Crommelins P30 Administrator Guide

N
OPERATION & INSTRUCTION MANUAL
Thank you for your selection of a CROMMELINS Generator.
This Operation Manual explains its use, installation, checking and
maintenance. CROMMELINS suggest that you retain this manual for ready
reference regarding proper handling of CROMMELINS Generator.
CROMMELINS™GENERATORS
Spare Parts & Service
Phone: 1300 554 524
Freecall Fax: 1800 636 281
spareparts@crommelins.com.au
www.crommelins.com.au
WA Metro 9350 5588
WA Regional 1800 655 588

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CROMMELINS™GENERATOR Operation & Instruction Manual
Thank you very much for purchasing a CROMMELINS™GENERATOR.
This manual covers operation and maintenance of the CROMMELINS™GENERATOR.
This CROMMELINS™GENERATOR can be used in the agricultural, mining, construction, hire
industries and general recreational appliances. With regards to DC application, the terminals are
used only for charging 12 volt battery. Never use this generator for any other purpose.
Please take a moment to familiarise yourself with the proper operation and maintenance procedures
in order to maximise the safe and efficient use of this product.
Keep this owner’s manual at hand, so that you can refer to it at anytime.
Due to constant efforts to improve our products, certain procedures and specifications are subject to
change without notice.
When ordering spare parts please always supply us with the model number, production number
(prod no.) and serial number (ser no.) from your product.
Please fill in the following blanks after checking the production number and serial number on your
product. (The location of these numbers, vary depending on product).
Safety Precautions 3-4
Symbols and Meanings 5
Pre-operation Checks 6-7
Operating Procedures 8
Wattage Information 9
Specifications Petrol Models 10
Specifications Diesel Models 11
Optional Parts 12
Maintenance Schedule 13
How –to Maintenance 14
Periodic Operation and Inspection 15
Transporting 15
Preparation for Storage 16
PROD NO.
SER NO.

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CROMMELINS™GENERATOR Operation & Instruction Manual
1. SAFETY PRECAUTIONS
Please make sure you review each precaution carefully.
Pay special attention to statement preceded by the following words.
“WARNING” indicates a strong possibility of severe personal injury or loss
of life if instructions are not followed.
“CAUTION” indicates a possibility of personal injury or equipment damage
if instructions are not followed.
Do not operate the generator near gasoline or gaseous fuel because of the potential danger of
explosion or fire.
Do not fill the fuel tank with fuel while the engine is running. Do not smoke or use an open
flame near the fuel tank. Be careful not to spill fuel during refuelling. If fuel is spilt, wipe
it off and let dry before starting the engine.
Do not place flammables near the generator.
Be careful not to place fuel, matches, gunpowder, oily cloths, straw, trash, or any other
flammables near the generator.
Do not operate the generator inside a room, cave, tunnel, or other insufficiently
ventilated area. Always operate it in a well-ventilated area, otherwise the engine
may become overheated, and the poisonous carbon monoxide gas, an odourless,
colorless, poisonous gas, contained in the exhaust gases will endanger human lives.
Operate generator only outdoors and far from open windows, doors, ventilation
intakes and other openings. Keep the generator at least 1 meter (3 feet) away,
including overhead, from any structure or building use.
Do not enclose the generator nor cover it with a box.
The generator has a built-in forced air cooling system, and may become overheated if it is enclosed.
If generator has been coved to protect it from the weather during non use, be sure to remove it and
keep it well away from the area during generator use.
Operate the generator on a level surface.
It is not necessary to prepare a special foundation for the generator. However, the generator will
vibrate on an irregular surface, so choose a level place without surface irregularities.
If the generator is tilted or moved during operation, fuel may spill and /or the generator may tip
over, causing a hazardous situation.
Proper lubrication cannot be expected if the generator is operated on a steep incline or slope. In
such a case, piston seizure may occur even if the oil is above the upper level.
Pay attention to the wiring or extension cords from the generator to the connected device.
If the wire is under the generator or in contact with a vibrating part, it may break and
possibly cause a fire, generator burnout, or electric shock hazard.
Replace damaged or worn cords immediately.

