 0.738 lbf.ftt°F = 32 + (1.8 x t°C)

t°C = (t°F - 32)/1.8

- 47 -

Circuit diagrams

- 48 -

1310 3200 01/00Applicable for CPG 90-120 John Deere - Power circuit

- 49 -

- 50 -

Mark

F1,,5G3K11K12K13N12OQ1,1Q1,2Q2Q3Q4Q5R5R12S2bS10T1,3X1X2X3X4X5X7X9X10X25SxKx

Name

Fuse 4AAlternatorAux, relay (lower volt,)Aux, relay (higher volt,)ContactorAutomatic Voltage RegulatorOptional EquipmentCircuit breaker 3poleCircuit breaker 3poleCircuit breaker 1poleCircuit breaker 1poleCircuit breaker 2poleCircuit breaker 2poleCoolant HeaterVoltage Adjustnent PotmeterEmergency stop (S2a see Engine Circ.)Supply voltage switchCurrent transfornerTerminal boardSocket outletSocket outletSocket outletSocket outletFlanged inletTerminal stripTerminal stripTerminal stripRemote Start/StopContactor Generator Ready(15s. Delayed)

- 51 -

- 52 -

1310 3200 00/00Applicable for CPG 90-120 John Deere - Engine circuit Qc1002TM

- 53 -

- 54 -

Mark

A1B7ECF10F11G1H0J02K5M1P1-3P4R3S2a

S4S6S7S7S20V2X10X17X19X25

(0)

Grid

b5f6f3Q4e1f1b9e1-f5b5f2c9-10d10e5a8

d10f7f6f6a5f2d1-f7f6-g6f3a6,e7

(0)

Name

Control ModuleFuel Level SensorEngine controllerFuseFuseBattery 12VPanel LightEngine connectorStarter RelayStarter MotorA-MetersV-meterResistor 120 ohmEmergency Stop Button(S2b: see Power Circuit)Voltmeter change-over switchCoolant Level SwitchLow Fuel Level SwitchLow Fuel Level Switch, WarningON/OFF SwitchDiodeTerminal stripFuel Level Unit ConnectorMotor Diagnostic PlugTerminal strip

Optional Equipment

- 55 -

Pri

nte

d in

Bel

giu

m 0

4/2

010

- 1

310

301

2 2

3

www.cp.com

WalshR

Text Box

AVR - 1089959204 Model - SX 460 Initial set up - Volt pot - next to the 5 wire connections - Turn counterclockwise. Stability pot - At top of AVR to the left of 50 - 60 HZ connection - Set halfway. Potentiometer - Set halfway

walshr

Text Box

1310312470 - 500 Hr 1310312471 - 1000 Hr 1310312472 - 2000 Hr

Instruction Manual for AC Generators CPG 90-120 JD · PDF fileChecking voltmeter P4 ......

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Transcript of Instruction Manual for AC Generators CPG 90-120 JD · PDF fileChecking voltmeter P4 ......