Promate PM6100D User manual

Operator Manual
Diesel Generator
IMPORTANT – Please make certain that persons who are to use this
equipment thoroughly read and understand these instructions and any
additional instructions provided prior to operation.
Record the model and serial numbers of your Generator below:
Model No._____________________ Serial No._______________________

FOREWORD
Thank you for purchasing our product. This operator manual is for proper
handling, minor checking and maintenance of the generator. Before using
your generator: Please read these instructions completely and carefully in
order to make the best use of it as well as operate it safely. Due to constant
efforts to improve our products, certain procedures and specifications are
subject to change without notice, if you have any questions, please contact
Promate Service.
CONTENTS
1 Safety Precautions 3
2 Name of Parts 4
3 Before Starting 4
3-1 Checking and Selecting Engine Oil 4
4 Starting 6
4-1 Recoil Starting 6
4-2 Electric starting 6
5 Operating Your Generator Set 7
5-1 Operating Your Generator 7
5-2 Checks During Operation 7
5-3 Load 7
6 Stopping Your Generator Set 7
7 Periodic Checks and Maintenance 8
7-1 Periodic Checks and Maintenance 8
Maintenance Schedule Chart 8
7-2 Long Term Storage 9
8 Service Information 10
Generator Exploded View 11
Diesel Generator Spare Parts List 12

1. Safety Precautions
The electric power generated by the diesel engine of the generator can be used for many
kinds of electric appliances. When handling it, please keep to the following matters. Please
make sure you review each precaution carefully.
EXHAUST PRECAUTIONS
•Never inhale exhaust gasses. They contain
carbon monoxide, a colorless, odorless and
extremely dangerous gas which can cause
unconsciousness or death.
•Never operate the generator indoor or in a
poorly ventilated area, such as tunnel, cave,
etc. Exercise extreme care when operating
the generator near people or animals. Keep
the exhaust pipe free of foreign objects.
REFUELING PRECAUTIONS
•Do not refuel indoors or in a poorly
ventilated area. Be sure to stop the
generator prior to refueling. Do not overfill
the tank. If fuel is spilt, wipe it away carefully
before starting the engine.
WHEN CHARGING THE BATTERY
•Battery electrolyte contains sulfuric acid. Be
careful of your eyes, skin and clothing. Flush
thoroughly with water and get prompt
medical attention in case of contacts,
especially if your eyes are affected.
•Charge the battery in a fully ventilated place.
•Be sure to confirm battery polarity.
OTHER SAFETY PRECAUTIONS
•Be careful of hot parts.
The muffler and other engine parts
become very hot while the engine is
running or just after it has stopped.
Operate the engine in a safe area and
keep children away from the running
engine.
•
Where to use the generator
Do not use it near flammables. Use
it more than 1 meter away from
buildings
or any other facilities.
•
When using the generator
Do not tip or move.
Do not cover it with a box or fence
it around.
Never unscrew the dipstick when using
the generator set, or else scald will be
caused by ejective oil. Do not touch
the
generator in the rain. And, do not
splash wat.er or touch with wet hand.
•
To avoid an electric shock, ground
the
generator from the ground
terminal.
•
Avoid using generator at the place
where the ground is not firm.
• Never connect generator to the wiring
of
a power company.
3

2. Name of Parts
3. Before Starting
Before starting the engine. check the generator set on the place where it is flat
by placing it horizontally.
3-1 Checking and selecting engine oil
•The engine may be damaged if operated
with insufficient lube oil. It is also dangerous
to supply too much lube oil to the engine
because a sudden increase in engine rpm
could be caused by its combustion. Always
check the lube oil level before starting the
engine and refill if necessary.
•Make sure to check oil level and to refill with
oil to the specified level before starting the
generator even though it is equipped with a
low oil pressure warning system.
Use proper lube oil to preserve your engine
ENGINE OIL
We recommend A.P.I engine service classification
of CC or CD. Always use the oil with the right
viscosity for the ambient temperature in which your
engine is being operated. Use the chart right side
for choosing your engine oil.
Lube oil capacity (L) 1.65
Upper Level (H)
Lower Level (H)
Oil filler cap/dipstick
4