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CROMMELINS™GENERATOR Operation & Instruction Manual
Do not operate in rain, wet or damp conditions, or with wet hands.
The operator may suffer severe electric shock if the generator is wet due to rain or snow.
If wet, wipe and dry it well before starting. Do not pour water directly over the generator, nor wash
it with water.
Ensure all necessary electrical grounding procedures are followed during each and every use. Failure
to do so can be fatal.
Do not contact the generator to a commercial power line as connection may short circuit the
generator and ruin it or cause electric shock hazard. Use the transfer switch for connecting to
domestic circuit.
No smoking while handling the battery. The battery emits flammable hydrogen gas,
which can explode if exposed to electric arcing or open flame.
Keep the area well-ventilated and keep open flames/sparks away when handling the battery.
Engine becomes extremely hot during and for some time after operation.
Keep combustible material well away from generator area.
Be very careful not to touch any parts of the hot engine especially the muffler area or
serious burns may result.
Keep children and all bystanders at a safe distance from work areas.
It is absolutely essential that you know the safe and proper use of the power tool or appliance that
you intend to use. All operators must read, understand and follow the tool/appliance owner’s
manual. Tool and appliance applications and limitations must be understood. Follow all directions
given on labels and warnings. Keep all instruction manuals and literature in a safe place for future
reference.
Use only 10AMP or 15AMP????? extension cords.
When a tool or appliance is used outdoors, use only extension cords marked “For Outdoor Use”.
Extension cords, when not in use should be stored in a dry and well ventilated area.
Always switch off generator’s AC circuit breaker and disconnect tools or appliances when not in use,
before servicing, adjusting, or installing accessories and attachments.
Make sure the engine is stopped before starting any maintenance, servicing or repair.
Make sure maintenance and repair of the generator are performed by properly trained personnel
only.

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CROMMELINS™GENERATOR Operation & Instruction Manual

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CROMMELINS™GENERATOR Operation & Instruction Manual
2. PRE-OEPERATION CHECKS
1. CHECK ENGINE OIL
Before checking or refilling oil, be sure generator is located on stable and level surface with
engine stopped.
Remove oil filler cap and check the engine oil level.
If oil level is below the lower level line, refill with suitable oil to upper level line.
Do not screw in the oil filler cap when checking oil level.
Change oil if contaminated.
2. RECOMMENDED ENGINE OIL
Use 4-stroke automotive detergent oil of API service class SE or higher grade SG, SH or SJ
recommended. SAE 10W-30 or 10W-40 is recommended for general, all-temperature use.
3. CHECK ENGINE FUEL
Do not refuel while smoking or near open flame or other such potential fire hazards. Otherwise
fire accident may occur.
Check fuel level at fuel level gauge
If fuel level is low, refill with unleaded automotive gasoline.
Be sure to use the fuel filter screen on the fuel filter neck.
Make sure you review each of the warnings in order to prevent fire hazard.
Do not refill tank while engine is running or hot.
Before filling fuel, turn the engine switch into fuel stop/close position.
Be careful not to allow dust, dirt, water or other foreign objects into fuel.
Wipe off split fuel thoroughly before starting engine.
Keep open flames away.
4. CHECKING COMPONENT PARTS
Check the following items before starting engine.
Fuel leakage from fuel hose, etc.
Bolts and nuts for looseness.
Components for damage or breakage.
Generator not resting on or against any adjacent wiring.
5. CHECK GENERATOR SURROUNDINGS
Make sure you review each warning in order to prevent fire hazard.
Keep area clear of flammables or other hazardous materials.
Keep generator at least 1 meter away from buildings or other structures.
Only operate generator in a dry, well ventilated area.
Keep exhaust pipe clear of foreign objects.
Keep generator away from open flames. NO SMOKING!
Keep generator on a stable and level surface.
Do not block generator air vents with paper or other material.
WARNING
WARNING
WARNING

