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Chicago Pneumatic CPG 90-120 JD, Instruction Manual

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Contents

Safety precautions for portable 
generators

................................................................6

Leading particulars

..............................................12

General description .........................................12

Bodywork .........................................................13

Markings ..........................................................13

Drain plugs and filler caps ..............................14

Control and indicator panel Qc1002™...........14

Output terminal board .....................................22

Triple voltage (3V)...........................................23

Spillage free skid .............................................24

Engine coolant heater......................................24

Operating instructions

.........................................24

Installation.......................................................24

Connecting the generator ................................24

Before starting .................................................26

Operating Qc1002™ .......................................26

Maintenance

......................................................... 28

Maintenance schedule ..................................... 28

Engine maintenance ........................................ 30

(*) Measuring the alternator 
insulation resistance........................................ 30

Engine oil specifications ................................. 30

Engine oil level check...................................... 31

Engine oil and oil filter change ....................... 31

Engine coolant specifications.......................... 31

Coolant check .................................................. 32

Storage of the generator

...................................... 33

Storage............................................................. 33

Preparing for operation after storage............. 34

Checks and trouble shooting

.............................. 34

Checking voltmeter P4 .................................... 34

Checking ammeters P1, P2 and P3 ................. 34

Alternator troubleshooting .............................. 35

Engine troubleshooting ................................... 34

Technical specifications for CPG 90-120 
John Deere

...................................................... 36, 40

Readings on gauges................................... 36, 40

Settings of switches.................................... 36, 40

Specifications of the engine/
alternator/unit ........................................... 36, 40

Conversion list of SI units into 
British units ..................................................... 46

Dataplate ......................................................... 46

Congratulations on the purchase of your AC generator. It is a solid, safe and reliable machine, built according to the
latest technology. Follow the instructions in this booklet and we guarantee you years of troublefree operation. Please
read 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 Pneumatic does
not assume responsibility for possible errors. Chicago Pneumatic reserves the right to make changes without prior
notice.

Summary of Contents for CPG 90-120 JD

Page 1: ...CPG 90 120 JD Instruction Manual for AC Generators English ...

Page 2: ......

Page 3: ...CHICAGO PNEUMATIC PORTABLE AIR DIVISION www cp com Printed matter N 1310 3012 23 04 2010 CPG 90 120 JD Instruction Manual for AC Generators Instruction manual 5 Circuit diagrams 47 ...

Page 4: ...ility The manufacturer does not accept any liability for any damage arising for modifications addi tions or conversions made without the manufacturer s approval in writing Copyright 2010 Chicago Pneumatic Any unauthorized use or copying of the contents or any part thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings ...

Page 5: ...torage 34 Checks and trouble shooting 34 Checking voltmeter P4 34 Checking ammeters P1 P2 and P3 34 Alternator troubleshooting 35 Engine troubleshooting 34 Technical specifications for CPG 90 120 John Deere 36 40 Readings on gauges 36 40 Settings of switches 36 40 Specifications of the engine alternator unit 36 40 Conversion list of SI units into British units 46 Dataplate 46 Congratulations on th...

Page 6: ...el 3 Electrical technician An electrical technician is trained and has the same qualifications as both the operator and the mechanical technician In addition the electrical technician may carry out electrical repairs within the various enclosures of the unit This includes work on live electrical components Skill level 4 Specialist from the manufacturer This is a skilled specialist sent by the manu...

Page 7: ...n working on the unit wear safety clothing Depending on the kind of activities these are safety glasses ear protection safety helmet including visor safety gloves protective clothing safety shoes Do not wear the hair long and loose protect long hair with a hairnet or wear loose clothing or jewellery 15 Take precautions against fire Handle fuel oil and anti freeze with care because they are inflamm...

Page 8: ...nding circuit breaker and check whether frequency voltage current and power factor comply with the ratings of the generator Safety during use and operation 1 When the unit has to operate in a fire hazardous environment each engine exhaust has to be provided with a spark arrestor to trap incendiary sparks 2 The exhaust contains carbon monoxide which is a lethal gas When the unit is used in a confin...

Page 9: ...d and depending on the nature of the hazard so must the eyes and skin 17 Remember that where there is visible dust the finer invisible particles will almost certainly be present too but the fact that no dust can be seen is not a reliable indication that dangerous invisible dust is not present in the air 18 Never operate the generator in excess of its limits as indicated in the technical specificat...

Page 10: ...acks 12 Do not remove any of or tamper with the sound damping material Keep the material free of dirt and liquids such as fuel oil and cleansing agents If any sound damping material is damaged replace it to prevent the sound pressure level from increasing 13 Use only lubricating oils and greases recommended or approved by Chicago Pneumatic or the machine manufacturer Ascertain that the selected lu...

