Green Power CC1200-NG User manual

CONTENT
INTRODUCTION ..................................................................................................................................1
SAFETY RULES ....................................................................................................................................2
COMPONENT IDENTIFICATION.....................................................................................................4
POWER PANEL LIST ..........................................................................................................................6
MAIN TECHNICAL SPECIFICATION AND DATA TABLE 1 ......................................................9
MAIN TECHNICAL SPECIFICATION AND DATA TABLE 2 ....................................................10
RUNNING CONDITION .................................................................................................................... 11
ENVIRONMENT REQUIREMENT ............................................................................................................ 11
GAS REQUIREMENT............................................................................................................................. 11
OPERATION........................................................................................................................................12
PRE-START PREPARATION ....................................................................................................................12
Generator Location........................................................................................................................12
Remove tightening brackets ...........................................................................................................12
Install the Support Leg (only for CC1500~CC5000 frame type generator sets)............................12
Add Engine Oil...............................................................................................................................13
Connect Generator to Gas Supply Source .....................................................................................13
Connect the Storage Battery ..........................................................................................................13
Grounding ......................................................................................................................................14
STARTING THE ENGINE ........................................................................................................................15
CONNECTING ELECTRICAL LOADS ......................................................................................................16
STOPPING THE ENGINE ........................................................................................................................16
POWER MANAGEMENT........................................................................................................................16
WAT TA G E REFERENCE CHART.............................................................................................................17
MAINTENANCE .................................................................................................................................18
ENGINE MAINTENANCE.......................................................................................................................19
Engine Oil ......................................................................................................................................19
Spark Plug......................................................................................................................................19
Air Filter ........................................................................................................................................20
Air-fuel Mixer.................................................................................................................................20
Cleaning.........................................................................................................................................20
GENERATOR MAINTENANCE ...............................................................................................................21
MAINTENANCE SCHEDULE ..................................................................................................................21
COMMON BREAKDOWNS AND TROUBLESHOOTING ........................................................... 22
STORAGE ............................................................................................................................................23
ENGINE STORAGE................................................................................................................................23
GENERATOR STORAGE ........................................................................................................................23
TRANSPORTATION ..........................................................................................................................23
ACCESSORY .......................................................................................................................................24
HOW TO INSTALL FOUR-WHEEL GENERATOR SET .................................................................................24
HOW TO INSTALL TWO-WHEEL (CC3000/4000/5000) GENERATOR SET ................................................25
HOW TO INSTALL TWO-WHEEL (CC1500/2000) GENERATOR SET .........................................................26
HOW TO OPERATE DUAL FUEL (NG/LPG) GENERATOR SET ..................................................................27
GENERATOR CIRCUIT DIAGRAM ...............................................................................................28

1
Introduction
“GREEN POWER” series gas powered generator set, they are mainly divided into frame
type, four-wheel type, handcart type and portable type on structure; and LPG type, NG
type, MG type and dual-fuel (LPG/NG) type on fuel.
Meaning of product model
For example: CC2000-LPG-B
ITEM MEANING
CC Corporation code, Shanghai “Chenchang” Power Technology Co., Ltd.
2000 product power code, maximum output power 2000 W.
LPG Fuel abbreviation. LPG: liquefied petroleum gas; NG: nature gas; MG:
methane gas; G: multi-fuel, LPG/NG, LPG/MG, NG/MG.
Bgenerator set frame code. B: frame type; X: portable type; L: four-wheel
type; T: handcart type.
Main types as follows:
Frame type Portable type
Four-wheel type Handcart type

