8857685 CLARKE | Alldatasheet

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OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS GC01/25-REV 1 GENERATOR MODEL NO: CP6550NESLR PART NO: 8857685

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 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 PROTECTION Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted and taken to a recycling centre for disposed in a manner compatible with the environment. By purchasing this product, the customer is taking on the obligation to deal with its safe disposal in accordance with the Waste Electrical and Electronic Equipment (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 GENERAL SAFETY RULES WORK AREA 1. ALWAYS use in a well ventilated area. 2. ALWAYS position the exhaust outlet away from people. 3. Read these safety instructions before using the equipment. 4. Keep children and animals away from the generator. FIRE PREVENTION 1. ALWAYS switch the engine OFF when re-fuelling. 2. ALWAYS refuel in a well ventilated area. 3. NEVER overfill the tank, only fill to the level specified. 4. NEVER smoke whilst re-fuelling and avoid smoking or using a naked flame near the generator. 5. 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. 4. Make sure you ground (earth) the generator. POSITIONING THE GENERATOR FOR USE 1. ALWAYS leave at least a 1 metre gap between the generator and any surrounding building or structure or the engine may overheat. 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. WARNING: EXHAUST FUMES CAN BE EXTREMELY DANGEROUS IF INHALED

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 4. NEVER move or tilt the generator whilst it is switched on. 5. NEVER cover or enclose the generator whilst it is in use. 6. Be aware of the weight of the generator, do not attempt to lift or move the generator without the assistance of another person. EXHAUST GAS PRECAUTIONS WARNING!: EXHAUST FUMES CAN BE FATAL 1. ALWAYS ensure that there is adequate ventilation when using the generator. 2. ALWAYS position the generator so that the exhaust is pointing away from people or animals. 3. NEVER use the generator indoors or in a enclosed area. (i.e. in warehouse, tunnel, well or a hold). ADDITIONAL SAFETY RULES FOR GENERATORS 1. ALWAYS make sure the applied load does not exceed the generator rating. Overloading the generator is dangerous and could cause serious damage. 2. ALWAYS disconnect the generator when carrying out any maintenance. 3. ALWAYS allow the generator to reach 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. NEVER connect the generator to a commercial or residential power supply; e.g. ring main. 7. NEVER allow the generator air vents to become blocked. 8. NEVER alter or tamper with the internal wiring of the generator. 9. NEVER touch any part of the engine, alternator or exhaust when the generator is in use as these get hot and could cause burns. 10.NEVER allow anyone, not fully familiar with generator sets to use this equipment. 11. This generator set is NOT suitable for use with electronic equipment such as televisions, hi-fi’s or computers etc. 12. Connect only those appliances that are in good working order. NOTE: Most portable electric tools are Class II (double insulated) appliances. Always check BEFORE connecting. Equipment that does not meet this standard (i.e. tools with metal casing) require a three conductor cable with an earth conductor. 13.DO NOT Alter the engine settings, the voltage and frequency of the generator output is directly linked to the engine speed. These settings are factory set. Should they need re-calibration - consult your CLARKE dealer.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 14. Connect only those appliances whose voltage (according to their data plate) corresponds to that produced by the generator. IMPORTANT!: This generator uses a floating chassis (refer to technical information sheet). Floating earth generators DO NOT require earthing. SAFETY SYMBOLS The following safety symbols are shown on the product or it’s packaging. Please read all of the safety and operating instructions carefully before using this product. Read instruction manual before use. Hot surface - Do not touch Dangerous voltage Poisonous fumes - Do not use the generator in an enclosed space. Flammable Caution - The user should be aware of a general hazard. This product produces high noise levels during operation. Ear protection is advised.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com UNPACKING AND ASSEMBLY Unpack your generator and check all are present. Should there be any missing or damaged during transit contact your CLARKE dealer. BEFORE USING THE GENERATOR Before using your generator check that the generator is:

  • In good condition and free from any damage.
  • Is clean and free from fuel or oil spillage or leaks.
  • Is correctly located for use. NOTE: To avoid accidental spillage of fuel, always use a funnel to fill the fuel tank. If fuel is spilled it must be wiped up from the unit before attempting to start the engine. CHECK THE ENGINE OIL LEVEL 1. Stand the generator on a level surface and check the oil level as follows. 2. Turn the oil filler cap/dipstick anti- clockwise to remove from the oil reservoir and wipe with a clean cloth. 3. Insert the dipstick back into the oil filler tube and then remove it again. 4. If the oil is below the Min. level on the dipstick, top up the oil reservoir with fresh oil.
  • DO NOT fill above the max level mark.
  • We recommend the use of SAE10W/30 oil in this generator. (CLARKE part number 3050845) WARNING: YOUR GENERATOR MAY NOT BE SUPPLIED WITH OIL - ALWAYS ENSURE THERE IS SUFFICIENT OIL BEFORE USE. CAUTION: ONLY CARRY OUT THIS CHECK WITH THE ENGINE OFF.

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

  • DO NOT tilt the generator when adding engine oil. This could result in overfilling and damage to the engine. 5. Replace and tighten the oil filler cap. ADDING/CHECKING THE FUEL LEVEL 1. To check the fuel level, open the fuel filler cap. 2. Slowly add fuel to the fuel tank (maximum 15 litres)
  • DO NOT overfill the fuel tank. 3. Replace the fuel filler cap securely. RECOMMENDED FUEL Your generator has been designed to use regular unleaded petrol with a octane number of 86 or higher. The user should confirm that current E10 fuels are suitable. WARNING: MAKE SURE THERE IS 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: FUEL IS HIGHLY FLAMMABLE AND POISONOUS. WARNING: SEE “GENERAL SAFETY RULES” ON PAGE 3 AND READ THEM CAREFULLY BEFORE REFUELING. WARNING: DO NOT FILL ABOVE THE TOP OF THE FUEL FILTER OR IT MAY OVERFLOW WHEN THE FUEL HEATS UP AND EXPANDS. WARNING: WIPE UP ANY SPILLED FUEL IMMEDIATELY. WARNING: AFTER REFUELING, MAKE SURE THE FUEL FILLER CAP IS TIGHTENED SECURELY.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 4. Replace the fuel filler cap securely. NOTE: Long range ‘LR’ models are fitted with a three position fuel tap as illustrated in fig.1. These positions are ON/OFF/ RESERVE.

  • Ensure the tap is set in the required position.
  • The fuel hose connectors are intact and there is no leakage.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com PREPARATION FOR USE This electric start machine is supplied with a 19AH dry charged battery, and a battery acid pack. The battery must be prepared as follows: Check to ensure the battery is in good condition, with no damage caused during transit. Should there be any apparent damage, please consult your CLARKE dealer immediately. 1. Disconnect and remove the battery from the frame. 2. Remove the vent plugs and fill to 12mm above the top of the separators. 3. Allow the battery pack to soak for 30 mins, then check the levels and top up as necessary. 4. Replace the vent plugs. Your battery is now ready for use, however we recommend that you put it on charge, at a rate of 2.5 Amps ONLY, for 4 hours. Should you do this, remember to re-check the battery levels when completed, and top up if necessary with distilled water (to BS4974). NOTE: You may charge at a lower rate than that specified, but a longer charge time will be necessary to achieve the same ampere hour input. NOTE: Before connecting to the generator, ensure the outside of the battery is completely dry. CONNECT THE BATTERY AS FOLLOWS: 1. Ensure the battery is firmly secured in its compartment within the frame. 2. Connect the battery terminals to the battery posts, ensuring you connect the POSITIVE connection FIRST. (When disconnecting ALWAYS disconnect the positive terminal last). NOTE: Smear the connections and terminals with petroleum jelly.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com EXTENSION CABLES All extension cables, from the generator set to the appliance, must be carefully selected, fitted and maintained. Cables in accordance with IEC 245-4 should be used. Cables should be inspected regularly, and should be replaced, not repaired in the event of a defect. The length and cross section of conductors should be selected according to the job to be done. The table below is an indication of the sizes that should be used. Ensure the cable is fully unwound when in use to avoid overheating, and the placing of extra load on the generator. OPERATION IMPORTANT: Ensure all precautions are taken, referring to this and the Honda engine manual before proceeding. Start the engine as follows (referring to engine manual) and allow to run for a few minutes at full speed in order for it to warm up. 1. Move the fuel valve lever to the ON position 2. To start a cold engine, move the choke lever to the On position. 3. Pull the recoil starter grip lightly until you feel resistance, then pull briskly. Return the starter grip gently. NOTE: DO NOT allow the starter grip to snap back against the engine at high speed causing damage. 4. To re-start a warm engine, leave the choke lever in the Off position. 5. To use the electric starter, turn the key to the start position until the engine starts. Conductor (mm²) Max Length (m) Current (Amps) Single Phase (kW) 1.5 25 10 2.3 2.5 40 16 3.7 4.0 60 28 6.5

