8877150 CLARKE | Alldatasheet

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OPERATION & MAINTENANCE INSTRUCTIONS DL0526 6.3KVA DIESEL GENERATOR MODEL NO: DG6500ADVES PART NO: 8877150

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com INTRODUCTION Thank you for purchasing this CLARKE 6.3kVA Diesel Generator. Before attempting to use this product, please read this manual thoroughly and follow the instructions carefully. In doing so you will ensure the safety of yourself and that of others around you, and you can look forward to your purchase giving you long and satisfactory service. GUARANTEE This product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt which will be required as proof of purchase. This guarantee is invalid if the product is found to have been abused or tampered with in any way, or not used for the purpose for which it was intended. Faulty goods should be returned to their place of purchase, no product can be returned to us without prior permission. This guarantee does not effect your statutory rights. ENVIRONMENTAL RECYCLING POLICY Through purchase of this product, the customer is taking on the obligation to deal with the WEEE in accordance with the WEEE regulations in relation to the treatment, recycling & recovery and environmentally sound disposal of the WEEE. In effect, this means that this product must not be disposed of with general household waste. It must be disposed of according to the laws governing Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal facility.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SPECIFICATIONS Engine Engine Model/Type D500XE/Diesel Power/Displacement 11HP-8kW/498cc RPM 3000 Ignition type Compression Fuel tank capacity (L) 15 (Safe Capacity) Fuel consumption at 3/4 Load (L/h) Approx. 1.86 Maximum run time at 3/4 load (h) Approx. 8 Engine oil type/capacity (L) SAE15W-40/1.75 Emissions (g/kWh) CO/HC/NOx 1.72/0.96/5.71 Sound pressure level (LpA dB) 95 Sound power level (LwA dB) 97 Guaranteed sound power (LwA dB) 97 Uncertainty factor (K dB) 2.8 Generator Rated Frequency (Hz) 50 Rated AC Voltage per socket x 2 (V) 110 (2 x 32A) Rated AC Voltage per socket x 1 (V) 230 (1 x 32A) Rated Output Power (W) 6kW Max Rated Output Power (W) 6.3kW Rated Output Current (A) 26A Max Rated Output Current (A) (110V/230V) 54.8A/27.4A Trip Amps 33A Starter Type Key, Auto/ATS Operating Temperatures -5oC to 40oC (23oF to 104oF) IP Rating IP23 Dimensions Length x Width x Height (mm) 920 x 520 x 720 Unpacked & Unfueled Weight (kg) 162

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com GENERAL SAFETY RULES WORK AREA 1. ALWAYS use in a well ventilated area. 2. ALWAYS position the exhaust outlet away from people. 3. NEVER use indoors or in a confined space. 4. ALWAYS read these safety instructions before using the equipment. 5. ALWAYS keep children away from the generator. FIRE PREVENTION 1. ALWAYS switch the engine OFF when refuelling. 2. ALWAYS refuel away from any source of heat. 3. ALWAYS refuel in a well ventilated area. 4. Only use standard diesel. DO NOT mix oil in with the diesel. 5. NEVER overfill the fuel tank, fill to the level specified, see page 10-11. 6. NEVER smoke whilst refuelling and avoid smoking or using a naked flame near the generator. 7. NEVER start the engine if there is spilled fuel. Any spillage must be wiped clean and the generator allowed to dry before attempting to start the engine. PREVENTION OF ELECTRIC SHOCK 1. NEVER use the generator in wet conditions unless it is well protected/covered. Under these conditions, adequate ventilation MUST be provided. 2. NEVER operate the generator with wet hands. 3. NEVER use water or any other liquids to clean the generator. ADDITIONAL SAFETY RULES FOR GENERATORS 1. ALWAYS ensure the applied load does not exceed the generator rating. Overloading the generator is dangerous and could cause serious damage. 2.ALWAYS disconnect and turn off the generator when carrying out any maintenance. WARNING: EXHAUST FUMES CAN BE EXTREMELY DANGEROUS IF INHALED