2
Safety Rules
Please read and understand this manual thoroughly before operating your generator.
Failure to follow instructions could result in serious injury or death.
Exhaust gas contains poisonous carbon monoxide, which is harmful to the health. Never
use the generator set at the confined places or poor ventilated locations. If it’s necessary
to run the generator set, be sure to provide the adequate ventilation.
Generator produces powerful voltage.
DO NOT touch bare wires or receptacles. DO NOT use electrical cords that are worn,
damaged or frayed. DO NOT operate generator in wet weather. DO NOT allow children or
unqualified persons to operate or service the generator. DO NOT use a ground fault circuit
interrupter (GFCI) in damp areas and areas containing conductive material such as metal
decking. Use approved transfer equipment to isolate generator from your electric utility
and notify your utility company before connecting your generator to your power system.
Sparks can result in fire or electrical shock.
When servicing the generator:
Disconnect the spark plug wire and place it where it cannot contact the plug. DO NOT
check for spark with the plug removed. Use only approved spark plug testers.
Running engines produce heat. Severe burns can occur on contact. Combustible
material can catch fire on contact.
DO NOT touch hot surfaces. Avoid contact hot exhaust gas. Never touching the
equipment until it’s cool. Maintain at least three feet of clearance on all sides to ensure
adequate cooling. Maintain at least five feet of clearance from combustible materials.
Propane (LPG) and nature gas (NG) is highly flammable and explosive. Fire or
explosion can cause severe burns or death if the gas is ignited.
Before starting the generator
ˈ
inspect your LPG tank and NG pipeline and valve for
damage or leaks, attach only approved tanks that have been properly filled by an
approved station, do not light or smoke cigarettes, replace the hose at the first sign of a
leak or if age-cracking becomes apparent.
When starting the generator do not attempt to start a damaged generator, make certain
that the LPG tank, air filter, spark plug, fuel lines and exhaust system are properly in place,
make certain that the generator resting firmly on level ground.
WARNING
WARNING
DANGER
WARNING
WARNING
DANGER

3
When operating the generator do not move or tip the generator during operation, do not
tip the generator or allow oil to spill.
When transporting or servicing the generator make certain that the generator is
disconnected and properly shut off, disconnect the spark plug wire.
When storing the generator store away from sparks, open flames, pilot lights, heat and
other sources of ignition.
Rapid retraction of the starter cord will pull hand and arm towards the engine faster
than you can let go. Unintentional startup can result in entanglement, traumatic
amputation or laceration. Broken bones, fractures, bruises or sprains could result
in.
When starting engine, pull the starter cord slowly until resistance is felt and then pull
rapidly to avoid kickback. DO NOT start or stop the engine with electrical devices plugged
in.
The battery contains acid. Acid is strongly corrosive.
DO NOT use, store or expose the battery in high temperature situations, as in the direct
sunlight, inside automobiles during hot weather, directly in front of a heater, etc. Be sure to
turn off the equipment and remove the battery after use.
Exceeding the generator’s running capacity can damage the generator and/or electrical
devices connected to it. DO NOT overload the generator. Start the generator and allow
the engine to stabilize before connecting electrical loads. Connect electrical equipment in
the off position, and then turn them on for operation. Turn electrical equipment off and
disconnect before stopping the generator. DO NOT tamper with the speed governor. DO
NOT modify the generator in any way.
Improper treatment or use of the generator can damage it, shorten its life and void your
warranty. Use the generator only for intended use. Operate only on level surfaces. DO
NOT expose generator to excessive moisture, dust, or dirt. DO NOT allow any material to
block the cooling slots. If connected devices overheat, turn them off and disconnect them
from the generator. DO NOT use the generator if electrical output is lost, equipment
sparks, smokes or emits flames and equipment vibrates excessively.
WARNING
WARNING
CAUTION
CAUTION

4
Component Identification
Frame Type :
1. Exhaust Outlet
2. Alternator
3. Battery
4. Oil Filter Cap/Dipstick
5. Oil Drain Plug
6. Spark Plug Cap
7. Choke Grip
8. Engine Switch
9. Recoil Starter Grip
10. Starter Plate
11. Air Filter
12. Mixer
13. Engine
14. Muffler Mantle

