8857860 CLARKE | Alldatasheet

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OPERATION & MAINTENANCE INSTRUCTIONS DL1225 8.5KVA PETROL GENERATOR MODEL NO: PG9500ADVES PART NO: 8857860

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com INTRODUCTION Thank you for purchasing this CLARKE Generator. Before attempting to operate the machine, it is essential that you read this manual thoroughly and carefully follow all instructions given. In doing so you will ensure the safety of yourself and that of others around you, and you can also look forward to the product giving you long and satisfactory service. Ensure the generator and its components suffered no damage during transit and that all components are present. Should any loss or damage be apparent, please contact your CLARKE dealer immediately. GUARANTEE This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt 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. If disposing of this product or any damaged components, do not dispose of with general waste. This product contains valuable raw materials. Metal products should be taken to your local civic amenity site for recycling of metal products.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SPECIFICATIONS CLARKE part no 8857860 PG9500ADVES Engine Engine Model SC460 Engine Power 16HP - 10.5kW Fuel Type E10 Unleaded Petrol (87 Octane Rate) Displacement (cc) 459 Starting system Electric & Hand Recoil Fuel tank capacity (Litre) 20 L (Safe Capacity) Fuel consumption 3.3 L/Hr Maximum run time @75% Load 6 hours 30 mins Engine oil type SAE10W-30 Engine oil capacity (L) 1.1L Battery Type 12V,18Ah, SLA Generator Rated Frequency (Hz) 50 AC Output Voltage (V) 230 & 110 Rated Power (W) 8000 Max. Rated Power (W) 8500 Dimensions L x W x H (mm) 730 x 660 x 630 Unpacked Weight (kg) 100 Environmental IP Rating (Generator/Sockets) IP23M/IP44 Sound pressure level 74 dB Sound power level 94 dB Guaranteed sound power level 97 dB Uncertainty factor 2.8 dB

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com GENERAL SAFETY RULES & SYMBOLS SAFETY SYMBOLS Read Instruction manual before use DANGER - highly flammable liquid. Caution - The user should be aware of a general hazard Engine and exhaust become hot during use - DO NOT touch Dangerous voltage. Risk of electric shock Poisonous fumes - DO NOT use in an enclosed space. Wear ear defenders For outdoor use only. DO NOT expose to rain. DO NOT use in the wet. These symbols are to be found on the product.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 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 keep children away from the generator. POSITIONING THE GENERATOR 1. ONLY use the folding handles to wheel the generator into position. NEVER use them to lift the generator off the ground. 2. ALWAYS leave a least a 1m gap between the generator and any surrounding building or structure. 3. ALWAYS ensure the generator is on a dry, solid, flat surface. 4. ALWAYS ensure the surrounding area is free from any material that could burn or be damaged by heat. 5. NEVER move or tilt the generator whilst it is switched on. FIRE PREVENTION 1. ALWAYS switch the engine OFF when refuelling. Allow generator to cool for at least 2 minutes before removing the fuel cap. Loosen cap slowly to relieve pressure in the tank. 2. ALWAYS refuel away from any source of heat. 3. ALWAYS refuel in a well ventilated area. 4. ONLY use standard unleaded petrol. 5. DO NOT overfill the fuel tank. DO NOT fill to the very top of the tank and leave room for petrol expansion. 6. NEVER smoke whilst refuelling and avoid smoking or using a naked flame near the generator. 7. DO NOT operate near an open flame, heat or flammable materials. This generator may emit highly flammable and explosive petrol vapours. 8. 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.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 3. NEVER use water or any other liquid to clean the generator. 4. ALWAYS ground the generator before using it to maximise safety, see ‘Ground The Generator’ section on page 14. 5. ALWAYS use a ground fault circuit interrupter (GFCI) (not included) in highly conductive areas such as metal decking or steel work. Extension cords with an in- line GFCI are recommended for these operations. GENERAL SAFETY RULES FOR GENERATORS 1. ALWAYS ensure the applied load does not exceed the generator rating. Overloading the generator is dangerous and could cause damage. 2.ALWAYS disconnect the generator when carrying out any maintenance. 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. 7. DO NOT touch hot parts. This generator produces heat when running. Temperatures near the exhaust can exceed 150°F/65°C. Allow the generator to cool down after use before touching the engine or areas of the generator that become hot during use. 8. If any part of the generator, electrical device or power cable is broken, damaged or defective, make sure it is repaired or replaced before using. Service or repair of the generator should only be performed by a qualified technician. 9. NEVER modify the generator in any way. Modifying or using the generator for any other purpose for which it is not designed may result in serious injury, machine damage and voiding of the warranty. 10.ALWAYS turn off all connected electrical devices before stopping the generator. 11.ALWAYS turn the engine switch to the ‘OFF’ position when the engine is not running.