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CROMMELINS™GENERATOR Operation & Instruction Manual
6. GROUNDING THE GENERATOR
To ground the generator to the earth, connect the grounding lug of the generator to the
grounding spike driven into the earth or to the conductor which has been already grounded
to the earth.
If such grounding conductor or grounding electrode is unavailable, connect the grounding
lug of the generator to the grounding terminal of the electric tool or appliance being used.
7. BATTERY INSTALLATION –(Electric Start Models)
Recommended Battery
Type –Lead-acid battery
Capacity (Ah/5hr) –12V-21AH or more
Size –Less than 185(L) x 125(W) x 150(H) mm
Death, personal injury and/or property damage may occur unless instructions are followed
carefully.
Use battery of recommended capacity.
Turn the starter switch to the “O” (stop) position when mounting or dismounting battery.
When mounting battery, connect the positive (+) cable first and then the negative (-) cable
to the battery. Be careful not to short battery cables. When dismounting battery, disconnect
negative (-) cable first.
RED CABLE –To positive (+) terminal
BLACK CABLE –To negative (-) terminal
Should a connection be made in an incorrect manner, the generator will not work.
Ensure bolts and nuts are tightened on terminals securely so they will not be loosened by
vibration.
Disconnect battery cables when charging battery.
WARNING

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CROMMELINS™GENERATOR Operation & Instruction Manual
3. OPERATING PROCEDURES
1. STARTING THE GENERATOR
Check the oil level before each operation as outlined by the article “CHECK ENGINE OIL”.
a) Turn the engine switch to the position “I” (on).
b) Turn the AC circuit breaker to the position “O” (off)
c) Open the fuel valve.
d) Set choke lever to close if the engine is cold.
e) Recoil starter model
Pull the starter handle slowly until passing the compression point (resistance will be felt),
then return the handle to its original position and pull briskly.
If the engine fails to start after several attempts, repeat above procedures with choke lever
returned to “OPEN” position.
Do not fully pull out the rope.
After starting, allow the starter handle to return to its original position while still holding the
handle.
f) Electric starter model
Insert the key into the key switch and turn it clockwise to the “I” (on) position to start the
engine, turn the key further to the start position, the engine will be started by starting motor.
Do not run the starting motor over 5 seconds continuously. If the engine fails to start,
return the key to the “I” (on) position and wait about 10 second then start again.
Do not turn the key switch to start position when the engine is running to prevent damage
of starting motor.
When starting the engine by recoil starter, set the key switch at the “I” (on) position and
pull the starter handle.
g) After the engine’s started, return the choke lever gradually to “OPEN” position.
h) Warm up the engine without load for a few minutes.
2. STOPPING THE GENERATOR
a) Turn off the power switch of the electric equipment and unplug the cord from receptacle of
the generator.
b) Allow the engine about 3 minutes to cool down at no-load before stopping.
c) Recoil starter model - Turn the engine switch to the position ”O” (off).
Electric starter model - Turn the key switch to the STOP position.
d) Close the fuel valve
3. OIL SENSOR
a) The oil sensor detects the fall in oil level in the crankcase and automatically stops the engine
when the oil level falls below a predetermined level.
b) When engine has stopped automatically, switch off generator’s AC circuit breaker, and check
the oil level. Refill engine oil to the upper level as instruction on page 6 and restart the engine.
c) If the engine does not start by usual starting procedures, check the oil level.
CAUTION
CAUTION

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CROMMELINS™GENERATOR Operation & Instruction Manual
4. WATTAGE INFORMATION
Some appliances need a “surge” of energy when starting.
This means that the amount of electrical power needed to start the appliance may exceed the
amount needed to maintain its use.
Electrical appliances and tools normally come with a label indicating voltage, cycles/Hz, amperage
(amps) and electrical power needed to run the appliance or tool.
Check with your nearest dealer or service centre with questions regarding power surge of certain
appliances or power tools.
Electrical loads such as incandescent lamps and hot plates require the same wattage to start
as is needed to maintain use.
Loads such as fluorescent lamps require 1.2 to 2 times the indicated wattage during start-up.
Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.
Electrical motors require a large starting current. Power requirements depend on the type of
motor and its use. Once enough “surge” is attained to start the motor, the appliance will
require only 50% to 30% of the wattage to continue running.
Most electrical tools require 1.2 to 3 times their wattage for running under load during use.
For example, a 5,000 watt generator can power a 1800 to 40000 watt electrical tool.
Loads such as submersible pumps and air compressors require a very large force to start.
They need 3 to 5 times the normal running wattage in order to start. For example, a 5,000
watt generator would only be able to drive a 1,000 to 1,700 watt pump.

