Chicago Pneumatic CPG 20 User manual

CPG 20-25 Kd
Instruction Manual
for CPG Generators
English

CHICAGO PNEUMATIC - PORTABLE AIR DIVISION
www.cp.com
Printed matter Nr
1310 3012 47
05/2011
CPG 20-25 Kd
Instruction Manual for CPG Generators
Instruction manual .............................................................................5
Circuit diagrams ...............................................................................42

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Warranty and Liability Limitation
Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability.
The manufacturer does not accept any liability for any damage arising from modifications, additions or conversions made without the manufacturer's approval in
writing.
Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including fire risk.
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.
Copyright 2011, 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.

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Contents
Safety precautions for portable
generators.......................................................................................
............................................................................................ 6
Leading particulars.................................................................
......................................................................................... 11
General description ................................................... 11
Bodywork ................................................................... 13
Markings .................................................................... 13
Drain plugs and filler caps ........................................ 13
Control and indicator panel Qc1002™..................... 14
Output terminal board ............................................... 19
Spillage free ............................................................... 19
Operating instructions.........................................................
......................................................................................... 20
Installation................................................................. 20
Connecting the generator .......................................... 20
Before starting ........................................................... 21
Maintenance .............................................................. 23
Maintenance ................................................................................
.......................................................................................... 23
Maintenance schedule ............................................... 23
Engine maintenance................................................... 25
(*) Measuring the alternator insulation resistance .......
................................................................................... 25
Engine oil specifications............................................ 25
Engine oil level check ................................................ 25
Engine oil and oil filter change ................................. 25
................................................................................... 26
Coolant check ............................................................ 27
Storage of the generator ..................................................
...........................................................................................28
Storage........................................................................28
Preparing for operation after storage........................28
Checks and trouble shooting.........................................
.......................................................................................... 28
Checking voltmeter P4 ...............................................28
Checking ammeter P3.................................................28
Alternator troubleshooting .........................................29
Engine trouble shooting .............................................30
Options available for CPG 20 and CPG 25
units....................................................................................................
.......................................................................................... 32
Circuit diagrams.........................................................32
Overview of the electrical options..............................32
Description of the electrical options ..........................32
Overview of the mechanical options...........................32
Description of the mechanical options .......................32
Technical specifications.....................................................
..........................................................................................34
Technical specifications for CPG 20 Kubota.............34
Technical specifications for CPG 25 Kubota.............37
Conversion list of SI units into British units...............40
Dataplate ....................................................................40
Congratulations on the purchase of your CPG 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.