5
Portable Type:
3. Muffler
2. Spark Plug Cap
11. Mixer
12. Air Filter
1. Choke Grip
4. Portable Handle
5. Alternator
6. Oil Filter Cap/Dipstick
8. Oil Drain Plug
7. Engine
9. Recoil Starter Grip
10. Starter Plate

6
Power Panel List
No. Power panel Electrical element on control
panel
Applicable
Type
Remark
A. Gas Inlet B. Circuit Breaker C. Ground Terminal D. AC Overload Protector E. AC Voltmeter F. AC Receptacle G. DC Overload Protector
1
H. 12V DC Receptacle
CC1200
Single Voltage (Single-phase) without Hour Meter(recoil)
A. AC Overload Protector B. DC Overload Protector C. Receptacle D. Power Indicator
2
E. 12V DC Receptacle
CC1200 Single Voltage
(Single-phase ǃ recoil) for portable type
A. Gas Inlet B. Keyed Ignition C. Circuit Protector D. AC Volt Meter E. Ground Terminal F. Circuit Breaker G. AC Receptacle H. AC Receptacle I. Hour Meter J. DC Overload Protector K. DC Red Terminal
3
L. DC Black Terminal
CC3000 CC4000 CC5000
Single Voltage (Single-phase) with Hour Meter ˄Electric Starter˅
A
B
C
D
E
A
B
CEF
DG
H
A
B
C
D
E
FGH
I
J
K
L

7
A. Gas Inlet B. Keyed Ignition C. Circuit Protector D. Hour Meter E. DC Overload Protector F. DC Red Terminal G. DC Black Terminal H. AC Volt Meter I. AC Red Terminal J. Circuit Breaker K. AC Black Terminal L. AC Receptacle
4
M. Ground Terminal
CC3000 ǃ CC4000 ǃ CC5000
Dual voltage ˄Three-phase ˅ with DC Terminal and Hour Meter
A. Gas Inlet B. Keyed Ignition C. Circuit Protector D. AC Volt Meter E. Ground Terminal F. Circuit Breaker G. AC Receptacle H. AC Receptacle I. Hour Meter J. DC Overload Protector
5
K. 12V DC Socket
CC3000ǃ CC4000ǃ CC5000
Single voltage ˄Single-phase ˅ with Hour Meter ˄Electric Starter˅
A
B
C
D E
F
G
H
I
J
K
L
M
A
B
C
D
E
FG
H
I J K

8
A. Gas Inlet B. Keyed Ignition C. Circuit Protector D. AC Volt Meter E. Ground Terminal F. Circuit Breaker G. AC Receptacle H. AC Receptacle I. AC Receptacle J. Hour Meter K. DC Overload Protector
6
L. 12V DC Socket
CC3000 ǃ CC4000 ǃ CC5000
Dual voltage ˄Single-phase˅ with Hour Meter ˄Electric Starter˅
A
B
C
D
E
F
G
H
I
J
K
L

9
Main Technical Specification and Data Table 1
Type
Item
CC700-LPG/NG CC1200-LPG
CC1200-NG
CC1200-G
CC1500-LPG
CC1500-NG
CC1500-G
CC2000-LPG
CC2000-NG
CC2000-G
Rated Frequency˄Hz˅50 60 50 60 50 60 50 60 50 60 50 60 50 60
Rated Output Power˄kW˅0.55 0.65 0.8 0.9 0.7 0.8 1.4 1.5 1.3 1.4 1.8 1.9 1.7 1.8
DC Voltage/Current DC˖12V/8.3A
Generator Mode
Single-Phase Synchronous Brush/Brushless
Alternator
Single-Phase Synchronous Brush Alternator
Power Code
CC152F-LPG CC152F-NG/G CC168F-LPG
CC168F-NG/
G
CC168F-LPG CC168F-NG/G
Power Type Single Cylinder, 4-stroke, OHV, Forced Air-cooled
BorehStroke˄mm˅52×38 68×45
Displacement˄CC˅81 163
Starting Mode Recoil Starter Recoil StarterǃRecoil/Electric Starter
Lube Oil Capacity˄L˅0.35 0.55
Fuel Consumption
(Rated Power)
LPG˖0.45kg/kW·h NG˖0.50m3/kW·h LPG˖0.34kg/kW·h NG˖0.36m3/kW·h