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

1 Control Panel 7 Folding Handles

2 Battery 8 Fuel Cap

3 Oil Fill Cap/Dipstick 9 Fuel Gauge

4 Oil Drain Plug 10 Choke

5 Recoil Starter 11 Spark Plug

6 Air Filter 12 Muffler/Exhaust

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

1 Electric Start Ignition 8 32A, 240V Plug Socket

2 Oil Level Alert Lamp 9 16A Breaker Switch

3 Data Centre (Volts & Hertz per hour) 10 16A, 110V Plug Socket

4 Main Breaker Switch 11 Earth Grounding Terminal

5 13A Breaker Switch 12 32A Breaker Switch

6 AC 230V Plug Socket 13 32A, 110V Plug Socket

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com UNPACKING Unpack your generator and check to ensure the following items are present. Should there be any deficiency or damage caused during transit contact your CLARKE dealer immediately. BEFORE USING THE GENERATOR Attach a suitable earth lead to a good earthing point (see page 14) - e.g. water pipe, ground spike etc., whenever you use this generator. Before using your generator check that the generator is:

  • In good condition and free from any damage.
  • Clean and free from fuel or oil spillage and the fuel system is intact.
  • Correctly located for use (see page 5). 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. 1 x 8.5kW Petrol Generator 2 x Folding Handle c/w fixings 2 x Axle, Washer & R Clip 1 x Spark Plug Box Spanner & Pouch 2 x Wheel & Axle Cover 1 x Tommy Bar 2 x Foot Assembly c/w fixings 1 x Pair of Ignition keys 1 x Lead Acid Battery (Not Connected, see page 11) 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 PAGE 12, 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 ASSEMBLY CAUTION: DUE TO THE WEIGHT OF THE GENERATOR, IT IS RECOMMENDED THAT THE ASSEMBLY IS UNDERTAKEN BY 2 PERSONS. FITTING THE WHEELS 1. Slide the axle through the wheel and place the washer on the axle on the frame side of the wheel. 2. Slide the axle assembly through the frame bracket and insert the R clip through the axle hole to secure in place. 3. Attach the wheel centre cap to the outside of the wheel. FITTING THE FEET 1. Insert an M6 bolt through the rubber pad and secure to the bottom of the foot support bracket with M6 nut. 2. Place the foot support bracket to the underside of the frame and insert two flange nuts and bolts and tighten.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com FITTING THE FOLDING HANDLES 1. Insert the rubber block in the end of the handle with the hinge bracket. 2. Fit the hinge bracket to the generator frame and secure with M8 washers, nut and bolt. 3. Slide the handle grip onto the end of the handle. CONNECTING THE BATTERY 1. Connect the negative wire to the negative (‘-’ / Black) terminal on the battery as shown on the right. 2. Connect the positive wire to the positive (‘+’ / Red) terminal on the battery.

  • Ensure both terminals are covered by the plastic covers as shown.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com PREPARATION BEFORE OPERATION ADDING ENGINE OIL WARNING: THIS GENERATOR IS SOLD WITHOUT OIL INCLUDED. DO NOT ATTEMPT START THE GENERATOR WITHOUT INSTALLING THE CORRECT OIL FIRST. Always check and add the correct engine oil before starting the generator. DO NOT use any special additives. Select the oil viscosity grade according to the expected operating tempera- ture (see chart).