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Safety precautions for portable generators
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the generator.
Introduction
The policy of Chicago Pneumatic is to provide the users
of their equipment with safe, reliable and efficient
products. Factors taken into account are among others:
- the intended and predictable future use of the
products, and the environments in which they are
expected 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 the
relevant instruction manual. Besides giving detailed
operating instructions, it also gives specific information
about safety, preventive maintenance, etc.
Keep the manual always at the unit location, easy
accessible to the operating personnel.
See also the safety precautions of the engine and possible
other equipment, which are separately sent along or are
mentioned on the equipment or parts of the unit.
These safety precautions are general and some statements
will therefore not always apply to a particular unit.
Only people that have the right skills should be allowed
to operate, adjust, perform maintenance or repair on
Chicago Pneumatic equipment. It is the responsibility of
management to appoint operators with the appropriate
training and skill for each category of job.
Skill level 1: Operator
An operator is trained in all aspects of operating the unit
with the push-buttons, and is trained to know the safety
aspects.
Skill level 2: Mechanical technician
A mechanical technician is trained to operate the unit the
same as the operator. In addition, the mechanical
technician is also trained to perform maintenance and
repair, as described in the instruction manual, and is
allowed to change settings of the control and safety
system. A mechanical technician does not work on live
electrical components.
Skill level 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 manufacturer or its
agent to perform complex repairs or modifications to the
equipment.
In general it is recommended that not more than two
people operate the unit, more operators could lead to
unsafe operating conditions. Take necessary steps to keep
unauthorized persons away from the unit and eliminate
all possible sources of danger at the unit.
When handling, operating, overhauling and/or
performing maintenance or repair on Chicago Pneumatic
equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local
safety requirements and ordinances. The following list is
a reminder of special safety directives and precautions
mainly applicable to Chicago Pneumatic equipment.
Neglecting the safety precautions may endanger people
as 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 resulting from
neglecting these precautions or by non-observance of
ordinary caution and due care required in handling,
operating, maintenance or repair, also if not expressly
mentioned in this instruction manual, is disclaimed by
Chicago Pneumatic.
The manufacturer does not accept any liability for any
damage arising from the use of non-original parts and for
modifications, additions or conversions made without the
manufacturer’s approval in writing.
If any statement in this manual does not comply with
local legislation, the stricter of the two shall be applied.
Statements in these safety precautions should not be
interpreted as suggestions, recommendations or
inducements that it should be used in violation of any
applicable laws or regulations.
General safety precautions
1 The owner is responsible for maintaining the unit in a
safe operating condition. Unit parts and accessories
must be replaced if missing or unsuitable for safe
operation.
2 The supervisor, or the responsible person, shall at all
times make sure that all instructions regarding
machinery and equipment operation and maintenance
are strictly followed and that the machines with all
accessories and safety devices, as well as the
consuming devices, are in good repair, free of
abnormal wear or abuse, and are not tampered with.
3 Whenever there is an indication or any suspicion that
an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers
shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition
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 and
within 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 other deposits.
7 To prevent an increase in working temperature,
inspect and clean heat transfer surfaces (cooler fins,
intercoolers, coolant jackets, etc.) regularly. See the
maintenance schedule.