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 3. ALWAYS ensure the generator reaches operating speed before connecting a load. 4. NEVER allow the generator to run out of fuel when a load is connected. 5. NEVER transport the generator with fuel in the tank. 6. DO NOT connect to a commercial or residential power supply; e.g. ring main unless you are using the appropriate ATS system. Always seek professional advice to install an ATS system. 7. NEVER allow the generator air vents to become blocked. POSITIONING THE GENERATOR 1. ALWAYS leave a least a 1.5m gap between the generator and any surrounding building or structures. 2. ALWAYS ensure the generator is on a solid, flat surface. 3. ALWAYS ensure the surrounding area is free from any material that could burn or be damaged by heat. 4. NEVER move or tilt the generator whilst it is switched on. GENERATOR LOCATION Place the generator in a well ventilated area. This will allow for removal of deadly exhaust gas. DO NOT place the generator where exhaust gas could accumulate and enter inside or be drawn into a potentially occupied building. Ensure exhaust gas (A) is kept away from any windows, doors, ventilation intakes, or other openings that can allow exhaust gas to collect in a confined area. Prevailing winds and air currents should be taken into account. WARNING: EXHAUST HEAT/GASES CAN IGNITE COMBUSTIBLES, STRUCTURES OR DAMAGE THE FUEL TANK, CAUSING A FIRE. KEEP AT LEAST 5FT (1.5M) CLEARANCE ON ALL SIDES OF THE GENERATOR INCLUDING OVERHEAD.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SYMBOLS Caution - Read instruction manual before use Warning - Hot Surface, DO NOT touch Warning - Dangerous voltage, risk of electrocution Warning - Poisonous fumes - DO NOT use the generator in an enclosed space Warning - Flammable Warning - The user should be aware of a general hazard Caution - High noise level when in use Warning - Sudden loud noise Caution - Wear eye protection when working with engine batteries Warning - Battery acid, corrosive substance Warning - Explosive material Caution - DO NOT let children play with generator Caution - DO NOT use in wet weather

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CONTROL PANEL OVERVIEW NO DESCRIPTION NO DESCRIPTION

1 LED Display 8 ATS (Automatic Transfer Switch) Socket

2 Start Key 9 DC Fuse

3 Emergency Stop Button 10 DC 12V 8.3A Socket

4 Pre-Heater Button 11 230V 32A Socket

5 Transfer Switch (110V - 230V) 12 110V 32A Sockets

6 Circuit Breakers 13 110V Overload Protector

7 Auto Socket 14 Earthing Terminal

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com BEFORE USING THE GENERATOR Before using your generator check that:

  • The generator is in good condition and free from any damage.
  • The generator is clean and free from fuel or oil spillage.
  • The generator is correctly located for use, see page 5.
  • The generator is correctly earthed, see page 9.
  • The fuel system is intact and there is no leakage. NOTE: ALWAYS use a funnel to fill the fuel tank to avoid accidental spillage of fuel. If fuel is spilled it must be cleaned up before use. CONNECTING THE BATTERY For safety reasons, the generator battery is not connected when shipped. Follow these steps to connect the battery. 1. Open the engine compartment door. WARNING: ENSURE THERE IS ADEQUATE FUEL IN THE TANK WHEN USING THE GENERATOR. RUNNING OUT OF FUEL OR STOPPING THE ENGINE SUDDENLY WITH A LOAD CONNECTED COULD CAUSE SERIOUS DAMAGE. WARNING: ALWAYS CHECK THE OIL LEVEL BEFORE STARTING SEE PAGES 9-10, FAILURE TO MAINTAIN THE CORRECT OIL LEVEL MAY SERIOUSLY DAMAGE THE ENGINE.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 2. Connect the positive wire (+, Red) to the positive terminal on the battery as shown. 3. Connect the negative wire (-, Black) to the negative terminal on the battery as shown. 4. Make sure both terminals are securely tightened 5. Ensure both terminals are covered by the plastic covers. EARTH TERMINAL Attach a suitable earth lead to a good earthing point - water pipe, ground spike etc., whenever you use this generator. 1. Ground the generator by connecting a suitable grounding wire to the earth terminal, as shown, which is located on the control panel. 2. Connect the other end of the grounding wire to a copper or brass grounding rod (not supplied) or suitable grounding point that is driven into the earth. CHECKING THE ENGINE OIL LEVEL WARNING: FAILURE TO PROPERLY GROUND THE GENERATOR BEFORE USE CAN RESULT IN ELECTROCUTION WARNING: TO CARRY OUT THIS CHECK, PLACE THE GENERATOR ON LEVEL GROUND WITH THE ENGINE SWITCHED OFF. WARNING: TAKE CARE NOT TO TOUCH ANY HOT PARTS OF THE GENERATOR WHEN CHECKING THE OIL LEVEL. CAUTION: FOR SAFETY SEASONS, THE GENERATOR IS SHIPPED WITHOUT OIL IN THE ENGINE. DO NOT ATTEMPT TO START THE ENGINE BEFORE FOLLOWING THE BELOW STEPS TO CHECK AND INSTALL ENGINE OIL.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 1. Turn the orange dipstick anti- clockwise and remove from the oil fill tube. 2. Wipe the dipstick with a clean cloth. 3. Insert the dipstick back into the oil fill tube and then remove it again. DO NOT screw in the dipstick when doing this. 4. If the oil level is at or below the ‘L’ mark on the dipstick, using a funnel, add oil to the crankcase.

  • Fill until the oil reaches the threads in the oil fill tube.
  • Oil capacity: 1.75 litre.
  • We recommend the use of the following oil: CLARKE SAE15W-40 Motor Oil 5. Replace the oil filler cap/dipstick. CHECKING THE FUEL LEVEL For safety seasons, the generator is shipped without diesel in the tank. Follow these steps to check and install diesel. RECOMMENDED FUEL Only use standard diesel. DO NOT mix oil with the diesel. WARNING: ALWAYS REFUEL IN A WELL VENTILATED AREA AWAY FROM ANY HEAT SOURCES. WARNING: ALLOW THE UNIT TO COOL DOWN BEFORE REFUELLING. WARNING: DO NOT LEAVE FUEL WITHIN THE REACH OF CHILDREN.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 1. Check the fuel level on the fuel gauge. The fuel gauge will show as red when you have fuel in the tank turning white as the fuel level decreases. 2. To add fuel (Diesel, B7), open the fuel filler cap. NOTE: If you mistakenly fill the tank with petrol, DO NOT start the generator. Contact a CLARKE authorised dealer or service centre about draining the fuel tank and system before using the generator again. 3. Just inside the fuel tank is a fuel filter which catches any contaminants as you refuel. 4. Slowly add fuel to the fuel tank (maximum safe fill level: 15 Litres) watching the fuel level gauge as you do so. NOTE: DO NOT overfill the fuel tank. 5. Replace the fuel filler cap securely.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com USING YOUR GENERATOR STARTING THE ENGINE NOTE: In cold conditions, press the Pre-Heat Button 5 minutes before attempting to start the generator. 1. Remove all connections from the AC sockets. 2. Switch the Circuit Breaker to the ‘OFF/DOWN’ position. 3. Choose which voltage is needed by turning the Transfer Switch to either 110V or 230V.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 4. Turn the Start Key clockwise to the start position and hold for 5 seconds, the engine should start. 5. Connect the relevant electrical device to either the 12V, 110V or 230V socket. 6. Switch the Circuit Breaker to the ‘ON/ UP’ position. ATS AND AUTO START This generator has the capacity to Auto and/or Automatic Transfer Switch (ATS) start. Connections for these start systems are NOT supplied with this generator. WARNING: AUTO AND ATS SYSTEM SHOULD ALWAYS BE SET UP AND INSTALLED BY A FULLY QUALIFIED ELECTRICIAN. 1. Remove all connections from the AC sockets. 2. Switch the Circuit Breaker to the ‘OFF/DOWN’ position.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 3. Turn the Start Key anti-clockwise to the Auto/ATS position. 4. Choose which voltage is needed by turning the Transfer Switch to either 110V or 230V. 5. Attach the Auto/ATS connection cable to the appropriate socket on the control panel. NOTE: Connections/Cables for these start systems are NOT supplied with this generator. 6. Connect the relevant electrical device to either the 12V, 110V or 230V socket. 7. Switch the Circuit Breaker to the ‘ON/ UP’ position.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CONNECTING ELECTRICAL DEVICES The generator can supply both 110V, 230V AC, but NOT at the same time, plus 12V DC. The sockets are laid out in the following order: (from left to right): 1. 2 x 32amp 110v (AC, Yellow Socket) 2. 1 x 32amp 230v (AC, Blue Socket) 3. 1 x 8.3amp 12V (DC, cigarette lighter socket) Follow the steps below to properly connect your device(s) to the generator. 1. Before connecting electrical devices, allow the generator to run for a few minutes to stabilise the speed and voltage output. 2. Select the device and make sure it is turned off. Plug the device into the generator and then turn the device on. Allow the engine to stabilise. 3. DO NOT attempt to plug in and start 110V & 230V devices at the same time. MAIN AC BREAKER The Main AC Circuit Breaker will activate (switch to the ‘OFF’ position) if the generator or circuit is overloaded. If the Main AC Breaker activates or any of the smaller individual circuit breakers. 1. Remove any connected devices from the generator. 2. Wait for a few minutes. 3. Restart the generator (see pages 12- 13). 4. Reconnect the devices to the generator, making sure you do not exceed the maximum capacity of the generator (see page 3).

