Cromtech TG6500VE User manual

CROMTECH AVR GENERATOR
OPERATION MANUAL
6500W AVR GENERATOR

Pg. 2
Thank you for purchasing a Cromtech 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 PUMP.
!NOTE: We connually seek advancements in product
design and quality. Therefore, there may be minor
discrepancies in actual machine and the printed manual.

INDEX:
Warranty ..................................................................... 4
Safety Warnings .......................................................... 5
TG6500VE Features ....................................................... 8
Generator Specicaons .............................................. 9
Features ..................................................................... 9
Geng Started ............................................................ 10
Unpacking .................................................................. 10
Assembly .................................................................... 10
Baery and Parts ......................................................... 12
Operang Checklist ...................................................... 13
Operang area ........................................................... 13
Operang condion ................................................... 13
Check engine oil ........................................................... 14
Check fuel levels .......................................................... 15
Electrical Devices ......................................................... 16
Grounding ................................................................... 16
Starng the Generator ................................................. 17
Connecng electrical devices .................................... 19
Maximum capacity .................................................... 19
Waage reference guide ........................................... 20
Charging a baery ..................................................... 21
Stopping the generator ............................................. 22
General Maintenance .................................................. 23
Maintenance schedule .............................................. 24
Generator maintenance ............................................ 24
Engine oil ................................................................... 25
Air lter ..................................................................... 26
Spark plug .................................................................. 27
Spark arrestor ............................................................ 28
Engine speed ......................................................... 28
Adjustments .......................................................... 28
Troubleshoong ......................................................... 29
Storage and Transport ................................................ 29
Storage ..................................................................... 29
Long term storage .................................................... 29
Transport .................................................................. 30
Pg. 3

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:
Ph: [phone] Fax: [phone]
recep[e-mail]
www.crommelins.com.au
PO Box 352, BENTLEY WA 6982
ABN 11 008 889 656
Pg. 4

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 may void your warranty.
! WARNING: This generator is intended for residenal
consumer use only. This generator is not designed for
permanent setup.
! 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.
!DANGER: FIRE OR EXPLOSION - Gasoline is highly
ammable and extremely explosive.
• Fire or explosion can cause severe burns or death.
• Keep ammable items away while handling gasoline.
• 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.
Pg. 5

• 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 odorless, colorless,
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 jewelry.
• 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 startup could result in an injury.
!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 three feet 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
Pg. 6

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.
• This generator must be properly connected to an
appropriate ground to help prevent electric shock.
Failure to properly ground generator can result in
electrocuon, especially if the generator is equipped
with a wheel kit. Consult an electrician for local
grounding requirements.
• 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.
Pg. 7

TG6500VE FEATURES & CONTROLS
Pg. 8
❶ Fuel cap
❷ Fuel level indicator
❸ Fuel tank
❹ Frame
❺ Wheels
❻ Cylinder head
❼ Muer guard
❽ Push handle
❾ Air lter
❿ Recoil starter
⓫ Support bracket
⓬ Fuel switch
⓭ Baery
⓮ Control panel
⓯ Engine switch
⓰ DC Baery charging
⓱ DC Overload switch
⓲ RCD Circuit breaker
⓳ AC Overload reset buon
⓴ DC Overload reset buon

GENERATOR SPECIFICATIONS
Model TG6500VE
Max. Output (W) 6500w
Cont. Rated Output (W) 6000w
Rated Voltage 230V / 50Hz
Power Factor 1.0
Engine Cromtech
Engine Features OHV, air cooled
Displacement 420cc
Fuel Type Petrol
Fuel Tank 25L
Oil Capacity 1.1L
Decibels at 7m (db) 74db
Weight (kg) 87kg
Packaging (LxWxH) 715x545x605mm
FEATURES
• 2x Outlets (single phase - 15 Amp)
• Electric start and recoil start
• Fold-out handles
• Steel frame with large wheels
• 4-Stroke, air cooled, OHV engine
• Hours operaon, Hz, Voltage meter
• Baery charging (12V-8.3Amp)
• Low oil alarm, overload alarm, output indicator
• Large 25L fuel tank
• 1 Year Cromtech warranty
Pg. 9