Page 11: ...en handling batteries e g when checking the charge condition 2 Install a sign prohibiting fire open flame and smoking at the post where batteries are being charged 3 When batteries are being charged an explosive gas mixture forms in the cells and might escape through the vent holes in the plugs Thus an explosive atmosphere may form around the battery if ventilation is poor and can remain in and ar...

Page 12: ...y a water cooled diesel engine manufactured by John Deere An overview of the main parts is given in the diagram below 1 Lifting beam 2 Guiding rod 3 Side doors 4 Engine exhaust 5 Data plate 6 Side door access to control and indicator panel 7 Output terminal board 8 Hole for forklift A Alternator AF Air filter C Coupling DH Drain and access hole in the frame DCW Drain Cooling Water E Engine F Fan F...

Page 13: ...e 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 not be used to lift the generator Always use the lifting rod in the roof of the generator to lift it Indicates ...

Page 14: ... circuit exceeds its setting The fuse can be reset by pushing the button H0 Panel light S2 Emergency stop button Push the button to stop the generator in case of an emergency When the button is pressed it must be unlocked before the generator can be restarted The emergency stop button can be secured in the locked position with the key to avoid unauthorized use S20 ON OFF switch Position O No volta...

Page 15: ...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 ST...

Page 16: ...and version display This view shows the controller type and the ASW version number Parameter display This view shows a number of Parameter settings and gives access to them An overview is given in Parameter list on page 18 Alarm list display This view shows the number of active alarms and gives access to them An overview is given in Alarm Display pop up window on page 20 LOG list display This view...

Page 17: ...vel and the running hours Voltage frequency running hours display This view shows the voltage frequency and running hours Engine speed display This view shows the engine speed and running hours Qc1002 Menu Description Status Display pop up window In case special statuses are entered a pop up window will automatically be entered for as long as the status is active The background screen is not updat...

Page 18: ...setting is switched on electric power will be supplied to the engine electronics after half a minute delay The unit can not be started as long as this parameter is switched on Unit Menu This menu is used to select whether tempreature and pressure should appear in C bar or F psi Language selection Icons is the default factory set language but 6 other languages can be selected English French German ...

Page 19: ... 19 This is the described menu flow for changing the unit type ...

Page 20: ... The newest alarm will be placed at the bottom of the list meaning that the older alarm stays at the display when a newer alarm comes up If one or more than one alarm is present an arrow at the right of the display will be shown Following general groups of Alarms exist Warning Alarm LED lights up Alarm pop up appears on the display Alarm relay is empowered if configured Trip of GB Warning actions ...

Page 21: ...for the remote contactor open close Fail classes All the activated alarms of the Qc1002 have their own pre defined fail class All alarms are enabled according to one of these three statuses disabled alarm no supervision of alarm OFF enabled alarm supervision of alarm all the time ON running alarm only supervision when the machine is running RUN SERVICE TIMER 1 SERVICE TIMER 2 ENGINE ALARM EMERGENC...

Page 22: ...y to X2 when a short circuit occurs at the load side or when the overcurrent protection 50 A is activated When activated Q2 interrupts one phase towards X2 It can be activated again after eliminating the problem Q3 Circuit breaker for X3 Interrupts the power supply to X3 when a short circuit occurs at the load side or when the overcurrent protection 50 A is activated When activated Q3 interrupts 2...

Page 23: ...d side or when the overcurrent protection is activated It must be reset manually after eliminating the problem R12 Output voltage adjust potentiometer Allows to adjust the output voltage Depending on which mode the generator is running in circuit breaker Q1 1 or Q1 2 will be operational Circuit breakers Q1 1 and Q1 2 cannot be switched on at the same time This is prevented by means of the auxiliar...

Page 24: ...nce with the local legislation Use coolant for the engine cooling system Refer to the Engine instruction book for the proper coolant mixture Check the tightness of the bolts and nuts Install the earthing rod as near as possible to the generator and measure its diffusion resistance max 1 kΩ in order not to have a contact voltage higher than 25 V at 30 mA leakage current Check that the cable end of ...

Page 25: ...le The voltage drop across a cable can be determined as follows 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 mounted on a site distribution panel supplied from the terminal board of the generator and in compliance with local regulations f...

Page 26: ...tage is applied to the Qc1002 module The unit can be started manually by pressing the START button on the Qc1002 module The unit starts a preheating cycle which takes 12 seconds After the preheating period the unit will start The starting attempt will take maximum 12 seconds Switch on circuit breaker Q1 1 Q1 2 in case no contactor is installed To start up the unit from a remote location proceed as...