•When checking the oil level, make sure
your engine is sitting level. If it is tilted,
you may add either too much or too
little oil. If you overfill, your engine will
consume too much oil and the oil
temperature will become dangerously
high if you do not add enough oil,
your engine could seize up.
•When checking the oil, simply dip the
dipstick into the oil pan. Do not screw
in the dipstick.
•Be sure to check the engine on a level
surface with the engine stopped.
3-2 Selection and handling of fuel oil
Only use diesel light oil.
When filling the fuel tank from drums, make
sure that no dust or water are mixed in the fuel.
This may lead to serious fuel-injection pump
and nozzle problems.
•Only use the recommended diesel fuel
oil. Use of non-recommended fuel may
cause the engine damage.
•Fuel should have a cetane value of
more than 45 in order to prevent
difficult starting, misfiring, and white
exhaust smoke.
•Diesel fuel oil substitutes are not
recommended; they may be harmful to
the fuel system components.
•Fuel should be free of water or dust
because these cause trouble in the fuel
injection pump and nozzle.
After purchasing fuel: Allow drum to
stand 3-4 days.
After 3-4 days: Put a suction pipe
halfway into the drum. (Water and dust
accumulate in the lower position of the
drum.)
•Refuel in a well-ventilated area with the
engine stopped.
•Do not smoke or allow flames or sparks
in the area where the engine is refueled
or where gasoline is stored.
•Do not overfill the tank and make sure
the filter cap is securely closed after
refueling.
•Be careful not to spill fuel when
refueling if any fuel is spilled, make
sure the area is dry before starting the
engine.
Overfill is dangerous. Do not fill the tank
beyond the top of the red plug inside the fuel
tank filter.
Fuel Tank Capacity (L) 13
4
5

4. Starting
4-1 Recoil starting
(1) Set the fuel cock (A) at the "O" (Open)
position.
A. Open the fuel cock
(2) Set the engine speed lever (B) to
"RUN" position.
B. Engine speed lever
(3) Pull out the recoil starting handle.
a. Pull out the handle to the point
where you feel strong resistance,
and then return it to the initial
position.
b. Push down the decompression
lever (C). It will return
automatically when the recoil
starter is pulled.
C. Decompression lever
c. Pull out the recoil starting handle
briskly with both hands.
•Never use any volatile liquid or gas
such as gasoline to cold starting the
machine, or else, severe damage
will occur.
•Keep the oil screw plug in the
bonnet except adding oil. If the
plug is not in place, rain dirt and
other contaminants may enter the
engine and cause accelerated wear
out (abrasion) of internal parts.
This can cause serious problems.
4-2 Electric starting
(1) Starting
a. Set the fuel cock (A) at the "O"
(Open) position.
A. Open the fuel cock
b. Set the engine speed lever
(B) to "RUN" position.
c. Turn the starting key clockwise to
"START" position.
d. Remove your hand from the key as
soon as the engine starts.
e. If the engine does not start after
10 seconds, wait a while (for
about 15 seconds) before
attempting to start again.
C
6