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 6. If the engine fails to start within 5 seconds, release the key and wait at least 10 seconds before operating the starter again. When the engine starts, release the key. NOTE: Using the starter for more than 5 seconds can overheat and damage the starter motor. 7. Set the engine speed by moving the throttle lever away from the MIN position IMPORTANT: Ensure no appliances are connected to the generator when starting the engine. 8. Check the condition of the appliance, including the supply cable and the extension cable if used, and ensure it is switched OFF. Ensure also that the operating voltage is the same as the output from the generator. 9. For generators with dual output, ensure the voltage selector switch is set to deliver the appropriate output - 115V or 230V, see fig’sbelow.. 10. With the engine running smoothly connect the appliance to the appropriate receptacle: BLUE - 230V, YELLOW - 115V. NOTE: If the AC circuit is overloaded the circuit protection switch will trip. To reset the circuit, first disconnect the appliance, and rectify the cause of the overload. Wait a short period and then press the reset button on the panel. BE AWARE! Some appliances draw more current on start-up than their normal running current, i.e. electric motors, and compressors. If in any doubt as to whether an appliance is compatible or not, please consult your CLARKE dealer.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com Additionally, please refer to the specifications sheet attached, to ensure the machine is used under the correct operating conditions. SHUTTING DOWN THE GENERATOR IMPORTANT: Never switch off the engine whilst an electrical appliance is connected. To stop the generator in an emergency simply set the engine switch to ‘OFF’. Move the throttle lever to the MIN position. 1. Set the engine switch to the “0” (OFF) position. 2. Turn the fuel valve knob to “OFF” (pointing left). 3. Disconnect any electric devices. MAINTENANCE ENGINE OIL (AFTER FIRST 20 HOURS OF USE) 1. Turn the oil filler cap anti-clockwise and remove from the oil reservoir. 2. Remove the drain plug and tilt the generator to allow the oil to drain out of the oil reservoir into a suitable container. NOTE: You may need assistance with this step as the generator is heavy. 3. Fill the oil reservoir with fresh oil.

  • DO NOT fill above the max level mark.
  • We recommend the use of SAE10W/30 oil in this generator. (CLARKE part number 3050845) 4. Replace the oil filler cap. CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS DANGEROUS, ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED ENGINE OIL.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com ENVIRONMENTAL PROTECTION One of the most damaging sources of pollution is oil. DO NOT throw away used engine oil in with your domestic waste or down drains and sinks. Place it in a leak proof container and dispose of it according to local regulations. AIR FILTER (EVERY 50 HOURS OF USE) 1. Remove the air filter cover, unscrewing the securing nut. 2. Remove the air filter panel and the air filter element. 3. If the air filter is damaged contact the CLARKE spare parts department for a replacement.

