Cromtech TG6000DVE User manual

CROMTECH DIESEL GENERATOR
OPERATION MANUAL
DIESEL 6000W GENERATOR
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Pg. 2
Thank you for purchasing a Cromtech Diesel Generator.
This manual provides understanding of the operaon
and maintenance of your generator. Please read this
manual carefully before operang.
For any quesons regarding operaon or maintenance,
please consult your local service agent. Find your local
service agent at www.crommelins.com.au.
IMPORTANT ICONS
Important informaon is disnguished by the nocaons
below. The Safety Alarm Symbol ( !) alerts you to
potenal hazards. Please obey all safety informaon in the
symbol to avoid any possible injury or even death.
!DANGER: Indicates a hazardous situaon which, if not
strictly complied with, will result in substanal property
damage, serious injury or DEATH.
!WARNING: Indicates a hazardous situaon which, if
not strictly complied with, may result in property damage.
!CAUTION: Indicates a hazardous situaon which, if
not strictly complied with, could result in property damage
or injury.
!NOTE: Indicates important informaon to simplify
operaon and understanding.
!WARNING: PLEASE READ AND UNDERSTAND THIS
MANUAL BEFORE OPERATING THE GENERATOR.
!NOTE: We connually seek advancements in product
design and quality. Therefore, there may be minor
discrepancies in actual machine and the printed manual.
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INDEX
Warranty ....................................................................... 4
Safety Warnings ............................................................ 5
TG6000DVE Features ..................................................... 8
Control panel ............................................................ 8
Generator Specicaons .............................................. 9
Operang Checklist ....................................................... 10
Operang area .......................................................... 10
Operang condion .................................................. 10
Check engine oil ........................................................ 11
Check fuel levels ........................................................ 12
Electrical devices ....................................................... 12
Check air cleaner element ........................................ 13
Check generator ........................................................ 13
Connect to electrical devices .................................... 13
Low oil warning system/stop device ............................ 14
Break-in Operaon ........................................................ 14
Maximum capacity ....................................................... 14
Waage reference guide .............................................. 15
Pre-start Instrucons .................................................... 16
Starng the Generator .................................................. 16
Electric start ............................................................. 16
Recoil start (manual start) .......................................... 17
Running the generator .................................................. 17
During operaon ........................................................... 17
Stopping the generator ................................................. 18
AC applicaon ............................................................... 18
Generator overload ...................................................... 19
General Maintenance ................................................... 19
Maintenance schedule .............................................. 19
Air cleaner element ................................................... 20
Fuel lter ................................................................... 20
Adjustments .............................................................. 20
Baery/baery charging ........................................... 20
Electrical Diagram ......................................................... 21
Storage and Transport .................................................. 22
Storage ...................................................................... 22
Long term storage ..................................................... 22
Starng posion ........................................................ 22
Troubleshoong ............................................................ 23
Pg. 3
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WARRANTY
CROMTECH™and CROMMELINS™ are a registered trademark of The
Crommelin Group. Crommelins warrants their goods against defects in
materials and workmanship under normal use and service.
The Crommelin Group warranty does not cover fair wear commensurate
with the age of the product, any damage caused by accident, abuse,
misuse, neglect or failure to observe proper operang instrucons or
proper machinery maintenance as described in the instrucon manual.
It is the owner’s responsibility to regularly maintain a product in
accordance with the owner’s manual and only use the equipment for its
designed purpose.
Our goods come with guarantees that cannot be excluded under the
Australian Consumer Law. You are entled to a replacement or refund
for a major failure and for compensaon for any other reasonably
foreseeable loss or damage. You are also entled to have goods repaired
or replaced if the goods fail to be of acceptable quality and the failure
does not amount to a major failure.
CONSUMER ADVICE
Any claim under these warranes must be made in the warranty period
from the date of purchase of the product.
There are over 185 naonal authorised service/repair agents available,
visit www.crommelins.com.au for their details and locaons.