  • Above 40oF (4oC), use SAE30 oil.
  • Between 10oF (-18oC) & 40oF (4oC), use 10W-30 oil.
  • Below 10oF (-18oC), use 5W-30 oil. 1. Place the generator on a flat, level surface. 2. Clean the area around the oil fill cap and remove the cap/dipstick. 3. Slowly fill the engine with the appropriate oil until it reaches the full mark on the dipstick.
  • Stop filling occasionally to check the oil level & be careful to not over fill. 4. Replace the oil fill cap/dipstick and finger tighten securely. NOTE: Check engine oil level before starting each time thereafter. NOTE: The engine is equipped with a low oil level sensor and the Oil Level Alert Lamp will light up (see Control Panel on Page 8). This will shut down the engine automatically when the oil level drops below a specified level.If the engine shuts down by itself and the fuel tank has enough petrol, check the engine oil level.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com ADDING FUEL RECOMMENDED FUEL: Only use standard unleaded petrol. DO NOT mix with oil. 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, open the fuel filler cap. 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 20L) watching the fuel level gauge as you do so. 5. Replace the fuel filler cap securely. NOTE: DO NOT overfill the fuel tank. 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 GROUND THE GENERATOR WARNING: TO REDUCE THE RISK OF ELECTRIC SHOCK AND TO MAXIMISE SAFETY, THE GENERATOR SHOULD BE PROPERLY GROUNDED BEFORE USE. Ground the generator by tightening the earth grounding terminal on the front control panel against a grounding wire. A generally acceptable grounding wire is a No. 14 SWG (Standard Wire Gauge)(2.108mm) stranded copper wire. This grounding wire should be connected at the other end to a copper, brass or steel grounding rod that is driven into the earth. Wire and grounding rods are not included with the generator USING YOUR GENERATOR STARTING THE ENGINE 1. Turn the Engine Switch to the ‘ON’ position. 2. Turn the Fuel Switch to the ‘ON’ position. WARNING: NEVER START OR STOP THE ENGINE WITH ELECTRICAL DEVICES PLUGGED IN AND TURNED ON. UNPLUG ALL ELECTRICAL LOADS FROM THE GENERATOR BEFORE STARTING THE ENGINE.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 3. Move the Engine Choke Lever to the ‘CHOKE’ position. FOR ELECTRIC START 1. Insert the key into the ignition. 2. Turn and hold key in the start switch to the ‘Start’ position until the generator starts. NOTE: To prolong the life of the starter components, DO NOT hold the key in the ‘Start’ position for more than 15 seconds, and pause for at least 1 minute between starting attempts. 3. Once the engine has started, move the choke lever to 1/2 CHOKE position until the engine runs smoothly and then fully to the ‘RUN’ position. If the engine falters, move the choke lever back to the 1/2 CHOKE position until the engine runs smoothly, then back to the ‘RUN’ position. NOTE: If the battery is discharged, use the manual recoil start instructions on page 14-16. NOTE: If the engine fires, but does not continue to run, move the choke lever to the ‘OFF’ position and repeat starting instructions.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com FOR MANUAL RECOIL START 1. Firmly grasp the recoil starter handle and pull slowly until increased resistant is felt. 2. Then pull rapidly up. 3. Once the engine has started, move the choke lever to 1/2 CHOKE position until engine runs smoothly and then fully to the ‘RUN’ position. If the engine falters, move the choke lever back to the 1/2 CHOKE position until engine runs smoothly, then back to the ‘RUN’ position. CONNECTING ELECTRICAL DEVICES 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 with the highest wattage 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. Repeat step 2 to plug in each additional device. DO NOT attempt to plug in and start multiple devices at the same time. GENERATOR CAPACITY Make sure the generator can supply enough running (rated) and starting (max.) watts for the items you will power at the same time. Follow these simple steps. 1. Select the items you will want to power at the same time. 2. Add together the running (rated) watts of these items. This is the amount of power the generator must produce to keep the items running. 3. Estimate how many starting (max.) watts you will need. Starting wattage is the short burst of power needed to start electric motor driven tools such as a circular saw or refrigerator. Because not all motors start at the same time, total starting WARNING: STARTER CORD KICKBACK (RAPID RETRACTION) WILL PULL YOUR HAND AND ARM TOWARD THE ENGINE FASTER THAN YOU CAN LET GO, WHICH COULD CAUSE SERIOUS INJURY. WHEN STARTING THE ENGINE, PULL THE CORD SLOWLY UNTIL RESISTANCE IS FELT AND THEN PULL RAPIDLY TO AVOID KICKBACK.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com (max.) watts can be estimated by adding only the items with the highest additional starting (max.) to the total rated watts. Example only: Total Running Watts: 1255 Highest Starting Watts: +1350 Total Starting Watts Needed = 2605 To prolong the life of the generator and attached devices, it is important to take care when adding electrical loads to the generator. There should be nothing connected to the generator outlets before starting its engine. The correct and safe way to manage the generator power is to sequentially add loads as follows: 1. With nothing connected to the generator, start the engine as described on pages 14-16 of this manual. 2. Plug in and turn on the first load, preferably the largest load you have. 3. Allow the generator output to stabilise (engine runs smoothly and any attached device operates properly). 4. Plug in and turn on the next load. 5. Again, allow the generator to stabilise. 6. Repeat steps 4 & 5 for each additional load. NEVER add more loads than the generator capacity. Take special care to consider surge loads in generator capacity as previously described. Tool/Appliance Running Watts Additional Starting Watts Refrigerator 700 1350 Portable Fan 40 120 Laptop 250 250 46 in. Flat Screen TV 190 190 Light (75 Watts) 75 75