10
Main Technical Specification and Data Table 2
Model
Item
CC3000-LPG
CC3000-NG
CC3000-G
CC40000-LPG
CC4000-NG
CC4000-G
CC50000-LPG
CC5000-NG
CC5000-G
Rated Frequency˄Hz˅50 60 50 60 50 60 50 60 50 60 50 60
Rated Output Power˄kW˅2.8 3.0 2.6 2.7 3.7 3.8 3.4 3.8 4.6 4.7 4.2 4.5
DC Voltage/Current DC˖12V/8.3A
Generator Mode Single-Phase Synchronous Brush Alternator Single-Phase/Three-Phases Synchronous Brush Alternator
Power Code CC177F-LPG CC177F-NG/G CC182F-LPG CC182F-NG/G CC188F-LPG CC188F-NG/G
Power Type Single Cylinder, 4-stroke, OHV, Forced Air-cooled
BorehStroke˄mm˅77×58 82×64 88×64
Displacement˄CC˅270 337 389
Starting Mode Recoil StarterǃRecoil/Electric Starter
Lube Oil Capacity˄L˅0.9 0.9 0.9
Fuel Consumption
(Rated Power)
LPG˖0.33kg/kW·h NG˖0.35m3/kW·h LPG˖0.32kg/kW·h NG˖0.35m3/kW·h
Remark: 1˅Rated Output Voltage˄50Hz˅: 220Vǃ230Vǃ240Vǃ380Vǃ220V/380Vǃ230V/400Vǃ240V/415V˗˄60Hz˅: 110Vǃ115Vǃ120Vǃ110V/220Vǃ
115V/230Vǃ120V/240V
2˅Power Factor(cosij): For three-phase generator cosij=0.8; others cosij=1.

11
Running Condition
Environment Requirement
ķTemperature˖
for NG powered generator set: -30℃40 ;
℃
for LPG powered generator set: -5℃40℃.
ĸHeight above sea level: below 2,000m.
Gas Requirement
NG Powered Generator Set
Recommended gas pressure: 2.06.0 kPa( 0.290.87 psi).
Main Gas Valve should be equipped on main gas pipe.
LPG Powered Generator Set
LPG Pressure Regulator should be equipped on LPG-bottle.
Regulator outlet pressure should be as follow:
Type CC1200-LPG CC2000-LPG CC3000-LPGCC5000-LPG
Flow rate
Qm-LPG1.1Kg/h
QV-NG1.2m3/h
Qm-LPG2.0Kg/h
QV-NG2.5m3/h
Regulator outlet
pressure
2.5 kPa 3.2 kPa(0.360.46 psi)

Out of the range may lead to abnormal running even damage of generator set.
NOTICE

12
Operation
Pre-start Preparation
Generator Location
ƽ
This generator must have at least five feet of clearance from combustible material.
ƽ
Leave at least three feet of clearance on all sides of the generator to allow for adequate cooling,
maintenance and servicing.
ƽ
Place the generator in a well-ventilated area.
ƽ
DO NOT place the generator near vents or intakes.
Remove tightening brackets
I
Be sure to remove the tightening brackets before operating the generator set.
Install the Support Leg (only for CC1500~CC5000 frame type generator sets)
Attach the support leg to the generator frame with cap screw(M8×30) and lock nut(M8) at the
position 1~8.
CAUTION
1
2
3
4
5
6
7
8
CAUTION