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CROMMELINS™GENERATOR Operation & Instruction Manual
5. SPECIFICATIONS
MODEL
P30
P35
P62
P75
P85
P100E
Generator
Type
Sincro, 2 Pole, Single Phase
Voltage regulating system
Capacitor
AC Output
Rated voltage-Frequency V-Hz
240 - 50
Rated output VA (WA)
2100
2500
4700
5200
6200
7500
Maximum output VA (WA)
2400
2800
4960
6000
6800
8000
Rated power factor
0.8
MODEL
EX17D
EX21D
EH36D
EX35D
EX40D
BS16
Engine
Type
SUBARU Air-cooled, 4-stroke, Gasoline Engine
Displacement mL
169
211
404
404
404
479
Fuel
Automotive Unleaded Gasoline
Fuel tank capacity L
12.8
(16.6)*1
7.0
22.0
(27.5)*1
8.4
Engine oil capacity L
0.6
1.2
1.2
1.7
Rated continuous operation H
10.5
9.0
8.5
7.5
6.6
Spark Plug
BR6HS
BPR6ES
BR6HS
RC12YC
Starting system
Recoil (Electric Start Optional)
Recoil +
Electric
¾ Load fuel consumption L/H
1.0
1.3
2.0
2.4
2.7
3.1
Noise Level (db@7m)
69
71
72
72
Direction of rotation
Counter - clockwise
Dimension
Length cm
71
71
85
85
85
80
Width cm
45
45
50
50
50
50
Height cm
50
50
54
54
54
65
Dry weight kg
40
42
74
74
75
95
Specifications are subject to change without notice.
*1: ( ) shows the filled amount up to the “LEVEL” position.

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CROMMELINS™GENERATOR Operation & Instruction Manual
6. SPECIFICATIONS
MODEL
D32E
D56
D69
D8EH
D8KEH
Generator
Type
Sincro, 2 Pole, Single Phase
Voltage regulating system
Capacitor
AC Output
Rated voltage-Frequency V-Hz
240 - 50
Rated output VA (WA)
2200
4100
4800
5000
Maximum output VA (WA)
2560
4500
5500
6000
Rated power factor
0.8
MODEL
DY272D
DY41D
DY42D
1B40
KD500
Engine
Type
SUBARU Air-cooled, 4 stroke,
overhead valve, diesel engine
Hatz
diesel
engine
Kohler
diesel
engine
Displacement mL
265
412
462
505
Fuel
Automotive Diesel
Fuel tank capacity L
3.2
4.5
5.0
Engine oil capacity L
0.9
1.1
1.5
Rated continuous operation H
Starting system
Electric
Start
Recoil Start (Electric
Start Optional)
Electric
Start
Electric
Start
¾ Load fuel consumption L/H
Noise Level (db@7m)
76db
79db
79db
82db
80db
Direction of rotation
Counter-clockwise
Dimension
Length cm
71
86
86
92
92
Width cm
45
52
52
71
71
Height cm
54
65
65
95
95
Dry weight kg
75
112
114
128
122

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CROMMELINS™GENERATOR Operation & Instruction Manual
7. OPTIONAL PARTS
Hire Pack Option
2 Wheel kit
Lifting handle
Central lifting bar
Weather proof outlets
Circuit breakers
Earth spike & lead
Earth leakage switch
Mine Spec Option for Petrol
Fire extinguisher
Bunding
Emergency stop
Circuit breakers
Earth spike & lead
Battery isolator
Earth leakage switch
Mine Spec Option for Diesel Electric Start Option
2 x Weatherproof (IP66) outlets • HD steel frame to suit e/start
Electric start with sealed battery • Starter motor, Key start
Earth leakage switch/RCD • Battery included
Earth stake & lead
Circuit breakers Optional Extras for most Models
Brushless Alternator • 2 or 4 Wheel kit
2 x Wheels with fold out handle • Carry handle
4 x Wheels (larger models) • Drip tray
Central lifting point • Long range fuel tank
Emergency stop button • Anderson jump start plug
Lockable battery isolator • Recoil lockout
Bunding
1kg fire extinguisher
Recoil lockout
Anderson jump start plug
(options vary depending on mine site)
CENTRAL LIFTING BAR
RECOIL START &
ELECTRIC START
CIRCUIT BREAKER
2x Power outlets with breaker
2x WHEEL KIT
Heavy duty wheels
LIFTING HANDLE
Easily move the
genset to any site
PETROL OR
DIESEL ENGINE
HEAVY DUTY
STEEL FRAME
Powder coated
POWER OUTLETS
Weather proof outlets
EARTH LEAKAGE
SWITCH/RCD
QUALITY
ALTERNATOR
CENTRAL
LIFTING BAR
RECOIL START
ELECTRIC START
RECOIL LOCKOUT
LONG RANGE
FUEL TANK OPTION
Extend the running
time up to 8hrs
EARTH LEAKAGE
SWITCH/RCD
EARTH SPIKE
& LEAD
CIRCUIT BREAKER
Breaker for each Outlet GENUINE
SUBARU DIESEL
ENGINE
HEAVY DUTY
STEEL FRAME
Powder coated frame
POWER OUTLETS
WITH RCD
Weather proof outlets
MUFFLER
Creates soft tone
DRIP TRAYS & BUNDING
Prevent spills from all liquids
FIRE EXTINGUISHER
OPTION
1kg, Class A, B & E fires
BATTERY & BATTERY
ISOLATOR
ANDERSON JUMP
START PLUG
AIR CLEANER