1255 Total Running Watts 1350 Highest Starting Watts

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com The chart below serves as a reference only for the estimated wattage requirements of common electrical devices. However, DO NOT solely reply on this chart as all appliances are built differently, ALWAYS check the wattage listed on the electrical device before consulting this chart: SHUTTING DOWN THE GENERATOR Shut off all loads then unplug the devices from the generator panel. NEVER start or stop the engine with electrical devices plugged in and turned on. 1. Let the engine run at no-load for several minutes to stabilise the internal temperature of the engine and generator. 2. Move the ON/OFF switch to the ‘OFF ‘position. Tool/Appliance Rated (Running) Watts Surge (Starting) Watts Hot Plate 2500 0 Saw - Circular 1500 1500 Saw - Mitre 1200 1200 Microwave 1000 0 Well Water Pump 1000 1000 Sump Pump 800 1200 Refrigerator/Freezer 800 1200 Computer 800 0 Television 500 0 Box Fan 300 600 Light Bulb 75 0

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 3. Turn the fuel switch to the ‘OFF’ position. MAINTENANCE & TROUBLESHOOTING MAINTENANCE SCHEDULE Proper routine maintenance of the generator will help prolong the life of the machine. Please perform maintenance checks and operations according to the Maintenance Schedule below. If there are any questions about the maintenance procedures listed in this manual, please contact the CLARKE service centre. WARNING: NEVER PERFORM MAINTENANCE OPERATIONS WHILE THE GENERATOR IS RUNNING. BEFORE MAINTENANCE OR SERVICING THE GENERATOR, TURN OFF THE GENERATOR, DISCONNECT ALL DEVICES AND ALLOW THE GENERATOR TO COOL DOWN First 5 Hours of use

  • Change engine oil (see page 21) Every 8 Hours of use or Daily
  • Clean debris (see page 20)
  • Check engine oil level (see page 12)
  • Check fuel level (see page 13) Every 25 Hours or use or Yearly
  • Clean engine air filter (see page 23) Every 50 Hours or use or Yearly