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8 All regulating and safety devices shall be maintained
with due care to ensure that they function properly.
They may not be put out of action.
9 Pressure and temperature gauges shall be checked
regularly with regard to their accuracy. They shall be
replaced whenever outside acceptable tolerances.
10 Safety devices shall be tested as described in the
maintenance schedule of the instruction manual to
determine that they are in good operating condition.
11 Mind the markings and information labels on the unit.
12 In the event the safety labels are damaged or
destroyed, they must be replaced to ensure operator
safety.
13 Keep the work area neat. Lack of order will increase
the risk of accidents.
14 When 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 inflammable
substances. Do not smoke or approach with naked
flame when handling such substances. Keep a fire-
extinguisher in the vicinity.
16aPortable generators (with earthing pin):
Earth the generator as well as the load properly.
16bPortable generators IT:
Note: This generator is built to supply a sheer
alternating current IT network.
Earth the load properly.
Safety during transport and installation
To lift a unit, all loose or pivoting parts, e.g. doors and
towbar, shall first be securely fastened.
Do not attach cables, chains or ropes directly to the lifting
eye; apply a crane hook or lifting shackle meeting local
safety regulations. Never allow sharp bends in lifting
cables, chains or ropes.
Helicopter lifting is not allowed.
It is strictly forbidden to dwell or stay in the risk zone
under a lifted load. Never lift the unit over people or
residential areas. Lifting acceleration and retardation
shall be kept within safe limits.
1 Before towing the unit:
- check the towbar, the brake system and the towing eye.
Also check the coupling of the towing vehicle,
- check the towing and brake capability of the towing
vehicle,
- check that the towbar, jockey wheel or stand leg is
safely locked in the raised position,
- ascertain that the towing eye can swivel freely on the
hook,
- check that the wheels are secure and that the tyres are
in good condition and inflated correctly,
- connect the signalisation cable, check all lights and
connect the pneumatic brake couplers,
- attach the safety break-away cable or safety chain to
the towing vehicle,
- remove wheel chocks, if applied, and disengage the
parking brake.
2 To tow a unit use a towing vehicle of ample capacity.
Refer to the documentation of the towing vehicle.
3 If the unit is to be backed up by the towing vehicle,
disengage the overrun brake mechanism (if it is not an
automatic mechanism).
4 Never exceed the maximum towing speed of the unit
(mind the local regulations).
5 Place the unit on level ground and apply the parking
brake before disconnecting the unit from the towing
vehicle. Unclip the safety break-away cable or safety
chain. If the unit has no parking brake or jockey
wheel, immobilize the unit by placing chocks in front
of and/or behind the wheels. When the towbar can be
positioned vertically, the locking device must be
applied and kept in good order.
6 To lift heavy parts, a hoist of ample capacity, tested
and approved according to local safety regulations,
shall be used.
7 Lifting hooks, eyes, shackles, etc., shall never be bent
and shall only have stress in line with their design
load axis. The capacity of a lifting device diminishes
when the lifting force is applied at an angle to its load
axis.
8 For maximum safety and efficiency of the lifting
apparatus all lifting members shall be applied as near
to perpendicular as possible. If required, a lifting
beam shall be applied between hoist and load.
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 not
possible, the necessary precautions must be taken to
prevent load-swinging, e.g. by using two hoists, each
at approximately the same angle not exceeding 30°
from the vertical.
11 Locate the unit away from walls. Take all precautions
to ensure that hot air exhausted from the engine and
driven machine cooling systems cannot be
recirculated. If such hot air is taken in by the engine or
driven machine cooling fan, this may cause
overheating of the unit; if taken in for combustion, the
engine power will be reduced.
12 Generators shall be stalled on an even, solid floor, in a
clean location with sufficient ventilation. If the floor
is not level or can vary in inclination, consult Chicago
Pneumatic.
13 The electrical connections shall correspond to local
codes. The machines shall be earthed and protected
against short circuits by fuses or circuit breakers.
14 Never connect the generator outlets to an installation
which is also connected to a public mains.
15 Before connecting a load, switch off the
corresponding circuit breaker, and check whether
frequency, voltage, current and power factor comply
with the ratings of the generator.
16 Before transportation of the unit, switch off all the
circuit breakers.