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SHUTTING DOWN THE GENERATOR 1. Make sure that the AC breaker is set to the ‘OFF/DOWN’ position. 2. Disconnect all electrical devices. 3. Let the engine run for 2-3 minutes so it stabilises. 4. Turn the Start Knob anti-clockwise to the ‘OFF -Auto/ATS’ position. 5. To stop the generator in an emergency simply push in the ‘EMERGENCY STOP’ button. CAUTION: MAKE SURE THAT THE APPLIANCE BEING CONNECTED IS IN GOOD WORKING ORDER, IF IT BEGINS TO ACT ABNORMALLY OR STOPS SUDDENLY, DISCONNECT IT FROM THE GENERATOR

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com MAINTENANCE Some adjustments will need to be made periodically to properly maintain the generator. All service and adjustments should be made at least once every year. It is important that the maintenance chart below is followed:

  • ** = Replace after first 20 hours of use.
  • *** = Recommended to be performed more often than in the schedule if operated in a dusty environment.
  • **** = Recommended to be performed by a CLARKE authorized dealer. Item Action Frequency Each Time of Use Every 1 Month or

20 Hrs

100 Hrs

(Page 18) Check Level * Replace ** * Engine Oil Filter (Page 19) Clean * Air Filter (Page 20) Check * Clean *** Replace * Fuel Tank Clean **** Fuel Filter (page 22) Check - Clean * Fuel Supply Line Check Every Two Years (Replace if Necessary)

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CHANGING THE ENGINE OIL 1. Unscrew and remove the oil filler cap/dipstick. 2. Place an oil collection tray under the drain plug. 3. Unscrew the drain plug and allow the used engine oil to drain from the crankcase into the oil collection tray. NOTE: Drain the engine oil when the engine is warm, this will ensure the oil flows out faster. 4. Replace the drain plug. 5. Using a funnel, add oil to the crankcase.