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com GENERATOR MAINTENANCE Generator maintenance consists of keeping the unit clean and dry. Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust, dirt, moisture or any corrosive vapours. Cooling air slots in the generator must not become clogged with snow, leaves, or any other foreign material. Check the cleanliness of the generator frequently and clean when dust, dirt, oil, mois- ture or other foreign substances are visible on its exterior surface. TO CLEAN THE GENERATOR 1. Use a damp cloth to wipe exterior surfaces clean. 2. A soft bristle brush may be used to loosen caked on dirt, oil etc. 3. A vacuum cleaner may be used to pick up loose dirt and debris. 4. Low pressure air (DO NOT exceed 25psi and ALWAYS wear eye protection) may be used to blow away dirt. Inspect the cooling air slots and openings on the generator. These openings must be kept clean and unobstructed.

  • Change engine oil (see page 21) Yearly
  • Replace engine air filter (see page 23)
  • Service fuel valve
  • Clean and service spark plug and replace if necessary (see page 22)
  • Inspect muffler (exhaust) and spark arrester (see page 23)
  • Clean cooling system WARNING: NEVER INSERT ANY OBJECT OR TOOL THROUGH THE AIR COOLING SLOTS, EVEN IF THE ENGINE IS NOT RUNNING. WARNING: DO NOT USE A GARDEN HOSE TO CLEAN THE GENERATOR. WATER CAN ENTER THE ENGINE FUEL SYSTEM AND CAUSE PROBLEMS. IN ADDITION, IF WATER ENTERS THE GENERATOR THOUGH THE COOLING AIR SLOTS, SOME WATER WILL BE RETAINED IN VOIDS AND CREVICES OF THE ROTOR AND STATOR WINDING INSULATION. WATER AND DIRT BUILD UP ON THE GENERATOR INTERNAL WINDINGS WILL EVENTUALLY DECREASE THE INSULATION RESISTANCE OF THE WINDINGS.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CHANGING THE OIL Change the oil after the first 5 hours of operation, then every 50 hours thereafter. If running this unit under dirty or dusty conditions, or in extremely hot weather, change the oil more often. Use the following instructions to change the oil while the engine is still warm. 1. Clean area around the oil drain plug. 2. Place a suitable oil container under the oil drain plug. 3. Remove the dipstick and oil drain plug from the engine and drain oil into the container. 4. Once the oil has completely drained, re-install the oil drain plug and tighten securely. 5. Refill the engine with the recommended oil (see page 12). 6. Wipe up any spilled oil. 7. Dispose of used oil at an appropriate recycling centre. 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. WARNING: HOT OIL MAY CAUSE BURNS. ALLOW THE ENGINE TO COOL BEFORE DRAINING THE OIL. AVOID PROLONGED OR REPEATED SKIN EXPOSURE WITH OIL. THOROUGHLY WASH EXPOSED AREAS WITH SOAP.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com INSPECTING OR REPLACING THE SPARK PLUG Use spark plug F6TC, BPR4ES or equivalent. Replace the spark plug once every year. This will help the engine start easier and run better. 1. Make sure the generator is off and remove the spark plug wire. 2. Use the spark plug spanner that is supplied to unscrew and then carefully remove the spark plug from the engine. NOTE: There is limited space for the spanner to turn, use the spanner tommy bar to gain leverage to loosen the plug. 3. Visually inspect the spark plug. if it is cracked or chipped, or if the electrodes are worn or burned, discard it and replace with a new spark plug. 4. If re-using the spark plug, use a wire brush to clean any dirt from around the spark plug base, then re-gap the spark plug. 5. Measure the plug gap with a spark plug gap gauge. the gap should be 0.7 - 0.8mm (0.028 - 0.031in). Carefully adjust the gap if necessary. 6. Screw the spark plug back into the spark plug hole using the spark plug spanner. DO NOT over-tighten. Recommended tightening a spark plug is 1/2 to 3/4 of a turn (15ft/lb torque/20.33Nm) after the spark plug gasket contacts the spark plug hole. 7. Reinstall the spark plug wire and cap. INSPECTING OR REPLACING THE SPARK ARRESTOR 1. Shut off the generator and allow the muffler (exhaust) to cool down completely before servicing the spark arrestor. 2. Unscrew the spark arrestor screen. 3. Clean the spark arrestor screen with a small wire brush and reinstall. 4. Replace the spark arrestor if it is damaged.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com INSPECTING OR REPLACING THE AIR FILTER The engine will not run properly and may be damaged if using a dirty air filter. Replace the air filter once a year. Clean or replace more often if operating under dusty condi- tions. 1. Remove air filter cover by unclipping the top and bottom. 2. Take the cover off and remove the foam air filter element from the casing. Wipe excessive oil and any dirt from inside the air filter casing. 3. Check and clean the foam air filter element. Good elements can be washed in soapy water. Dry the element in a clean cloth (DO NOT twist it). Add a few drops of engine oil to the air filter element and spread it evenly.