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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 confined space,
conduct the engine exhaust to the outside atmosphere
by a pipe of sufficient diameter; do this in such a way
that no extra back pressure is created for the engine. If
necessary, install an extractor. Observe any existing
local regulations.
Make sure that the unit has sufficient air intake for
operation. If necessary, install extra air intake ducts.
3 When operating in a dust-laden atmosphere, place the
unit so that dust is not carried towards it by the wind.
Operation in clean surroundings considerably extends
the intervals for cleaning the air intake filters and the
cores of the coolers.
4 Never remove a filler cap of the coolant system of a
hot engine. Wait until the engine has sufficiently
cooled down.
5 Never refill fuel while the unit is running, unless
otherwise stated in the Chicago Pneumatic Instruction
Book (AIB). Keep fuel away from hot parts such as
air outlet pipes or the engine exhaust. Do not smoke
when fuelling. When fuelling from an automatic
pump, an earthing cable should be connected to the
unit to discharge static electricity. Never spill nor
leave oil, fuel, coolant or cleansing agent in or around
the unit.
6 All doors shall be shut during operation so as not to
disturb the cooling air flow inside the bodywork and/
or render the silencing less effective. A door should
be kept open for a short period only e.g. for inspection
or adjustment.
7 Periodically carry out maintenance works according
to the maintenance schedule.
8 Stationary housing guards are provided on all rotating
or reciprocating parts not otherwise protected and
which may be hazardous to personnel. Machinery
shall never be put into operation, when such guards
have been removed, before the guards are securely
reinstalled.
9 Noise, even at reasonable levels, can cause irritation
and disturbance which, over a long period of time,
may cause severe injuries to the nervous system of
human beings.
When the sound pressure level, at any point where
personnel normally has to attend, is:
- below 70 dB(A): no action needs to be taken,
- above 70 dB(A): noise-protective devices should be
provided for people continuously being present in the
room,
- below 85 dB(A): no action needs to be taken for
occasional visitors staying a limited time only,
- above 85 dB(A): room to be classified as a noise-
hazardous area and an obvious warning shall be placed
permanently at each entrance to alert people entering
the room, for even relatively short times, about the
need to wear ear protectors,
- above 95 dB(A): the warning(s) at the entrance(s) shall
be completed with the recommendation that also
occasional visitors shall wear ear protectors,
- above 105 dB(A): special ear protectors that are
adequate for this noise level and the spectral
composition of the noise shall be provided and a
special warning to that effect shall be placed at each
entrance.
10 Insulation or safety guards of parts the temperature of
which can be in excess of 80°C (175°F) and which
may be accidentally touched by personnel shall not be
removed before the parts have cooled to room
temperature.
11 Never operate the unit in surroundings where there is
a possibility of taking in flammable or toxic fumes.
12 If the working process produces fumes, dust or
vibration hazards, etc., take the necessary steps to
eliminate the risk of personnel injury.
13 When using compressed air or inert gas to clean down
equipment, do so with caution and use the appropriate
protection, at least safety glasses, for the operator as
well as for any bystander. Do not apply compressed
air or inert gas to your skin or direct an air or gas
stream at people. Never use it to clean dirt from your
clothes.
14 When washing parts in or with a cleaning solvent,
provide the required ventilation and use appropriate
protection such as a breathing filter, safety glasses,
rubber apron and gloves, etc.
15 Safety shoes should be compulsory in any workshop
and if there is a risk, however small, of falling objects,
wearing of a safety helmet should be included.
16 If there is a risk of inhaling hazardous gases, fumes or
dust, the respiratory organs must be protected 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 specifications and avoid
long no-load sequences.
19 Never operate the generator in a humid atmosphere.
Excessive moisture causes worsening of the generator
insulation.
20 Do not open electrical cabinets, cubicles or other
equipment while voltage is supplied. If such cannot be
avoided, e.g. for measurements, tests or adjustments,
have the action carried out by a qualified electrician
only, with appropriate tools, and ascertain that the
required bodily protection against electrical hazards is
applied.
21 Never touch the power terminals during operation of
the machine.
22 Whenever an abnormal condition arises, e.g.
excessive vibration, noise, odour, etc., switch the
circuit breakers to OFF and stop the engine. Correct
the faulty condition before restarting.