To make a claim under the warranty, you must return the product
(with proof of purchase) to the closest warranty agent or to the place of
purchase.
Where a failure does not amount to a major failure, Crommelins
Machinery is entled to choose between providing you with a repair,
replacement or refund. To obtain compensaon, you would need to
provide documentary evidence of the loss or damage suered, and
documentary evidence that such loss or damage was a reasonably
foreseeable consequence of a failure by The Crommelins Group to comply
with a consumer guarantee under the Australian Consumer Law.
Crommelins Operaons Pty Ltd trading as The Crommelin Group,
Crommelins Australia and Crommelins Machinery
THE CROMMELIN GROUP:
Phone [phone] Fax [phone]
recep[e-mail]
www.crommelins.com.au
PO Box 352, BENTLEY WA 6982
ABN 11 008 889 656
Pg. 4
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SAFETY WARNINGS
! WARNING: DO NOT Operate this generator unl
you have read ALL safety, operaon, and maintenance
instrucons listed in this manual.
• Failure to follow the instrucons may result in property
damage, INJURY or DEATH.
• The warnings and precauons discussed in this manual
cannot cover all possible condions and situaons that
may occur. It must be understood by the operator that
common sense and cauon are factors which cannot
be built into this product, but must be supplied by the
operator.
! WARNING: Modicaons to any part of the
generator is not allowed and will void your warranty.
! WARNING: This generator is intended for residenal
consumer use only. This generator is not designed for
permanent applicaon.
! WARNING: Before each use, check for loose or
damaged parts, signs of oil or fuel leaks, and any other
condion that may aect proper operaon. Repair or
replace all damaged or defecve parts immediately.
• Locate all operang controls and safety labels.
• Operate only on level surfaces.
• DO NOT expose generator to excessive moisture, dust,
or dirt.
• Keep all safety guards in place and in proper working
order at all mes.
• DO NOT allow any material to block the cooling slots.
• DO NOT allow children or untrained persons to operate
the generang set.
• DO NOT run the generang set unaended. Turn o the
generang set before leaving the area.
Pg. 5
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SAFETY WARNINGS
!DANGER: FIRE OR EXPLOSION - Diesel fuel is
ammable and explosive.
• Fire or explosion can cause severe burns or death.
• Keep ammable items away while handling fuel.
• Fill fuel tank outdoors and in a well-venlated area with
the generator stopped.
• Always wipe o spilled fuel and wait unl the fuel has
dried before starng the generator.
• DO NOT operate the generator with known leaks in the
fuel system.
• Use proper fuel storage and handling procedures. DO
NOT store fuel or other ammable materials nearby.
• Empty the fuel tank before storing or transporng the
generator.
• Keep re exnguisher handy and be prepared if a re
starts.
!DANGER: TOXIC FUMES - The exhaust of the generator
engine contains carbon monoxide, an odourless, colourless,
poison gas. Using engine indoors CAN KILL YOU!
• NEVER use generator inside any building or any kind of
enclosure, EVEN IF doors and windows are open.
• Place the generator in a well-venlated area and
consider wind and air currents when posioning the
generator.
!DANGER: MOVING PARTS - Moving parts can cause
severe injury. Keep hands and feet away.
• DO NOT operate generator with covers, shrouds, or
guards removed.
• DO NOT wear loose-ng clothing, dangling
drawstrings or items that could become caught. Tie up
long hair and remove jewellery.
• NEVER place ngers, hands, or body near the engine
when it is running.
!DANGER: KICKBACK - Rapid retracon of the starter
cord will pull hand and arm towards the engine faster
than you can let go.
• Unintenonal start-up could result in an injury.
Pg. 6
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SAFETY WARNINGS
!WARNING: HOT SURFACE - The running generator
produces heat. Severe burns can occur on contact.
• DO NOT touch generator while operang or just aer
stopping. Avoid contact with hot exhaust gases.
• Maintain at least one metre of clearance on all sides to
ensure adequate cooling.
• Combusble material can catch re on contact.