  • If the filter is dirty, wash it in a solution of warm water and mild detergent and then rinse thoroughly.
  • Leave the filter to dry completely, once it is dry immerse the filter in clean engine oil and squeeze the filter to remove excess oil. 4. Replace the filter into its original position and replace and secure the air filter cover. 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 SPARK PLUG (EVERY 50 HOURS OF USE) 1. Remove the spark plug cap from the spark plug. 2. Fit the spark plug box spanner over the spark plug as shown and use the lever to turn it. 3. When the spark plug has been removed, check for discoloration and use a wire brush to remove any carbon build up. 4. Check the spark plug gap with a feeler gauge which should be between 0.6 and 0.7 mm.

  • Adjust if necessary. 5. Check the overall condition of the spark plug and replace if damaged. NOTE: Spark plugs are available from CLARKE Spare Parts department 020 8988 7400. 6. Reinstall the spark plug and replace the spark plug cap. FUEL TANK FILTER (EVERY 100 HOURS OF USE) 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 for a replacement. 4. Replace the filter and fuel tank cap. STORAGE 1. Always store in a damp free environment away from children. CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING THE SPARK PLUG.

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 Engine switch is off Set the engine switch to ON Fuel valve OFF Move the lever to ON position. Choke open (Off) Move the lever to CLOSED position unless engine is warm. Lack of engine oil. (with Oil Alert feature fitted) Add more oil. No fuel Add more fuel. Bad fuel due to long term storage with fuel in tank Drain the fuel tank and carburetor. Refuel with fresh fuel. Spark plug defective, foul or wrongly gapped. Clean, re-gap or replace the spark plug. The generator fails to generate electricity (no AC output) The device you are trying to power is faulty Make sure the device you want to power is working properly. Selector switch in wrong position Set the selector switch Tripped circuit breaker Reset the AC safety trip Poor connection or defective lead Check the connection and/or replace lead The generator is difficult to start The air filter is dirty Clean the air filter. Erratic supply Incorrect engine rpm Adjust the engine speed Internal alternator problem Contact CLARKE servicing

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

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SPARE PARTS Frame SH0211009 Alternator mount SH0270004 Engine mount SH0270027 Alternator NAC5500 BC-A0/T SH0130090 IP23 Alternator cover SH0280040 Control box D/V wired cw covers SH0491001 Control box 5 SKT CON5 SH0090193 Mounting set C/BOX SH0130106 Collar SH0130063 Grommet SH0130070 MCB GTEC 25AMP 1 pole SH0360011 MCB GTEC 50AMP 1 pole SH0360020 MCB Cover 2 SH0360038 Switch Merz Z101 20/25A SH0430005 Socket 115v 16a SH0440001 Socket 230v 16a SH0440002 Battery Box SH0210093 Battery Box Lid SH0210094 Battery YB16CL-B19A/H SH0540001 Alternator end cover SH0130067 Diode PCB assy SH0130073 Capacitor 22uf SH0370015 Diode PCB assy SH0130073 Fuel tank (steel) 15.5 L SH0210092 Fuel tap inline SH0480002 Fuel filter small in-line SH0480003 Filler neck SH0480005 Filler cap SH0480006

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SPECIFICATION Item Specification Model No CP6550NESLR Dimensions (L x W x H) 710 x 510 x 600 mm Weight 87 kg Engine type Honda GX390 Displacement 389cc Engine power 13HP Fuel capacity 15.5 L Fuel consumption 2.16 L/h Running time (full tank) 7.2 H Fuel type Unleaded Lubrication Oil Capacity/grade 1.1 L (SAE 10W30) Spark plug type BPR 6ES Rated power 6.5 kVA Voltage AC 230/115 V AC Rated frequency 50 Hz 1ph Earthing Floating Sound output 71 dB(A) @7m Measured sound power 96.512 dB Guaranteed sound power 97 dB

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