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23 Check the electric cables regularly. Damaged cables
and insufficient tightening of connections may cause
electric shocks. Whenever damaged wires or
dangerous conditions are observed, switch the circuit
breakers to OFF and stop the engine. Replace the
damaged wires or correct the dangerous condition
before restarting. Make sure that all electric
connections are securely tightened.
24 Avoid overloading the generator. The generator is
provided with circuit breakers for overload protection.
When a breaker has tripped, reduce the concerned
load before restarting.
25 If the generator is used as stand-by for the mains
supply, it must not be operated without control system
which automatically disconnects the generator from
the mains when the mains supply is restored.
26 Never remove the cover of the output terminals during
operation. Before connecting or disconnecting wires,
switch off the load and the circuit breakers, stop the
machine and make sure that the machine cannot be
started inadvertently or there is any residual voltage
on the power circuit.
27 Running the generator at low load for long periods
will reduce the lifetime of the engine.
Safety during maintenance and repair
Maintenance, overhaul and repair work shall only be
carried 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 good condition.
2 Parts shall only be replaced by genuine Chicago
Pneumatic 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 to
the starting equipment.
On engine-driven units the battery shall be
disconnected and removed or the terminals covered
by insulating caps.
On electrically driven units the main switch shall be
locked in open position and the fuses shall be taken
out. A warning sign bearing a legend such as “work in
progress; do not supply voltage” shall be attached to
the fuse box or main switch.
4 Prior to stripping an engine or other machine or
undertaking major overhaul on it, prevent all movable
parts from rolling over or moving.
5 Make sure that no tools, loose parts or rags are left in
or on the machine. Never leave rags or loose clothing
near the engine air intake.
6 Never use flammable solvents for cleaning (fire-risk).
7 Take safety precautions against toxic vapours of
cleaning liquids.
8 Never use machine parts as a climbing aid.
9 Observe scrupulous cleanliness during maintenance
and repair. Keep away dirt, cover the parts and
exposed openings with a clean cloth, paper or tape.
10 Never weld on or perform any operation involving
heat near the fuel or oil systems. Fuel and oil tanks
must be completely purged, e.g. by steam-cleaning,
before carrying out such operations. Never weld on,
or in any way modify, pressure vessels. Disconnect
the alternator cables during arc welding on the unit.
11 Support the towbar and the axle(s) securely if working
underneath the unit or when removing a wheel. Do not
rely on jacks.
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 lubricants
comply with all applicable safety regulations,
especially with regard to explosion or fire-risk and the
possibility of decomposition or generation of
hazardous gases. Never mix synthetic with mineral
oil.
14 Protect the engine, alternator, air intake filter,
electrical and regulating components, etc., to prevent
moisture ingress, e.g. when steam-cleaning.
15 When performing any operation involving heat,
flames or sparks on a machine, the surrounding
components shall first be screened with non-
flammable material.
16 Never use a light source with open flame for
inspecting the interior of a machine.
17 When repair has been completed, the machine shall be
barred over at least one revolution for reciprocating
machines, several revolutions for rotary ones to
ensure that there is no mechanical interference within
the machine or driver. Check the direction of rotation
of electric motors when starting up the machine
initially and after any alteration to the electrical
connection(s) or switch gear, to check that the oil
pump and the fan function properly.
18 Maintenance and repair work should be recorded in an
operator’s logbook for all machinery. Frequency and
nature of repairs can reveal unsafe conditions.
19 When hot parts have to be handled, e.g. shrink fitting,
special heat-resistant gloves shall be used and, if
required, other body protection shall be applied.
20 When using cartridge type breathing filter equipment,
ascertain that the correct type of cartridge is used and
that its useful service life is not surpassed.
21 Make sure that oil, solvents and other substances
likely to pollute the environment are properly
disposed of.
22 Before clearing the generator for use after
maintenance or overhaul, submit it to a testrun, check
that the CPG power performance is correct and that
the control and shutdown devices function correctly.

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Tool applications safety
Apply the proper tool for each job. With the knowledge
of correct tool use and knowing the limitations of tools,
along with some common sense, many accidents can be
prevented.
Special service tools are available for specific jobs and
should be used when recommended. The use of these
tools will save time and prevent damage to parts.
Battery safety precautions
Batteries
When servicing batteries, always wear protecting
clothing and glasses.
1 The electrolyte in batteries is a sulphuric acid solution
which is fatal if it hits your eyes, and which can cause
burns if it contacts your skin. Therefore, be careful
when 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
around the battery for several hours after it has been
charged. 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) in parallel
to the unit battery (CB) with booster cables: connect
the + pole of AB to the + pole of CB, then connect the
- pole of CB to the mass of the unit. Disconnect in the
reverse order.