13
Add Engine Oil
DO NOT attempt to crank or start the engine before it has been properly filled with the
recommended type and amount of oil.
Model CC500
CC700
CC1200
CC1500
CC2000
CC3000
CC4000
CC5000
Oil Capacity 0.35L 0.55L 0.90L
Lube Oil Type SAE5W-30 (Ambient Temperature < 4℃)
SAE10W-30 (Ambient Temperature > 4℃)
Connect Generator to Gas Supply Source
1. Keep the main gas valve closed and “Engine Switch” on “off” position.
2. Embed two clips on the two ends of approved gas pipeline.
3. Attached the gas pipeline to the gas inlet and gas supply source.
4. Use plus driver to tighten the clips on the ends of gas pipeline until it’s not easy to pull down from
gas pipeline.
All gas pipe joints should be fixed by clips tightly.
Connect the Storage Battery
For the Generator Set with Electric Starter, you need to connect the battery as follow:
For CC4000,CC5000
˖
For CC1500,CC2000 and CC3000
˖
Attach the red lead to the red terminal (positive, +) on the battery with the cap screw.
Attach the black lead to the black terminal (negative, -) on the battery with the cap screw.
CAUTION
Black
Negative
(-)
Red
Positive
(
+
)

14
Grounding
Your generator must be properly connected to an
appropriate ground to help prevent electric shock.
We strongly recommend that you consult with a qualified
electrician to ensure compliance with local electrical
codes.

15
Starting the Engine
Disconnect all electrical loads from the generator before starting the engine.
1. Open the Main gas valve.
2. Turn the Engine Switch to the “On” position.
Note: There is no this operation for portable generator set.
3. Move the Choke Grip to the “Choke” or “Close” position.
4. Start the engine.
For recoil start :
˄1˅Pull the Starter Grip slowly until resistance is felt and then pull rapidly.
˄2˅After the engine started, return the Starter Grip gently to prevent damage to the starter or
housing.
For electric start :
Turn the Keyed Ignition to the “Start” position and hold until engine starts. If the engine fails to
start within five seconds, release the key and wait at least 5 seconds before attempting to start the
engine again.
Note: this operation only for generator set with electric starter.
5. As engine warms up, move the Choke Grip to “Run” or “Open” position.
if your engine is starting, do a inspection on the top cooling
fan˄if the fan is installed in your generator˅, and ensure it is
operating. Otherwise, you should shut down the engine.
Choke Grip
NOTICE
CAUTION

16
Connecting Electrical Loads
Let the engine stabilize and warm up for a few minutes after starting.
1. Plug in and turn on Circuit Breaker from “OFF” to “ON” position.
2. Turn on the desired electrical loads.
ƽ
DO NOT overload the generator.
ƽ
DO NOT use parallel with any other generators.
ƽ
Connection to the household electrical system must be made by a qualified electrician.
Stopping the Engine
1. Turn off and unplug all electrical loads. Never start or stop the generator with electrical devices
plugged in or turned on.
2. Let the generator run at no-load for several minutes to stabilize.
3. Turn the Engine Switch to the “Off” position.
4. Turn off the Main gas valve.
Do Not Overload Generator Capacity
Follow these simple steps to calculate the running and starting watts necessary for your purposes.
1. Select the electrical devices you plan on running at the same time.
2. Total the running watts of these items.
This is the amount of power you need to keep your items running.
3. Identify the highest starting wattage of all devices identified in step 1. Add this number to the
number calculated in step 2. Surge wattage is the extra burst of power needed to start some electric
driven equipment. Following the steps listed under “Power Management” will guarantee that only
one device will be starting at a time.
Power Management
Use the following formula to convert voltage and amperage to watts:
Volts × Amps = Watts
To prolong the life of your generator and attached devices, follow these steps to add electrical load:
1. Start the generator with no electrical load attached.
2. Allow the engine to run for several minutes to stabilize.
3. Plug in and turn on the first item. It is best to attach the item with the largest load first.
4. Allow the engine to stabilize.
5. Plug in and turn on the next item.
6. Allow the engine to stabilize.
7. Repeat steps 5-6 for each additional item.
Note: Never exceed the generator capacity when adding loads.
WARNING