  • If the air filter element has been damaged, replace it with a new one. Contact the CLARKE service centre. 4. Reinstall the air filter element within the casing and reinstall the air filter cover.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION The generator fails to start Battery not charged Charge battery Engine switch is in the OFF position Turn engine switch to the ON position No Fuel Fill fuel tank (see page 13) Stale petrol or water in petrol Drain entire system and refill with fresh fuel (see page 25-26) Engine oil level is low Engine is equipped with Low Oil Shutoff. If engine oil level is low, it must be filled before unit will start. Check engine oil level and fill if necessary (see page 12) Fuel switch is in the OFF position Turn fuel switch to the ON posi- tion (see page 14) Spark plug faulty, fouled, or improperly gapped Replace spark plug (see page 22) Engine stored without treating or draining petrol, or refueled with bad petrol Drain fuel. Refuel with fresh pet- rol (see page 25-26) Dirty fuel filter Replace fuel filter or contact the CLARKE service department (see page 13) Engine lacks power Dirty air filter Check air filter element. Clean or replace as needed (see page 23) Engine stored without treating or draining petrol, or refueled with bad petrol Drain fuel. refuel with fresh pet- rol (see page 25-26). If problem continues, contact the CLARKE service department The generator is difficult to start The air filter is dirty. Clean the air filter (see page 23).

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com If this does not solve your problem contact the CLARKE service department. STORAGE The generator should be started at least once every seven days and be allowed to run for at least 30 minutes. If this can’t be done and the unit must be stored for more than 30 days, use the following information as a guide to prepare it for storage. DRAINING THE FUEL SYSTEM It is important to avoid gum deposits from forming in the essential fuel system parts such as the carburettor, fuel hose or tank during storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer, as follows: 1. Remove all fuel from the generator, by draining the fuel tank as follows:

  • Place a suitably sized fuel container under the fuel drain plug on the carburettor. AC receptacle does not work OUTPUT indicator is OFF, and OVERLOAD indicator is ON Check AC load (see page 16- 18). Stop and restart the engine. Check the cooling air inlet. Stop and restart the engine. AC Circuit protector has tripped Check AC load and reset AC cir- cuit breakers (see Control Panel on page 8) GFCI (Ground Fault Circuit Interrupter) system has activated (if used) Reset the GFCI Item plugged in is defective Try a different device. WARNING: NEVER STORE THE ENGINE WITH FUEL IN THE TANK, INDOORS OR IN AN ENCLOSED, POORLY VENTILATED AREA. DRAIN FUEL INTO AN APPROVED CONTAINER OUTDOORS, AWAY FROM OPEN FLAME. BE SURE THE ENGINE IS COOL. DO NOT SMOKE. PROBLEM POSSIBLE CAUSE SOLUTION