- 11 -
Leading particulars
General description
The CPG 20 and CPG 25 are CPG generators, built for continuous running at sites where no electricity is available or as stand-by in cases of interruption of the mains. The generator
is equipped with a voltage selector switch which allows operation at 60 Hz, 480V L-L (277V L-N) 3PH, 240V L-L (139V L-N) 3 PH or 240V L-L (120V L-N) 1PH. The CPG 20
and CPG 25 generators are driven by a fluid-cooled diesel engine, manufactured by KUBOTA. An overview of the main parts is given in the diagram below.
1 Lifting beam
2 Side doors
3 Engine exhaust
4 Data Plate
5 Door, access to control and indicator panel
6 Output terminal board
7 Hole for forklift
8 Emergency stop button (ESB)
9 Filler cap fuel (FCF)
10 Filler cap coolant (FCW)

- 12 -
A Alternator
AF Air filter
BS Battery switch (optional equipment)
C Coupling
DFO Drain flexible engine oil
DFW Drain flexible coolant
DH Drain and access hole (in the frame)
DPF Drain plug fuel
EEngine
FFan
FCW Filler cap coolant
FCO Filler cap engine oil
FF Fuel filter
G1 Battery
OF Oil filter
OLD Engine oil level dipstick

- 13 -
Bodywork
The alternator, the engine, the cooling system, etc. are
enclosed in a sound-insulated bodywork that can be
opened by means of side doors (and service plates).
The recess in the roof has a lifting rod in the middle.
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 earth
terminal is located at the side of the frame.
Markings
A brief description of all markings provided on the
generator is given hereafter.
Drain plugs and filler caps
The drain holes for the engine oil, the coolant and the plug
for the fuel, are located and labelled on the frame; the fuel
drain plug at the front, the others at the service side.
The drain flexible for engine oil can be brought to the
outside of the generator through the drain hole.
The filler cap for the engine coolant is accessible via an
opening in the roof. The fuel filler cap is located in the side
panel.
Never use the guiding rods to lift the
generator.
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 not be
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.
!
diesel
Indicates the drain for the coolant.
Indicates the drain plug for the engine fuel.
Use GENOIL 15W40 only.
Indicates the different earthing connections
on the generator.
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.
Read the instruction manual
before using the lifting eye.
Indicates the 3-way valve.
Indicates the partnumbers of the
different service packs and of
the engine oil. These parts can
be ordered to the factory.
Position 1 Closed Position 2
The drain hole can also be used to guide
external fuel tank connections. When
connecting an external fuel tank, use the 3-
way valves. Refer to External fuel tank
connection (with/without quick couplings).
!

- 14 -
Control and indicator panel Qc1002™
General description Qc1002™ control panel
A1..... Qc1002™ display
F10 ... Fuse
The fuse activates when the current from the
battery to the engine control circuit exceeds its
setting. The fuse can be reset by pushing the
button.
H0..... Panel light
S20... ON/OFF/REMOTE switch
To start up the unit (locally or remote).
X25... Terminal strip
Qc1002™ Module
The Qc1002™ module is located inside the control panel.
This control module will carry out all necessary tasks to
control and protect a generator, regardless of the use of the
generator.
This means that the Qc1002™ module can be used for
several applications.
Pushbutton and LED functions
Following pushbuttons are used on the
Qc1002™
Following LEDs 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.
Qc 1002
145
Power Green LED indicates that the unit is powered up.
Remote Green LED indicates that the Remote Mode is
selected.
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.
Remote
Power
Alarm
Qc 1002
145

- 15 -
Qc1002™ Menu Overview
At Qc1002™, the LCD will show following information:
–inNormal condition (scroll through the information using
UP and DOWN):
• Status (eg: preheat, crank, run, cooldown, extended stop
time, …)
• Controller type & version
• Parameter list
• Alarm list
•LOGlist
• Service Timer 1 & Service Timer 2
• Battery Voltage
• Fuel level
• Voltage - frequency - running hours
–inAlarm condition (scroll through the information using
UP and DOWN):
• a list of all active Alarms
It's possible to scroll through the views, using the UP and
DOWN buttons. The scrolling is continuous.
If a Special status comes up, the Status Display is shown.
If an Alarm comes up, the Alarm Display is shown.
Controller type 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 16.
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 17.
LOG list display
This view shows the alarm memory and gives access to it.
An overview is given in “LOG list” on page 18.
Service timer 1 & Service timer 2 display
This view shows both Service timers. The service timer
indication is shown when service time has run out. It can
be removed by resetting the timers or acknowledging the
Service timer indication.
The service timer indications count and give an alarm
when value is reached.
Resetting the Service Timers can be done through the
Parameter display.
Battery Voltage display
This view shows the Battery voltage and the running
hours.
Fuel level display
This view shows the Fuel level and the running hours.
Voltage - frequency - running hours display
This view shows the voltage, frequency 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 updated when the status
pop-up window is active.
These special statuses are:
Qc1002
v1.00.0
Parameter
Alarm List
0 Alarm(s)
LOG List
Service 1
Service 2
59h
59h
13.2 VBattery
00168.1h
PREHEAT
75%Fuel
00168.1h