  • Fill until the oil reaches the threads in the oil fill tube.
  • Oil capacity: 1.75 litre.
  • We recommend the use of the following oil: CLARKE SAE15W-40 Motor Oil 6. Replace the oil filler cap/dipstick. ENVIRONMENTAL PROTECTION One of the most damaging sources of pollution is oil, DO NOT throw away used engine oil in with your domestic rubbish or pour it down drains or sinks. Place it in a leak proof container and take it to your local waste disposal site. CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS HARMFUL, ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED ENGINE OIL.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CHECKING/CLEANING THE OIL FILTER 1. Locate the oil filter in the lower half of the engine bay. 2. Unscrew and remove the retaining bolt. 3. Using pliers, remove the oil filter. 4. Clean the filter using a small amount of diesel and a brush.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 5. Replace the oil filter and retaining bolt. CHECKING/CLEANING THE AIR FILTER 1. Unclip and lift the air filter cover/service panel. 2. Remove the air filter element. 3. Make sure that the air filter is clean and not damaged.

  • If the air filter is damaged contact CLARKE spare parts department for a replacement.
  • If the filter is dirty, vacuum the filter, making sure not to damage it. CAUTION: DO NOT USE THE GENERATOR WITHOUT THE AIR FILTER FITTED, THIS CAN DAMAGE THE GENERATOR. WARNING: DO NOT USE FLAMMABLE SOLVENTS OR PETROL TO CLEAN THE AIR FILTER.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 4. Replace the filter to its original position and close the air filter cover/service panel. CLEANING/DRAINING THE FUEL LINE FILTER NOTE: Before proceeding with this process, make sure the fuel tank is empty 1. Locate the fuel filter the top half of the engine bay. 2. Using pliers, disconnect the 3 fuel supply lines by pinching the tube clip and pulling the supply line off the fuel filter. 3. Loosen the support collar and take the fuel filter out. 4. Clean or replace the fuel filter. 5. Place the fuel filter back in the support collar and tighten. CAUTION: ALWAYS CARRY THIS PROCEDURE OUT IN A WELL VENTILATED AREA AND AWAY FROM ANY NAKED FLAME.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 6. Using pliers to pinch the tube clip, reconnect the 3 fuel supply lines. CLEAN FUEL TANK FILTER Just inside the fuel tank is a fuel filter. Check this filter periodically and remove any contaminants which may have accumulated. 1. Remove the fuel tank cap. 2. Lift out the filter inside. 3. Clean the filter with solvent. If the filter is damaged, contact CLARKE Spare Parts department 020 8988 7400 for a replacement. 4. Replace the filter and fuel tank cap.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com TROUBLESHOOTING If this does not solve your problem, please contact the CLARKE service department. PROBLEM CAUSE SOLUTION The generator fails to start Ignition switch is off Set the ignition switch to ‘on’ Not enough oil in the generator Add more oil, see page 9-10 No fuel Add more fuel, see page 10-11 Battery level low Charge battery The generator fails to generate electricity The device you are trying to power is faulty Make sure the device you want to power is working properly The AC breaker is switched off Switch the AC breaker on 110V Overload has tripped Reset the 110V sockets by pressing the overload protector The generator is difficult to start The air filter is dirty Clean the air filter, see page 20

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com MAINTENANCE RECORD ENGINE OIL OIL FILTER AIR FILTER FUEL FILTER BI-ANNUAL SERVICE

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com DECLARATION OF CONFORMITY - UKCA

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com DECLARATION OF CONFORMITY - CE

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com ASSOCIATED CLARKE PRODUCTS 110V Generator Plug- GP32/1 230V Generator Plug - GP32/2

  • 32A, 110V Generator Plug (Yellow)
  • 0.21kg Weight
  • Part No. 6160720
  • 32A, 230V Generator Plug (Blue)
  • 0.21kg Weight
  • Part No. 6160730 6” Plastic Filler Funnel- CHT516 20 Litre Fuel Can - JC20LG
  • Side handle for secure grip.
  • 0.12kg Weight
  • Part No. 1801516
  • 0.9mm Steel
  • 4.29kg Weight
  • Part No. 7649900

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com