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

  • Unscrew the fuel drain plug.
  • Turn the fuel switch to the ‘ON’ position to open the drain.
  • Once the fuel has drained, replace the drain plug and turn the fuel switch to the ‘OFF’ position. 2. Start and run the engine until the engine stops from lack of fuel. 3. While engine is still warm, drain the oil from the crankcase (see page 21) 4. Remove the spark plug (see page 22) and pour about 1/2 ounce (15ml) of engine oil into the cylinder. Cover the spark plug hole with a rag and pull the recoil starter handle a couple of times to lubricate the piston ring and cylinder bore. 5. Reinstall and tighten the spark plug. DO NOT connect the spark plug wire. 6. Clean the generator outer surfaces, using a non-abrasive cleaning solution. 7. Check that the cooling air slots and openings on the generator are open and unobstructed.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 8. Store the unit in a clean dry place. If possible, store the unit indoors and cover it to give protection from dust and dirt, making sure the cover DOES NOT retain moisture. 9. DO NOT store petrol from one season to the next. 10. Replace the petrol container if it starts to rust. Rust and/or dirt in petrol will cause problems with the carburettor and fuel system. 11. If it is not practical to empty the fuel tank and the unit is to be stored for some time, use a commercially available fuel stabiliser added to the petrol to increase the life of the petrol. CLARKE GENERATOR ACCESSORIES Extension Lead - EL16 Generator Plug - GP32/2

20 Litre Jerry Can -

  • 14m/1.52mm 230V Cable.
  • 16A Plug to 13A Socket
  • Part No. 3220847
  • 230V 32A Generator Plug
  • Part No. 6160730
  • 0.8mm Thick Steel Construction
  • Locking Pin on Cap
  • Part No. 7650220

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com ALTERNATOR DIAGRAM No Description No Description

01 Alternator Assembly 10 Voltage Regulator

02 Rotor 11 Wiring Board

03 Stator 12 Flat Washer

04 Plain Washer 13 Spring Washer

05 Rotor Bar 14 Alternator Bracket

06 Carbon Brush 15 Flange Bolt

07 Flange Bolt 16 Flange Bolt

08 Flange Bolt 17 Lock Nut

09 Alternator End Cover

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com ENGINE DIAGRAM No Description No Description

01 Bolt, M6 x 60 08 Bolt, Stud, Intake

02 Cover Comp. Head 09 Bolt, Stud, Exhaust

03 Gasket, Head Cover 10 Cylinder Head Compartment

04 Breather Tube 11 Spark Plug

05 Bolt, M6 x 12 12 Head Gasket, Cylinder

06 Cover 13 Dowel Pin

07 Bolt, M10 x 87

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

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com No Description No Description

01 Handlebar Rubber Cover 14 Vibration Absorber Rear

02 Handlebar Arm 15 Flange Nut

03 Handlebar Plastic Plug 16 Ground Terminal

04 Flange Bolt 17 Vibration Absorber

05 Washer 18 Flange Bolt

06 Flange Bolt 19 Washer

07 Support 20 Flange Nut

08 Flange Nut 21 Axle

09 Flange Nut 22 Flat Washer

10 Flange Bolt 23 Wheel Assembly

11 Flange Bolt 24 R- Clip, Dowel Pin

12 Vibration Absorber Front 25 Frame Components

13 Vibration Absorber Rear 26 Brackets, Rubber Foot Pad

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com FUEL TANK DIAGRAM No Description No Description

01 Fuel Tank Cap 06 Bushing

02 Fuel Filter 07 Fuel Tank Rubber Mat

03 Fuel Level Gauge 08 Fuel Valve

04 Flange Bolt 09 Clamp

05 Fuel Tank Washer 10 Fuel Pipe

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com MUFFLER/EXHAUST DIAGRAM No Description No Description

01 Support Bracket 07 Spring Washer

02 Flange Bolt 08 Hex Nut

03 Flange Bolt 09 Muffler

04 Washer 10 Flange Nut

05 Flange Nut 11 Air Cleaner Bracket

06 Muffler Gasket 12

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