- 16 -
If a special status has elapsed, the active view will be
entered 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 to change a
setting is about to be done (user password = 2003).
Menu's shown on the Parameter list LCD:
– Running hours adjust
This menu is used to adjust the amount of running hours. The
running hours can only be raised, not lowered.
– Unit Type
– Service Timer 2 reset
– Service Timer 1 reset
These menus are used to reset the service timers. When a
service timer alarm occurs and is acknowledged, the service
timer will be reset automatically.
– 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, Italian, Spanish
and Cyrillic (Russian). All information in the Parameter List
display is always in English.
– Generator Underfrequency: failclass, enable, delay,
setpoint
– Generator Overfrequency: failclass, enable, delay,
setpoint
– Generator Undervoltage: failclass, enable, delay, setpoint
– Generator Overvoltage: failclass, enable, delay, setpoint
It's possible to scroll between configuration menu's by
using the pushbuttons UP and DOWN.
Pushing the ENTER button activates the configuration
menu which is shown at the display.
START OFF/
EXTENDED STOP
TIMER
COOLDOWN
Unit type 1 for CPG 20-25 !
!
This is the described menu flow for changing the unit type:
Qc 1002
145
Qc1002
145
Parameter Running time
Unit type
Unit type

- 17 -
Alarm Display (pop-up window)
In case an Alarm occurs, a pop-up window will
automatically be displayed for as long as the alarm is
active, no matter which view is active. The flashing red
alarm LED will light up. The alarm icons will be shown
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 red alarm LED will light up
continuously.
The Alarm Display can always be left by pushing the
BACK button.
If more than one alarm comes up, it's possible to scroll
through the alarm messages with the UP and DOWN
pushbuttons. 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 + Generator Contactor
opens
– Trip and Stop: ‘Trip of GB’ actions + unit stops after
Cooldown
– Shutdown: ‘Trip of GB’ actions + unit stops immediately
List of possible alarms:
An alarm should always be acknowledged
before solving the problem that causes the
alarm.
!
LOW OIL PRESSURE
HIGH COOLANT
TEMPERATURE
CHARGING
ALTERNATOR
LOW FUEL LEVEL
GENERATOR
OVERVOLTAGE
GENERATOR UNDER-
VOLTAGE
GENERATOR OVER-
FREQUENCY
GENERATOR UNDER-
FREQUENCY
SERVICE TIMER 1

SERVICE TIMER 2
ENGINE ALARM
EMERGENCY STOP
START FAILURE
STOP FAILURE





- 18 -
LOG list
The unit will keep an event log of the latest 30 events.
Events are:
– shutdowns
– service timer 1/2 reset
– unit type changes
Together with each event, the running hours at the time of
the event will be stored.
Remort Start operation
Installation wirings:
– X25.1 & X25.2 to be wired for the remote start switch.
– X25.3 & X25.4 to be wired 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).
1 Controller type
2 Event number
3Event
4 Running hours
Time: 00001h
EVENT LOG #04
Water
Qc1002
1
3
4
2