•If the starting motor is working for too
long, the battery will go flat and motor
seize up will occur. Always leave the
starting key turned on, at the "ON"
position, while the engine is running.
(2) Battery
Check the level of the fluid in the battery every
month. When the level has dropped to the
lower mark replenish with distilled water up to
the upper mark.
•If the battery fluid is short, the engine
may not start because too little
electricity is reaching the starter motor.
Always keep the fluid level between the
upper and lower limits.
•If too much battery fluid is supplied,
the fluid may spill and corrode the
surrounding parts.
5. Operating Your
Generator Set
5-1 Operating your generator
(1) Warm up the engine without load for 3
minutes.
(2) This generator is equipped with low
oil warning system. The engine will stop
automatically in case of low oil pressure or
a lubrication oil shortage. The engine will
stop immediately without a lubrication oil
refill. Check the oil level and refill.
(3) Do not loosen or readjust either the engine
speed limiting bolt or fuel injection limiting
bolt [They had been already well adjusted
before leaving factory), otherwise
performance may be affected.
5-2 Checks during operation
(1) Any abnormal sound or vibration?
(2) The engine misfiring or running rough?
(3) What about the color of the exhaust gas?
(Is it black or too white?). If you notice any
situation mentioned above, please contact
your dealer.
5-3 Load
To add load according to specified parameter.
A.C application
(1) Set AC breaker to "ON". Pilot lamp will
illuminate, the speed of generator must
reach rated speed [lever at top).
(2) Insert the receptacle with the plugs of
electric instruments to be connected, keep
the switches of the connected electric
instruments to "OFF'.
•The instruments which require much
starting current and some kinds of motors
may be unable to be use even if they are
within the applicable scope.
•The circuit breaker turns "OFF' when the
current exceeding the applicable scope is
used or when the applied instrument is
defective.
•The current of the instruments which
should not exceed the rated current
showed on the socket, or else it may
damage the machine.
DC application
(1) When the instruments connect with the DC
terminal, please make sure to the positive
polarity.
(2) DC output 12V 8.3A - 100W. 10
6. Stopping Your
Generator Set
(1) Pull out the plug of an electric appliance
from the receptacle
(2) Set the AC breaker to "OFF'
(3) From lowest to highest load, run the engine
for about 3 minutes with no load.
(4) Return the engine speed lever to the
"STOP" position
(5) In electric-start models, return the starter
key to the "OFF" position
(6) Set the fuel chock lever to "S" (closed)
position.
Slowly pull out the recoil handle until pressure
is felt (that is, to the point in the compression
stroke where the intake and exhaust valves are
closed), and leave the handle in this position
this prevents rust from forming while the
engine is not in use.
When stopping the engine, reduce the load
slowly. Do not stop the engine suddenly since
it may cause the temperature to rise
abnormally.
5
6
6
7

7.1 Periodic checks and maintenance
Periodic checks and maintenance are very
important for keeping the engine in good
condition and durable. The mark (•) indicates
that special tools and skills are required, you
must contact your dealer.
Shut off the engine before performing any
maintenance. If the engine must run, make
sure the area is well ventilated. The exhaust
contains poisonous carbon monoxide gas.
Operation Hours
Item
Daily
First month
Every 3 months
Every 6 months
Every year or
or 20 Hrs. or 100 Hrs. or 300 Hrs. Every 1000 Hrs.
Check and tighten bolts and
nuts ○
Check and resupply engine oil ○
Replace engine oil ○1st time
○
2nd time &
thereafter
Clean and replace oil filter ○●Replace
if necessary
Check oil leakage
○
Replace air cleaner element Service
more frequently when
used in dusty areas ○
Drain the fuel tank Monthly
Clean and replace fuel filter
○Clean
○Replace
Check fuel injection nozzle
●
Check fuel injection pump
●
Check fuel piping
○
Replace if
necessary
Adjust intake/exhaust valves
head clearance ○1st time ○
Check and lap intake/ exhaust
valve seat ●
Replace piston rings
●
Check battery liquid Monthly
Maintenance Schedule
7
7
8

7-1.1 Changing engine oil
Remove the oil filler cap, remove the drain plug
and drain the used oil while the engine is still
warm. The plug is located on the bottom of the
cylinder block. Tighten the drain plug and refill
with the recommended oil.
7-1.2 Cleaning the oil filter
Loosen the fixing bolt and then pull out the oil
filter
7-1.3 Changing the air cleaner element
Do not wash the air cleaner element with
detergent because this is a wet type element.
Never run the engine without the element
or with a defective element.
7-1.4 Cleaning and replacing the fuel
filter
The fuel filter also must be cleaned
regularly to insure maximum engine
output.
Clean
Every 3 months or 100 hours
Replace
Every 6 months or 300 hours
7-1.5 Checking the injection nozzle
injection pump etc.
This requires special tools and skills, so
contact your dealer.
7-1.6 Replacing piston ring
This requires special tools and skills, so
contact your dealer.
7-2 Long term storage
If your generator set should be stored for a
long time, the following preparation should
be made:
(1) Operate the diesel engine about 3 minutes,
and stop it
(2) Stop the engine. Drain the engine lube oil
while the engine is still warm and fill with
new oil
(3) Recoil starting Push the decompression
lever down (non- compression position)
and hold it while you pull the recoil starter
2 or 3 times. (Do not start the engine)
Electric starting Turn the engine for 2-3
seconds with decompression. Lever set at
the non- compression position, and the
starter key at the "START' position. (Do not
start the engine)
(4) Pull the decompression lever up. Pull the
recoil starter slowly. Stop when it feels
tight. This closes the intake and exhaust
valves in compression position and helps
prevent rust from forming
(5) Clean and store it in a dry place.
Change
Change
Drain Plug
8
9