Maintain at least one metre of clearance from
combusble materials.
!WARNING: ACID (For types equipped with baery) -
Be careful when using any baery.
• Keep away from open ame, heat or spark.
• Baery will exhaust hydrogen while charging.
Only charge a baery in a well venlated place.
• Avoid spilled baery acid. If contact with skin is made,
wash immediately with clean water.
!WARNING: ELECTRICAL SHOCK - This generator
produces powerful voltage and the electricity CAN KILL
YOU.
• To reduce the risk of electrical shock, DO NOT use
electrical cords that are worn, frayed, bare or otherwise
damaged.
• DO NOT touch bare wires or receptacles.
• DO NOT operate generator in wet weather.
Keep the generator dry.
• DO NOT handle generator or electrical cords while
standing in water, while barefoot, or while hands or
feet are wet.
• DO NOT allow unqualied persons or children to
operate or service the generator.
• DO NOT connect this generator directly to a power
supply
Pg. 7
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TG6000DVE FEATURES
CONTROL PANEL
Pg. 8
❶ Fuel cap
❷ Fuel level indicator
❸ Fuel tank
❹ Frame
❺ Decompression Lever
❻ Muer guard
❶ On/O Switch
❷ Power indicator
❸ Volt Frequency Time Meter
❹ AC Reset switch/s
❺ RCD Breaker
❻ 2x 15 Amp Outlets
❼ Earth screw
❼ Air cleaner
❽ Recoil start
❾ Ignion switch
❿ VHT Meter
⓫ Outlets
⓬ Circuit breakers
⓭ Grounding screw
⓮ Rubber mounts
⓯ Alternator
⓰ Oil drain plug
⓱Oil ller cap/dipsck
⓲ Fuel connecting nut
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GENERATOR SPECIFICATIONS
Model TG6000DVE
Max. Output (W) 6000w
Cont. Rated Output (W) 5500w
Rated Voltage 240V / 50Hz
Power Factor 1.0
Engine 9.8hp Cromtech 188FG
Engine Features OHV, air cooled
Displacement 474cc
Fuel Type Diesel
Fuel Tank 12.5L
Oil Capacity 5.5L
Decibels at 1m (db) 95db
Weight (kg) 103.5kg
Packaging (LxWxH) 800x550x640mm
FEATURES
• 2x Outlets (single phase - 15amp IP66 rate)
• RCD Protecon
• AC Overload protecon
• VHT Meter (Volts, Hertz, Time)
• Diesel powered
• Electric start and recoil start
• Fold-out handles
• Low oil alarm, overload alarm, output indicator
• Large 12.5L fuel tank
• 1 Year Cromtech Warranty
Pg. 9
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OPERATING CHECKLIST
1. OPERATING AREA - This generator is for outdoor use.
• Only use OUTSIDE and place the generator in a
well-venlated area.
• Only operate the generator on a at, level surface
and in a clean, dry operang environment.
• Allow one metre clearance on all side of the
generator while operang it outdoors.
• Generators used for construcon sites may be
subject to addional rules and regulaons.
• DO NOT connect generator to power supply.
• When operang wear ear protecon.
! DANGER: TOXIC FUMES - The exhaust of the
generang set contains carbon monoxide, an
odourless, colourless, poison gas.
Using engine indoors CAN KILL YOU.
• NEVER use inside any building or any kind of
enclosure, EVEN IF doors and windows are open.
• Place the generator in a well-venlated area and
carefully consider wind and air currents when
posioning generator.
2. OPERATING CONDITION - Check for loose or damaged
parts, signs of oil or fuel leaks, and any other condion
that may aect proper operaon. Repair or replace all
damaged or defecve parts immediately.
• Remove any excessive dirt or debris, especially
around the muer and recoil starter.
• DO NOT move or p the generator during operaon.
Use generator only for intended uses. If you have
quesons about intended use, ask your local dealer.
! DANGER: Failing to correct problem(s) before
operaon could result in property damage, serious
injury or DEATH.