- 19 -
Output terminal board
The output terminal board option is situated below the
control and indicator panel.
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, by turning it anti-clockwise, before the
generator can be restarted. The emergency stop
button can be secured in the locked position with
the key, to avoid unauthorized use.
Q1, Q2Main circuit breaker
Interrupts the power supply to X1 when a short-
circuit occurs at the load side, or when the earth
leak detector (30 mA) or the overcurrent protection
(CPG 20: 32 A, CPG 25: 32 A) is activated or
when the shunt trip is energized. It must be reset
manually after eliminating the problem.
X1 .... Main power supply (400 V AC)
Terminals L1, L2, L3, N (= neutral) and PE (=
earthing), hidden behind the control panel door and
behind a small transparent door.
Spillage free
A Spillage free skid with forklift slots allows the customer
to transport the generator easily with a forklift.
It avoids accidental spilling of engine fluids.
Electronic speed regulator
The electronic speed regulator makes sure that the output
frequency of the generator is fixed (60 Hz), independent
of the amount of load.

- 20 -
Operating instructions Installation
– Place the generator on a horizontal, even and solid floor.
– The generator should be kept with the doors closed, in
order to avoid the ingress of water and dust. Dust ingress
reduces the lifetime of filters and may reduce your
generator's performance.
– Check that the engine exhaust is not directed towards
people. If the generator is operated indoors, install an
exhaust pipe of sufficient diameter to duct the engine
exhaust towards the outside. Check for sufficient
ventilation so that the cooling air is not recirculated. If
necessary, consult Chicago Pneumatic.
– Leave enough space for operation, inspection and
maintenance (at least 1 meter at each side).
– Check that the inner earthing system is in compliance 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 make sure not to have a contact voltage higher than 25
V.
– Check that the cable end of the earthing rod is connected
to the earth terminal.
Connecting the generator
Precautions for non-linear and sensitive
loads
The most common non-linear, 3-phase loads are thyristor/
rectifier-controlled loads, such as convertors supplying
voltage to variable speed motors, uninterruptable power
supplies and Telecom supplies. Gas-discharge lighting
arranged in single-phase circuits generate high 3rd
harmonics and risk for excessive neutral current.
Loads most sensitive to voltage distortion include
incandescent lamps, discharge lamps, computers, X-ray
equipment, audio amplifiers and elevators.
Consult Chicago Pneumatic for measures against the
adverse influence of non-linear loads.
Quality, minimum section and maximum
length of cables
The cable connected to the terminal board of the generator
must be selected in accordance with local legislation. The
type of cable, its rated voltage and current carrying
capacity are determined by installation conditions, stress
and ambient temperature. 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 allowable 3-
phase currents (in A), in an ambient temperature of 40°C,
for cable types (multiple and single core PVC insulated
conductors and H07 RN-F multiple core conductors) and
wire sections as listed, in accordance with VDE 0298
installation method C3. Local regulations remain
applicable if they are stricter than those proposed below.
In your own interest, always strictly
observe all relevant safety instructions.
Do not operate the generator in excess of
the limitations mentioned in the Technical
Specifications.
Local rules concerning the setting up of low
voltage power installations (below 1000 V)
must be respected when connecting site
distribution panels, switch gear or loads to
the generator.
At each start-up and at any time a new load
is connected, the earthing of the generator
must be verified. Earthing must be done
either by the earthing rod or, if available,
by an existing, suitable earthing
installation. The protective system against
excessive contact voltage is not effective
unless a suitable earthing is made.
The generator is wired for a TN-system to
IEC 364-3, i.e. one point in the power
source directly earthed - in this case the
neutral. The exposed conductive parts of
the electric installation must be directly
connected to the functional earth.
If operating the generator in another
power system, e.g. an IT-system, other
protective devices required for these types
must be installed. In any case only a
qualified electrician is authorized to
remove the connection between the neutral
(N) and earth terminals in the terminal box
of the alternator.
!
Non-linear loads draw currents with high
contents in harmonics, causing distortion in
the wave form of the voltage generated by
the alternator.
!