8. SERVICE INFORMATION
HOW TO ORDER REPLACEMENT
PARTS
Even quality-built equipment such as the
generator you have purchased will need
occasional replacement parts to maintain its
good condition over the years.
To order replacement parts and consumable
parts, please contact Promate Service (details
below) and be ready with the following
information:
1. Model No., Serial No. and all
specifications that are shown on
the Model No./Serial No. plate.
2. Part number or numbers as shown
in the Parts List section.
3. A brief description of the trouble
with the generator.
LIMITED WARRANTY
Warranty Coverage: Powertech Asia Pacific
Inc., (the Company) warrants to the original
retail customer that it will repair or replace,
free of charge, any parts found by the
Company or its authorized service
representative to be defective in material or
workmanship. This warranty covers the cost
of replacement parts and labor for defects in
material or workmanship.
Not Covered:
•Shipping/Handling charges for sending
the product to the Company or its
authorized service representative for
warranty service. Shipping/Handling
repaired or replaced products back to the
customer; these charges must be borne
by the customer.
•If a separate operator's manual and
engine warranty from the engine
manufacturer is included with this
product, only that warranty will apply to
the engine.
•Damage caused by abuse, accident, the
effects of corrosion, erosion and normal
wear and tear.
•Warranty is void if the customer fails to
install, maintain and operate the product
in accordance with the instructions and
recommendations of the Company set
forth in the owner's manual, or if the
product is used as rental equipment.
•The Company will not pay for repairs or
adjustments to the product, or for any
costs of labor performed without the
Company's prior authorization.
•Consumable parts such as battery, spark
plugs, and air cleaner.
Warranty Period: One (1) year from the date
of purchase on products used solely for
consumer applications; if a product is used for
business or commercial applications,
the warranty period will be limited to ninety
(90) days from the date of purchase.
For warranty service, the customer must
provide dated proof of purchase and must
notify the Company within the warranty
period.
EXCLUSIONS AND LIMITATIONS: THE
COMPANY MAKES NO OTHER WARRANTY OF
ANY KIND, EXPRESS OR IMPLIED. IMPLIED
WARRANTIES, INCLUDING WARRANTIES OF
MERCHANTABILITY AND OF FITNESS FOR A
PARTICULAR PURPOSE, ARE HEREBY
DISCLAIMED. THE WARRANTY SERVICE
DESCRIBED ABOVE IS THE EXCLUSIVE
REMEDY UNDER THIS WARRANTY;
LIABILITY FOR INCIDENTAL AND
CONSEQUENTIAL DAMAGES IS EXCLUDED
TO THE EXTENT
PERMITTED BY LAW.
This warranty gives you specific legal rights,
and you may also have other rights which
vary from state to state. Some states do not
allow a disclaimer of implied warranties or the
exclusion or limitation of incidental and
consequential damages, so the above
disclaimers and exclusions may not apply to
you.
CONTACT THE POWERTECH Asia Pacific Inc.,
PRODUCT SERVICE DEPARTMENT AT (02) 8 984 2620 | ([phone]
[e-mail] www.facebook.com/PromateServicePH/
10