Pg. 10
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3. CHECK ENGINE OIL
! WARNING: This engine is not lled with oil. Any
aempt to crank or start the engine before it has
been properly lled (with the recommended type and
amount of oil) may result in engine damage and void
your warranty.
1. ENGINE OIL - Place the generator on a level surface
with engine stopped.
• Remove the dipsck and wipe it clean.
• Reinstall dipsck into tube; rest on oil ll neck,
DO NOT thread cap into tube.
2. Remove the dipsck again and check oil level. Level
should be at top of indicator on dipsck.
3. If lower, ll to the upper limit (marked with “H”) of
the dipsck with the recommended oil. Reinsert and
fully ghten the dipsck.
! WARNING: Oil is a major factor aecng
performance and service life of an engine.
Use SAE30 oil.
! CAUTION: LEVEL GROUND - Operate generator
only on levelled surface. The engine is equipped with
a low oil sensor (applicable types) that will automac
stop the engine when the oil level falls below the safe
limit. To avoid the inconvenience of an unexpected
shut-down, ll to the upper limit and check the oil
level regularly.
Pg. 11
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4. CHECK FUEL LEVELS
! CAUTION: Only diesel fuel can be used. The fuel
must be ltered. Fuel should be free of water or dust
as this can result in problems with the fuel injecon
generator and nozzle.
FILLING THE FUEL TANK - With the engine stopped,
check the fuel level gauge. Rell the fuel tank if
necessary.
• Use clean, fresh, regular diesel fuel only.
• DO NOT mix with other fuels.
• Be sure not to ll above the upper limit mark,
always ll to the level indicator, or ll to 25mm
below full level (to allow room for fuel expansion in
hot temperatures).
! DANGER: FIRE OR EXPLOSION - Diesel is
ammable and explosive. A re or explosion can cause
severe burns or death.
• Keep ammable items away while handling diesel
fuel.
• Fill fuel tank outdoors and in a well-venlated area
with the engine stopped.
• Always wipe o spilled fuel and wait unl the fuel
has dried before starng the engine.
• DO NOT operate the engine with known leaks in
the fuel system.
• Use proper fuel storage and handling procedures.
DO NOT store fuel or other ammable materials
nearby.
• Empty the fuel tank before storing or transporng
this engine.
• Keep re exnguisher handy and be prepared if a
re starts.
! CAUTION: To insure easy starng, do not use fuel
le over from the previous season.
5. ELECTRICAL DEVICES
! NOTE: Disconnect all electrical devices from the
generator before starng the engine.
• The generator may be hard to start with electrical
devices connected.
Pg. 12
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6. CHECK AIR CLEANER ELEMENT
! WARNING: Never run the generator without the
air cleaner element as damage to the engine may
occur.
• The air cleaner must be changed when the output
of engine decreases or if the exhaust colour looks
darker than normal. See page 19.
7. CONNECTING ELECTRICAL DEVICES
! NOTE: This generator is ed with an RCD Circuit
Breaker. ALWAYS test RCD switch before every use.
! CAUTION: Do not use any appliance with a
damaged cord or switch.
! NOTE: Allow the engine to stabilise and warm up
for a few minutes aer starng.
! NOTE: Make sure the electrical devices are in their
‘OFF’ posion and the load current is not higher than
the maximum withstanding current of a single socket.
Pg. 13
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LOW OIL WARNING SYSTEM/STOP DEVICE
! NOTE: The device works automacally to stop the
engine when the oil pressure falls below the regulatory
level to prevent engine seizure
• The oil temperature will rise too high if the engine is
operated with insucient oil.
• Too much oil is dangerous as it may cause sudden
excessive engine revs.
• Be sure to check oil is at opmum specied levels.
BREAK-IN OPERATION
! WARNING: While your generator is sll new,
applicaon of heavy loads may shorten the life of the
engine. Follow the break-in procedures during the rst
20-30 hours.
1. Avoid applying any heavy load during break-in period.
2. Change engine oil regularly (Every 20 hours or one
month aer inial use, and every 3 months or 100
hours thereaer).