GETTING STARTED
! NOTE: DO NOT Operate this generator unl you have
read ALL safety, operaon, and maintenance Instrucons
listed in this manual.
1. UNPACKING - Remove the generator from the shipping
carton
I. Place the shipping carton on a solid, at surface.
Ii. Carefully cut each corner of the carton box from top
to boom. Fold each side at on the ground.
Iii. Remove everything from the carton except the
generator.
2. ASSEMBLY - Your generator requires some assembly. If
you have any quesons regarding the assembly of your
generator, please have your model number and serial
number ready and consult your local dealer for help.
INSTALL WHEEL KIT - Put wheel stop pin through
wheel and mounng lug hole, then x it with the clip.
❶Clip
❷ Wheel
❸ Wheel stop pin
INSTALL SUPPORT BRACKET - Connect bracket nuts,
seats, support bracket and bolt to frame.
❶ Support bracket nut M8
❷ Damping seat nut M6
❸ Support bracket
❹ Damping seat
❺ Damping seat nut M6 x18
❻ Support bracket bolt M8 x16
Pg. 10

INSTALL THE HANDLE - Place the push handle in the
bracket. Push the pin through the bracket and handle
and x with the clip provided.
❶Clip
❷ Pin
❸ Push handle
ATTACH NEGATIVE BATTERY WIRE - The sealed baery
on the generator is fully charged and pre-installed
except for the negave (black) baery cable.
1. Cut o e wrap securing loose end of negave
(black) cable.
2. Connect the negave (black) baery cable to
the negave(-) terminal on the baery.
3. Verify if it is correct and secure the connecons
between the baery and generang set.
❶ Posive (+) terminal (red)
❷ Negave ( - ) terminal (black)
Pg. 11
SUPPORT
BRACKET

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.
! DANGER: TOXIC FUMES - The exhaust of the
generang set contains carbon monoxide, an odorless,
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. 12

CHECK ENGINE OIL
! WARNING: This engine is not lled with oil from the
factory. 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 4-stroke
automove oil SAE30.
! CAUTION: LEVEL GROUND - Operate generator
only on leveled 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 inconvenient of an unexpected
shutdown, ll to the upper limit and check the oil level
regularly.
Pg. 13

CHECK FUEL LEVELS
! CAUTION: Pressure can build up in the fuel tank.
Allow the generator to cool for at least two minutes before
removing fuel cap. Loosen the fuel cap slowly to relieve any
pressure in the tank
• ENGINE FUEL - With the engine stopped, check the fuel
level gauge. Rell the fuel tank if necessary.
• Use clean, fresh, regular unleaded gasoline only.
• DO NOT mix oil with gasoline.
• Be sure not to ll above the upper limit mark, always ll
to the level indicator, or ll to 25mm le from fuel tank
(to allow room for fuel expansion).
! DANGER: FIRE OR EXPLOSION - Gasoline is highly
ammable and extremely explosive. A re or explosion
can cause severe burns or death.
• Keep ammable items away while handling
gasoline.
• 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: NEVER use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
• It is important to prevent gum deposits from forming
in fuel system, such as the carburetor, fuel lter, fuel
hose or tank during storage. Also, any alcohol-blended
fuels (called gasohol, ethanol or methanol) can aract
moisture, which leads to separaon and formaon of
acids during storage.
• Acidic fuel can damage the fuel system of an engine
while in storage. Be sure to review the Storage
instrucons.
Pg. 14

• Gasoline/Alcohol Blends: up to 10% alcohol, 90%
unleaded gasoline by volume is approved as a fuel.
Other gasoline/alcohol blends are not approved.
Eects of old, stale or contaminated fuel may void your
warranty.
! CAUTION: To minimise gum deposits in your fuel
system and to insure easy starng, do not use gasoline le
over from the previous season.
ELECTRICAL DEVICES
! NOTE: Disconnect all electrical devices from the
generator and switch o the AC circuit breaker before start
the engine.
• The generang set may be hard to start with electrical
devices.
GROUNDING
! WARNING: ELECTRIC SHOCK - Failure to properly
ground the generator can result in electric shock.
• The generator must be properly connected to an
appropriate ground. It helps prevent electrical shock
if a ground fault condion exists in the generator or in
connected electrical devices, especially when the unit is
equipped with a wheel kit.
• Proper grounding also helps dissipate stac electricity,
which oen builds up in ungrounded devices.
• A ground terminal on control panel generator has been
provided. For remote grounding, connect of a length of
heavy gauge(4mm) copper wire between the generator
ground terminal and a copper rod driven into the
ground.
• Your local state electrical codes may require proper
grounding of the unit. We strongly recommend that
you consult with a qualied electrician for grounding
requirements in your area.
Pg. 15

STARTING THE GENERATOR
1. Perform the operang checklist (page 12).
2. Turn the fuel valve to the ‘ON’ posion
3. Put the choke valve switch to ‘CLOSE’ posion
! NOTE: Choke posion for starng may vary
depending upon temperature and other factors. If re-
starng a warm engine, the choke should be le in the
HALF or OFF posion.
4. ELECTRIC START - Push the rocker ignion switch to
‘I’ run posion. Then push fully and hold switch in ‘II’
posion unl the engine is started. Aer the engine is
started, release the buon (It will return to the ‘I’ run
posion).
5. MANUAL START - Turn the rocker ignion switch to the
‘I’ run posion. Then take hold of the recoil handle and
slow pull unl there is a sense of resistance, and then
quickly pull to start.
! CAUTION: Ensure that the recoil rope is not
damaged and repair if required.
Pg. 16