17
Wattage Reference Chart
Use the chart to determine approximate wattage requirements for your equipment.
Note: Starting watts can exceed three times the running watts.
The values in the following table are approximate. Refer to your tool or appliance for actual wattage
consumption.
Item Running Watts Starting Watts
Essentials
Light bulb 100W 100W 0
Refrigerator / Freezer 1200W 2400W
Freezer 500W 500W
Sump Pump 600W 1800W
Well Pump 1HP 2000W 4000W
Water Heater 4000W 0
Security System 180W 0
AM / FM Radio 300W 0
Garage Door Opener 1/2HP 500W 600W
Battery Charger 12V DC 110W 0
Heating / Cooling
Air Conditioner 12000 BTU 1700W 2500W
Fan 300W 600W
Furnace Fan 1/3 HP 1200W 2000W
Home Appliances
Microwave 1000W 1000W 0
Electric range – one element 1500W 0
Electric skillet 1250W 0
Coffee Maker 1500W 0
Clothes Washer 1200W 0
Entertainment
CD / DVD Player 100W 0
VCR 100W 0
Stereo Receiver 450W 0
Television 27” 500W 0
PC with 15” Monitor 800W 0
Job Site
Belt Sander 3” 1000W 1500W
Bench Grinder 6” 700W 1500W
Circular Grinder 1500W 1500W
Compressor 1 1/2 HP 2500W 2500W
Edge Trimmer 500W 500W
Hand Drill 1/2” 1000W 1000W
Lawn Mower 1200W 1800W
Paint Sprayer 600W 1200W
Table Saw 2000W 2000W

18
Maintenance
MAINTENANCE IMPORTANCE
ƽ
Complete all scheduled maintenance in a timely manner. Correct any issue before
operating the generator.
ƽ
Improper maintenance will void your warranty. Tampering with the factory set governor
will void your warranty.
ƽ
To ensure the best quality, use only genuine “Green Power” parts or their equivalents for
repair or replacement.
MAINTENANCE SAFETY
ƽ
Read the instructions before you begin, and make sure you have the tools and skills
required.
ƽ
Always follow the procedures and maintenance instructions in the owner

s manual.
WARNING

19
Engine Maintenance
To prevent accident happening, remove and ground spark plug wire before performing any service.
Engine Oil
Change oil when the engine is warm. Refer to the oil specification to select the proper grade of oil
for your operating environment.
1. Remove the oil drain plug.
2. Allow the oil to drain completely.
3. Reinstall the oil drain plug.
4. Remove oil fill cap/dipstick to add oil.
5. Add engine oil according to specification and reinstall oil fill cap/dipstick.
Change engine oil after the first 20 running hours. Check engine oil level before every use.
Spark Plug
1. Remove the spark plug cable from the spark plug.
2. Use the spark plug tool that shipped with your generator to remove the plug.
3. Inspect the electrode on the plug. It must be clean and not worn to produce the spark required for
ignition.
4. Make certain the spark plug gap as follow table.
5. Refer to below table when replacing the plug.
6. Carefully thread the plug into the engine.
7. Use the spark plug tool to firmly install the plug.
8. Attach the spark plug wire to the plug.
Inlet/Outlet Valve Clearance and Spark Plug Gap
Item
Inlet Valve
Clearance
˄cold˅
Outlet Valve
Clearance
˄cold˅
Spark Plug Gap
Spark Plug Screwing
Moment
CC1200-NG/LPG 0.20˄mm˅0.25˄mm˅
CC1500-NG/LPG
CC2000-NG/LPG
0.06~0.08
˄mm˅
0.08~0.10
˄mm˅
CC3000-NG/LPG
CC4000-NG/LPG
CC5000-NG/LPG
0.06~0.08
˄mm˅
0.08~0.10
˄mm˅
18~20˄N·m˅
Note: Allow the engine to cool before removing the spark plug. Otherwise, it will be damaged.
CAUTION
CAUTION