MAXIMUM CAPACITY
! WARNING: DO NOT overload the generator.
Exceeding the capacity of generator can damage the
generator and/or electrical devices connected to it.
• You must make sure your generator can supply the
rated (running) and surge (starng) was for the
electrical device/s you are powering.
• Follow these simple steps to calculate the running and
starng was necessary for your purposes.
1. Select the electrical device/s you will
be powering
2. Calculate that the total amount of power
you need to run all devices is less than
the rated output of the generator. You
may need to check the items rated (running) was in
their manuals.
3. Idenfy how many surge (starng) was you may need.
Surge waage is the short burst of power needed
to start electric motor-driven appliances such as a
refrigerator or water generator.
Pg. 14
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! CAUTION: If connected devices overheat.
Immediately turn them o and disconnect from the
generator.
! NOTE: AC OVERLOAD RESET BUTTON/S - If the AC
power outlet is overloaded, the AC circuit breaker will cut
out the power to the device. If tripped remove device/
load and reset buon.
• If tripping connues, remove the device and have it
checked by a licensed electrician.
! NOTE: Not all motors can start at the same me, total
surge was can be esmated by adding only the electrical
device(s) with the highest addional surge was to the
total rated was.
WATTAGE REFERENCE GUIDE ONLY
ELECTRICAL EQUIPMENT RATED POWER (W)
Tablet computer 27” 120W
Electric Cooker 1000W
Personal Computer (standard) 250-600W
Refrigerator (standard) 50-200W
Kele 1800W
2.0hp Air Condioner 1800W
Electric Hammer 1000W
Water Generator 800W
Pg. 15
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PRE-START INSTRUCTIONS
! NOTE: When starng the generator for the rst me,
restarng the engine aer it stopped due to fuel shortage
or starng the engine aer fuel lter cleaning. Follow
these steps.
• Always check that there is no air trapped in the fuel
line. Trapped air needs to be cleared before starng.
1. To clear air in the fuel line, loosen the fuel
connecon nut that is between the injecng
generator and fuel line
(See page 8).
2. Ensure the ignion is in the
‘OFF’ posion.
3. Bleed the fuel line by pulling
the recoil starter to start the
ow of fuel.
4. Connue unl there is no air bubbles coming out
and the fuel is owing freely.
5. Tighten fuel connecon nut.
STARTING THE GENERATOR
ELECTRIC STARTING
! NOTE: Always keep the starng key turned to ‘ON’
while the engine is running.
1. The preparaon for starng the engine is the same as
the recoil start.
2. Open the fuel tap to the ‘ON’ posion (Fig 1).
3. Set the engine speed lever to ‘RUN’ posion (Fig 2).
Fig 1.
Engine
speed
lever
Fig 2.
Pg. 16
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Pg. 17
4. Push down the decompression lever (it will return
automacally when the engine is starng).
5. Turn the starng key clockwise to ‘START’ posion.
6. As soon as it starts, release your hand and let the
key automacally return to its inial posion. If the
generator doesn’t start aer 10 seconds, please wait at
least 15 seconds before aempng again.
RECOIL STARTING (MANUAL START)
! NOTE: Rapid retracon of the starter cord will pull hand
and arm towards the engine faster than you can let go.
Unintenonal start-up could result in an injury.
• Never pull out the recoil start when the diesel engine
is running, as damage may occur.
1. Open the fuel tap to the ‘ON’ posion.
2. Set the engine speed lever to ‘RUN’ posion.
3. Set ignion key switch to ‘ON’ posion.
4. Push down the decompression lever (it will return
automacally when the recoil starter is pulled).
5. Pull out the recoil start handle and prepare to start the
generator.
6. Pull the rope to the point where resistance is felt.
Return the recoil handle to the inial posion.
7. Grip the recoil handle rmly and pull quickly and briskly
(Two hands might be needed).