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CROMMELINS™GENERATOR Operation & Instruction Manual
8. MAINTENANCE SCHEDULE
DAILY
Check oil level
Check all components according to “PRE-OPERATION CHECKS.”
EVERY
50 HOURS
Wash cleaner element. - more often if used in dirty/dusty environments.
Check spark plug, clean if necessary.
EVERY
100 HOURS
Change engine oil. *- more often if used in dirty/dusty environments.
Clean spark arrestor.
EVERY
200 HOURS
Adjust spark plug gap.
Clean fuel strainer.
EVERY
500 HOURS
Replace spark plug and cleaner element.
Clean and adjust carburettor, valve clearance, and valve seat along with cylinder
head.
EVERY
1000 HOURS
(24 MTHS)
Inspect control panel parts.
Check rotor and starter.
Replace engine mount rubber.
Overhaul engine.
Change fuel lines.
NOTE: (*)
Initial oil change should be performed after first twenty (20) hours of use. Thereafter change
oil every 100 hours.
Before changing oil, check for a suitable way to dispose of the old oil.
Do not pour it down sewage drains, onto garden soil or into open streams.
Your local zoning or environmental regulations will give you more detailed instruction on
proper disposal.

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CROMMELINS™GENERATOR Operation & Instruction Manual
9. “HOW-TO” MAINTENANCE
Make sure the engine is stopped before starting any maintenance, servicing or repair.
NOTE
It is recommended to use ear protection when performing operation, maintenance and repair
of the generator set.
1. ENGINE OIL CHANGE
a) Change engine oil every 100 hours. (For new engine, change oil after 20 hours).
b) Drain oil by removing the drain plug and the oil filler cap while the engine is warm.
c) Reinstall the drain plug and fill the engine with oil until it reaches the upper level on the oil
filler cap.
d) Use fresh and high quality lubricating oil to the specified level as directed on page 6. If
contaminated or deteriorated oil is used or the quantity of the engine oil is not sufficient,
engine damage will result and its life will be greatly shortened.
2. SERVICING THE AIR CLEANER
Maintaining an air cleaner in proper condition is very important.
Dirt induced through improperly installed, improperly serviced or inadequate elements causes
damage and wears out the engine. Always keep the element clean.
a) Remove the bolt of air cleaner cover.
b) Remove the air cleaner cover and cleaner element.
c) Urethane foam: wash urethane foam element in kerosene or diesel fuel. Then saturate the
element in a mixture of 3 parts kerosene or diesel fuel and 1 part engine oil. Squeeze the
element to remove the mixture and install it in the air cleaner.
NOTE
Instead of washing oil (kerosene), it is possible to wash the urethane foam element in a solution
of mild detergent and warm water. Then rinse the element thoroughly in clean water. Allow the
element to dry thoroughly. Soak the element in clean engine oil and squeeze out excel oil.
3. CLEANING AND ADJUSTING SPARK PLUG
a) If the plug is contaminated with carbon, remove it and clean it with a plug cleaner or wire
brush.
b) Adjust the electrode gap to 0.6 to 0.7mm (Spark Plug: BR6HS)
4. CLEANING FUEL STRAINER
Dirt and water in the fuel are removed by the fuel strainer.
a) Remove the strainer cup and throw away water and dirt.
b) Clean the screen and strainer cup with gasoline.
c) Tightly fasten the cup to main body, making sure to avoid fuel leak.
CAUTION