Model: Promate 6100D ES
11

DIESEL GENERATOR PARTS LIST
Ref
No.
Description Part No. Qty.
Ref
No.
Description Part No. Qty.
1 Diesel Engine
SD186FAG3/
1
38
Screw M5x10
GB/T818-2000
2
SD186FAG3E
39
Fuel Tank Gas Assy
SDG2500CL-04030
1
2
Flat Washer φ 10
GB/T97.1-2002
8
40
Fuel Tank Gap Gasket
SDG2500CL-04004
1
3
Washer φ 10
GB/T93-1987
8
41
Filter Cup
SD178F-10300
1
4
Nut M10
GBT6170-2000
8
42
Bolt M6x22
GBT5783-2000
8
5 Front Cover
SDG4000CL-
03001
1 43 Flat Washer φ 6 GB/T96.1-2002 8
6
Bolt M8x28
GB/T5789-1986
4
44
Collar
SD1700F-01202
8
7
Bolt M5x15
GB/T5789-1986
6
45
Shock Absorber Block
SD170F-01201
8
8 Ventilating Fan
SDG4000CL-
03101
1 46 Fuel Tank Assy SDG2500CL-04010 1
9 Diode
SDG4000CL-
03102
2 47 Flat Washer φ 6 GB/T97.1-2002 11
10 Rotor
SDG5500CL-
03100
1 48 Washer φ 6 GB/T93-1987 9
11
Bearing6204
GB278-86
1
49
Nut M6
GB/T6170-2000
11
12
Flat Washer φ 10
GB/T96.1-2002
1
50
Fuel Oil Rerun Pipe
SD170F-10012
1
13 Bolt M10x265
SDG5500CL-
03005
1 51 Clamp SD170F-10013 8
14 Stator
SDG5500CL-
03200
1 52 Filter Element Assy SD170F-10300 1
15 Stator Cleading
SDG5500CL-
03201
1 53 Fuel Oil Filter Gasket SDG2500CL-04002 1
16 Bolt M6x175
SDG5500CL-
03006
4 54 Shim Plate SDG2500CL-04001 1
17 End Cover
SDG4000CL-
03002
1 55 Screw M5x8 GB/T818-2000 3
18 Capacitator
SDG5500CL-
03004
1 56 Fuel Tank cock Gasket SD170F-10405 1
19 Wire Holder
SDG2500CL-
03300
1 57 Fuel Tank cock Assy SD107F-10400 1
20
Washer φ 5
GB/T93-1987
12
58
Clamp
SD170F-10011
2
21
Nut M5
GB/T6170-2000
16
59
Fuel Oil Pipe
SD170F-10009
1
22
Flat Washer φ 5
GB/T97.1-2002
18
60
Decorative Laminate
SDG4000CL-04500
1
23
Bolt M5x18
GB/T5789-1986
4
61
Fly Nut M6
GB62-1988
2
24 Bottom Cover
SDG4000CL-
03003
1 62 Battery Platen
SDG2500CLE-
01211
1
25 Bolt M5x10 GB/T5789-1986 2 63 Battery Hanger Bolt
SDG2500CLE-
01212
2
26 Bolt M10x45 GB/T5783-2000 4 64 Battery Spacer
SDG2500CLE-
05201
1
27 Absorber
SDG5500CL-
05100
4 65 Bolt M6x12 GB/T5789-1986 4
28 Screw M4x8 GB/T818-2000 2 66 Battery Rack
SDG5500CLE-
01210
1
29 Solenoid
SDG2500CX-
05300
1 67 Battery Wire Black
SDG2500CLE-
05203
1
30 Stop Cable
SDG5500CX-
05400
1 68 Battery Wire Red
SDG2500CLE-
05202
1
31
Flat Washer φ 3
GB/T97.1-2002
4
69
Low Oil Pressure alarm
SD170-01300B
1
32
Screw M3x8
GB/T818-2000
4
70
Bolt M6x16
GB/T5783-2000
1
33
Screw M5x16
GB/T818-2000
4
71
Grounded Wire
SDG2500CL-02401
1
34
Control Panel
SDG5500-02000
1
72
Grounded Plate
SDG2500CL-02402
1
35
Frame
SDG5500-01 100
1
73
Cotter Pin φ 3
GB91-86
4
36
Floating Beacon
Gasket
SDG2500CL-
04003
1 74 Wheel φ 100 SDG3500SE-01310 4
37 Floating Beacon Assy
SDG2500CL-
04020
1 75 Flat Washer φ 16 GB/T96.1-2002 8
Model: Promate 6100D ES
12