Page 27: ... indicators and control panel to avoid unauthorized access To stop the unit when the Qc1002 module is in position proceed as follows Switch off the load Stop the engine by putting the remote start stop switch in position stop or by using the STOP button on the Qc1002 module When the unit is stopped with the STOP button in Remote mode it will automatically go to Manual Mode Put the starter switch S...

Page 28: ... the loose components Refer to the parts list for more information on the contents of the service kits x x x e g a k a e l l i o d n a t n a l o o c l e u f r i a r o f k c e h C x x x l e v e l t n a l o o c d n a l i o k c e h C x x x r o t a r a p e s r e t a w r e t l i f l e u f n i r e t a w n i a r d r o k c e h C x x x l w o b t s u D r e n a e l c r i a t c e p s n I x x x r o t a c i d m...

Page 29: ... 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 a regular basis At least once a month the engine should run for m...

Page 30: ...istance of at least 5 MΩ Refer to the alternator operating and maintenance instructions for more details Engine oil specifications High quality mineral hydraulic or synthesized hydrocarbon oil with rust and oxidation inhibitors anti foam and anti wear properties is recommended The viscosity grade should correspond to the ambient temperature and ISO 3448 as follows Specifications GENOIL GENOIL from...

Page 31: ...vals For intervals see section Maintenance schedule on page 28 Check engine oil level according to the instructions in the Engine Operation Manual and if necessary top up with oil Engine oil and oil filter change See section Maintenance schedule on page 28 Engine coolant specifications The use of the correct coolant is important for good heat transfer and protection of liquid cooled engines Coolan...

Page 32: ...protection against corrosion cavitation and formation of deposits the concentration of the additives in the coolant must be kept between certain limits as stated by the manufacturer s guidelines Topping up the coolant with water only changes the concentration and is therefore not allowed Liquid cooled engines are factory filled with this type of coolant mixture Coolant check Monitoring coolant con...

Page 33: ...system the coolant with the lowest properties influences the quality of the mixed coolant Fill To assure proper operation and the release of trapped air run the engine until normal engine operation temperature is reached Turn off the engine and allow to cool Recheck coolant level and add if necessary Storage of the generator Storage Store the generator in a dry frost free room which is well ventil...

Page 34: ...g 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 currents on the corresponding ammeters Both readings should be the same Engine troubleshooting Refer to the engine s operator manual for the engine troubleshooting An extensive Engine troubleshooting manual is available at John Deere For more information contact ...

Page 35: ...rotection Check frequency voltage regulator Winding failure Check windings High voltage at no load Voltage potentiometer out of setting Reset voltage Failed regulator Substitute regulator Lower than rated voltage at load Voltage potentiometer out of setting Reset voltage potentiometer Intervention by protection Current too high power factor lower than 0 8 speed lower than 10 of rated speed Failed ...

Page 36: ...onditions 1 Rated frequency 60 Hz 60 Hz Rated speed 1800 rpm 1800 rpm Generator service duty PRP PRP Absolute inlet pressure 100 kPa 100 kPa Relative air humidity 30 30 Air inlet temperature 77 F 25 C Limitations 2 Maximum ambient temperature 122 F 50 C Altitude capability 13 000 ft 4000 m Relative air humidity maximum 85 85 Minimum starting temperature unaided 0 F 18 C Minimum starting temperatur...

Page 37: ...g kWh Fuel autonomy at full load with standard tank 25 8 h 25 8 h Maximum sound power level LWA measured according to 2000 14 EC OND 69 dB A 69 dB A Sound Level 23 Feet 75 Load 69 dB A 69 dB A Capacity of fuel tank 160 US gal 605 l Single step load acceptance 85 85 Application data Mode of operation PRP PRP Site land use land use Operation single single Start up and control mode manual auto manual...

Page 38: ...r of wires 12 12 Engine Standard ISO 3046 ISO 3046 ISO 8528 2 ISO 8528 2 Make JOHN DEERE JOHN DEERE Rated net output 126 hp 94 kW Rating type acc ISO 3046 7 ICXN ICXN Coolant water water Combustion system direct injection direct injection Aspiration turbo turbo Number of cylinders 4 4 Swept volume 4 5 l 4 5 l Speed governing electronic electronic Capacity of oil sump 2 2 US gal 8 5 l Capacity of c...

Page 39: ...3 5xIn Circuit breaker 3 phase lower voltage 208 V Number of poles 3 3 Thermal release It 250 A 250 A Magnetic release Im 3 5xIn 3 5xIn Outlet sockets 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 Technical specifications for CPG 90 John Deere ...