10. PERIODIC OPERATION AND INSPECTION
When generator is used as an emergency electrical power source, periodic operation and inspection
is required to ensure machine will operate when needed.
Fuel (gasoline/diesel) and engine oil will deteriorate overtime, and this may cause the engine to be
difficult to start and will result in improper engine operation and fault.
Since the fuel (gasoline/diesel) will have deteriorated overtime, replace with fresh fuel
periodically, every (3) months is recommended.
a) Check the fuel (gasoline/diesel), engine oil and air cleaner.
b) Start engine.
c) With appliances such as lights activated, run the engine for over ten minutes.
d) Check for the following:
Proper engine running.
Adequate output and the indicator lamp turned on properly.
The engine switch normally operated.
No leakage of engine oil and fuel (gasoline/diesel).
11. TRANSPORTING
When transporting the generator, make sure that the fuel (gasoline/diesel) is drained from the tank.
To prevent fuel spillage due to the vibration and impact, never transport the generator with
the fuel (gasoline/diesel) filled in the tank.
Secure the tank cap thoroughly.
To avoid the risk of the gasoline flammability, never leave the generator in an area exposed
to direct sunlight or high temperatures for a long time.
Keep the fuel (gasoline/diesel) in the exclusive gasoline/diesel storage tank made by steel
when transporting.
a) Turn the engine switch to the “STOP” position.
b) Drain the fuel from the tank.
c) Secure the tank cap.
Do not place any heavy objects on the generator.
Select and place the generator in the proper position of the transport vehicle so that the
generator does not move or fall down. Fix the generator with rope were necessary.
WARNING
CAUTION
CAUTION

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CROMMELINS™GENERATOR Operation & Instruction Manual
12. PREPARATION FOR STORAGE
The following procedures should be followed prior to storage of your generator for periods of 6
months or longer.
Drain fuel from fuel tank carefully by disconnecting the fuel line. Gasoline/diesel left in the
fuel tank will eventually deteriorate making engine starting difficult.
Remove the carburettor float chamber and also drain the carburettor.
Change engine oil.
Check for loose bolts and screws, tighten them if necessary.
Clean generator thoroughly with oiled cloth. Spray with preservative if available. (NEVER USE
WATER TO CLEAN GENERATOR)
Pull starter handle until resistance is felt, leaving handle in that position.
Store generator in a well ventilated, low humidity area.
13. TROUBLE SHOOTING
When generator engine fails to start after several attempts, or if no electricity is available at the
output socket, check the following chart. If your generator still fails to start or generate electricity,
contact your nearest SUBARU engine dealer or service agent for further information or corrective
procedures. To locate your nearest service agent go to www.crommelins.com.au.
When Engine Fails to Start:
Check if choke lever is in its proper position.
Set the choke lever to “CLOSE” position.
Check if fuel valve is open.
If closed, open fuel valve.
Check fuel level.
If empty, refill fuel tank making sure not to overfill.
Check if engine switch if in OFF position.
Turn engine switch to “ON”.
Check to make sure generator is not connected to an
appliance.
If connected, turn off the power switch on the
connected appliance and unplug.
Check spark plug for loose spark plug cap.
If loose, push spark plug cap back into place.
Check spark plug for contamination.
Remove spark plug and clean electrode.
NO Electricity Is Generated at Receptacle:
Check to make sure AC circuit breaker is in the “ON”
position.
After making sure that the total wattage of the
electrical appliance is within permissible limits and
there are no defects in the appliance, turn the AC
circuit breaker to the “ON” position. If breakers
continue to actuate, consult your nearest service
agent.
Check AC receptacle and DC terminals for loose
connection.
Carbon brushes are excessively worn.
Check to see if engine starting was attempted with
appliances already connected to generator.
Turn off switch on the appliance, and disconnect
cable from receptacle. Reconnect after generator
has been started properly.
Low power.
Carbon brushes are excessively worn.
This manual suits for next models
21
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