8. Return the recoil gently back to prevent damaging the
starter. Do not allow the handle grip to snap back.
RUNNING THE GENERATOR
! WARNING: Unapproved adjustment will damage
your engine and/or your electrical devices and void your
warranty.
• The speed has been set at the factory and should not
require readjustment. Consult your local authorised
service agent for advice.
• Warm up the engine for about 3 minutes without load
before using generator.
DURING OPERATION
! WARNING: Check for unusual sounds or vibraons
during operaon.
• Check for misring or the engine running rough
• If you noce any above problems, stop the engine and
consult you local service agent.
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STOPPING THE GENERATOR
! WARNING: NEVER stop the engine with electrical
devices connected and the connected devices turned ‘ON’.
1. Turn o all electrical equipment and disconnect all from
the generator.
2. Allow the generator to run at no load for 3 minutes
to stabilize internal temperatures of the engine and
generang set.
3. ELECTRIC START - Switch the ignion switch to the
‘OFF’ posion.
4. Turn the fuel tap to the ‘OFF’ posion
! CAUTION: If the engine connues to run even aer
the speed lever is moved to the ‘STOP’ posion, turn the
fuel tap to the ‘OFF’ posion to stop the engine. DO NOT
stop the engine with the decompression lever.
AC APPLICATION
! NOTICE: Do not run generator for extended periods
with no load or minimal load (e.g. when charging
baeries or powering low waage equipment such as TVs
and Radios). This may cause premature excessive carbon
build up or high oil consumpon. To prevent this, run the
generator periodically with an increased load.
1. Start the engine and make sure the pilot lamp turns on.
If it doesn’t, the lament may be damaged.
2. The speed of the generator must reach rated speed
(lever set to the ‘ON’) before applying load.
3. The generators speed has been factory set at 3000rpm
50Hz.
Engine
speed
lever
Pg. 18
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GENERAL MAINTENANCE
! NOTE: It’s the operator’s responsibility to complete
all scheduled maintenance in a mely manner. Correct
any issue before operang the generang set. Always
follow the inspecon and maintenance recommendaons
and schedules in this manual.
• Before servicing the generator, stop the generator,
disconnect all electric devices and baery (if equipped)
and allow the generator to cool down.
MAINTENANCE SCHEDULE - Follow the service intervals
indicated in the chart below. Service your generator more
frequently when operang in adverse condions.
• Contact your local service agent for parts or engine
maintenance needs.
• See maintenance schedule on next page.
Change lube oil
Pg. 19
GENERATOR OVERLOAD
! CAUTION: If an overloading of the circuit trips the
AC circuit Breaker, reduce the electrical load on the
circuit, wait a few minutes before resuming operaon.
• To reset an overload, shut down and restart the
generator.
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GENERAL MAINTENANCE
CHECK/CHANGE AIR CLEANER ELEMENT
! WARNING: Never run the generator without the air
cleaner element as damage to the engine may occur.
• The air cleaner must be changed when the output of
engine decreases or if the exhaust colour looks darker
than normal.
1. Loosen the wing nut,
detach the cover and
remove the air cleaner
element.
2. Wash in warm water. DO
NOT wash with detergent.
3. Squeeze thoroughly and
dry with a clean cloth.
4. Saturate in clean engine oil. Squeeze in a clean,
absorbent cloth to remove
all excessive oil.
5. Place element back in the
air cleaner and reaach the
cover. Tighten wing nut.
CHECK/CHANGE FUEL FILTER
! WARNING: Change lter regularly to insure maximum
engine output.
• CLEAN FILTER - Every 6 months or 300 hours.
• REPLACE FILTER - Every year or 1000 hours.
ADJUSTMENTS
! WARNING: Tampering with the factory set governor
will damage your generator and void your warranty.
CHECK BATTERY / CHARGING BATTERY
• Before starng check baery for damage. Baery ed
is maintenance-free, check for green light on baery to
ensure it is charged. If baery requires charging use a
compable baery charger. Baery type 12v 36ah.
Pg. 20
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