! WARNING: Rapid retracon of the starter cord will
pull hand and arm towards the engine faster than you
can let it go. Unintenonal startup could result in an
injury.
! CAUTION: ENGINE FAILURE - If the engine fails to
start aer 3 aempts or stops aer starng; inspect
and ensure that the generator is placed on horizontal
surface and check the engine oil levels.
• DURING STARTING - DO NOT hold the ignion
switch in the ‘II’ posion for more than 5 seconds. It
is possible that it may damage the motor. If the unit
fails to start within rst me. Wait 10 seconds and
restart the procedure.
• DURING OPERATION - The baery supplies power
for the solenoid valve of the carburetor. When the
unit is turned o, make sure that the starng switch
is in the ‘O’ o posion otherwise the baery
voltage will be drained.
• LOW OIL ALERT - If the engine is equipped with
an engine oil alert, it is possible to prevent engine
starng when the oil is lower than the minimum
level.
• DURING RUNNING-IN - Rounely inspect the engine
oil. See maintenance secon for recommended
maintenance period/s.
6. Once the generator is operang stably, set the
choke valve to ‘OPEN’ posion.
7. The generator is now ready to be used.
! CAUTION: When connecng the generator with
electrical equipment. DO NOT start or stop the engine while
electrical equipment is in their ‘ON’ status.
Pg. 17

CONNECT TO ELECTRICAL DEVICES
! WARNING: This generator is ed with an RCD Circuit
Breaker. ALWAYS test RCD switch before every use.
! CAUTION: Inspect power cords for damage before
using. There is a hazard of electrical shock from crushing,
cung or heat damage.
1. Allow the engine to stabilise and warm up for a few
minutes aer starng.
2. Make sure the electrical devices are in their ‘OFF’
posion and the load current is not higher than the
maximum withstanding current of single socket.
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 enough
rated(running) and surge (starng) was for the
electrical devices you will power at the same me.
Follow these simple steps to calculate the running and
starng was necessary for your purposes.
1. Select the electrical devices you will be powering at the
same me.
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 tools or appliances such as a
circular saw or refrigerator.
Pg. 18

! 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.
! NOTE: Not all motors 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 from step 2.
WATTAGE REFERENCE GUIDE
ELECTRICAL EQUIPMENT RATED POWER (W)
Tablet computer 27” 120W
Energy saving globes 5-50W
Electric Cooker 1000W
Personal Computer (standard) 100-250W
Refrigerator (standard) 50-200W
Washing Machine 700W - 2000w (heat), 500w (spin)
Electric Fan 50W
Kele 1800W
2.0hp Air Condioner 1800W
Electric Welding Machine 2500W
Electric Hammer 1000W
Water Pump 800W
Pg. 19

CHARGING A BATTERY (APPLICABLE TYPES)
! WARNING: Baeries give o explosive hydrogen gas
while recharging. An explosive mixture will remain around
the baery for a long me aer it has been charged.
The slightest spark can ignite the hydrogen and cause an
explosion, resulng in blindness or other serious injury.
• Charge the baery only with baery charging sockets
provided
• Charge the baery in dry environment.
! WARNING: DO NOT allow smoking, open ame,
sparks or any other source of heat around a baery. Wear
protecve goggles, rubber apron and rubber gloves when
working around a baery.
• Baery electrolyte uid is an extremely causc sulfuric
acid soluon that can cause severe burns. If spill occurs
ush area with clear water immediately.
1. CHARGING VOLT BATTERIES - Check uid level in all
baery cells. If necessary, add ONLY dislled water to
cover separators in baery cells. DO NOT use tap water.
• If the baery is equipped with vent caps, make sure
they are installed and are ght.
• If necessary, clean baery terminals.
• Connect baery charge cable clamp with red handle
to the posive(+) baery terminal.
• Connect baery charge cable clamp with black
handle to the negave(-) baery terminal.
• Start engine. Let the engine run while baery
recharges.
• When baery has charged, shut down engine.
! WARNING: Use an automove hydrometer to
test baery state of charge and condion. Follow the
hydrometer manufacturer’s instrucons carefully.
Generally, a baery is considered to be at 100% state of
charge when specic gravity of its uid (as measured by
hydrometer) is 1.260 or higher.
Pg. 20