Page 40: ...e conditions 1 Rated frequency 60 Hz 60 Hz Rated speed 1800 rpm 1800 rpm Generator service duty PRP PRP Absolute inlet pressure 100 kPa 100 kPa Relative air humidity 30 30 Air inlet temperature 77 F 25 C Limitations 2 Maximum ambient temperature 122 F 50 C Altitude capability 13 000 ft 4000 m Relative air humidity maximum 85 85 Minimum starting temperature unaided 0 F 2 C Minimum starting temperat...

Page 41: ...el autonomy at full load with standard tank 24 h 24 h Maximum sound power level LWA measured according to 2000 14 EC OND 69 dB A Preliminary 69 dB A Sound Level 23 Feet 75 Load 69 dB A Preliminary 69 dB A Capacity of fuel tank 160 US gal 605 l Single step load acceptance 85 85 Application data Mode of operation PRP PRP Site land use land use Operation single single Start up and control mode manual...

Page 42: ...12 12 Engine Standard ISO 3046 ISO 3046 ISO 8528 2 ISO 8528 2 Make JOHN DEERE JOHN DEERE Model HF 285 HF 285 Rated net output 140 hp 104 kW Rating type acc ISO 3046 7 ICXN ICXN Coolant water water Combustion system direct injection direct injection Aspiration turbo turbo Number of cylinders 4 4 Swept volume 4 5 l 4 5 l Speed governing electronic electronic Capacity of oil sump 2 2 US gal 8 5 l Cap...

Page 43: ...breaker 3 phase lower voltage 208 V Number of poles 3 3 Thermal release It 333 A 333 A Magnetic release Im 3 5xIn 3 5xIn Outlet sockets 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 Power circuit Technical specifications for CPG 120 John Deere ...

Page 44: ...maximum of 300 hours is continuous running No overload is permitted on these ratings 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 may be run for an unlimited number of hours per year between stated maintenance intervals and under the stated ambient conditions A 10 overload is permitted...

Page 45: ... 94 94 94 94 94 91 88 86 2500 88 88 88 88 88 88 88 88 88 85 83 80 3000 88 88 88 88 88 88 88 88 88 85 83 80 3500 82 82 82 82 82 82 82 82 82 80 77 75 4000 82 82 82 82 82 82 82 82 82 80 77 75 temperature C height m derating factor 0 5 10 15 20 25 30 35 40 45 50 55 0 100 100 100 100 100 100 100 100 100 97 94 91 500 100 100 100 100 100 100 100 100 100 97 94 91 1000 100 100 100 100 100 100 100 100 100 9...

Page 46: ...ifference of 1 8 F Dataplate 1 bar 14 504 psi 1 g 0 035 oz 1 kg 2 205 lb 1 km h 0 621 mile h 1 kW 1 341 hp UK and US 1 l 0 264 US gal 1 l 0 220 lmp gal UK 1 l 0 035 cu ft 1 m 3 281 ft 1 mm 0 039 in 1 m min 35 315 cfm 1 mbar 0 401 in wc 1 N 0 225 lbf 1 Nm 0 738 lbf ft t F 32 1 8 x t C t C t F 32 1 8 ...

Page 47: ... 47 Circuit diagrams ...

Page 48: ... 48 1310 3200 01 00 Applicable for CPG 90 120 John Deere Power circuit ...

Page 49: ... 49 ...

Page 50: ...Circuit breaker 3pole Circuit breaker 3pole Circuit breaker 1pole Circuit breaker 1pole Circuit breaker 2pole Circuit breaker 2pole Coolant Heater Voltage Adjustnent Potmeter Emergency stop S2a see Engine Circ Supply voltage switch Current transforner Terminal board Socket outlet Socket outlet Socket outlet Socket outlet Flanged inlet Terminal strip Terminal strip Terminal strip Remote Start Stop ...

Page 51: ... 51 ...

Page 52: ... 52 1310 3200 00 00 Applicable for CPG 90 120 John Deere Engine circuit Qc1002TM ...

Page 53: ... 53 ...

Page 54: ...Fuel Level Sensor Engine controller Fuse Fuse Battery 12V Panel Light Engine connector Starter Relay Starter Motor A Meters V meter Resistor 120 ohm Emergency Stop Button S2b see Power Circuit Voltmeter change over switch Coolant Level Switch Low Fuel Level Switch Low Fuel Level Switch Warning ON OFF Switch Diode Terminal strip Fuel Level Unit Connector Motor Diagnostic Plug Terminal strip Optiona...

Page 55: ... 55 ...

Page 56: ...Printed in Belgium 04 2010 1310 3012 23 www cp com ...

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